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2004 Chevrolet S-10 Service and Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: S-10 Year: 2004 Body Style: Compact Pickup Truck Generation Generation: Second Generation (GMT355) Codes Platform Code: GMT355 👋 Introduction Market Position Vehicle Segment: Compact pickup truck, often used for work, recreation, and personal transportation Target Audience Manual: Professional technicians, experienced DIY mechanics, vehicle enthusiasts Competitive Analysis Key Competitors: Ford Ranger, Toyota Tacoma, Nissan Frontier, Dodge Dakota Key Features Manual Advantage: Direct access to OEM-level diagnostic and repair procedures, ensuring accuracy and efficiency Vehicle Appeal: Durable, versatile, and relatively affordable compact truck with a long production run 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Printed Book (likely) Coverage Scope: Covers ALL models and ALL repairs A-Z Page Count Estimated Page Count: 1500-2000+ (typical for comprehensive service manuals) 📖 Manual Coverage Systems Covered Engine Service: Engine mechanical, lubrication, cooling, fuel delivery, ignition, emission controls, starting, charging Transmission Service: Manual and automatic transmission overhaul, clutch, driveshafts, differentials Chassis Service: Suspension (front and rear), steering system, braking system (ABS included) Electrical System: Wiring diagrams, lighting, instruments, power distribution, starting and charging systems, body electrical features, multiplexing/data bus Body And Frame: Body construction, exterior trim, interior trim, doors, windows, seats, HVAC system, structural repairs, collision repair Procedures Included Maintenance Procedures: Routine maintenance schedules, fluid changes, filter replacements, inspections Diagnostic Procedures: Troubleshooting guides, symptom analysis, diagnostic trouble codes (DTCs) interpretation Repair Procedures: Step-by-step instructions for component removal, installation, and repair Adjustment Procedures: Wheel alignment, brake adjustments, clutch adjustments, idle speed settings Special Tools And Equipment: Identification and usage of specialized tools required for specific repairs Technical Depth Depth Of Information: Vehicle-specific, dealer-level technical information for maintenance, service, and repair Accuracy Level: Exact same information used by dealership technicians Diagnostic Capability: Advanced diagnostic strategies and fault isolation procedures Rebuild Instructions: Detailed specifications and procedures for engine, transmission, and axle overhauls 📊 Manual Specifications File Format Digital Format Capabilities: Searchable text, printable pages, high-resolution diagrams Print Quality Diagram Clarity: Clear, detailed diagrams and illustrations Binding Type Physical Binding: Professionally bound (typically paperback or spiral-bound for durability) Paper Type Durability: Durable, shop-friendly paper stock Completeness Manual Scope: Comprehensive, covering all aspects of vehicle maintenance, diagnosis, and repair. ⚙️ Engine Specifications Primary Engine Engine Options 2004: 2.2L Ecotec L61 I4, 4.3L Vortec LV3 V6 Performance 2.2L L61 Horsepower: 143 hp @ 5400 rpm 2.2L L61 Torque: 144 lb-ft @ 4000 rpm 4.3L Lv3 Horsepower: 190-200 hp @ 4400-4800 rpm (depending on specific application) 4.3L Lv3 Torque: 250-260 lb-ft @ 2800-3200 rpm (depending on specific application) Fuel System Fuel Injection: Sequential Port Fuel Injection (SFI) Fuel Type: Unleaded Gasoline Technical Details Bore X Stroke 2.2L: 86 mm x 94.6 mm Bore X Stroke 4.3L: 101.6 mm x 92 mm Compression Ratio 2.2L: 9.5:1 Compression Ratio 4.3L: 9.1:1 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Transmission Optional Optional Transmission: 4-Speed Automatic Transmission (4L60-E/4L65-E) Features Drive Type: Rear-Wheel Drive (RWD) or All-Wheel Drive (AWD) Transmission Fluid 4L60E: Dexron-III/VI ATF 📐 Dimensions Exterior Wheelbase Short Bed: 111.0 inches Wheelbase Long Bed: 125.9 inches Bed Length Short: 72.9 inches Bed Length Long: 97.8 inches Weights Curb Weight Range: Approx. 