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Chevrolet CHEVY S-10 EXTREME 1994-2004 Repair Service Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: S-10 Extreme Model Variant: S-10 Extreme Year: 1994-2004 Body Style: Pickup Truck Codes Platform: GMT 400 / GMT 425 👋 Introduction Market Position...
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Chevrolet CHEVY S-10 EXTREME 1994-2004 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
S-10 Extreme
Model Variant:
S-10 Extreme
Year:
1994-2004
Body Style:
Pickup Truck
Codes
Platform:
GMT 400 / GMT 425
👋 Introduction
Market Position
Target Audience:
DIY mechanics, professional technicians, S-10 Extreme enthusiasts.
Competitive Analysis
Value Proposition:
Provides comprehensive, factory-level repair information for the S-10 Extreme, enabling cost-effective maintenance and repair compared to dealership services.
Key Features
Content Highlight:
Detailed illustrations, step-by-step instructions, wiring diagrams, and troubleshooting procedures.
Manual Utility:
Essential for understanding complex systems and performing accurate repairs, saving time and money.
📋 Manual Details
Coverage Areas
Regions:
North America
Coverage Type:
Comprehensive Repair and Service
Page Count
Approximate Page Count:
Estimated 2000-3000+ pages (based on typical factory manual size and scope)
Manual Type
Type:
Factory Repair Service Manual
Language
Language:
English
Format
Format:
Digital (PDF)
Delivery Method:
Digital Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine Mechanical, Lubrication, Cooling, Fuel Injection, Ignition, Emission Control
Drivetrain Systems:
Manual Transmission, Automatic Transmission, Transfer Case (4WD), Axles, Drive Shafts, Differentials
Suspension Steering Brakes:
Front Suspension, Rear Suspension, Steering Column, Power Steering, Brake System (Hydraulic, ABS), Parking Brake
Electrical Systems:
Charging System, Starting System, Ignition System, Lighting, Instrumentation, Powertrain Control Module (PCM), Body Control Module (BCM), Airbags, Cruise Control, Wiper/Washer Systems
HVAC Systems:
Heating, Ventilation, Air Conditioning (HVAC), Defogger
Body And Interior:
Body and Accessories, Interior Trim, Door Mechanisms, Glass, Seats, Instrument Panel
Procedures Included
Maintenance Procedures:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication, Tune-ups
Repair Procedures:
Engine Overhaul, Transmission Rebuild, Brake Component Replacement, Suspension Component Replacement, Electrical Component Diagnosis and Replacement, HVAC System Repair
Diagnostic Procedures:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Electrical Schematics, Component Testing
Technical Specifications:
Torque Specifications, Fluid Capacities, Piston Ring Gap, Valve Clearances, Bearing Clearances
Technical Depth
Depth:
In-depth diagnostics, component-level repair, full rebuild procedures for major components, detailed electrical schematics and troubleshooting trees.
📊 Manual Specifications
File Format
File Type:
PDF
File Size:
520 MB
File Compression:
ZIP Archive
Software Requirements:
Adobe Acrobat Reader (free download), WinZip or WinRAR (for extraction)
Print Quality
Printability:
Printable pages for specific tasks
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper Quality:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.2L I4 (Vortec 2200)
Engine 1 Displacement:
2198 cc
Engine 1 Configuration:
Inline 4-cylinder
Engine 1 Fuel Delivery:
Multi-port Fuel Injection (MPI)
Engine 1 Horsepower Range:
Approx. 118-120 hp
Engine 1 Torque Range:
Approx. 130-135 lb-ft
Optional Engine
Engine 2:
4.3L V6 (Vortec 4300)
Engine 2 Displacement:
4300 cc (262 ci)
Engine 2 Configuration:
90-degree V6
Engine 2 Fuel Delivery:
Multi-port Fuel Injection (MPI)
Engine 2 Horsepower Range:
Approx. 160-190 hp (depending on year and configuration)
Engine 2 Torque Range:
Approx. 230-260 lb-ft (depending on year and configuration)
Performance
Ignition Type:
Distributorless Ignition System (DIS) or Distributor ignition (earlier models)
Fuel System
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type Standard:
Manual Transmission (e.g., NV3500 5-speed)
Optional
Transmission Type Optional:
Automatic Transmission (e.g., 4L60-E 4-speed)
Features
Transfer Case:
Available 4WD with manual or automatic transfer case engagement.
