Vehicle Segment:
Compact Car
Target Audience:
Budget-conscious consumers, first-time car buyers, economy-focused drivers
Primary Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Dodge Neon, Nissan Sentra
Value Proposition:
Affordability, practicality, readily available parts, straightforward mechanicals
Manual Value:
Essential for DIY maintenance and repair, reduces reliance on expensive dealership services, aids in troubleshooting and diagnostics
Covered Years:
1995, 1996, 1997, 1998, 1999, 2000, 2001
Covered Models:
Chevrolet Cavalier, Pontiac Sunfire
Covered Body Styles:
Coupe, Sedan, Convertible, Wagon (Cavalier only)
Estimated Page Count:
1500-2000+
Manual Classification:
Factory Service Manual / Repair Manual
Language Content:
English
Delivery Format:
PDF Download
Powertrain:
Engine Mechanical (2.2L OHV, 2.3L Quad 4, 2.4L Twin Cam, 3.1L V6), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System
Transmission:
Manual Transmissions (Getrag 5-speed), Automatic Transmissions (4T40-E, 4T45-E)
Chassis:
Suspension (Front Struts, Rear Shock Absorbers, Control Arms), Steering System (Power Rack and Pinion), Brakes (Front Disc, Rear Drum/Disc), Wheel Bearing Replacement
Electrical:
Wiring Diagrams, Lighting, Ignition Switch, Power Distribution, Fuses and Relays, Charging System, Starting System, Body Control Modules, Instrument Cluster
Body And Interior:
Body Panels, Doors, Windows, Seats, HVAC System, Body Hardware, Trim Components, Convertible Top Systems (if applicable)
Maintenance Procedures:
Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Inspections and Replacement, Fluid Level Checks and Top-offs, Brake Pad Replacement, Tire Rotation
Repair Procedures:
Engine Overhaul/Rebuild, Transmission Removal and Installation, Brake System Service, Suspension Component Replacement, Electrical Component Diagnosis and Replacement, Fuel System Component Repair, Exhaust System Repair
Diagnostics And Troubleshooting:
Diagnostic Trouble Codes (DTCs), Engine Performance Issues, Transmission Shifting Problems, Electrical System Faults, HVAC System Malfunctions, ABS System Diagnosis
Diagnostic Capabilities:
Detailed diagnostic flowcharts, component testing procedures, wiring harness schematics, sensor data interpretation
Rebuild Procedures:
Comprehensive engine and transmission rebuild specifications, torque values, clearances, and assembly sequences
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures
Cavalier Sunfire 2.2L OHV Inline-4:
2.2L (2198cc) SOHC Inline-4, 115-125 hp, 130-135 lb-ft torque (variable by year/tune)
Cavalier Sunfire 2.3L Quad 4 Inline-4:
2.3L (2319cc) DOHC Inline-4, 150-180 hp, 155-170 lb-ft torque (High Output versions available)
Cavalier Sunfire 2.4L Twin Cam Inline-4:
2.4L (2392cc) DOHC Inline-4, 150-170 hp, 165-175 lb-ft torque (LD9 Engine)
Cavalier Sunfire 3.1L V6:
3.1L (3135cc) OHV V6, 155-170 hp, 185-190 lb-ft torque (L82/LG7 Engines)
Acceleration 0 60 Mph:
Approximately 8-11 seconds (depending on engine and transmission)
Fuel Delivery:
Multi-port Fuel Injection (MPFI)
Recommended Fuel:
87 Octane Unleaded Gasoline (higher for Quad 4 High Output and performance variants)
Standard Transmission Type:
5-Speed Manual Transmission (Getrag F23)
Optional Transmission Type:
4-Speed Automatic Transmission (4T40-E / 4T45-E)
Automatic Transmission Features:
Electronically controlled, overdrive, torque converter lock-up
Manual Transmission Fluid:
GM Synchromesh Transmission Fluid or equivalent (e.g., Dexron III/VI, check manual for exact spec)
Automatic Transmission Fluid:
Dexron III or Dexron VI automatic transmission fluid (ATF)
NHTSA Driver Frontal Crash Rating:
4/5 Stars (for models equipped with dual airbags)
NHTSA Passenger Frontal Crash Rating:
4/5 Stars (for models equipped with dual airbags)
Anti Lock Brakes:
Optional on many trims, standard on some later models
Airbags:
Driver and Passenger airbags became standard in later years of this generation
Seat Belts:
3-point front and rear seat belts
Audio System:
Basic AM/FM stereo with cassette player, optional CD player available on higher trims or as an upgrade
Speakers:
Typically 4 or 6 speaker configurations
Cruise Control:
Optional or standard on higher trims
Auxiliary Inputs:
N/A (Pre-auxiliary era, aftermarket solutions common)
Oil Change Interval:
Every 7,500 miles or 6 months (using synthetic oil), or 3,000-5,000 miles (conventional oil) – refer to manual for exact year/engine
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on driving conditions
Spark Plug Replacement:
Typically every 60,000-100,000 miles for platinum/iridium plugs, or 30,000 miles for standard plugs
Coolant Flush Interval:
Every 30,000-50,000 miles or 2-5 years
Engine Oil Specification:
SAE 5W-30 (most common, check manual for specific engine variant and temperature range)
Coolant Specification:
GM Type II (Orange) Antifreeze/Coolant, or equivalent silicate-free, ethylene glycol based coolant
Brake Fluid Specification:
DOT 3
Common Engine Problems:
Head gasket leaks (especially on 2.2L OHV), intake manifold gasket leaks, oil leaks, PCV system issues, intake manifold runner control (IMRC) problems on Quad 4 engines
Common Transmission Problems:
Automatic transmission solenoid failures, torque converter shudder, clutch wear on manual transmissions
Common Suspension Steering Problems:
Worn front struts, ball joints, tie rod ends, power steering pump leaks, tie rod boots
Common Electrical Problems:
Faulty ignition switch, dashboard warning lights (ABS, Check Engine), faulty fuel pumps, wiring harness corrosion
Common Body Issues:
Rust on wheel wells, rocker panels, and door bottoms; interior trim creaks and rattles
Chevrolet Legacy:
Chevrolet, a division of General Motors, has a long history of producing affordable and reliable American vehicles.
Cavalier Model Line:
The Cavalier was a staple in Chevrolet's lineup for decades, known for its value and practicality. The 1995 redesign brought a more modern aesthetic and improved safety features.
Sunfire Model Line:
The Pontiac Sunfire was introduced as a sportier, more youthful sibling to the Cavalier, sharing the same J-Body platform and many mechanical components.
Manufacturing Location:
North America (primarily Lordstown, Ohio, USA)
Production Period:
1995-2001 (for this specific manual coverage)
General Reputation:
Often recognized for affordability and as a reliable starter vehicle, though performance varied significantly with engine choice.
Consumer Reports Ratings:
Variable; often cited for average to below-average reliability in certain model years and powertrain combinations.
Emissions Standards:
Designed to meet U.S. Federal EPA emissions standards for the respective model years.