3500 - 4200 lbs Towing Capacity Max: Up to 5,600 lbs (with proper configuration) Payload Capacity Max: Up to 1,500 lbs (with proper configuration) 🛡️ Safety Features Ratings NHTSA Rollover Rating: Four-star (driver and passenger frontal, side impact) Active Features ABS: Standard on most models, Antilock Braking System Passive Features Airbags: Driver and passenger front airbags Seat Belts: Three-point safety belts with pretensioners 💡 Technology Features Infotainment Infotainment Options: AM/FM stereo with CD player, optional premium audio system Dashboard Features: Analog gauges for speedometer, tachometer, fuel, and temperature; warning lamps Driver Assistance Cruise Control: Available Connectivity Auxiliary Input: Not typically standard, may be an aftermarket addition 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months (synthetic oil recommended), or 3,000 miles/3 months (conventional oil). Tire Rotation Interval: Every 7,500 miles Spark Plug Replacement 2.2L: Approximately 100,000 miles (if using iridium-tipped plugs) Spark Plug Replacement 4.3L: Approximately 100,000 miles (if using iridium-tipped plugs) Fluid Specifications Engine Oil Specification: SAE 5W-30 (API Certified, ILSAC GF-3 or Dexos) Engine Oil Capacity 2.2L: 5.0 quarts (4.7 liters) with filter Engine Oil Capacity 4.3L: 4.5 quarts (4.3 liters) with filter Coolant Specification: GM P/N 12346790 (Orange) or equivalent; 50/50 mix of Dex-Cool coolant and distilled water Brake Fluid Specification: DOT 3 Known Issues Common Wear Items: Ball joints, tie rod ends, sway bar links, rear leaf spring bushings, fuel pump Common Electrical Issues: HVAC blower motor resistor failure, instrument cluster issues, intermittent interior lights Common Powertrain Issues: Throttle position sensor (TPS) failure on V6, occasional intake manifold gasket leaks 📚 Vehicle History Brand Heritage Chevrolet Truck Legacy: Chevrolet has a long-standing reputation for producing durable and capable trucks since the early 20th century....
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2004 Chevrolet S-10 Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
S-10
Year:
2004
Body Style:
Compact Pickup Truck
Generation
Generation:
Second Generation (GMT355)
Codes
Platform Code:
GMT355
👋 Introduction
Market Position
Vehicle Segment:
Compact pickup truck, often used for work, recreation, and personal transportation
Target Audience Manual:
Professional technicians, experienced DIY mechanics, vehicle enthusiasts
Competitive Analysis
Key Competitors:
Ford Ranger, Toyota Tacoma, Nissan Frontier, Dodge Dakota
Key Features
Manual Advantage:
Direct access to OEM-level diagnostic and repair procedures, ensuring accuracy and efficiency
Vehicle Appeal:
Durable, versatile, and relatively affordable compact truck with a long production run
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
Printed Book (likely)
Coverage Scope:
Covers ALL models and ALL repairs A-Z
Page Count
Estimated Page Count:
1500-2000+ (typical for comprehensive service manuals)
📖 Manual Coverage
Systems Covered
Engine Service:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, emission controls, starting, charging
Transmission Service:
Manual and automatic transmission overhaul, clutch, driveshafts, differentials
Chassis Service:
Suspension (front and rear), steering system, braking system (ABS included)
Electrical System:
Wiring diagrams, lighting, instruments, power distribution, starting and charging systems, body electrical features, multiplexing/data bus
Body And Frame:
Body construction, exterior trim, interior trim, doors, windows, seats, HVAC system, structural repairs, collision repair
Procedures Included
Maintenance Procedures:
Routine maintenance schedules, fluid changes, filter replacements, inspections
Diagnostic Procedures:
Troubleshooting guides, symptom analysis, diagnostic trouble codes (DTCs) interpretation
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair
Adjustment Procedures:
Wheel alignment, brake adjustments, clutch adjustments, idle speed settings
Special Tools And Equipment:
Identification and usage of specialized tools required for specific repairs
Technical Depth
Depth Of Information:
Vehicle-specific, dealer-level technical information for maintenance, service, and repair
Accuracy Level:
Exact same information used by dealership technicians
Diagnostic Capability:
Advanced diagnostic strategies and fault isolation procedures
Rebuild Instructions:
Detailed specifications and procedures for engine, transmission, and axle overhauls
📊 Manual Specifications
File Format
Digital Format Capabilities:
Searchable text, printable pages, high-resolution diagrams
Print Quality
Diagram Clarity:
Clear, detailed diagrams and illustrations
Binding Type
Physical Binding:
Professionally bound (typically paperback or spiral-bound for durability)
Paper Type
Durability:
Durable, shop-friendly paper stock
Completeness
Manual Scope:
Comprehensive, covering all aspects of vehicle maintenance, diagnosis, and repair.