Differential Type:
Open differential standard, limited-slip differential available.
📐 Dimensions
Exterior
Wheelbase Range:
Typically 118.0 inches (Longer wheelbases may have been available on some models)
Overall Length Range:
Approx. 190-200 inches (depending on cab and bed configuration)
Track Width Front Rear:
Varies by model and configuration. Specific data within manual.
Weights
Curb Weight Range:
Approx. 3,500 - 4,200 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Acceptable (Refer to specific model year tests)
NHTSA Front Impact Passenger:
Good (Refer to specific model year tests)
Active Features
ABS:
Anti-lock Braking System (ABS) available or standard on later models.
Passive Features
Airbags:
Driver and Passenger Airbags standard on later models.
Seat Belts:
Three-point seat belts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette player, optional premium sound systems.
Instrumentation:
Analog gauges for speedometer, tachometer, fuel level, engine temperature, oil pressure. Warning lights for various systems.
Driver Assistance
Cruise Control:
Available cruise control system.
Connectivity
Oem Diagnostics:
OBD-II compliant from 1996 onwards, facilitating electronic diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000 - 7,500 miles or 6-12 months (refer to manual for specific engine/oil type).
Tire Rotation Interval:
Every 5,000 - 7,500 miles.
Spark Plug Replacement:
Varies by spark plug type (e.g., 30,000 - 100,000 miles for platinum/iridium).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 10W-30 (refer to manual for specific viscosity and API rating).
Coolant Type:
Ethylene Glycol based, typically Dex-Cool (Orange) or traditional green (check manual).
Transmission Fluid Type Auto:
Dexron III/VI ATF (refer to manual for specific type and capacity).
Transmission Fluid Type Manual:
GL-4 or GL-5 gear oil (specific viscosity and type in manual).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual).
Power Steering Fluid Type:
Dexron III/VI ATF (refer to manual).
Known Issues
Common Problems Engine:
Intake manifold gasket leaks (V6), coolant leaks, oil leaks, camshaft position sensor issues.
Common Problems Transmission:
Clutch wear (manual), torque converter shudder (automatic), transmission fluid leaks.
Common Problems Suspension Steering:
Ball joint wear, tie rod end wear, idler arm wear, steering box play.
Common Problems Electrical:
Faulty HVAC blower motor resistor, instrument cluster issues, window regulator failures.
Common Problems Body:
Rust in common areas (fenders, cab corners, frame rails), door hinge wear.
📚 Vehicle History
Brand Heritage
Chevrolet Truck Legacy:
Chevrolet has a long-standing reputation for producing durable and capable pickup trucks.
Model Evolution
S10 Generation:
The S-10 was Chevrolet's compact pickup truck, introduced in 1982. The 1994-2004 models represent the second generation, which received significant updates.
S10 Extreme Trim:
The S-10 Extreme was a sport-oriented trim package that featured unique styling cues, often including ground effects, special wheels, and interior accents, aimed at a younger demographic.
Production
Manufacturing Locations:
Primarily produced in North America (e.g., Shreveport, Louisiana; St. Louis, Missouri).
🏆 Awards & Recognition
Recognitions
Truck Of The Year Competitor:
While not typically winning major truck of the year awards against larger trucks, the S-10 was a strong contender in the compact segment.
Sales Performance:
The S-10 was a very popular model for Chevrolet, consistently ranking among the best-selling compact trucks during its production run.
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