Chevrolet CAVALIER 1995-2001 Service Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Cavalier Year Range: 1995-2001 Codes Platform Code: J-Body 👋 Introduction Market Position Segment: Compact/Subcompact Car Target Audience: Budget-conscious buyers, first-time car owners, DIY...

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Type: Car

Vendor:

Sku: 98623

Tags: 1995 1996 1997 1998 1999 2000 2001 Car Cars CAVALIER Chevrolet Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Cavalier

Year Range:

1995-2001

Codes

Platform Code:

J-Body

👋 Introduction

Market Position

Segment:

Compact/Subcompact Car

Target Audience:

Budget-conscious buyers, first-time car owners, DIY mechanics

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Escort, Dodge Neon

Key Features

Value Proposition:

Affordable transportation with reasonable reliability and maintenance costs.

Body Styles:

Coupe, Sedan, Convertible, Wagon (depending on market/specific sub-model)

📋 Manual Details

Coverage Areas

Engine Coverage:

2.2L OHV, 2.3L Quad 4, 2.4L DOHC Quad 4, 3.1L V6

Transmission Coverage:

3-speed Automatic, 4-speed Automatic, 5-speed Manual

Chassis Coverage:

Suspension, Steering, Brakes, Body

Electrical Coverage:

Wiring Diagrams, Lighting, Instruments, Accessories, Powertrain Control

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication, cooling

Fuel System:

Fuel pump, injectors, lines, tank, evaporative emissions (EVAP)

Ignition System:

Coils, spark plugs, wiring, distributor (if applicable), ignition control module

Exhaust System:

Manifolds, catalytic converter, mufflers, pipes

Powertrain Control:

ECM/PCM diagnosis, sensors, actuators, OBD-II diagnostics

Transmission Mechanical:

Automatic transmission overhaul, manual transmission repair, clutch system

Suspension Front:

MacPherson struts, control arms, ball joints, sway bar

Suspension Rear:

Beam axle or independent suspension (depending on trim), shock absorbers, springs

Steering System:

Power steering pump, rack and pinion, steering column

Brake System:

Front disc, rear drum/disc, ABS (if equipped), hydraulic lines, master cylinder, calipers, wheel cylinders

Electrical Battery Charging:

Battery, alternator, starter motor

Lighting Exterior:

Headlights, taillights, turn signals, brake lights

Lighting Interior:

Dome light, dashboard illumination

Instrumentation:

Gauges, warning lights, warning chimes

HVAC System:

Heating, ventilation, air conditioning (compressor, evaporator, condenser, refrigerant)

Body Interior:

Seats, trim, dashboard removal, door panels

Body Exterior:

Bumpers, fenders, hood, doors, trunk lid, glass replacement

Body Electrical:

Power windows, power locks, mirrors, wipers

Safety Systems:

Airbag system (SRS) diagnosis and replacement (cautionary procedures)

Procedures Included

Routine Maintenance:

Oil change, filter replacement, fluid checks, lubrication, tire rotation

Troubleshooting:

Diagnostic charts, symptom analysis, electrical circuit tracing

Repair Replacement:

Component removal, installation, and adjustment for all major systems

Engine Rebuild:

Detailed steps for engine overhaul, including torque specifications and clearances

Transmission Overhaul:

Step-by-step guides for automatic and manual transmission disassembly and reassembly

Brake Service:

Pad/shoe replacement, rotor/drum resurfacing or replacement, brake bleeding

Electrical Diagnosis:

Wiring diagrams interpretation, use of multimeters, troubleshooting electrical faults

HVAC Service:

Refrigerant handling (with proper safety precautions), component replacement

Body Panel Replacement:

Guidance on removing and installing body panels and trim

Technical Depth

Depth:

Comprehensive, covering all aspects from basic maintenance to major component overhauls and diagnostics.

Diagnostic Capabilities:

Detailed diagnostic procedures, including common symptoms and causes, wiring diagrams for tracing faults, and OBD-II code interpretation.

Specifications:

Includes critical torque values, clearances, fluid capacities, and part numbers for repairs.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval

Printability:

Printable pages for hands-on use

Print Quality

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

2.2L (134 ci)

Engine 1 Configuration:

Inline 4-cylinder, OHV

Engine 1 Fuel Delivery:

Multi-port Fuel Injection (MPFI)

Secondary Engine

Engine 2 Displacement:

2.3L (140 ci)

Engine 2 Configuration:

Inline 4-cylinder, DOHC (Quad 4)

Engine 2 Fuel Delivery:

Multi-port Fuel Injection (MPFI)

Tertiary Engine

Engine 3 Displacement:

2.4L (146 ci)

Engine 3 Configuration:

Inline 4-cylinder, DOHC (Quad 4, Twin Cam)

Engine 3 Fuel Delivery:

