2004 Chevrolet Pickup S10 Service and Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: S10 Pickup Year: 2004 Codes Platform: GMT360 👋 Introduction Market Position Original Equipment Manufacturer: Authentic factory service manual equivalent, mirroring the content provided...

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Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

S10 Pickup

Year:

Codes

Platform:

GMT360

👋 Introduction

Market Position

Original Equipment Manufacturer:

Authentic factory service manual equivalent, mirroring the content provided to dealership technicians.

Competitive Analysis

Alternatives:

Outperforms generic Haynes or Chilton manuals in terms of depth, accuracy, and completeness for specific repairs.

Key Features

Diagnostic Tools:

Includes diagnostic procedures and specifications, enabling accurate troubleshooting without proprietary dealership equipment for many tasks.

Illustration Quality:

Features detailed diagrams, illustrations, and photographs to guide repair processes.

Compatibility:

Compatible with Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac operating systems.

Accessibility:

Provided as a single, easy-to-use PDF for efficient navigation, eliminating the need for multiple physical books.

📋 Manual Details

Coverage Areas

All Models Trims:

All Repairs:

Page Count

Estimated Page Count:

Varies by specific engine and configuration, but comprehensive coverage implies over 1500 pages in a typical factory service manual.

Manual Type

Type:

Factory Service and Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Complete service, diagnosis, and repair for all engines offered in 2004 S10, including 2.2L 4-cylinder and 4.3L V6.

Fuel System:

Fuel injection, fuel pump, fuel filter, injectors, fuel pressure testing, evaporative emission control (EVAP).

Cooling System:

Radiator, water pump, thermostat, cooling fan, coolant types and capacities.

Lubrication System:

Oil pump, oil filter, oil pressure, oil types and capacities.

Ignition System:

Spark plugs, ignition coils, distributorless ignition system (DIS) components, timing.

Starting Charging:

Alternator, starter motor, battery, charging system diagnosis.

Transmission Auto:

4L60-E automatic transmission service, diagnosis, overhaul, and specifications.

Transmission Manual:

Manual transmission service, clutch replacement, specifications for available manual gearboxes (e.g., NV1500, NV3500).

Transfer Case:

Service and repair for available 2WD and 4WD transfer cases (e.g., NP236, NP241C).

Driveshaft Axle:

Driveshaft U-joints, CV joints, rear axle service, differential service and specifications.

Suspension:

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

Steering:

Steering column, power steering pump, steering rack/gearbox, tie rods, alignment.

Brakes:

Front and rear brake systems (disc/drum), ABS, brake pad/shoe replacement, rotor/drum resurfacing, brake fluid specifications.

Electrical System:

Complete wiring schematics, component testing, fuses, relays, lighting, power distribution.

Body Interior:

Door panel removal, seat adjustment, interior trim, exterior body panel alignment, glass replacement.

HVAC:

Air conditioning system service, refrigerant handling, heater core, blower motor, climate control diagnostics.

Safety Restraint:

Airbag system diagnosis and service, seat belt mechanisms.

Driver Controls:

Cruise control system, wipers and washers, horn.

Instrumentation:

Instrument cluster removal and service, gauge operation, warning lights.

Multiplex Can Communication:

Diagnosis and understanding of vehicle network communication systems (CAN bus).

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, tune-ups.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnosis.

Repair:

Step-by-step instructions for component removal, installation, and repair.

Rebuilds:

Detailed overhaul procedures for engines and transmissions.

Wiring Schematics:

Comprehensive, vehicle-specific wiring diagrams for all electrical systems.

Technical Depth

Depth:

Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable within the PDF for quick information retrieval.

Print Quality

Printability:

High-quality, printable pages allowing users to print specific sections or the entire manual.

Image Scalability:

Images and diagrams can be blown up for detailed viewing and printing.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine 1:

2.2L L61 Ecotec Inline-4

Engine 1 Displacement:

2198 cc (134 cu in)

Engine 1 Horsepower:

120 hp @ 5200 rpm (approx.)

Engine 1 Torque:

140 lb-ft @ 3600 rpm (approx.)

Optional Engine

Engine 2:

4.3L Vortec L35 V6

Engine 2 Displacement:

4300 cc (262 cu in)

Engine 2 Horsepower:

180-190 hp @ 4400-4800 rpm (approx., depending on configuration)

Engine 2 Torque:

245-260 lb-ft @ 2800-3200 rpm (approx., depending on configuration)

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Transmission Std 2Wd:

NV1500 5-speed Manual (2WD models)

Transmission Std 4Wd:

NV3500 5-speed Manual (4WD models)

Optional

Transmission Opt:

4L60-E 4-speed Automatic

Features

Automatic Features:

Electronic control, overdrive, torque converter lock-up.

📐 Dimensions

Exterior

Wheelbase Short Bed:

111.5 inches (2832 mm)

Wheelbase Long Bed:

122.5 inches (3111 mm)

Overall Length Short Bed:

187.7 inches (4768 mm)

Overall Length Long Bed:

198.7 inches (5047 mm)

Weights

Curb Weight Est:

3500-4000 lbs (1588-1814 kg), varies by configuration.

🛡️ Safety Features

Ratings

NHTSA Front Driver Impact Rating:

4 Stars (for 2004 models)

NHTSA Front Passenger Impact Rating:

4 Stars (for 2004 models)

NHTSA Side Impact Driver Rating:

NR (Not Rated) / 3 Stars (depending on testing configuration)

NHTSA Side Impact Rear Passenger Rating:

NR (Not Rated)

Active Features

Standard Anti-lock Braking System (ABS) on all models.

Passive Features

Airbags:

Driver and front passenger airbags.

Seatbelts:

Three-point front seatbelts, lap belts in rear (if applicable).

💡 Technology Features

Infotainment

Audio System:

Factory installed AM/FM stereo with CD player or cassette player, depending on trim level and options.

Driver Assistance

Cruise Control:

Cruise control system available on most models.

Connectivity

Onboard Diagnostics:

OBD-II (On-Board Diagnostics II) compliant for emissions and engine diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000-7,500 miles (8,000-12,000 km) or 6 months, depending on driving conditions and oil type used (refer to manual for specifics).

Tune Up Interval:

Spark plug replacement typically around 100,000 miles, but check manual for specific engine recommendations.

Fluid Specifications

Engine Oil:

SAE 5W-30 is common for both 2.2L and 4.3L engines, but verify with manual for API service classification (e.g., API SN or newer).

Transmission Fluid Auto:

Dexron-III/VI Automatic Transmission Fluid (ATF).

Transmission Fluid Manual:

Gear oil (e.g., SAE 75W-90) for manual transmissions, consult manual for exact specification and capacity.

Coolant:

GM-specific orange coolant (50/50 mix with distilled water) or equivalent Extended Life (ELC) coolant.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Problems:

Possible issues include ignition coil failure, fuel pump issues, minor oil leaks from gaskets, and some HVAC actuator problems. The manual will provide diagnostic procedures for these and other common faults.

📚 Vehicle History

Brand Heritage

Chevrolet Truck Legacy:

Part of Chevrolet's long-standing tradition of producing durable and capable pickup trucks.

Model Evolution

S10 Generation:

This manual covers the second generation S10 (1994-2004), with the 2004 model year being the final year of production.

Production

Manufacturing Location:

Primarily assembled in North America (e.g., USA, Mexico, Canada).