🏷️ Basic Information

Make:

Chevrolet

Model:

Cavalier

Year:

1996

Platform:

J-Body

👋 Introduction

Segment:

Compact Car

Target Audience:

Owners seeking to perform their own maintenance and repairs, professional mechanics working on the Chevrolet Cavalier.

Competitors:

Ford Escort, Honda Civic, Toyota Corolla, Nissan Sentra.

Value Proposition:

Provides official factory-level repair information, enabling accurate diagnosis and repair, saving money on labor costs, and ensuring proper vehicle maintenance.

📋 Manual Details

Covered Sections:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body and Frame, Diagnostic Trouble Codes (DTCs), Maintenance Schedules, Troubleshooting Guides, Wiring Diagrams.

Estimated Pages:

1500+

Type:

Official Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

2.2L L4 (VIN 4), 2.4L DOHC L4 (VIN 8), 3.1L V6 (VIN T). Includes troubleshooting, diagnosis, repair, and overhaul procedures.

Transmission:

4-speed Automatic (4T40-E), 5-speed Manual. Includes diagnosis, repair, and overhaul for both.

Drivetrain:

Front Wheel Drive (FWD), CV Axles, Differential, Clutch (Manual).

Suspension Steering:

Front MacPherson Struts, Rear Torsion Beam Axle, Power Steering System, Steering Column, Wheel Alignment Specifications.

Brakes:

Front Disc Brakes, Rear Drum Brakes, Anti-lock Braking System (ABS) (if equipped), Brake System Diagnosis and Repair.

Electrical System:

Battery, Charging System, Starting System, Ignition System, Lighting, Gauges, Instruments, Fuses, Relays, Body Control Modules, Powertrain Control Modules (PCM), Diagnostic Trouble Codes (DTCs), Wiring Diagrams for all systems.

HVAC:

Air Conditioning System, Heater, Ventilation, Blower Motor, Controls, Refrigerant Handling Procedures.

Body Frame:

Body Panels, Doors, Hood, Trunk, Glass, Interior Trim, Seats, Bumpers, Frame Repair (if applicable).

Maintenance:

Oil Changes, Filter Replacements, Fluid Checks and Replenishments, Spark Plug Replacement, Belt Replacement, Tire Rotation, Brake Pad Replacement, Tune-up procedures.

Repair:

Complete engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical component diagnosis and repair, HVAC system repair, fuel system repair, exhaust system repair.

Diagnostics Troubleshooting:

Systematic troubleshooting charts, pinpoint tests for electrical issues, diagnostic trouble code (DTC) interpretation and resolution, common problem diagnosis.

Depth:

Comprehensive. Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed electrical system diagnostics and component-level repair.

📊 Manual Specifications

Quality:

High-resolution, searchable PDF with clear text and images. Printable.

Readability:

Excellent. Designed for clarity of text and diagrams, ensuring ease of use for mechanics and DIY enthusiasts.

Binding:

N/A (Digital PDF Download)

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

2.2L L4:

Engine Code: VIN 4 (2200). Features: Overhead Valves (OHV), Multi-Port Fuel Injection (MPFI). Approximate Horsepower: 115 hp @ 5200 rpm. Approximate Torque: 130 lb-ft @ 3200 rpm.

2.4L DOHc L4:

Engine Code: VIN 8 (LD9). Features: Dual Overhead Camshafts (DOHC), Sequential Fuel Injection (SFI), Dual Counter-rotating Balance Shafts. Approximate Horsepower: 150 hp @ 6000 rpm. Approximate Torque: 155 lb-ft @ 4400 rpm.

3.1L V6:

Engine Code: VIN T (3100 SFI). Features: Overhead Valves (OHV), Sequential Fuel Injection (SFI). Approximate Horsepower: 160 hp @ 5200 rpm. Approximate Torque: 185 lb-ft @ 3600 rpm.

Fuel Recommendation:

Unleaded Regular (87 Octane) for 2.2L and 3.1L. Unleaded Premium (91 Octane) recommended for 2.4L DOHC for optimal performance.

Injection Type:

Multi-Port Fuel Injection (MPFI) or Sequential Fuel Injection (SFI) depending on engine.

