Chevrolet S10 Chevy S-10 Pickup Complete Workshop Service Repair Manual 1996
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🏷️ Basic Information Identification Make: Chevrolet Model: S-10 Pickup Alias Model: Chevy S-10 Pickup Year: 1996 Generation Generation Designation: Second Generation (Second Facelift) Codes Platform Code: GMT325 👋 Introduction Market Position Segment: Compact Pickup Truck Market Role: Popular for personal use, light commercial applications, and fleet vehicles. Competitive Analysis Key Competitors 1996: Ford Ranger, Toyota Tacoma (Hilux), Nissan Hardbody, Dodge Dakota. Key Features Value Proposition: Affordable, versatile, and reliable compact pickup offering various configurations. Manual Benefit: Empowers owners and technicians to perform repairs and maintenance efficiently, saving costs. 📋 Manual Details Coverage Areas Coverage Scope: Complete Service, Repair, and Workshop Procedures Page Count Estimated Page Count: Extensive (precise number not specified, but implies comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Delivery Format: Downloadable Digital File Device Compatibility: PC, MAC, Tablets, Smartphones Required Software: Adobe Reader (free) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, emission control system, engine diagnostics. Transmission Systems: Manual transmission, automatic transmission, clutch, drivetrain, driveshaft, axles, differentials. Chassis Systems: Suspension (front and rear), steering system, brake system (front and rear disc/drum), wheels, tires. Electrical Systems: Starting system, charging system, battery, lighting system, instrument cluster, power windows, power locks, audio system, wiring diagrams, fuses, relays, body control modules. Body And Interior: Body panels, doors, windows, seats, interior trim, HVAC system (heating, ventilation, and air conditioning). Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, lubrication. Repair Procedures: Engine overhaul, transmission overhaul, brake pad replacement, suspension component replacement, electrical component diagnosis and repair, body panel repair, interior component repair. Troubleshooting: Diagnostic charts, symptom-based troubleshooting, common problem diagnosis. Technical Specifications: Torque specifications, clearances, alignment data, electrical specifications, diagnostic trouble codes (DTCs). Special Tools: Identification and usage of specialized tools required for specific repairs. Technical Depth Depth: Comprehensive, A-Z coverage for all service and repair needs. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Print Capability: Printable by page, chapter, or entire document. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Displacement Base: 2.2L (133 cu in) Engine Type Base: 4-cylinder, Inline Engine Code Base: RPO LN2 Performance Horsepower Base: ~105 hp @ 4800 rpm (estimated) Torque Base: ~125 lb-ft @ 2800 rpm (estimated) Optional Engine 1 Engine Displacement Opt1: 4.3L (262 cu in) V6 Engine Type Opt1: V6, OHV, 90-degree Engine Code Opt1: RPO L35 (Vortec) Horsepower Opt1: ~165 hp @ 4500 rpm (estimated) Torque Opt1: ~235 lb-ft @ 3200 rpm (estimated) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPFI) for both engines. Fuel Type: Unleaded Gasoline Engine Management ECU Type: ECM (Engine Control Module) with OBD-II (On-Board Diagnostics II) compliant. 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission Transmission Code Automatic: RPO M30 (Hydra-Matic 4L60-E) Features Drivetrain Options: Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD) options available with transfer case. 📐 Dimensions Exterior Wheelbase Short: 108.3 inches (2751 mm) Wheelbase Long: 118.0 inches (2997 mm) Bed Lengths: Short Bed (6.5 ft), Long Bed (7.5 ft) Weights Curb Weight Range: Approx. 3200 - 3800 lbs (1451 - 1724 kg), varies by configuration. Gvw Range: Approx. 4500 - 5300 lbs (2041 - 2404 kg), varies by configuration. 🛡️ Safety Features Ratings NHTSA Ratings Driver Front Impact: Not specifically rated for 1996 model, general safety features present. IIHS Ratings: Not specifically rated for 1996 model. Active Features ABS: Anti-lock Braking System (ABS) available, typically on rear wheels for RWD models, all wheels for 4WD. Passive Features Airbags: Driver-side airbag standard. Seatbelts: Three-point seatbelts for front occupants. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player. Basic speaker configurations. Driver Assistance Cruise Control: Optional cruise control system. Connectivity OBD Ii Compliance: Fully OBD-II compliant for emissions and diagnostic data, facilitating modern scanner use. 🔧 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. 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 platinum tipped plugs (check specific plug type). Coolant Flush: Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years. Fluid Specifications Engine Oil Type 2.2L: API SG or higher, SAE 5W-30 recommended for most temperatures. Engine Oil Type 4.3L V6: API SG or higher, SAE 5W-30 recommended for most temperatures. Transmission Fluid Manual: Dexron III (or equivalent) ATF, or specific manual transmission fluid as per GM specifications. Transmission Fluid Automatic: Dexron III (or equivalent) ATF. Coolant Type: GM P/N 10528160 or equivalent (Dex-Cool compatible, extended life coolant recommended for later models, but conventional green ethylene glycol type is common for this year). Brake Fluid: DOT 3...
Not specifically rated for 1996 model, general safety features present.
IIHS Ratings:
Not specifically rated for 1996 model.
Active Features
ABS:
Anti-lock Braking System (ABS) available, typically on rear wheels for RWD models, all wheels for 4WD.
Passive Features
Airbags:
Driver-side airbag standard.
Seatbelts:
Three-point seatbelts for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player. Basic speaker configurations.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
OBD Ii Compliance:
Fully OBD-II compliant for emissions and diagnostic data, facilitating modern scanner use.
🔧 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.
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 platinum tipped plugs (check specific plug type).
Coolant Flush:
Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.
Fluid Specifications
Engine Oil Type 2.2L:
API SG or higher, SAE 5W-30 recommended for most temperatures.
Engine Oil Type 4.3L V6:
API SG or higher, SAE 5W-30 recommended for most temperatures.
Transmission Fluid Manual:
Dexron III (or equivalent) ATF, or specific manual transmission fluid as per GM specifications.
Transmission Fluid Automatic:
Dexron III (or equivalent) ATF.
Coolant Type:
GM P/N 10528160 or equivalent (Dex-Cool compatible, extended life coolant recommended for later models, but conventional green ethylene glycol type is common for this year).
Brake Fluid:
DOT 3
Known Issues
Common Problem 1:
Lower intake manifold gaskets (4.3L V6) can leak coolant or oil.
Common Problem 2:
Brake wear due to frequent stopping or heavy loads.
Common Problem 3:
Suspension wear (ball joints, tie rod ends, bushings) from road use.
Common Problem 4:
Fuel pump failures can occur with age.
Common Problem 5:
Rust and corrosion, particularly on rocker panels, cab corners, and wheel wells.
📚 Vehicle History
Brand Heritage
Chevrolet Truck History:
Chevrolet has a long-standing history of producing reliable and capable trucks, dating back to the early 20th century.
Model Evolution
S10 Introduction:
The S-10 was introduced in 1982 as Chevrolet's compact pickup truck to compete with smaller, more fuel-efficient imports.
Second Generation Details:
The second generation debuted in 1994, featuring a more aerodynamic design and improved chassis. The 1996 model represents the first facelift of this generation, with styling updates.
Production
Manufacturing Locations:
United States (e.g., St. Louis, Missouri; Fort Wayne, Indiana) and Brazil.
Production Span Second Gen:
1994-2004 (North America)
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
The S-10 platform (across various iterations) has received several 'Truck of the Year' awards from automotive publications over its lifespan, reflecting its market impact.
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