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2001 Chevrolet Cavalier Service and Repair Manual
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Basic Information Identification Make: Chevrolet Model: Cavalier Year: 2001 Product Type: Service and Repair Manual Introduction Market Position Market Segment: Compact car, popular for affordability, fuel efficiency, and practicality. Competitive...
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| Basic Information | |
| Identification | |
| Make: | Chevrolet |
| Model: | Cavalier |
| Year: | 2001 |
| Product Type: | Service and Repair Manual |
| Introduction | |
| Market Position | |
| Market Segment: | Compact car, popular for affordability, fuel efficiency, and practicality. |
| Competitive Analysis | |
| Key Competitors: | Ford Focus, Honda Civic, Toyota Corolla, Dodge Neon, Nissan Sentra. |
| Key Features | |
| Vehicle Platform: | GM J-body platform (shared with Pontiac Sunfire). |
| Body Styles: | Available as coupe and sedan, offering versatility for different needs. |
| Trim Levels: | Typically included base, LS, and sporty Z24 trims, catering to different buyer preferences and budgets. |
| Manual Details | |
| Coverage Areas | |
| Coverage Scope: | All Models & All Repairs A-Z |
| Data Specificity: | Vehicle Specific - Exact same manual used by dealership technicians |
| Page Count | |
| Page Count: | Estimated 1500-2000+ pages (typical for comprehensive service manuals of this era) |
| Manual Type | |
| Manual Type: | Factory Service Manual (FSM) / Workshop Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Detailed diagnosis, disassembly, inspection, repair, and assembly of all engine components (e.g., cylinder head, pistons, crankshaft, camshafts, valve train). |
| Engine Performance: | Fuel delivery, ignition system, emissions control, cooling system, lubrication system, engine diagnostics, performance tuning. |
| Transmission Manual: | Diagnosis, disassembly, inspection, repair, and assembly of manual transmissions, including clutch system. |
| Transmission Automatic: | Diagnosis, overhaul, repair, and troubleshooting of automatic transmissions, including torque converter, valve body, and electronic controls. |
| Drivetrain: | Front-wheel drive axle shafts, CV joints, differential assembly, wheel bearings. |
| Suspension: | Front and rear suspension components, shock absorbers, struts, control arms, bushings, alignment specifications. |
| Steering: | Power steering system diagnosis and repair, steering gear, tie rods, steering column. |
| Brakes: | Front and rear disc/drum brake systems, ABS (Anti-lock Braking System) diagnosis and repair, brake fluid specifications, master cylinder, calipers, wheel cylinders. |
| Electrical System: | Battery, starting system, charging system (alternator), wiring diagrams, fuses, relays, lighting systems. |
| Engine Control System: | ECM/PCM (Engine Control Module/Powertrain Control Module) diagnostics, sensor inputs (e.g., crankshaft position, camshaft position, MAP, MAF, O2), actuator outputs. |
| Body And Trim: | Interior trim removal and installation, exterior trim, doors, windows, locks, mirrors, bumpers, hoods, trunk lid. |
| HVAC: | Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant types, components (compressor, condenser, evaporator). |
| Restraints: | Airbag system diagnosis and repair, seat belts, SRS module. |
| Body Control Module: | Diagnosis and repair of BCM functions, including interior/exterior lighting, power locks, windows, and instrument cluster. |
| Procedures Included | |
| Scheduled Maintenance: | Detailed maintenance schedules for oil changes, filter replacements, fluid checks and changes, spark plugs, belts, hoses, etc. |
| Troubleshooting: | Systematic diagnostic procedures for identifying and resolving common and uncommon faults, including symptom-based troubleshooting guides. |
| Repair Procedures: | Step-by-step instructions for component removal, installation, and adjustment for all vehicle systems. |
| Torque Specifications: | Precise torque values for all fasteners and critical components. |
| Special Tools: | Identification and usage of specialized tools required for specific repairs. |
| Wiring Diagrams: | Comprehensive electrical wiring schematics for all vehicle systems, aiding in diagnosis and repair. |
| Diagnostic Trouble Codes: | Explanation of OBD-II (On-Board Diagnostics II) codes, their meaning, and associated diagnostic procedures. |
| Component Testing: | Methods for testing the functionality of individual electrical and mechanical components. |
| Alignment Procedures: | Front and rear wheel alignment specifications and adjustment procedures. |
| Technical Depth | |
| Depth Of Coverage: | Complete rebuilds and overhaul procedures for major components. |
| Diagnostic Capability: | Advanced diagnostic strategies and troubleshooting for complex electronic and mechanical issues. |
| Data Availability: | Includes specifications for tolerances, clearances, fluid capacities, electrical resistance, and voltage measurements. |
| Manual Specifications | |
