🏷️ Basic Information

Make:

Chevrolet

Model:

S10 Pickup / Blazer

Product Name:

Chevrolet Chevy Pickup S10 & Chevy Blazer Complete Workshop Service Repair Manual

Years Covered:

1990, 1991, 1992, 1993, 1994

👋 Introduction

Market Position:

The S10 Pickup and Blazer of this era occupied a significant segment of the compact truck and SUV market, known for their utility, relatively compact size, and affordability. This manual serves enthusiasts and professional mechanics alike looking to maintain or restore these popular GM vehicles.

Competitive Analysis:

Competed directly with vehicles like the Ford Ranger, Toyota Tacoma/Hilux, Nissan Hardbody/Frontier, and Mitsubishi Mighty Max. The S10/Blazer offered a range of powertrains and configurations catering to a broad customer base.

Key Features:

Comprehensive coverage of multiple engine options, 2WD/4WD systems, and body styles. Provides detailed diagnostic procedures and illustrations essential for DIY repair and maintenance.

📋 Manual Details

Model Variants Covered:

All S10 Pickup and Blazer models, including various trim levels, body styles (2WD/4WD, regular cab, extended cab, 2-door, 4-door for Blazer), and engine/transmission combinations.

Transmission Types Covered:

Manual transmissions (e.g., NVG 3500, SM465) and automatic transmissions (e.g., TH700R4/4L60, 4L60E).

Estimated Page Count:

Varies by specific edition but typically exceeds 1000 pages for comprehensive workshop manuals of this era.

Manual Type:

Complete Workshop Service and Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, disassembly, assembly, inspection, diagnosis, repair, timing belt/chain service, cooling system, lubrication system, fuel delivery system (carburetor/TBI/MPI), exhaust system.

Engine Electrical:

Ignition system, starting and charging system, fuel injection system (ECM, sensors, actuators), emissions control systems, cruise control, diagnostic trouble codes (DTCs).

Transmission Manual:

Clutch system, manual transmission disassembly, assembly, inspection, repair, fluid specifications.

Transmission Automatic:

Automatic transmission overhaul, disassembly, assembly, inspection, torque converter, hydraulic system, electronic controls, fluid specifications.

Drivetrain:

Front and rear drive axles, differentials, CV joints, driveshafts, transfer case (for 4WD models).

Suspension:

Front suspension (independent/solid axle depending on configuration), rear suspension (leaf springs), shock absorbers, struts, ball joints, control arms, bushings, alignment specifications.

Steering:

Power steering system, steering gear/rack and pinion, tie rods, steering column, alignment specifications.

Brakes:

Front and rear brake systems (disc/drum), hydraulic system, power booster, ABS system (if equipped), brake fluid specifications, bleeding procedures.

Electrical System:

Battery, starter, alternator, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), horn, wipers, power windows, power locks, instrument cluster.

Body Interior:

Body panel removal and installation, door mechanisms, interior trim, seats, headliner, dashboard, HVAC system (heater core, A/C evaporator), body sealing.

Body Exterior:

Bumpers, fenders, hood, grille, doors, tailgate/rear hatch, glass replacement, mirrors, trim pieces, paint and finish guidelines.

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, air filter replacement, coolant flushes, brake fluid changes.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, diagnostic trouble code (DTC) interpretation.

Repair:

Step-by-step instructions for component removal, repair, overhaul, and reinstallation for all major vehicle systems.

Component Rebuilds:

Detailed instructions for rebuilding engines, transmissions, differentials, and other major mechanical components.

Specifications And Data:

Torque specifications, clearances, fluid capacities, part numbers, wiring diagrams, diagnostic values.

Wiring Diagrams:

Includes detailed electrical wiring diagrams for all major systems, essential for diagnosing electrical faults.

Technical Depth:

Comprehensive, covering everything from basic scheduled maintenance and minor repairs to complete engine and transmission overhauls, and advanced electrical diagnostics.

Diagnostic Tools:

Specifies required special tools and diagnostic equipment (e.g., pressure gauges, multimeters) and provides procedures for their use.

📊 Manual Specifications

File Format:

PDF

Accessibility:

Printable, searchable text, viewable on PC, Mac, tablets, and smartphones with Adobe Reader.

Print Quality:

High-resolution scans, allowing for clear reproduction of text and diagrams.

Binding Type:

N/A (Digital Download - printable)

Paper Type:

N/A (Digital Download - user printable)

⚙️ Engine Specifications

Engine 1:

2.5L (151 cu in) Iron Duke I4 (Tech IV)

Engine 2:

4.3L (262 cu in) Vortec V6 (LG5/LB4)

Engine 3:

2.8L (173 cu in) LR2 V6

Engine 4:

4.3L (262 cu in) Vortec V6 (LG5/LB4)

Hp 2.5L I4:

Approx. 100-112 hp

Hp 4.3L V6:

Approx. 160-205 hp (depending on year and configuration)

Fuel System Early Models:

Throttle Body Injection (TBI) or Carburetor (less common)

Fuel System Later Models:

Multi-Port Fuel Injection (MPFI) on V6, TBI or MPFI on I4

Torque Specs Availability:

Comprehensive torque specifications for all critical engine fasteners, including cylinder head bolts, main bearing caps, connecting rod bolts, and intake/exhaust manifolds.