Multi-port Fuel Injection (MPFI)

V6 Engine

Engine 4 Displacement:

3.1L (189 ci)

Engine 4 Configuration:

V6, OHV

Engine 4 Fuel Delivery:

Multi-port Fuel Injection (MPFI)

Performance

Engine 1 Horsepower Approx:

120 hp @ 5200 rpm

Engine 1 Torque Approx:

130 lb-ft @ 3200 rpm

Engine 4 Horsepower Approx:

160 hp @ 4800 rpm

Engine 4 Torque Approx:

185 lb-ft @ 3200 rpm

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Octane Recommendation:

87 Octane (89 Octane for 3.1L V6 recommended for optimal performance)

🔧 Transmission

Standard

Transmission Type Std:

5-speed Manual

Optional

Transmission Type Opt 1:

3-speed Automatic (THM-125C)

Transmission Type Opt 2:

4-speed Automatic (4T40-E)

Features

Automatic Features:

Electronically controlled, Lock-up torque converter

Fluid Specifications

Automatic Transmission Fluid:

Dexron III/Mercon (GM P/N 12378515 or equivalent)

Manual Transmission Fluid:

Dexron/Mercon ATF or specific manual transmission fluid (refer to manual for exact spec)

📐 Dimensions

Exterior

Wheelbase Approx:

101.4 inches (2576 mm)

Length Approx:

174.7 inches (4437 mm) (Coupe/Sedan)

Width Approx:

67.1 inches (1704 mm)

Height Approx:

52.3 inches (1328 mm) (Coupe)

Weights

Curb Weight Range:

2700-3000 lbs (1225-1360 kg) (Varies by body style and engine)

Gross Vehicle Weight Rating Gvw:

Varies by model, consult VIN plate

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Acceptable (1997-2001 models, 4-star rating)

NHTSA Front Impact Passenger:

Good (1997-2001 models, 5-star rating)

IIHS Side Impact:

Poor to Marginal (depending on year and specific test)

Active Features

Optional on most trims, standard on some higher trims and later models

Passive Features

Airbags:

Driver and passenger airbags (standard for most of the generation)

Seatbelts:

Front and rear seat belts, shoulder belts with pretensioners

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo radio with cassette player; optional CD player available on higher trims.

Speakers:

Standard 4-speaker system; optional 6-speaker system.

Driver Assistance

Cruise Control:

Available as an option on most trims.

Connectivity

OBD Ii:

Features OBD-II (On-Board Diagnostics II) compliance, facilitating easier emissions and powertrain diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles or 6 months, whichever comes first (synthetic oil may extend intervals, refer to manual)

Air Filter Replacement:

Every 15,000-30,000 miles or annually

Spark Plug Replacement:

Every 60,000-100,000 miles (depending on spark plug type)

Coolant Flush:

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

Transmission Fluid Change:

Every 50,000-100,000 miles (depending on driving conditions, consult manual)

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Certified)

Engine Oil Capacity:

4.5 quarts (4.3 L) with filter (2.2L OHV and 2.3/2.4L Quad 4); 5.0 quarts (4.7 L) (3.1L V6)

Coolant Type:

GM P/N 10528494 or equivalent (Green or Orange Long-Life)

Brake Fluid Type:

DOT 3

Power Steering Fluid:

Dexron III/Mercon ATF

Known Issues

Common Problem 1:

Intake manifold gasket leaks (especially on Quad 4 engines)

Common Problem 2:

Alternator failure

Common Problem 3:

Headlight switch issues

Common Problem 4:

Excessive oil consumption (particularly with certain Quad 4 variants)

Common Problem 5:

Door lock actuator failure

Common Problem 6:

EVAP system leaks (check engine light)

📚 Vehicle History

Brand Heritage

Chevrolet History:

Chevrolet, a division of General Motors (GM), has a long history of producing popular and affordable vehicles for the North American market.

Model Evolution

Cavalier Generation:

This manual covers the third generation of the Chevrolet Cavalier, which debuted in 1995, offering a significant redesign over its predecessor.

Design Updates:

The 1995 redesign brought a more aerodynamic and modern appearance. Minor updates occurred throughout the production run.

Production

Production Location:

Various GM assembly plants in North America, including Lordstown, Ohio.

Production Years:

1995-2005 (This manual specifically covers 1995-2001)

🏆 Awards & Recognition

Recognitions

Model Reputation:

The Cavalier was a strong seller due to its low price point and fuel efficiency, though not typically a recipient of major performance or luxury awards.

Ratings

Consumer Reports Reliability:

Reliability varied by powertrain and specific year; generally considered average to below average in its class compared to Japanese competitors.

Certifications

Safety Certifications:

Met all Federal Motor Vehicle Safety Standards (FMVSS) in effect for its production years.