2.2L L4:

4.5 US quarts (4.3 L) with filter change.

2.4L L4:

4.5 US quarts (4.3 L) with filter change.

3.1L V6:

4.5 US quarts (4.3 L) with filter change.

🔧 Transmission

Transmission 1:

5-speed Manual (Getrag F23 or similar) - Standard on most models.

Transmission 2:

4-speed Automatic (4T40-E) - Optional.

Automatic Transmission Fluid:

Dexron III (or equivalent) is recommended. Capacity typically around 7-8 quarts for a complete refill.

Manual Transmission Fluid:

GM Synchromesh (or equivalent GL-4 specification) is recommended. Capacity approximately 2.2 liters.

📐 Dimensions

Wheelbase:

Approximately 103.2 inches (2621 mm)

Length:

Approximately 179.7 inches (4564 mm)

Width:

Approximately 67.5 inches (1715 mm)

Height:

Approximately 53.3 inches (1354 mm) for Coupe, 53.4 inches (1356 mm) for Sedan/Coupe.

Curb Weight:

Varies by model and engine, generally between 2700 - 2900 lbs (1225 - 1315 kg).

Trunk Volume:

Approximately 13.2 cubic feet (374 liters) for Coupe, 14.3 cubic feet (405 liters) for Sedan. (May vary slightly by body style).

🛡️ Safety Features

NHTSA Frontal Impact:

NHTSA frontal impact ratings for 1996 Cavaliers were generally 3-star or 4-star for driver and passenger. Specific ratings can vary by model year and testing procedures.

ABS:

Anti-lock Braking System (ABS) was an optional feature on most 1996 Cavalier models.

Airbags:

Driver-side airbag was standard. Passenger-side airbag was optional on some configurations.

Seatbelts:

Front and rear seat belts, with shoulder belts for front occupants.

💡 Technology Features

Audio System:

Factory AM/FM stereo with cassette player was standard. Optional CD player or premium sound systems were available on higher trim levels.

Controls:

Manual controls for climate and audio systems.

Cruise Control:

Optional on most models.

Connectivity Features:

No modern connectivity features like Bluetooth or USB. Factory wiring harnesses are basic.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on oil type and driving conditions. Refer to manual for specific recommendations.

Air Filter Replacement:

Approximately every 15,000-30,000 miles (24,000-48,000 km).

Spark Plug Replacement:

Varies by plug type. Conventional: 30,000 miles. Platinum/Iridium: 60,000-100,000 miles.

Coolant Flush:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-5 years, depending on coolant type.

Engine Oil:

SAE 5W-30 or 5W-40 synthetic blend recommended for most conditions. Check owner's manual for specific recommendations. API Service SJ or higher.

Coolant:

GM P/N 1052736 (Green) or equivalent. A 50/50 mix of ethylene glycol and distilled water.

Brake Fluid:

DOT 3 Brake Fluid.

Common Problems 1:

Head gasket failures (especially on early 2.4L LD9 engines), intake manifold gaskets leaking, power steering pump leaks, EGR valve issues, ABS sensor failures, window regulator failures, rust on body panels (especially wheel wells and rocker panels).

Common Problems 2:

CV joint wear, exhaust system corrosion, interior trim pieces becoming loose or brittle with age.

Common Tire Sizes:

Commonly 195/70R14, 205/60R15. Check door jamb sticker for specific fitment.

Bolt Pattern:

5 x 100 mm (5 x 3.94 inches).

📚 Vehicle History

Chevrolet Legacy:

Chevrolet, a division of General Motors, has a long history dating back to 1911, known for producing a wide range of vehicles from economy cars to performance vehicles and trucks.

Cavalier Lineage:

The Cavalier was introduced for the 1982 model year as Chevrolet's entry into the compact segment. It was built on GM's J-body platform and went through several generations, with the 1995-2005 models representing the third generation, characterized by more rounded styling and improved features.

Manufacturing Locations:

Primarily produced in the United States (e.g., Lordstown, Ohio) and Mexico.

Production Years:

1982-2005

🏆 Awards & Recognition

Historical Awards:

While not a recipient of major awards in 1996, the Cavalier was a significant volume seller for Chevrolet, popular for its affordability and fuel efficiency in the compact car segment during its production run.