🔧 Transmission

Standard Transmission S10:

4-speed Manual (SM465/NVG 4500 variants) or 5-speed Manual (NVG 3500 variants)

Standard Transmission Blazer:

5-speed Manual (NVG 3500 variants)

Optional Transmission S10 Blazer:

3-speed Automatic (TH700R4/4L60 variants) or 4-speed Automatic (4L60E variants, particularly late 90s, though this manual covers up to '94)

Transfer Case Options:

Part-time 4WD transfer cases (e.g., NP231C, NP241C) with manual or electric shift options.

📐 Dimensions

Wheelbase S10 Std Bed:

Approx. 118.5 inches

Wheelbase S10 Ext Bed:

Approx. 123.5 inches

Wheelbase Blazer:

Approx. 107.1 inches (2-door) / 111.5 inches (4-door)

Curb Weight Range:

Varies significantly based on configuration, typically 3,000 - 4,500 lbs.

🛡️ Safety Features

NHTSA Ratings General:

Safety ratings for this period vary; early 90s vehicles often lacked the comprehensive testing and advanced features of modern cars. The manual will cover safety-related systems but not provide crash test results.

Active Safety Features:

Anti-lock Braking System (ABS) often optional, particularly on rear-wheel anti-lock systems for S10, and more commonly on Blazer models.

Passive Safety Features:

Seat belts (three-point front, lap rear), crumple zones, side-impact door beams (structural reinforcement).

💡 Technology Features

Infotainment Systems:

Basic AM/FM radio with cassette player or CD player (optional). Analog gauges and controls. Limited to standard audio systems; no advanced infotainment or digital displays.

Driver Assistance Features:

Limited; primarily focused on ABS for braking. No modern driver-assistance systems like adaptive cruise control, lane keeping assist, or automatic emergency braking.

Connectivity Options:

None beyond basic radio antenna and speaker connections. No Bluetooth, USB ports, or smartphone integration.

🔧 Maintenance

Oil Change Interval:

Typically 3,000 - 5,000 miles or 3-6 months, depending on oil type and driving conditions. Manual will specify exact intervals and oil grades.

Transmission Fluid Change Interval:

Automatic: 30,000 - 60,000 miles. Manual: Check level periodically, change as needed or at higher mileage intervals. Manual will detail specific recommendations.

Coolant Change Interval:

Typically every 2 years or 30,000 miles for conventional coolant. Extended life coolants (if available for this era) would have longer intervals. Manual will specify.

Engine Oil Specification V6:

Typically SAE 10W-30 or 10W-40. Manual will specify API service classification.

Engine Oil Specification I4:

Typically SAE 5W-30 or 10W-30. Manual will specify API service classification.

Automatic Transmission Fluid:

Dexron III (or equivalent specification)

Manual Transmission Fluid:

GL-4 Gear Oil (e.g., 75W-90 or 80W-90). Manual will confirm.

Brake Fluid:

DOT 3

Common Issues S10 Blazer:

TBI/MPFI fuel injector issues, ignition module failures, rear main seal leaks, transmission clutch wear (manual), automatic transmission torque converter shudder or pump issues, dashboard cluster light failures, radiator leaks, HVAC blower motor resistor failures, catalytic converter issues, ball joint wear, rust on body panels and frame (especially in certain climates).

Oil Filter Part Number Example:

Examples may include AC-Delco PF932, Fram PH8A, or equivalents. Manual will list specific OEM and equivalent part numbers.

Engine Oil Capacity V6:

Approx. 4.5 - 5 quarts (with filter). Manual will confirm exact capacity for specific engine variants.

📚 Vehicle History

Chevrolet Heritage:

Chevrolet has a long history of producing trucks and utility vehicles, from the original Task Force trucks to the C/K series. The S10/Blazer represented a move into the increasingly popular compact truck and SUV segments.

S10 Blazer Evolution:

The S10 Pickup and its SUV counterpart, the S10 Blazer, were introduced for the 1982 model year as Chevrolet's first compact trucks. The generation covered by this manual (1982-1993 for the first generation, with updates) saw significant refinements, including the introduction of the highly regarded 4.3L V6 engine and improved interior and exterior styling. The second generation was introduced for 1994.

Production Plants:

General Motors produced S10 Pickups and Blazers at various plants across North America, including Moraine, Ohio; Shreveport, Louisiana; and St. Catharines, Ontario (Canada).

🏆 Awards & Recognition

Motor Trend Truck Of The Year S10:

The S10 Pickup was named Motor Trend's Truck of the Year for 1991, recognizing its updated styling and mechanicals.