🏷️ Basic Information

Make:

Chevrolet

Model:

Cavalier

Year:

1992

Platform Code:

J-body (GM J platform)

👋 Introduction

Segment:

Compact car, entry-level to mid-range.

Target Audience:

Budget-conscious buyers, first-time car owners, commuters.

Key Competitors 1992:

Ford Escort, Honda Civic, Toyota Corolla, Nissan Sentra, Plymouth Sundance/Dodge Shadow.

Value Proposition:

Affordable price point, fuel efficiency, practical design, wide availability of parts and service.

Model Variants:

Available in coupe, sedan, and hatchback body styles.

📋 Manual Details

Coverage Scope:

All models and all repairs A-Z

Estimated Page Count:

Approx. 1500-2000 pages (typical for comprehensive factory service manuals of this era)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Printed (typical for original issue, potential for digital formats like PDF for reproductions)

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, cylinder head, block assembly, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (carburetor & TBI), ignition system (distributor, coil, plugs), emissions control systems.

Engine Performance:

Diagnosis and testing of engine performance issues, fuel injection (TBI) system diagnostics, emissions testing and adjustments.

Transmission Manual:

Manual transmission overhaul, clutch system, shifting mechanisms, linkage adjustments, fluid specifications.

Transmission Automatic:

Automatic transmission overhaul (e.g., TH125-C/3T40), torque converter, hydraulic controls, shift linkage, cooling, diagnosis and repair of automatic transmission issues.

Suspension:

Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), alignment procedures, steering knuckle, wheel bearings, service and replacement of suspension parts.

Steering:

Power steering system, steering column, steering rack/gearbox, power steering pump, fluid specifications, bleeding procedures, diagnosis of steering problems.

Brakes:

Front disc brakes (calipers, rotors, pads), rear drum brakes (wheel cylinders, shoes, drums), parking brake system, hydraulic system (master cylinder, brake lines, hoses), ABS (if equipped), bleeding procedures, brake fluid specifications.

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), ignition system, lighting system (headlights, taillights, interior lights), accessory circuits, fuses, relays, wiring diagrams for all major systems.

Body And Frame:

Body panel removal and installation, door mechanisms, window regulators, interior trim, seat components, exterior trim, bumpers, glass replacement, rust repair considerations, chassis lubrication.

Heating Ventilation Air Conditioning:

HVAC system diagnosis, heater core, evaporator core, A/C compressor, refrigerant handling (R-12), blower motor, controls, ducting, service procedures for A/C system.

Instrumentation And Controls:

Dashboard components, gauges, warning lights, switches, control panels, driver interfaces.

Routine Maintenance:

Oil change intervals, filter replacement, spark plug replacement, air filter replacement, fluid level checks and top-offs, tire rotation.

Troubleshooting:

Systematic diagnostic procedures for all major vehicle systems, symptom-based troubleshooting charts.

Component Removal And Installation:

Detailed, step-by-step instructions for removing and installing virtually every mechanical and electrical component.

Engine Rebuilding:

Complete engine overhaul procedures, including disassembly, cleaning, inspection, measuring (clearances, tolerances), and reassembly with torque specifications.

Transmission Repair:

Detailed procedures for rebuilding both manual and automatic transmissions, including overhaul kits and component replacement.

Brake System Service:

Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper/wheel cylinder rebuild, master cylinder replacement, brake line repair, bleeding the brake system.

Electrical Diagnostics:

Using multimeters, testing circuits, diagnosing electrical faults, wiring harness repair, connector servicing, component testing.

Wheel Alignment:

Specifications and procedures for front and rear wheel alignment, caster, camber, toe adjustments.

Emissions Control Service:

Inspection and servicing of emission control components such as catalytic converters, oxygen sensors, EGR valves, and charcoal canisters.

Depth Of Information:

Vehicle specific, not generic. Covers everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostics, specifications, and wiring diagrams.

Diagnostic Charts:

Includes specific diagnostic flowcharts and troubleshooting trees for common and uncommon issues.

Torque Specifications:

Comprehensive list of all necessary torque specifications for engine, chassis, and drivetrain components.

Schematics:

Detailed wiring diagrams for all electrical systems, including engine control, lighting, and accessories.

Exploded Views:

Illustrations and exploded views of various components and assemblies to aid in identification and reassembly.

📊 Manual Specifications

File Type:

Likely originally printed. Digital versions may be available as PDFs, often scanned from original publications.

Print Quality:

Originals typically feature high-quality printing with clear text and diagrams. Scanned PDFs can vary in quality.

Binding:

Originals often hardbound or perfect-bound for durability. Digital files do not have binding.

Paper Quality:

Originals printed on durable paper suitable for workshop use.

⚙️ Engine Specifications

Engine Code 1 4 Cyl:

2.2L L4 (VIN 'A') - 2198cc OHV

Engine Code 2 4 Cyl:

2.0L L4 (VIN 'C') - 1998cc SOHC (Optional)

Engine Code 3 4 Cyl:

2.3L L4 Quad 4 (VIN 'D') - 2300cc DOHC (Optional, performance oriented)

Horsepower 2 2L:

Approx. 96 hp @ 4800 rpm (Varies slightly by year/application)

Torque 2 2L:

Approx. 125 lb-ft @ 2800 rpm (Varies slightly by year/application)

Horsepower 2 0L:

Approx. 97 hp @ 4800 rpm (Varies slightly by year/application)

Torque 2 0L:

Approx. 118 lb-ft @ 2800 rpm (Varies slightly by year/application)

Horsepower Quad 4:

Approx. 160 hp @ 6000 rpm (For the HO version, standard Quad 4 may be less)

Torque Quad 4:

Approx. 150 lb-ft @ 4800 rpm (For the HO version)

Fuel Delivery Standard:

Throttle Body Injection (TBI) on most engines.

