brake CHEVROLET S10 2004 Repair Manual

Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the front suspension, ball joints, steering
linkage, parking brake cable guides, propshaft splines,
universal joints, constant velocity joint and brake
pedal springs.
+A good time to check your brakes is during tire
rotation. See Brake System Inspection on page 6-31.
**Drive axle service. See Part D: Recommended Fluids
and Lubricants on page 6-32for proper lubricant to use:
•Check uid level and add uid as needed. If driving in
dusty areas or when towing a trailer, drain uid and
rell every 15,000 miles (25 000 km).
•If your vehicle has a locking differential, drain uid
and rell at rst engine oil change.
•More frequent lubrication may be required for
heavy-duty or off-road use.
3,000 Miles (5 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
❑Lubricate chassis components (or every 3 months,
whichever occurs first).(See footnote #.)
❑Check rear/front axle fluid level and add fluid as
needed. Check constant velocity joints and axle seals
for leaking.(See footnote **.)
6,000 Miles (10 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
❑Lubricate chassis components (or every 3 months,
whichever occurs first).(See footnote #.)
❑Check rear/front axle fluid level and add fluid as
needed. Check constant velocity joints and axle seals
for leaking.(See Footnote **.)
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-74for proper rotation pattern and additional
information.(See footnote +.)
6-7

Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the front suspension, ball joints, steering
linkage, parking brake cable guides, propshaft splines,
universal joints, constant velocity joint and brake
pedal springs.
+A good time to check your brakes is during tire
rotation. See Brake System Inspection on page 6-31.
**Drive axle service. See Part D: Recommended Fluids
and Lubricants on page 6-32for proper lubricant to
use:
❑Check uid level and add uid as needed.
❑If your vehicle has a locking differential, drain uid
and rell at rst engine oil change.
7,500 Miles (12 500 km)
❑Change engine oil and filter (or every 12 months,
whichever occurs first).An Emission Control
Service.
❑Lubricate chassis components (or every 12 months,
whichever occurs first).(See footnote #.)
❑Check rear/front axle fluid level and add fluid as
needed. Check constant velocity joints and axle seals
for leaking.(See footnote **.)
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-74for proper rotation pattern and additional
information.(See footnote +.)
15,000 Miles (25 000 km)
❑Change engine oil and filter (or every 12 months,
whichever occurs first).An Emission Control
Service.
❑Lubricate chassis components (or every 12 months,
whichever occurs first).(See footnote #.)
❑Inspect engine air cleaner filter. SeeEngine Air
Cleaner/Filter on page 5-18for more information.An
Emission Control Service. (See footnote †.)
❑Check rear/front axle fluid level and add fluid as
needed. Check constant velocity joints and axle seals
for leaking.(See footnote **.)
6-18

At Least Four Times a Year
Tailgate Lubrication Service
Lubricate tailgate latch bolt, handle assembly pivot
points, and hinges with lubricant recommended
in Part D.
At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
specified in Part D.
Body Lubrication Service
Lubricate all body door and fuel door hinges, latches
and locks, including the glove box and console
doors, the body hood, secondary latch, pivots, spring
anchor, release pawl and any moving seat hardware.
Lubricate the hood safety lever pivot and prop rod pivot.
Part D tells you what to use. More frequent lubrication
may be required when exposed to a corrosive
environment.
Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. SeeParking Brake on page 2-25if
necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. Try to start the engine in each gear. The starter
should work only in PARK (P) or NEUTRAL (N).
If the starter works in any other position, your
vehicle needs service.
6-27

Automatic Transmission Shift Lock
Control System Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle. It should be parked on a level
surface.
2. Firmly apply the parking brake. SeeParking Brake
on page 2-25if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.3. With the engine off, turn the key to the RUN
position, but do not start the engine. Without
applying the regular brake, try to move the shift
lever out of PARK (P) with normal effort. If the shift
lever moves out of PARK (P), your vehicle needs
service.Ignition Transmission Lock Check
While parked, and with the parking brake set, try to turn
the ignition key to LOCK in each shift lever position.
•The key should turn to LOCK only when the
shift lever is in PARK (P).
•The key should come out only in LOCK.
6-28