| File Format | |
| File Format: | Physical book (print) |
| Print Quality | |
| Print Quality: | High-quality paper and durable binding suitable for workshop environments. |
| Binding Type | |
| Binding Type: | Perfect bound or spiral bound (common for ease of use on a workbench). |
| Paper Type | |
| Paper Type: | Durable, often coated paper to resist grease and dirt. |
| Content Completeness | |
| Completeness Level: | Comprehensive, covering maintenance, troubleshooting, diagnostics, repair, and specifications for all vehicle systems. |
| Engine Specifications | |
| Primary Engine | |
| Engine Code: | 2.2L Ecotec (L61) |
| Engine Type: | Inline-4 Cylinder, DOHC, 16-valve |
| Displacement: | 2198 cc (134 cu. in.) |
| Performance | |
| Horsepower: | Approximately 125-135 hp @ 5000-5200 RPM (depending on specific calibration) |
| Torque: | Approximately 135-140 lb-ft @ 3800-4000 RPM (depending on specific calibration) |
| Fuel System | |
| Fuel Delivery: | Sequential Electronic Fuel Injection (SEFI), Multi-Port Fuel Injection (MPFI) |
| Fuel Type: | Unleaded gasoline, 87 octane recommended |
| Engine Variants | |
| Optional Engine: | 2.4L DOHC Ecotec (LDA) - Found in Z24 models, offering increased performance. |
| Optional Engine Hp: | Approximately 150 hp @ 5600 RPM (for 2.4L LDA) |
| Optional Engine Torque: | Approximately 155 lb-ft @ 4400 RPM (for 2.4L LDA) |
| Transmission | |
| Standard | |
| Transmission Type Std: | 5-speed Manual Transmission |
| Optional | |
| Transmission Type Opt: | 4-speed Automatic Transmission (4T40-E / 4T45-E) |
| Features | |
| Clutch Type: | Single dry plate, hydraulically actuated (for manual transmission). |
| Automatic Features: | Electronically controlled, torque converter lock-up. |
| Dimensions | |
| Exterior | |
| Wheelbase: | Approximately 104.3 inches (2649 mm) |
| Length: | Approx. 175.0-179.4 inches (4445-4557 mm) depending on body style. |
| Width: | Approx. 67.7-68.4 inches (1720-1737 mm) |
| Height: | Approx. 54.8-55.7 inches (1392-1415 mm) |
| Weights | |
| Curb Weight: | Approx. 2700-2900 lbs (1225-1315 kg) depending on configuration. |
| Safety Features | |
| Ratings | |
| NHTSA Front Impact: | Good (Driver), Good (Passenger) - based on 2001 model year testing, though specific Cavalier models may vary. |
| Passive Features | |
| Airbags: | Driver and front passenger airbags standard. Optional side airbags may be available on some trims. |
| Seat Belts: | Three-point seat belts for all occupants, front pretensioners. |
| Active Features | |
| ABS: | Anti-lock Braking System (ABS) often standard or optional on many trims. |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory-installed AM/FM stereo with cassette and CD player options. Basic speaker configurations. |
| Driver Assistance | |
| Cruise Control: | Optional on most trims, typically electronically controlled. |
| Connectivity | |
| Auxiliary Input: | Not standard; aftermarket solutions or cassette adapters were common. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 7,500 miles or 6 months (using synthetic oil), or 3,000 miles/3 months (using conventional oil), check manual for specifics based on driving conditions. |
| Coolant Flush: | Every 60,000 miles or 5 years (using Dex-Cool coolant). |
| Spark Plug Replacement: | Every 100,000 miles for iridium-tipped spark plugs (Ecotec engines). |
| Fluid Specifications | |
| Engine Oil Spec: | SAE 5W-30 Synthetic (API certified), Dexos compliant if available/specified. |
| Coolant Spec: | GM P/N 12378550 (Orange Dex-Cool Extended Life Coolant) or equivalent. |
| Brake Fluid Spec: | DOT 3 brake fluid. |
| Transmission Fluid Manual: | GM Manual Transmission Fluid (MTF) P/N 12346003 or equivalent. |
| Transmission Fluid Automatic: | Dexron III / Dexron VI Automatic Transmission Fluid (ATF). |
| Known Issues | |
| Common Problems Engine: | Ecotec engines can be prone to oil consumption issues, valve cover gasket leaks, and occasional ignition coil failures. |
| Common Problems Suspension: | Worn control arm bushings, strut mount bearings, and tie rod ends are common wear items. |
| Common Problems Electrical: | Window regulator failures, power lock actuator issues, and sometimes instrument cluster problems. |
| Common Problems HVAC: | Blend door actuator failures and AC system leaks are not uncommon. |
| Vehicle History | |
| Brand Heritage | |
| Chevrolet Legacy: | Chevrolet has a long history of producing reliable and accessible vehicles for the mass market. |
| Model Evolution | |
| Cavalier Generations: | The 2001 model belongs to the third generation of the Chevrolet Cavalier, which ran from 1995 to 2005. This generation saw significant updates in styling and technology over its predecessors. |
| Production | |
| Assembly Locations: | Primarily assembled in Lordstown, Ohio, USA. |
| Awards & Recognition | |
| Recognitions | |
| Safety Awards: | While not receiving specific major awards, the Cavalier's safety ratings generally aligned with the compact car segment of its time. Specific certifications are detailed within the manual. |