Fuel Delivery Optional:

Some later models or specific trims might have Multi-Port Fuel Injection (MPFI) on certain engines, but TBI was common for '92.

Fuel Type:

Unleaded gasoline, typically 87 octane (check manual for specific octane recommendations).

Valvetrain 2 2L:

Overhead Valve (OHV) with pushrods and rocker arms.

Valvetrain Quad 4:

Dual Overhead Camshaft (DOHC), 4 valves per cylinder.

🔧 Transmission

Standard Transmission:

5-speed manual transmission.

Optional Transmission:

3-speed automatic transmission (e.g., TH125-C or GM 3T40).

Drive Type:

Front-Wheel Drive (FWD).

Manual Transmission Fluid:

Dexron-III/Mercon Automatic Transmission Fluid (ATF) or equivalent for manual transmissions (verify in manual).

Automatic Transmission Fluid:

Dexron-III/Mercon Automatic Transmission Fluid (ATF) or equivalent.

📐 Dimensions

Wheelbase:

Approximately 101.2 inches (2570 mm).

Overall Length:

Varies by body style (e.g., Coupe: ~172 inches, Sedan: ~178 inches).

Overall Width:

Approximately 67.4 inches (1712 mm).

Overall Height:

Varies by body style (e.g., Coupe: ~51.6 inches, Sedan: ~53.4 inches).

Curb Weight:

Ranges from approximately 2400 - 2700 lbs (1090 - 1225 kg) depending on body style and equipment.

Standard Wheel Size:

14-inch or 15-inch steel or alloy wheels.

Standard Tire Size:

Typically P185/70R14 or P195/60R15 (check manual for exact fitment).

Bolt Pattern:

4 x 100mm (4 x 3.94 inches).

🛡️ Safety Features

NHTSA Crash Test Results:

Information for 1992 models is limited; expect basic safety features for the era. Check NHTSA archives for specific data, though it may be sparse for this year.

Active Safety Features:

Four-wheel disc brakes (optional on some trims/models), Anti-lock Braking System (ABS) optional on higher trims or specific models.

Passive Safety Features:

Seat belts (driver, passenger, rear), reinforced safety cage, padded dashboard and steering column.

Airbags:

Driver-side airbag was optional or standard on some later '92 models, but not universal.

💡 Technology Features

Audio System:

Factory AM/FM stereo radio, often with cassette player. Optional CD player available on higher trims.

Controls:

Manual climate controls, dashboard-mounted radio and HVAC controls.

Cruise Control:

Optional on most models.

Connectivity Features:

None in the modern sense. Connectivity would be limited to power windows/locks if optioned.

🔧 Maintenance

Oil Change Interval:

Every 3,000 miles or 3 months (typical for the era; consult manual for specific recommendations based on driving conditions).

Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on inspection.

Spark Plug Replacement:

Every 30,000-60,000 miles depending on spark plug type (copper vs. platinum).

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic transmissions, check manual for manual transmission service.

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years.

Engine Oil Viscosity:

Typically SAE 5W-30 or 10W-30 (verify with manual for specific engine).

Coolant Type:

GM-specified Type 1 coolant (green) or equivalent silicate-free ethylene glycol based antifreeze.

Brake Fluid Type:

DOT 3 brake fluid.

Common Wear Items:

Struts, ball joints, tie rod ends, exhaust system components, alternator, starter, fuel pumps, oxygen sensors, coolant leaks (intake manifold gaskets, water pump).

Electrical Gremlins:

Corrosion on grounds, faulty window motors, dashboard indicator light issues, and intermittent electrical faults can occur due to age.

Engine Specific Issues 2 2L:

Intake manifold gasket leaks (common on GM engines of this era), oil consumption can increase with mileage.

Engine Specific Issues Quad 4:

While powerful, the Quad 4 could be prone to head gasket issues if overheated, and requires precise maintenance. Some models had issues with timing belts.

📚 Vehicle History

Chevrolet Heritage:

Chevrolet, a division of General Motors, has a long history of producing reliable and affordable vehicles for the American market since 1911.

Cavalier J Body Generation:

The 1992 Cavalier is part of the second generation of the J-body platform, which debuted in 1982. This generation received significant updates and facelifts over its lifespan, with the 1982-1987 models being the first iteration and the 1988-1994 models representing a redesigned and updated version.

1992 Updates:

The 1992 model year saw continued refinement of the second-generation Cavalier, focusing on aerodynamics and updated styling. This included revised front and rear fascias.

Manufacturing Location:

Primarily manufactured in North America (USA and Canada).

🏆 Awards & Recognition

Historical Accolades:

While the Cavalier was a strong seller, it was generally not a recipient of major industry awards for performance or luxury. Its success was primarily driven by its affordability and practicality.