⚙️ Engine Specifications
Primary Engine
Engine Options 2004:
2.2L Ecotec L61 I4, 4.3L Vortec LV3 V6
Performance
2.2L L61 Horsepower:
143 hp @ 5400 rpm
2.2L L61 Torque:
144 lb-ft @ 4000 rpm
4.3L Lv3 Horsepower:
190-200 hp @ 4400-4800 rpm (depending on specific application)
4.3L Lv3 Torque:
250-260 lb-ft @ 2800-3200 rpm (depending on specific application)
Fuel System
Fuel Injection:
Sequential Port Fuel Injection (SFI)
Fuel Type:
Unleaded Gasoline
Technical Details
Bore X Stroke 2.2L:
86 mm x 94.6 mm
Bore X Stroke 4.3L:
101.6 mm x 92 mm
Compression Ratio 2.2L:
9.5:1
Compression Ratio 4.3L:
9.1:1
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual Transmission
Optional
Optional Transmission:
4-Speed Automatic Transmission (4L60-E/4L65-E)
Features
Drive Type:
Rear-Wheel Drive (RWD) or All-Wheel Drive (AWD)
Transmission Fluid 4L60E:
Dexron-III/VI ATF
📐 Dimensions
Exterior
Wheelbase Short Bed:
111.0 inches
Wheelbase Long Bed:
125.9 inches
Bed Length Short:
72.9 inches
Bed Length Long:
97.8 inches
Weights
Curb Weight Range:
Approx. 3500 - 4200 lbs
Towing Capacity Max:
Up to 5,600 lbs (with proper configuration)
Payload Capacity Max:
Up to 1,500 lbs (with proper configuration)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
Four-star (driver and passenger frontal, side impact)
Active Features
ABS:
Standard on most models, Antilock Braking System
Passive Features
Airbags:
Driver and passenger front airbags
Seat Belts:
Three-point safety belts with pretensioners
💡 Technology Features
Infotainment
Infotainment Options:
AM/FM stereo with CD player, optional premium audio system
Dashboard Features:
Analog gauges for speedometer, tachometer, fuel, and temperature; warning lamps
Driver Assistance
Cruise Control:
Available
Connectivity
Auxiliary Input:
Not typically standard, may be an aftermarket addition
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months (synthetic oil recommended), or 3,000 miles/3 months (conventional oil).
Tire Rotation Interval:
Every 7,500 miles
Spark Plug Replacement 2.2L:
Approximately 100,000 miles (if using iridium-tipped plugs)
Spark Plug Replacement 4.3L:
Approximately 100,000 miles (if using iridium-tipped plugs)
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 (API Certified, ILSAC GF-3 or Dexos)
Engine Oil Capacity 2.2L:
5.0 quarts (4.7 liters) with filter
Engine Oil Capacity 4.3L:
4.5 quarts (4.3 liters) with filter
Coolant Specification:
GM P/N 12346790 (Orange) or equivalent; 50/50 mix of Dex-Cool coolant and distilled water
Brake Fluid Specification:
DOT 3
Known Issues
Common Wear Items:
Ball joints, tie rod ends, sway bar links, rear leaf spring bushings, fuel pump
Common Electrical Issues:
HVAC blower motor resistor failure, instrument cluster issues, intermittent interior lights
Common Powertrain Issues:
Throttle position sensor (TPS) failure on V6, occasional intake manifold gasket leaks
📚 Vehicle History
Brand Heritage
Chevrolet Truck Legacy:
Chevrolet has a long-standing reputation for producing durable and capable trucks since the early 20th century.
Model Evolution
S10 Introduction:
The S-10 was first introduced in 1982 as Chevrolet's entry into the compact pickup truck segment.
Second Generation Debut:
The second generation (GMT355) debuted for the 2004 model year, featuring a significant redesign.
Production
Production End Us:
The S-10 was discontinued in the U.S. after the 2004 model year, replaced by the Chevrolet Colorado.
Production Locations:
Primarily produced in North America (e.g., St. Louis, Missouri; Shreveport, Louisiana).
🏆 Awards & Recognition
Recognitions
Truck Of The Year Awards:
While the S-10 itself didn't win major 'Truck of the Year' awards in 2004, its platform benefited from ongoing development within GM's truck lineup.
Ratings
Consumer Reports Ratings:
Consumer Reports typically rated the S-10 in the average to below-average range for reliability in later years, often citing electrical issues and powertrain problems.
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