Parking Brake and Automatic
Transmission Park (P) Mechanism
Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake, set the
parking brake.
•To check the parking brake’s holding ability: With
the engine running and transmission in
NEUTRAL (N), slowly remove foot pressure from
the regular brake pedal. Do this until the vehicle is
held by the parking brake only.
•To check the PARK (P) mechanism’s holding ability:
With the engine running, shift to PARK (P). Then
release the parking brake followed by the regular
brake.
Underbody Flushing Service
At least every spring, use plain water to flush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
6-29

Throttle System Inspection
Inspect the throttle system for interference or binding,
and for damaged or missing parts. Replace parts
as needed. Replace any components that have high
effort or excessive wear. Do not lubricate accelerator
and cruise control cables.
Transfer Case and Front Axle
(Four-Wheel Drive) Inspection
Every 12 months or at engine oil change intervals, check
front axle and transfer case and add lubricant when
necessary. A fluid loss could indicate a problem; check
and have it repaired, if needed. Check vent hose at
transfer case for kinks and proper installation. More
frequent lubrication may be required on off-road use.
Brake System Inspection
Inspect the complete system. Inspect brake lines and
hoses for proper hook-up, binding, leaks, cracks,
chafing, etc. Inspect disc brake pads for wear and rotors
for surface condition. Inspect other brake parts,
including calipers, parking brake, etc. Check parking
brake adjustment. You may need to have your brakes
inspected more often if your driving habits or
conditions result in frequent braking.
6-31

Part D: Recommended Fluids and
Lubricants
Fluids and lubricants identified below by name, part
number or specification may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM
Standard GM6094M and displays
the American Petroleum Institute
Certified for Gasoline Engines
starburst symbol. To determine the
proper viscosity for your vehicle’s
engine, seeEngine Oil on
page 5-13.
Engine Coolant50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. SeeEngine Coolant on
page 5-23.
Hydraulic Brake
SystemDelco Supreme 11
®Brake Fluid or
equivalent DOT-3 brake fluid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Usage Fluid/Lubricant
Power Steering
SystemGM Power Steering Fluid (GM Part
No. U.S. 89021184, in Canada
89021186).
Automatic
TransmissionDEXRON
®-III Automatic
Transmission Fluid.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
®
(GM Part No. U.S. 12346241, in
Canada 10953474).
Chassis
LubricationChassis Lubricant (GM Part No.
U.S. 12377985, in Canada
88901242) or lubricant meeting
requirements of NLGI #2, Category
LB or GC-LB.
Front Wheel
BearingsWheel bearing lubricant meeting
requirements of NLGI #2, Category
GC or GC-LB (GM Part No. U.S.
1051344, in Canada 993037).
Front and Rear
Axle (Standard
Differential)SAE 80W-90 Axle Lubricant (GM
Part No. U.S. 1052271, in Canada
10950849).
Rear Axle
(Locking
Differential)Axle Lubricant; use only GM Part
No. U.S. 1052271, in Canada
10950849.Do not add friction
modier.
6-32

