🏷️ Basic Information

Make:

Chevrolet

Model:

S-10 EXTREME

Generation:

Second Generation (1994-2004)

Year Range:

1994-2004

Product Name:

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

👋 Introduction

Target Audience:

Professional mechanics, DIY enthusiasts, S-10 EXTREME owners seeking to perform their own maintenance and repairs.

Value Proposition:

Provides dealer-level technical information at a fraction of the cost, empowering users to save on labor and perform repairs correctly.

Accessibility:

Instant download, no postal delivery wait times, usable across multiple operating systems.

Usability:

No additional software required beyond free Adobe Acrobat Reader. File extraction via common utilities like WinZip or WinRAR.

📋 Manual Details

Primary Coverage:

Chevrolet S-10 EXTREME

Model Years Covered:

1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004

Estimated Page Count:

Data not explicitly provided, but extensive coverage implies thousands of pages typical for a full workshop manual.

Type:

Workshop Service Repair Manual

Language:

English

Digital Format:

PDF

File Size Mb:

520 MB

📖 Manual Coverage

Engine:

Comprehensive coverage including diagnosis, repair, and specifications for both 2.2L I4 and 4.3L V6 engines.

Air Conditioning:

AC system operation, diagnosis, refrigerant handling, component repair.

Airbags:

SRS system components, diagnosis, safety precautions, repair procedures.

ABS:

Anti-lock Braking System operation, diagnosis, component testing, repair.

Brake System:

Front and rear brake systems, including hydraulic components, calipers, rotors, drums, parking brake, and bleeding procedures.

Charging System:

Alternator, battery, charging circuit diagnosis and repair.

Clutch:

Clutch assembly, hydraulic system, and linkage for manual transmission vehicles.

Cooling System:

Radiator, water pump, thermostat, hoses, fan, coolant specifications, and service.

Cruise Control:

Operation, diagnosis, and repair of the cruise control system.

Defogger:

Rear defogger system operation and repair.

Differential:

Rear axle differential service, lubrication, and repair.

Axle:

Front and rear axle components, CV joints, wheel bearings.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, alignment specifications.

Heating And Ventilation:

HVAC system components, blower motor, heater core, blend doors, and actuators.

Instrument Panel:

Gauges, warning lights, instrument cluster diagnosis and repair.

Maintenance:

Routine maintenance procedures, schedules, fluid checks, filter replacements.

Automatic Transmission:

AT specifications, diagnosis, repair, fluid specifications.

Manual Transmission:

MT specifications, diagnosis, repair, clutch service.

Power Steering:

Power steering pump, rack and pinion, fluid, and system diagnosis.

Body And Accessories:

Body panels, doors, glass, interior trim, seats, bumpers, and accessory systems.

Starter System:

Starter motor, solenoid, ignition switch, and starting circuit diagnosis.

Steering Column:

Steering column components, ignition lock cylinder, and steering wheel removal/installation.

Transfer Case:

Four-wheel drive transfer case operation, maintenance, and repair (if applicable to EXTREME models).

Wiper Washer:

Wiper motor, blades, washer pump, and fluid system.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems.

User Manual Sections:

Likely includes extracts or references to essential user manual information for operation and basic checks.

General Procedures:

Routine maintenance, inspections, adjustments, troubleshooting, diagnostics, component removal and installation, rebuild procedures.

Diagnostic Procedures:

Step-by-step diagnostic flowcharts, symptom-based troubleshooting, use of diagnostic tools.

Repair Procedures:

Detailed instructions for component repair and replacement, often with torque specifications and special tool requirements.

Depth:

Comprehensive workshop level, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic fluid changes to complete engine and transmission overhauls.

📊 Manual Specifications

Format:

PDF

Portability:

Readable on any device with Adobe Acrobat Reader, including Windows and Mac operating systems.

Diagrams:

High Definition diagrams, crucial for understanding complex assemblies and wiring.

Text Readability:

Well-structured content with clear, concise instructions.

Binding:

N/A (Digital format). Ready to print for personalized binding.

Paper Type:

N/A (Digital format). Printable on standard paper.

Bookmarks:

Bookmarks for every chapter, facilitating easy navigation and quick access to specific information.

⚙️ Engine Specifications

Engine Options:

2.2L I4 (LL2) and 4.3L V6 (L35 Vortec)

2.2L I4 Horsepower:

Approx. 118-125 hp (specific output varied by year/tune)

4.3L V6 Horsepower:

Approx. 160-190 hp (Vortec variants offered higher output)

4.3L V6 Torque:

Approx. 200-260 lb-ft (Vortec variants offered higher torque)

Fuel Delivery:

Multi-port Fuel Injection (MPFI)

ECU Type:

PCM (Powertrain Control Module) controlled, with specific programming for each engine and transmission combination.

🔧 Transmission

Manual:

5-speed manual transmission (e.g., NV1500, NV3500) was common.

Automatic:

4-speed automatic transmission (e.g., 4L60-E) was available.

Transfer Case Availability:

Available in 2WD and 4WD configurations, with the 4WD models featuring a transfer case (e.g., NP233, NP243).

📐 Dimensions

Body Styles:

Regular Cab, Extended Cab (S-Cab), primarily short or long bed configurations.

Curb Weight Range:

Approx. 3,300 - 3,800 lbs (Varies significantly by configuration, engine, and drivetrain).

🛡️ Safety Features

NHTSA Crash Test Results:

NHTSA ratings for this era of S-10 are generally modest. The manual would detail system design for safety, but specific historical ratings should be cross-referenced.

ABS:

Anti-lock Braking System (ABS) was an option or standard depending on year and trim.

Airbags:

Driver-side airbag was standard for much of this period. Passenger airbags became more common in later years. Side airbags were generally not available.

💡 Technology Features

Audio Systems:

Factory radio options included AM/FM, cassette players, and CD players. Speakers varied by trim. Upgrades are common.

Early Features:

Limited driver assistance technology compared to modern vehicles. ABS was the primary active safety feature.

Oem Connectivity:

No integrated Bluetooth or advanced connectivity features from the factory. OnStar was introduced in later years but not necessarily standard on all S-10s.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 miles or 3-6 months with conventional oil, longer with synthetic. Refer to manual for precise year/engine specific intervals.

Engine Oil Type:

Recommended: SAE 5W-30 for most operating conditions. Always confirm specific API service classification.

Coolant Type:

Dex-Cool (GM P/N 12346493 or equivalent) or traditional green ethylene glycol coolant, depending on original fill. Check for correct type.

Transmission Fluid Atf:

Dexron-III/Mercon (GM P/N 88861950 or equivalent) for automatic transmissions. Manual transmissions require specific gear oil.

Common Problems:

Potential issues include intake manifold gasket leaks (Vortec V6), fuel pump failures, AC system leaks, body rust (especially in northern climates), and various electrical gremlins common in vehicles of this age. Manual details troubleshooting.

📚 Vehicle History

Chevrolet Truck Lineage:

The S-10 was Chevrolet's compact pickup truck, a successor to the LUV and a predecessor to the Colorado, filling a vital market segment.

Second Generation Updates:

The second generation (1994-2004) introduced significant styling changes, including the smoother, more aerodynamic body. The EXTREME package was a sport-oriented trim. Updates focused on engine refinements (Vortec for the 4.3L), interior comfort, and safety features.

Manufacturing Locations:

Primarily produced in the United States at GM's facilities.

🏆 Awards & Recognition

Automotive Press Awards:

The S-10 was generally well-regarded in its class for its utility and the performance of the 4.3L V6. Specific awards for the EXTREME trim are less common, but the platform received recognition for its value.