Chevrolet S-10 CHEVY 1994-2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: S-10 Codes Platform: GMT325 Engine Code 2 8L: LR2 Engine Code 4 3L: L35 Engine Code 2 2L: 4ZD1 👋 Introduction Market Position Segment: Compact Pickup Truck Target Audience: DIY mechanics, fleet maintenance, professional repair shops. Competitive Analysis Key Competitors: Ford Ranger, Toyota Tacoma, Dodge Dakota, Nissan Hardbody/Frontier Key Features Durability: Renowned for its robust construction and reliability, especially with the V6 engine. Versatility: Offered in various cab styles (Regular, Extended), bed lengths, and drivetrain configurations (2WD, 4WD). Value Proposition: Provided a cost-effective and capable utility vehicle for personal and commercial use. 📋 Manual Details Coverage Areas Covered Years: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Covered Models: Chevrolet S-10, GMC Sonoma (platform sharing) Regions Covered: North America (primarily US & Canada) Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF (Digital) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, manual transmission, automatic transmission, driveline, transfer case (4WD) Chassis: Suspension (front/rear), steering system, braking system (front disc, rear drum/disc), wheels, tires Body And Interior: Body structure, exterior panels, doors, windows, seats, trim, HVAC system, power accessories Electrical: Wiring diagrams, lighting, instruments, charging system, starting system, body control modules, diagnostics Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement Repair: Engine component replacement (heads, pistons, etc.), transmission rebuilds, brake caliper/rotor replacement, suspension arm/ball joint replacement, steering rack replacement Diagnostics: Troubleshooting guides, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs) Adjustment: Brake adjustment, clutch adjustment, headlight aiming Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications. 📊 Manual Specifications File Format Searchability: Searchable PDF text, allowing quick access to specific information. Readability: High-resolution scans ensuring clarity of diagrams, illustrations, and text. Print Quality Print Usability: Printable pages suitable for home or professional workshop use. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 2 2L 4 Cylinder: 2.2L (2198cc) Inline-4, SOHC, Fuel Injection. Horsepower: ~118 hp @ 4800 rpm, Torque: ~132 lb-ft @ 2800 rpm. (4ZD1) Engine 2 8L V6: 2.8L (2771cc) V6, OHV, MPFI. Horsepower: ~122 hp @ 4400 rpm, Torque: ~154 lb-ft @ 2400 rpm. (LR2) Engine 4 3L V6: 4.3L (4300cc) V6, OHV, MPFI. Horsepower: ~160-190 hp @ 4000-4400 rpm, Torque: ~235-250 lb-ft @ 2400-2800 rpm. (L35, Vortec variant in later years) Performance Compression Ratio 4 3L: 9.25:1 Fuel System Fuel Injection Type: Multi-port Fuel Injection (MPFI) / Sequential Fuel Injection (SFI) in later models. Fuel Type: Unleaded Gasoline Engine Cooling Coolant Type: Dex-Cool (Orange) or equivalent silicate-free antifreeze/coolant, 50/50 mix with distilled water. Coolant Capacity: Approx. 10.5-11.5 quarts (9.9-10.9 liters) depending on engine and radiator size. 🔧 Transmission Standard Transmission Manual 4 Cyl: 5-speed manual (e.g., Isuzu AR5, New Venture Gear NV1500) Transmission Manual V6: 5-speed manual (New Venture Gear NV3500) Optional Transmission Automatic 2Wd V6: 4-speed automatic (e.g., GM 4L60-E) Transmission Automatic 4Wd V6: 4-speed automatic (e.g., GM 4L60-E with specific transfer case integration) Features Transfer Case: Electronic shift transfer case (Autotrac) available on 4WD models in later years. Fluid Specs Automatic Automatic Transmission Fluid: Dexron III (or equivalent) Automatic Transmission Fluid (ATF). Capacity: Approx. 5.7 quarts (5.4 liters) for dry fill. Fluid Specs Manual Manual Transmission Fluid: GL-4 rated gear oil, SAE 75W-90 or 80W-90. Capacity varies by transmission type. 📐 Dimensions Exterior Wheelbase Short: 108.3 inches (2751 mm) Wheelbase Long: 118.0 inches (2997 mm) Bed Length Short: 6.1 feet (1.85 m) Bed Length Long: 7.4 feet (2.25 m) Weights Curb Weight Range: Approx. 3300 - 4200 lbs (1497 - 1905 kg) depending on configuration. Towing Capacity Max: Up to 5000 lbs (2268 kg) with appropriate engine, axle ratio, and towing package. Payload Capacity Max: Up to 1500 lbs (680 kg) depending on configuration. 🛡️ Safety Features Ratings NHTSA Rollover Resistance 2Wd: 3 Stars NHTSA Rollover Resistance 4Wd: 3 Stars Active Features ABS: Anti-lock Braking System (ABS) standard on front wheels, optional on rear wheels depending on year and trim. Passive Features Airbags: Driver and passenger airbags became standard across the lineup during this generation (often starting in 1994 or 1995). 💡 Technology Features Infotainment Radio Options: AM/FM stereo with cassette and/or CD player options. Upgraded sound systems available. Speaker Configuration: Standard 2-speaker or optional 4/6 speaker configurations. Driver Assistance Cruise Control: Optional on most trims and engines. Anti Theft: Factory immobilizer systems or dealer-installed anti-theft options may be present on later models. Connectivity OBD Ii Port: Standard OBD-II diagnostic port from 1996 onwards, facilitating electronic diagnostics. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil...