Additional Program Information
Courtesy Transportation is available during the
Bumper-to-Bumper warranty coverage period, but itis
notpart of the New Vehicle Limited Warranty. A
separate booklet entitled “Warranty and Owner
Assistance Information” furnished with each new vehicle
provides detailed warranty coverage information.
Courtesy Transportation is available only at participating
dealers and all program options, such as shuttle
service, may not be available at every dealer. Please
contact you dealer for specific information about
availability. All Courtesy Transportation arrangements
will be administered by appropriate dealer personnel.
Canadian Vehicles:For warranty repairs during
the Complete Vehicle Coverage period of the General
Motors of Canada New Vehicle Limited Warranty,
alternative transportation may be available under the
Courtesy Transportation Program. Please consult
your dealer for details.
General Motors reserves the right to unilaterally modify,
change or discontinue Courtesy Transportation at
any time and to resolve all questions of claim eligibility
pursuant to the terms and conditions described
herein at its sole discretion.
Vehicle Data Collection and Event
Data Records
Your vehicle, like other modern motor vehicles, has a
number of sophisticated computer systems that monitor
and control several aspects of the vehicle’s
performance. Your vehicle uses on-board vehicle
computers to monitor emission control components to
optimize fuel economy, to monitor conditions for
airbag deployment and, if so equipped, to provide
anti-lock braking and to help the driver control the
vehicle in difficult driving situations. Some information
may be stored during regular operations to facilitate
repair of detected malfunctions; other information
is stored only in a crash or near crash event by
computer systems commonly called event data
recorders (EDR).
In a crash or near crash event, computer systems, such
as the Airbag Sensing and Diagnostic Module (SDM)
in your vehicle may record information about the
condition of the vehicle and how it was operated, such
as engine speed, brake applications, throttle position,
vehicle speed, seat belt usage, airbag readiness, airbag
performance data, and the severity of a collision. This
information has been used to improve vehicle crash
performance and may be used to improve crash
performance of future vehicles and driving safety. Unlike
the data recorders on many airplanes, these on-board
systems do not record sounds, such as conversation of
vehicle occupants.
7-9

Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to
General Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you’ll notify us.
Please call us at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
Transmission, Transaxle, Transfer
Case Unit Repair Manual
This manual provides information on unit repair service
procedures, adjustments, and specifications for GM
transmissions, transaxles, and transfer cases.
RETAIL SELL PRICE: $50.00
7-11

A
Accessory Power Outlets.................................3-17
Adding Equipment to Your Air Bag-Equipped
Vehicle.......................................................1-53
Adding Washer Fluid.......................................5-38
Additional Program Information........................... 7-9
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment...........................5-104
Add-On Equipment..........................................4-48
Adjusting the Speakers
(Balance/Fade)....................3-40, 3-44, 3-53, 3-64
After Off-Road Driving.....................................4-25
Air Bag
Readiness Light..........................................3-26
Air Bag System..............................................1-47
Adding Equipment to Your
Air Bag-Equipped Vehicle..........................1-53
How Does an Air Bag Restrain?....................1-50
Servicing Your Air Bag-Equipped Vehicle.........1-52
What Makes an Air Bag Inflate?....................1-50
What Will You See After an Air Bag Inflates?......1-51
When Should an Air Bag Inflate?...................1-50
Where Are the Air Bags?..............................1-48
Air Cleaner/Filter, Engine.................................5-18
Airbag Sensing and Diagnostic Module (SDM)...... 7-9
AM ...............................................................3-76
AM-FM Radio.................................................3-38
Antenna, Fixed Mast.......................................3-78Antenna, XM™ Satellite Radio Antenna System....3-78
Anti-lock Brake System..................................... 4-7
Anti-Lock Brake, System Warning Light..............3-29
Appearance Care............................................5-94
Care of Safety Belts....................................5-97
Chemical Paint Spotting..............................5-101
Cleaning the Inside of Your Vehicle................5-95
Cleaning the Outside of Your Vehicle..............5-98
Finish Damage..........................................5-101
Sheet Metal Damage..................................5-101
Underbody Maintenance.............................5-101
Vehicle Care/Appearance Materials...............5-102
Weatherstrips..............................................5-98
Approaching a Hill..........................................4-18
Ashtrays........................................................3-18
Assist Handles...............................................2-40
Audio System(s).............................................3-36
AM-FM Radio.............................................3-38
Care of Your Cassette Tape Player................3-76
Care of Your CD Player...............................3-78
Care of Your CDs........................................3-77
Fixed Mast Antenna.....................................3-78
Radio with Cassette and CD.........................3-51
Radio with CD............................................3-41
Radio with Six-Disc CD................................3-61
Setting the Time for Radios with
Radio Data Systems (RDS).......................3-37
Setting the Time for Radios without
Radio Data Systems (RDS).......................3-37
1