Market Segment:
Compact car, popular with first-time buyers and budget-conscious consumers.
Key Competitors:
Ford Escort, Honda Civic, Toyota Corolla, Nissan Sentra, Dodge Neon.
Vehicle Attributes:
Affordability, fuel efficiency, reliability, practical design, available in coupe, sedan, and convertible body styles.
Coverage Summary:
Comprehensive servicing, repair, diagnostics, and troubleshooting for all major mechanical, electrical, and body systems.
Estimated Page Count:
Over 1000 pages (typical for a factory workshop manual of this era covering multiple years and engine variants).
Manual Type:
Factory Workshop Service Repair Manual
Format:
Digital Download (PDF)
Powertrain:
Engine, Fuel System, Exhaust System, Ignition System, Cooling System, Lubrication System, Transmission (Manual & Automatic).
Chassis:
Suspension (Front & Rear), Steering System, Brakes (Hydraulic, ABS), Wheels & Tires.
Electrical:
Battery, Charging System, Starting System, Lighting, Ignition, Instrumentation, Body Control Modules, Powertrain Control Modules (PCM), HVAC Controls, Audio Systems, Anti-theft Systems.
Body:
Exterior Body Panels, Doors, Glass, Interior Trim, Seats, Bumpers, Structural Components.
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, belt inspections, spark plug replacement, tune-ups.
Engine Repair:
Engine overhaul, piston and ring replacement, cylinder head removal and installation, camshaft and timing belt/chain service, valve adjustment, oil pump service.
Transmission Service:
Automatic transmission fluid and filter changes, manual transmission clutch replacement, gearbox overhaul, shift linkage adjustment.
Brake Service:
Brake pad and rotor replacement, brake caliper service, brake fluid bleeding, ABS system diagnosis and repair.
Electrical Diagnostics:
Wiring diagrams, component testing, circuit diagnosis, scan tool usage for OBD-II codes.
Diagnostic Troubleshooting:
In-depth troubleshooting charts, symptom-based diagnostics, fault code explanations.
Rebuilding Procedures:
Complete engine and transmission rebuilding procedures, including torque specifications and assembly sequences.
Specifications Data:
Detailed technical specifications for all components, including clearances, tolerances, and torque values.
Engine Code:
L43 (2.2L SOHC)
Displacement:
2.2 Liters (2198 cc)
Horsepower Range:
Approx. 115-125 hp (depending on year and specific tuning)
Torque Range:
Approx. 130-135 lb-ft
Fuel System:
Electronic Fuel Injection (EFI), Throttle Body Injection (TBI) in earlier models.
Engine Code:
LD9 (2.4L DOHC)
Displacement:
2.4 Liters (2384 cc)
Horsepower Range:
Approx. 150 hp
Torque Range:
Approx. 155 lb-ft
Fuel System:
Multi-Port Fuel Injection (MPFI)
Engine Code:
VIN Code 'R' (3.1L V6)
Displacement:
3.1 Liters (3135 cc)
Horsepower Range:
Approx. 150-170 hp (depending on year and specific tuning)
Torque Range:
Approx. 175-180 lb-ft
Fuel System:
Multi-Port Fuel Injection (MPFI)
Type:
3-Speed Automatic (e.g., TH125-4L2, 4T40-E)
Type:
4-Speed Automatic (e.g., 4T40-E for later models)
Fluid Type:
Dexron III (or equivalent) for automatic transmissions. Manual transmissions typically use GL-4 gear oil.
Wheelbase:
Approx. 101.3 inches (2573 mm)
Length:
Approx. 170.5 - 177.3 inches (4331 - 4503 mm) depending on body style
Width:
Approx. 67.4 inches (1712 mm)
Height:
Approx. 53.3 - 54.2 inches (1354 - 1377 mm) depending on body style
Curb Weight:
Approx. 2500 - 2900 lbs (1134 - 1315 kg) depending on engine and options
NHTSA Front Impact:
Likely 4 stars for driver, 4 stars for passenger (based on contemporary testing of similar vehicles).
IIHS Side Impact:
Varies by year and specific test protocols. Some models may have received 'Acceptable' or 'Marginal' ratings.
ABS:
Optional on many models, standard on some higher trims or later years.
Airbags:
Driver and passenger airbags standard from 1997 onwards. Earlier models may have had optional driver airbag only.
Seatbelts:
Front and rear seat belts, shoulder belts for front occupants.
Oil Change Interval:
Typically every 5,000 - 7,500 miles or 6-12 months with synthetic oil. Refer to manual for specific recommendations.
Timing Belt Replacement:
For 2.2L SOHC (L43) and 2.4L DOHC (LD9) engines: Typically every 90,000 - 100,000 miles. Critical to follow manual due to potential for catastrophic engine damage if belt breaks.
Coolant Flush:
Every 30,000 - 50,000 miles or 2-5 years, depending on coolant type.
Engine Oil:
API Service SG, SH, or SJ category. Viscosity typically SAE 5W-30 or 10W-30 (refer to manual based on temperature).
Coolant:
GM specification 6043-M, typically a green ethylene glycol-based antifreeze. 50/50 mix with distilled water.
Head Gaskets:
Some earlier models, particularly with the 2.2L engine, were known to have head gasket issues. The manual will provide diagnosis and repair procedures.
Intake Manifold Gaskets:
Plastic intake manifold gaskets on some V6 engines can become brittle and leak coolant or vacuum.
Transmission Hard Shifting:
Automatic transmission control solenoids or valve body issues can lead to harsh shifts or failure to shift.
Power Window Motors:
Power window regulators and motors can fail over time.
Idler Pulley Noise:
The tensioner or idler pulley on the accessory drive belt can sometimes develop bearing noise.
Chevrolet Legacy:
Chevrolet, a division of General Motors (GM), has a long history of producing popular and accessible vehicles for the American market.
Third Generation:
This 1995-2005 period covers the third generation of the Chevrolet Cavalier, which underwent a significant redesign in 1995, moving to the GM J-body platform. This generation saw increased refinement, updated styling, and improved safety features compared to its predecessors.
Manufacturing Locations:
Primarily manufactured by General Motors in the United States (e.g., Lordstown, Ohio) and Canada.
Initial Release Recognition:
The Cavalier was consistently a strong seller and often cited in lists of affordable and economical vehicles upon its release in this generation.
Consumer Reports Rankings:
Typically ranked as average to below average in reliability and owner satisfaction by publications like Consumer Reports, particularly in later years of this generation. This manual is crucial for addressing these common issues.