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Sku: 96465

Collections: ALL Chevrolet

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Tags: 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Cars Chevrolet Misc S-10 CHEVY Truck

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Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Codes

Platform:

GMT325

Engine Code 2 8L:

Engine Code 4 3L:

Engine Code 2 2L:

👋 Introduction

Market Position

Segment:

Compact Pickup Truck

Target Audience:

DIY mechanics, fleet maintenance, professional repair shops.

Competitive Analysis

Key Competitors:

Ford Ranger, Toyota Tacoma, Dodge Dakota, Nissan Hardbody/Frontier

Key Features

Durability:

Renowned for its robust construction and reliability, especially with the V6 engine.

Versatility:

Offered in various cab styles (Regular, Extended), bed lengths, and drivetrain configurations (2WD, 4WD).

Value Proposition:

Provided a cost-effective and capable utility vehicle for personal and commercial use.

📋 Manual Details

Coverage Areas

Covered Years:

1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004

Covered Models:

Chevrolet S-10, GMC Sonoma (platform sharing)

Regions Covered:

North America (primarily US & Canada)

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, cooling system, exhaust system, manual transmission, automatic transmission, driveline, transfer case (4WD)

Chassis:

Suspension (front/rear), steering system, braking system (front disc, rear drum/disc), wheels, tires

Body And Interior:

Body structure, exterior panels, doors, windows, seats, trim, HVAC system, power accessories

Electrical:

Wiring diagrams, lighting, instruments, charging system, starting system, body control modules, diagnostics

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement

Repair:

Engine component replacement (heads, pistons, etc.), transmission rebuilds, brake caliper/rotor replacement, suspension arm/ball joint replacement, steering rack replacement

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs)

Adjustment:

Brake adjustment, clutch adjustment, headlight aiming

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.

📊 Manual Specifications

File Format

Searchability:

Searchable PDF text, allowing quick access to specific information.

Readability:

High-resolution scans ensuring clarity of diagrams, illustrations, and text.

Print Quality

Print Usability:

Printable pages suitable for home or professional workshop use.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine 2 2L 4 Cylinder:

2.2L (2198cc) Inline-4, SOHC, Fuel Injection. Horsepower: ~118 hp @ 4800 rpm, Torque: ~132 lb-ft @ 2800 rpm. (4ZD1)

Engine 2 8L V6:

2.8L (2771cc) V6, OHV, MPFI. Horsepower: ~122 hp @ 4400 rpm, Torque: ~154 lb-ft @ 2400 rpm. (LR2)

Engine 4 3L V6:

4.3L (4300cc) V6, OHV, MPFI. Horsepower: ~160-190 hp @ 4000-4400 rpm, Torque: ~235-250 lb-ft @ 2400-2800 rpm. (L35, Vortec variant in later years)

Performance

Compression Ratio 4 3L:

9.25:1

Fuel System

Fuel Injection Type:

Multi-port Fuel Injection (MPFI) / Sequential Fuel Injection (SFI) in later models.

Fuel Type:

Unleaded Gasoline

Engine Cooling

Coolant Type:

Dex-Cool (Orange) or equivalent silicate-free antifreeze/coolant, 50/50 mix with distilled water.

Coolant Capacity:

Approx. 10.5-11.5 quarts (9.9-10.9 liters) depending on engine and radiator size.

🔧 Transmission

Standard

Transmission Manual 4 Cyl:

5-speed manual (e.g., Isuzu AR5, New Venture Gear NV1500)

Transmission Manual V6:

5-speed manual (New Venture Gear NV3500)

Optional

Transmission Automatic 2Wd V6:

4-speed automatic (e.g., GM 4L60-E)

Transmission Automatic 4Wd V6:

4-speed automatic (e.g., GM 4L60-E with specific transfer case integration)

Features

Transfer Case:

Electronic shift transfer case (Autotrac) available on 4WD models in later years.

