Years Covered:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Product Type:
Factory Workshop Service Repair Manual
Segment:
Compact Pickup Truck
Competitors:
Ford Ranger, Toyota Tacoma, Dodge Dakota, Nissan Hardbody/Frontier.
Versatility:
Offered in various configurations including regular cab, extended cab, short bed, long bed, 2WD, and 4WD, catering to a wide range of utility and lifestyle needs.
Powertrain Options:
Reliable and capable engine options, including the durable 4.3L Vortec V6, which was a standout performer in its class.
Durability:
Known for its robust build quality and ability to withstand demanding work and off-road use.
Major Systems:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, HVAC, Electrical, Fuel System, Cooling System, Exhaust System, Body, Interior
Estimated Pages:
Thousands (typical for a comprehensive factory manual)
Type:
Workshop Service Manual
Format:
Downloadable (likely PDF)
Powertrain:
Internal combustion engines (2.2L OHV, 4.3L Vortec V6, 5.0L Vortec V8), automatic transmissions (4L60-E, 4L80-E), manual transmissions (NV3500, Getrag 291), transfer cases (for 4WD models), axles, driveshafts, differentials.
Chassis:
Front and rear suspension (independent front suspension, leaf springs rear), steering system (power steering), brake system (disc/drum, ABS), wheels and tires.
Electrical:
Battery, charging system, starting system, ignition system, lighting, instruments, gauges, power windows, power locks, audio system, body control modules, Powertrain Control Module (PCM), diagnostic trouble codes (DTCs).
Comfort And Convenience:
HVAC system (air conditioning, heating), interior trim, seating, airbags, cruise control.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, belt inspection and replacement, spark plug replacement, brake pad and rotor replacement, tire rotation and balancing.
Diagnostics:
Troubleshooting common issues, symptom-based diagnostics, wiring diagrams for electrical systems, diagnostic flowcharts, PCM and sensor testing.
Repair And Rebuild:
Engine overhaul, transmission rebuild, brake caliper and master cylinder replacement, suspension component replacement (ball joints, tie rods, shocks/struts), power steering pump replacement, starter and alternator replacement, fuel pump replacement, exhaust system repair.
Body And Frame:
Body panel removal and installation, door mechanism repair, bumper repair, frame straightening (if applicable), corrosion prevention.
Depth:
Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring diagrams.
Format:
PDF (Portable Document Format) - Searchable text, bookmark navigation.
Quality:
High Resolution (Hi-Res) illustrations, photos, and diagrams.
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download - Printable pages)
Engine 1:
2.2L OHV Inline-4 (LL2), 118 hp @ 5000 rpm, 130 lb-ft torque @ 3200 rpm (typical for early models)
Engine 2:
4.3L Vortec OHV V6 (L35), 190-200 hp @ 4400-4800 rpm, 250-260 lb-ft torque @ 2800-3200 rpm (depending on year and specific variant)
Engine 3:
5.0L Vortec OHV V8 (LT4/L39 - less common in S-10, more in larger siblings, but possible in some specialty models or later years), 230 hp @ 4800 rpm, 280 lb-ft torque @ 3200 rpm
Fuel Type:
Unleaded Gasoline
System Type:
Multi-Port Fuel Injection (MPI) / Electronic Fuel Injection (EFI)
ECM Provider:
Delphi / AC-Delco
Transmission 1:
4-speed automatic (4L60-E)
Transmission 2:
5-speed manual (NV3500, Getrag 291)
AWD System:
Electronic shift-on-the-fly 4WD (StabiliTrak on some later models)
Automatic Fluid:
Dexron-III (or equivalent) Automatic Transmission Fluid (ATF)
Manual Fluid:
GL-4 Gear Lubricant (specific viscosity varies by transmission model)
Wheelbase Short Bed:
118.0 inches (2997 mm)
Wheelbase Long Bed:
122.9 inches (3122 mm)
Overall Length Short Bed:
192.4 inches (4887 mm)
Overall Length Long Bed:
207.4 inches (5268 mm)
Bed Length Standard:
73.9 inches (1877 mm)
Bed Length Long:
86.1 inches (2187 mm)
Curb Weight Range:
Approx. 3,400 - 4,200 lbs (1542 - 1905 kg)
Gvw Range:
Approx. 5,300 - 6,200 lbs (2404 - 2812 kg)
Wheel Bolt Pattern:
5 x 4.75 inch (5x120.65 mm)
Tire Sizes:
Commonly P235/75R15, P215/70R15, P265/70R16 depending on trim and configuration.
NHTSA Driver Front Impact:
Acceptable (for 1994-1998 models)
NHTSA Passenger Front Impact:
Good (for 1994-1998 models)
ABS:
Anti-lock Braking System (ABS) available on rear wheels, and on all four wheels in later years.
Airbags:
Driver and passenger front airbags standard from 1994.
Seatbelts:
Front 3-point seat belts with shoulder belt height adjusters, rear seat belts.
Audio System:
Factory AM/FM stereo with cassette player and optional CD player. Aftermarket head units are common upgrades.
Speaker Configuration:
Typically 2 or 4 speakers (door or dash mounted).
ABS:
Available Anti-lock Braking System.
Cruise Control:
Standard on most higher trims, optional on others.
OBD Ii:
On-Board Diagnostics II (OBD-II) compliant from 1996 onwards, facilitating emissions testing and diagnostic code reading.
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions and oil type used. Check manual for specific recommendations.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Coolant Flush:
Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years. Use recommended coolant type.
Engine Oil Recommendation:
API Certified SAE 5W-30 or 10W-30 (refer to manual for specific engine type and temperature range). Capacity: 4.5 qts (4.2L) for 4-cyl, 5.0 qts (4.7L) for V6.
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Power Steering Fluid:
Dexron-III (or equivalent) ATF.
Coolant Type:
Dex-Cool Extended Life (for orange coolant systems) or conventional green ethylene glycol coolant (check original fill type). Minimum 50/50 mix with distilled water.
Intake Manifold Gaskets:
Common on 4.3L V6 engines to develop coolant leaks due to gasket material degradation.
Rear Main Seal:
Can leak oil on V6 engines, requiring transmission removal for replacement.
Brake Actuator Leaks:
ABS actuator modules can leak on some models.
Evaporative Emissions System:
Purge solenoids and vent solenoids can fail, leading to check engine lights.
Suspension Wear:
Ball joints, tie rod ends, and sway bar links can wear out, causing steering looseness and noise.
Chevy Truck Legacy:
The S-10 nameplate builds upon Chevrolet's long-standing reputation for producing durable and versatile trucks.
First Generation:
The second generation (1994-2004) introduced a significant redesign with a more aerodynamic exterior and improved interior comfort. It saw continuous updates throughout its lifespan, including engine revisions and feature additions.
Manufacturing Locations:
Primarily assembled in the United States and Brazil. Key U.S. plants included St. Louis, Missouri, and Shreveport, Louisiana.
Production Years:
Production of the S-10 in North America concluded in 2004, succeeded by the Chevrolet Colorado.
Truck Of The Year:
While the S-10 itself didn't consistently win major 'Truck of the Year' awards during its specific generation compared to some competitors, it was a consistently strong seller and highly regarded for its value and capability in the compact pickup segment.
Consumer Reports:
Consumer Reports ratings varied by year and specific configurations, with common feedback on reliability focusing on powertrain durability but sometimes noting suspension and electrical component issues.
