🏷️ Basic Information

Make:

Chevrolet

Model:

Suburban

Year:

1996

Platform Code:

GMT400

👋 Introduction

Positioning:

The 1996 Chevrolet Suburban was a full-size SUV, positioned as a versatile vehicle for families, towing, and heavy-duty use, offering substantial passenger and cargo capacity.

Competitors:

Ford Expedition (introduced in late 1996 for 1997 model year, earlier F-Series based SUVs), Dodge Ramcharger, Jeep Grand Cherokee (smaller competitor).

Vehicle Features:

Body-on-frame construction, rear-wheel drive or 4-wheel drive options, spacious interior, robust towing capabilities, available V8 engines.

Value:

Provides dealership-level diagnostic and repair information, enabling DIY enthusiasts and professional technicians to accurately maintain and repair the 1996 Suburban.

📋 Manual Details

Primary Coverage:

1996 Chevrolet Suburban

Model Variants Covered:

All trim levels and configurations

Estimated Page Count:

1500+

Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

Likely Printed (Original Factory Document); Digital (PDF) versions are common for resale

📖 Manual Coverage

Powertrain:

Engine, Transmission, Drivetrain, Fuel System, Exhaust System, Cooling System

Chassis:

Suspension (Front and Rear), Steering, Brakes (Hydraulic and ABS), Wheels and Tires

Body And Interior:

Body Panels, Doors, Seats, HVAC, Interior Trim, Glass, Bumpers

Electrical:

Wiring Diagrams, Lighting, Instruments, Gauges, Power Accessories, Engine Control Module (ECM), Body Control Module (BCM), Audio System

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis and repair, including component replacement and refrigerant handling (R-134a).

Lighting:

Headlamps, tail lamps, interior lighting, power windows, power door locks, mirrors, and wiper/washer systems.

Maintenance:

Oil Changes, Filter Replacements, Fluid Checks, Lubrication, Tune-ups

Repair:

Engine Overhaul, Transmission Rebuild, Brake Service, Suspension Component Replacement, Electrical Component Diagnosis and Replacement

Diagnostics:

Troubleshooting charts, symptom-based diagnostics, diagnostic trouble codes (DTCs) for OBD-I and early OBD-II systems

Specifications:

Torque specifications, clearances, fluid capacities, electrical values, diagnostic parameters

Engine Mechanical:

Engine assembly/disassembly, cylinder head removal, piston/connecting rod service, crankshaft/bearing service, timing chain/gear replacement.

Transmission Servicing:

Fluid and filter changes, linkage adjustment, seal replacement, complete transmission overhaul procedures for both automatic transmissions.

Brake System Repair:

Disc and drum brake service, caliper and wheel cylinder replacement, master cylinder service, brake line repair, ABS system diagnostics and component replacement.

Suspension And Steering:

Ball joint replacement, tie rod end service, shock absorber/strut replacement, power steering system diagnosis and repair, wheel alignment specifications.

Electrical System Troubleshooting:

Detailed wiring diagrams, fuse and relay identification, starter and alternator testing, battery service, diagnostic connector pinouts.

Depth:

Comprehensive: Covers everything from routine maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and component-level repair instructions.

📊 Manual Specifications

Digital Searchability:

High (if digital PDF), allowing for quick keyword searches of specific components or procedures.

Quality:

High (original print), featuring clear diagrams, schematics, and text.

Type:

Likely Softcover or Hardcover (original); Digital format has no binding.

Type:

Durable paper stock, designed for shop environment (original print).

⚙️ Engine Specifications

Engine Code Common:

L31 (Vortec 5.7L V8)

Engine Displacement:

5.7 L (350 cu in)

Engine Configuration:

V8, Overhead Valves (OHV)

Horsepower Approx:

255 hp @ 4600 rpm

Torque Approx:

330 lb-ft @ 2800 rpm

Fuel Induction:

Sequential Electronic Fuel Injection (SFI) - Vortec technology

Fuel Type:

Unleaded gasoline

Alternative Engines:

6.5L Turbo Diesel (VIN 'F') was also available, offering different performance characteristics and maintenance requirements.

🔧 Transmission

Transmission Type:

4-speed automatic (4L60-E for gasoline engines)

Transmission Type Diesel:

4-speed heavy-duty automatic (4L80-E for diesel engines)

Drive Modes:

Rear Wheel Drive (RWD) or Electronic 4-Wheel Drive (4WD) with Insta-Trac system.

Transmission Fluid Type:

Dexron III (or equivalent)

📐 Dimensions

Wheelbase Inches:

130.0

Length Inches:

219.5

Width Inches:

77.8

Height Inches:

73.6

Curb Weight Lbs Approx:

4,800 - 5,500 (depending on configuration)

Gvw Rating Lbs Approx:

6,400 - 7,200

Cargo Volume Cu Ft Behind 2Nd Row:

Approximately 92.1

Cargo Volume Cu Ft Behind 3Rd Row:

Approximately 45.8 (if applicable)

🛡️ Safety Features

NHTSA Frontal Crash Driver Approx:

Not independently rated by modern standards; designed to meet 1996 safety regulations.

ABS:

Standard 4-wheel anti-lock braking system (ABS).

Airbags:

Driver-side airbag standard.

Seatbelts:

Front and rear seatbelt systems.

💡 Technology Features

Audio System:

Factory AM/FM stereo with cassette player, optional CD player. Speaker configurations varied by trim. Analog climate controls.

Cruise Control:

Standard cruise control on most models.

OBD Standard:

OBD-I, transitioning to early OBD-II compliance by late 1996. This manual would cover both diagnostic protocols.

🔧 Maintenance

Oil Change Interval:

Typically 3,000 - 5,000 miles, or as specified in the owner's manual based on driving conditions.

Transmission Fluid Service:

Every 30,000 - 60,000 miles, depending on usage and fluid type.

Spark Plug Replacement:

Around 60,000 - 100,000 miles for standard plugs, or per manual recommendations for specific types.

Engine Oil Type:

API SJ or higher, SAE 5W-30 or 10W-30 (check manual for specific grade based on temperature).

Coolant Type:

Green ethylene glycol-based coolant, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3.

Common Failures:

Heater core leaks, intake manifold gasket leaks (early Vortec V8s), rear main seal leaks, ABS sensor failures, potential transmission cooler line leaks.

Diesel Specific Issues:

Glow plug system issues, injector pump failures (Stanadyne DB2), head gasket failures on early 6.5L models.

Oil Filter Example:

AC-Delco PF1218 or equivalent Wix/Fram/Mann.

Air Filter Example:

AC-Delco A3073C or equivalent.

📚 Vehicle History

Chevrolet Truck Legacy:

Chevrolet has a long history of producing robust trucks and SUVs, with the Suburban being a pioneering full-size SUV dating back to the 1930s.

Generation:

This 1996 model belongs to the GMT400 platform generation (1992-1999), which saw significant updates and the introduction of the Vortec engine line.

Manufacturing Locations:

Primarily United States (e.g., Janesville, Wisconsin).

Sales Trend:

The Suburban was a strong seller in its segment throughout the 1990s, known for its utility and capacity.

🏆 Awards & Recognition

Segment Awards:

While specific awards for the 1996 model year might be difficult to pinpoint, the Suburban consistently ranked high in consumer satisfaction for utility and durability within the large SUV segment during this era.

Consumer Reports:

Often cited for its capability but could receive mixed reviews on ride quality and fuel economy compared to smaller vehicles.