Fluid Specs Automatic

Automatic Transmission Fluid:

Dexron III (or equivalent) Automatic Transmission Fluid (ATF). Capacity: Approx. 5.7 quarts (5.4 liters) for dry fill.

Fluid Specs Manual

Manual Transmission Fluid:

GL-4 rated gear oil, SAE 75W-90 or 80W-90. Capacity varies by transmission type.

📐 Dimensions

Exterior

Wheelbase Short:

108.3 inches (2751 mm)

Wheelbase Long:

118.0 inches (2997 mm)

Bed Length Short:

6.1 feet (1.85 m)

Bed Length Long:

7.4 feet (2.25 m)

Weights

Curb Weight Range:

Approx. 3300 - 4200 lbs (1497 - 1905 kg) depending on configuration.

Towing Capacity Max:

Up to 5000 lbs (2268 kg) with appropriate engine, axle ratio, and towing package.

Payload Capacity Max:

Up to 1500 lbs (680 kg) depending on configuration.

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance 2Wd:

3 Stars

NHTSA Rollover Resistance 4Wd:

3 Stars

Active Features

Anti-lock Braking System (ABS) standard on front wheels, optional on rear wheels depending on year and trim.

Passive Features

Airbags:

Driver and passenger airbags became standard across the lineup during this generation (often starting in 1994 or 1995).

💡 Technology Features

Infotainment

Radio Options:

AM/FM stereo with cassette and/or CD player options. Upgraded sound systems available.

Speaker Configuration:

Standard 2-speaker or optional 4/6 speaker configurations.

Driver Assistance

Cruise Control:

Optional on most trims and engines.

Anti Theft:

Factory immobilizer systems or dealer-installed anti-theft options may be present on later models.

Connectivity

OBD Ii Port:

Standard OBD-II diagnostic port from 1996 onwards, facilitating electronic diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil type used. Refer to manual for specific recommendations.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Spark Plug Replacement:

Typically 60,000-100,000 miles (96,000-160,000 km) for conventional or iridium plugs, depending on type.

Coolant Flush:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.

Transmission Fluid Change Automatic:

Every 30,000-50,000 miles (48,000-80,000 km), especially under heavy use.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 or 10W-30 (check manual for specific viscosity recommendations based on temperature) for most engines. API certified oil.

Engine Oil Capacity:

2.2L: Approx. 4.5 quarts (4.3 L); 2.8L V6: Approx. 4.5 quarts (4.3 L); 4.3L V6: Approx. 4.5 quarts (4.3 L).

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Power Steering Fluid:

GM Power Steering Fluid or equivalent Dexron III ATF.

Known Issues

Intake Manifold Gaskets:

Leaking intake manifold gaskets, particularly on the 4.3L Vortec V6, leading to coolant or vacuum leaks.

Rear Main Seal:

Rear main crankshaft seal leaks are a common concern, especially on higher-mileage vehicles.

Oil Pressure Sensor:

Failure of the oil pressure sensor/switch, leading to inaccurate readings or potential engine damage if ignored.

Blower Motor Resistor:

Blower motor resistor failure, causing HVAC fan speed issues (only high speed works).

Clutch Pedal Assembly:

Wear in the clutch pedal pivot points or bushings on manual transmission models.

📚 Vehicle History

Brand Heritage

Chevrolet Truck Lineage:

Follows in the tradition of Chevrolet's long-standing reputation for durable and capable pickup trucks, building on the C/K series legacy.

Model Evolution

Generation Start:

Second generation introduced for the 1994 model year, marking a significant redesign.

Major Updates:

Mid-cycle refresh in 1998 included revised styling (front end, grille, headlights), updated interior, and introduction of the Vortec 4.3L V6 engines. Introduction of Z85 suspension package for improved handling. Four-door extended cab (Sportside and Stepside bed options) became more prominent.

Production

Assembly Locations:

Primarily assembled in the United States (e.g., Moraine, Ohio; St. Louis, Missouri) and Mexico.

Gm Platform Sharing:

Shared the GMT325 platform with the GMC Sonoma and Isuzu Hombre.

🏆 Awards & Recognition

Recognitions

Motor Trend Truck Of The Year:

While the S-10 itself didn't win this specific award during its debut, its platform siblings and Chevrolet trucks have a history of recognition, and the S-10 was a highly popular and consistent seller in its segment.

Ratings

Consumer Reports Reliability:

Reliability ratings varied by year and engine, with some years receiving average to above-average scores, particularly for the 4.3L V6 engine and manual transmissions.