Chevrolet S-10 1994-2004 Factory Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: S-10 Years Covered: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Product Type: Factory Workshop Service Repair Manual Codes Platform: GMT330 👋 Introduction Market Position Segment: Compact Pickup Truck Competitors: Ford Ranger, Toyota Tacoma, Dodge Dakota, Nissan Hardbody/Frontier. Key Features Versatility: Offered in various configurations including regular cab, extended cab, short bed, long bed, 2WD, and 4WD, catering to a wide range of utility and lifestyle needs. Powertrain Options: Reliable and capable engine options, including the durable 4.3L Vortec V6, which was a standout performer in its class. Durability: Known for its robust build quality and ability to withstand demanding work and off-road use. 📋 Manual Details Coverage Areas Major Systems: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, HVAC, Electrical, Fuel System, Cooling System, Exhaust System, Body, Interior Page Count Estimated Pages: Thousands (typical for a comprehensive factory manual) Manual Type Type: Workshop Service Manual Language Language: English Format Format: Downloadable (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Internal combustion engines (2.2L OHV, 4.3L Vortec V6, 5.0L Vortec V8), automatic transmissions (4L60-E, 4L80-E), manual transmissions (NV3500, Getrag 291), transfer cases (for 4WD models), axles, driveshafts, differentials. Chassis: Front and rear suspension (independent front suspension, leaf springs rear), steering system (power steering), brake system (disc/drum, ABS), wheels and tires. Electrical: Battery, charging system, starting system, ignition system, lighting, instruments, gauges, power windows, power locks, audio system, body control modules, Powertrain Control Module (PCM), diagnostic trouble codes (DTCs). Comfort And Convenience: HVAC system (air conditioning, heating), interior trim, seating, airbags, cruise control. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, belt inspection and replacement, spark plug replacement, brake pad and rotor replacement, tire rotation and balancing. Diagnostics: Troubleshooting common issues, symptom-based diagnostics, wiring diagrams for electrical systems, diagnostic flowcharts, PCM and sensor testing. Repair And Rebuild: Engine overhaul, transmission rebuild, brake caliper and master cylinder replacement, suspension component replacement (ball joints, tie rods, shocks/struts), power steering pump replacement, starter and alternator replacement, fuel pump replacement, exhaust system repair. Body And Frame: Body panel removal and installation, door mechanism repair, bumper repair, frame straightening (if applicable), corrosion prevention. Technical Depth Depth: Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring diagrams. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) - Searchable text, bookmark navigation. Print Quality Quality: High Resolution (Hi-Res) illustrations, photos, and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download - Printable pages) ⚙️ Engine Specifications Primary Engine Engine 1: 2.2L OHV Inline-4 (LL2), 118 hp @ 5000 rpm, 130 lb-ft torque @ 3200 rpm (typical for early models) Engine 2: 4.3L Vortec OHV V6 (L35), 190-200 hp @ 4400-4800 rpm, 250-260 lb-ft torque @ 2800-3200 rpm (depending on year and specific variant) Engine 3: 5.0L Vortec OHV V8 (LT4/L39 - less common in S-10, more in larger siblings, but possible in some specialty models or later years), 230 hp @ 4800 rpm, 280 lb-ft torque @ 3200 rpm Performance Fuel Type: Unleaded Gasoline Fuel System System Type: Multi-Port Fuel Injection (MPI) / Electronic Fuel Injection (EFI) Engine Management ECM Provider: Delphi / AC-Delco 🔧 Transmission Standard Transmission 1: 4-speed automatic (4L60-E) Optional Transmission 2: 5-speed manual (NV3500, Getrag 291) Features AWD System: Electronic shift-on-the-fly 4WD (StabiliTrak on some later models) Fluid Specs Automatic Fluid: Dexron-III (or equivalent) Automatic Transmission Fluid (ATF) Manual Fluid: GL-4 Gear Lubricant (specific viscosity varies by transmission model) 📐 Dimensions Exterior Wheelbase Short Bed: 118.0 inches (2997 mm) Wheelbase Long Bed: 122.9 inches (3122 mm) Overall Length Short Bed: 192.4 inches (4887 mm) Overall Length Long Bed: 207.4 inches (5268 mm) Cargo Bed Length Standard: 73.9 inches (1877 mm) Bed Length Long: 86.1 inches (2187 mm) Weights Curb Weight Range: Approx. 3,400 - 4,200 lbs (1542 - 1905 kg) Gvw Range: Approx. 5,300 - 6,200 lbs (2404 - 2812 kg) Wheels Tires Wheel Bolt Pattern: 5 x 4.75 inch (5x120.65 mm) Tire Sizes: Commonly P235/75R15, P215/70R15, P265/70R16 depending on trim and configuration. 🛡️ Safety Features Ratings NHTSA Driver Front Impact: Acceptable (for 1994-1998 models) NHTSA Passenger Front Impact: Good (for 1994-1998 models) Active Features ABS: Anti-lock Braking System (ABS) available on rear wheels, and on all four wheels in later years. Passive Features Airbags: Driver and passenger front airbags standard from 1994. Seatbelts: Front 3-point seat belts with shoulder belt height adjusters, rear seat belts. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player and optional CD player. Aftermarket head units are common upgrades. Speaker Configuration: Typically 2 or 4 speakers (door or dash mounted). Driver Assistance ABS: Available Anti-lock Braking System. Cruise Control: Standard on most higher trims, optional on others. Connectivity OBD Ii: On-Board Diagnostics II (OBD-II) compliant from...

