Model Years Covered:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Body Styles Covered:
Regular Cab, Extended Cab, Crew Cab (late model years)
Trim Levels Covered:
Base, LS, Xtreme, SS, ZR2
Chassis Code:
GMT330 (for the second generation, primarily covered by this manual)
Segment:
Compact Pickup Truck
Target Audience:
DIY mechanics, professional technicians, S-10 owners seeking detailed repair information.
Key Competitors:
Ford Ranger, Toyota Tacoma, Dodge Dakota, Nissan Hardbody.
Manual Value Proposition:
Unmatched comprehensiveness for DIY and professional repair, saving time and money.
Instruction Style:
Step-by-step instructions with clear, actionable guidance.
Visual Aids:
Inclusion of exploded views for component identification and reassembly.
Comprehensive Coverage:
Engine, transmission, drivetrain, chassis, suspension, steering, brakes, electrical systems, body and interior, HVAC, fuel system, emissions control, diagnostics, troubleshooting.
Estimated Page Count:
1000+ pages (typical for a comprehensive factory-level service manual)
Manual Type:
Service and Repair Manual
Engine Mechanical:
Disassembly, assembly, inspection, repair for all covered engine variants.
Engine Performance:
Fuel delivery, ignition system, cooling system, lubrication system, emissions controls, engine diagnostics.
Transmission Manual:
Repair, overhaul, and adjustment of manual transmissions.
Transmission Automatic:
Repair, overhaul, and adjustment of automatic transmissions, including torque converter.
Drivetrain And Axles:
Front and rear axle assemblies, drive shafts, universal joints, differentials, transfer case (4WD).
Suspension System:
Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings.
Steering System:
Steering gear, power steering pump, steering linkage, wheel alignment specifications.
Brake System:
Disc brakes, drum brakes, ABS system (if equipped), brake lines, master cylinder, parking brake.
Electrical System:
Battery, charging system, starting system, lighting, instruments, power accessories, wiring diagrams.
Body And Interior:
Body panels, doors, latches, glass, interior trim, seats, HVAC system.
Diagnostic Troubleshooting:
Systematic diagnostic procedures, fault codes, symptom analysis.
Preventive Maintenance:
Oil changes, filter replacements, fluid checks, lubrication schedules.
Major Repairs:
Engine rebuilds, transmission overhauls, differential repairs.
Component Replacement:
Replacement of wear items like brakes, suspension parts, belts, hoses, spark plugs.
Electrical Diagnostics:
Troubleshooting electrical circuits, testing sensors, actuators, and control modules.
HVAC Service:
Refrigerant handling, system diagnostics, component replacement.
Wheel Alignment:
Specifications and procedures for front and rear wheel alignment.
Torque Specifications:
Detailed torque values for all critical fasteners.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all systems.
Depth Of Information:
Factory-level diagnostic and repair procedures, including detailed explanations and troubleshooting charts.
Diagrams And Illustrations:
Numerous exploded views, component diagrams, and step-by-step illustrations.
Diagnostic Tools:
Information on required special tools and diagnostic equipment.
2.2L I4 (Vin F):
2.2L (2198cc) OHV 4-cylinder, 118 hp @ 4800 rpm, 130 lb-ft @ 3200 rpm. Engine code: RPO L43.
2.2L Ecotec I4 (Vin 5):
2.2L (2198cc) DOHC 4-cylinder, 143 hp @ 5400 rpm, 154 lb-ft @ 3800 rpm. Engine code: RPO L61 (introduced later in the model run).
4.3L V6 (Vin X):
4.3L (4300cc) OHV V6, 158-190 hp depending on year/application, 230-250 lb-ft torque. Engine code: RPO L35 (first gen style), RPO LB4 (later Vortec).
Horsepower Range:
118 hp to 190 hp
Torque Range:
130 lb-ft to 250 lb-ft
Injection Type:
Multi-port Fuel Injection (MPFI) for most variants, Throttle Body Injection (TBI) in early years of the generation.
Fuel Type:
Unleaded gasoline
Oil Change Interval:
Typically every 3,000 to 7,500 miles, or 6 months, depending on oil type and driving conditions (refer to manual for specifics).
Transmission Fluid Interval:
Automatic: Every 50,000 to 100,000 miles; Manual: Inspect as needed, fluid change typically at higher mileage (refer to manual).
Coolant Change Interval:
Every 30,000 to 100,000 miles, depending on coolant type (e.g., conventional vs. Dex-Cool).
Spark Plug Replacement:
Varies by plug type (e.g., copper plugs around 30,000 miles, iridium/platinum plugs 60,000-100,000 miles).
Engine Oil:
SAE 5W-30 or 10W-30 (depending on temperature and engine), API Certified (refer to manual for exact specs and viscosity).
Transmission Fluid Automatic:
Dexron-III (or equivalent) automatic transmission fluid (ATF).
Transmission Fluid Manual:
GL-4 or GL-5 manual transmission fluid (viscosity varies).
Coolant:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Check for specific GM recommendations (e.g., Dex-Cool for later models).
Brake Fluid:
DOT 3 brake fluid.
Intake Manifold Gaskets:
Leaking intake manifold gaskets (especially on 4.3L V6 engines).
Rear Main Seal:
Leaking rear main crankshaft seal on V6 engines.
Clutch Release Bearing:
Noise from the clutch release bearing on manual transmission models.
ABS Sensors:
Failure of ABS wheel speed sensors, leading to ABS warning light and malfunction.
Transmission Hard Shifting:
Occasional hard shifting or delayed engagement in automatic transmissions.
Blower Motor Resistor:
Failure of the HVAC blower motor resistor, affecting fan speed control.
Chevy Truck Legacy:
Chevrolet has a long-standing reputation for durable and versatile trucks.
Second Generation S10:
The 1994-2004 models represent the second generation of the S-10, introduced with a significant redesign.
Design Updates:
Facelifts and updates occurred in 1998 and 2001, bringing revised styling, interior enhancements, and new engine options.
Manufacturing Locations:
Primarily manufactured in the United States (e.g., Shreveport, Louisiana; St. Louis, Missouri).
Production End Date:
Production for the S-10 pickup in North America concluded in 2004.