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Sku: 93633

Collections: ALL Chevrolet

Availability: In stock

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

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Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Years Covered:

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

Product Type:

Factory Workshop Service Repair Manual

Codes

Platform:

GMT330

👋 Introduction

Market Position

Segment:

Compact Pickup Truck

Competitors:

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

Key Features

Versatility:

Offered in various configurations including regular cab, extended cab, short bed, long bed, 2WD, and 4WD, catering to a wide range of utility and lifestyle needs.

Powertrain Options:

Reliable and capable engine options, including the durable 4.3L Vortec V6, which was a standout performer in its class.

Durability:

Known for its robust build quality and ability to withstand demanding work and off-road use.

📋 Manual Details

Coverage Areas

Major Systems:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, HVAC, Electrical, Fuel System, Cooling System, Exhaust System, Body, Interior

Page Count

Estimated Pages:

Thousands (typical for a comprehensive factory manual)

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

Downloadable (likely PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Internal combustion engines (2.2L OHV, 4.3L Vortec V6, 5.0L Vortec V8), automatic transmissions (4L60-E, 4L80-E), manual transmissions (NV3500, Getrag 291), transfer cases (for 4WD models), axles, driveshafts, differentials.

Chassis:

Front and rear suspension (independent front suspension, leaf springs rear), steering system (power steering), brake system (disc/drum, ABS), wheels and tires.

Electrical:

Battery, charging system, starting system, ignition system, lighting, instruments, gauges, power windows, power locks, audio system, body control modules, Powertrain Control Module (PCM), diagnostic trouble codes (DTCs).

Comfort And Convenience:

HVAC system (air conditioning, heating), interior trim, seating, airbags, cruise control.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, belt inspection and replacement, spark plug replacement, brake pad and rotor replacement, tire rotation and balancing.

Diagnostics:

Troubleshooting common issues, symptom-based diagnostics, wiring diagrams for electrical systems, diagnostic flowcharts, PCM and sensor testing.

Repair And Rebuild:

Engine overhaul, transmission rebuild, brake caliper and master cylinder replacement, suspension component replacement (ball joints, tie rods, shocks/struts), power steering pump replacement, starter and alternator replacement, fuel pump replacement, exhaust system repair.

Body And Frame:

Body panel removal and installation, door mechanism repair, bumper repair, frame straightening (if applicable), corrosion prevention.

Technical Depth

Depth:

Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format) - Searchable text, bookmark navigation.

Print Quality

Quality:

High Resolution (Hi-Res) illustrations, photos, and diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download - Printable pages)

⚙️ Engine Specifications

Primary Engine

Engine 1:

2.2L OHV Inline-4 (LL2), 118 hp @ 5000 rpm, 130 lb-ft torque @ 3200 rpm (typical for early models)

Engine 2:

4.3L Vortec OHV V6 (L35), 190-200 hp @ 4400-4800 rpm, 250-260 lb-ft torque @ 2800-3200 rpm (depending on year and specific variant)

Engine 3:

5.0L Vortec OHV V8 (LT4/L39 - less common in S-10, more in larger siblings, but possible in some specialty models or later years), 230 hp @ 4800 rpm, 280 lb-ft torque @ 3200 rpm

Performance

Fuel Type:

Unleaded Gasoline

Fuel System

System Type:

Multi-Port Fuel Injection (MPI) / Electronic Fuel Injection (EFI)

Engine Management

ECM Provider:

Delphi / AC-Delco

🔧 Transmission

Standard

Transmission 1:

4-speed automatic (4L60-E)

Optional

Transmission 2:

5-speed manual (NV3500, Getrag 291)

Features

AWD System:

Electronic shift-on-the-fly 4WD (StabiliTrak on some later models)

Fluid Specs

Automatic Fluid:

Dexron-III (or equivalent) Automatic Transmission Fluid (ATF)

Manual Fluid:

GL-4 Gear Lubricant (specific viscosity varies by transmission model)

📐 Dimensions

Exterior

Wheelbase Short Bed:

118.0 inches (2997 mm)

Wheelbase Long Bed:

122.9 inches (3122 mm)

Overall Length Short Bed:

192.4 inches (4887 mm)

Overall Length Long Bed:

207.4 inches (5268 mm)

Cargo

Bed Length Standard:

73.9 inches (1877 mm)

Bed Length Long:

86.1 inches (2187 mm)

Weights

Curb Weight Range:

Approx. 3,400 - 4,200 lbs (1542 - 1905 kg)

Gvw Range:

Approx. 5,300 - 6,200 lbs (2404 - 2812 kg)

Wheels Tires

Wheel Bolt Pattern:

5 x 4.75 inch (5x120.65 mm)

Tire Sizes:

Commonly P235/75R15, P215/70R15, P265/70R16 depending on trim and configuration.

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact:

Acceptable (for 1994-1998 models)

NHTSA Passenger Front Impact:

Good (for 1994-1998 models)

Active Features

Anti-lock Braking System (ABS) available on rear wheels, and on all four wheels in later years.

Passive Features

Airbags:

Driver and passenger front airbags standard from 1994.

Seatbelts:

Front 3-point seat belts with shoulder belt height adjusters, rear seat belts.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player and optional CD player. Aftermarket head units are common upgrades.

Speaker Configuration:

Typically 2 or 4 speakers (door or dash mounted).

Driver Assistance

Available Anti-lock Braking System.

Cruise Control:

Standard on most higher trims, optional on others.

Connectivity

OBD Ii:

On-Board Diagnostics II (OBD-II) compliant from 1996 onwards, facilitating emissions testing and diagnostic code reading.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Coolant Flush:

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

Fluid Specifications

Engine Oil Recommendation:

API Certified SAE 5W-30 or 10W-30 (refer to manual for specific engine type and temperature range). Capacity: 4.5 qts (4.2L) for 4-cyl, 5.0 qts (4.7L) for V6.

Brake Fluid:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Power Steering Fluid:

Dexron-III (or equivalent) ATF.

Coolant Type:

Dex-Cool Extended Life (for orange coolant systems) or conventional green ethylene glycol coolant (check original fill type). Minimum 50/50 mix with distilled water.

Known Issues

Intake Manifold Gaskets:

Common on 4.3L V6 engines to develop coolant leaks due to gasket material degradation.

Rear Main Seal:

Can leak oil on V6 engines, requiring transmission removal for replacement.

Brake Actuator Leaks:

ABS actuator modules can leak on some models.

Evaporative Emissions System:

Purge solenoids and vent solenoids can fail, leading to check engine lights.

Suspension Wear:

Ball joints, tie rod ends, and sway bar links can wear out, causing steering looseness and noise.

📚 Vehicle History

Brand Heritage

Chevy Truck Legacy:

The S-10 nameplate builds upon Chevrolet's long-standing reputation for producing durable and versatile trucks.

Model Evolution

First Generation:

The second generation (1994-2004) introduced a significant redesign with a more aerodynamic exterior and improved interior comfort. It saw continuous updates throughout its lifespan, including engine revisions and feature additions.

Production

Manufacturing Locations:

Primarily assembled in the United States and Brazil. Key U.S. plants included St. Louis, Missouri, and Shreveport, Louisiana.

Production End

Production Years:

Production of the S-10 in North America concluded in 2004, succeeded by the Chevrolet Colorado.

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

While the S-10 itself didn't consistently win major 'Truck of the Year' awards during its specific generation compared to some competitors, it was a consistently strong seller and highly regarded for its value and capability in the compact pickup segment.

Ratings

Consumer Reports:

Consumer Reports ratings varied by year and specific configurations, with common feedback on reliability focusing on powertrain durability but sometimes noting suspension and electrical component issues.