🏷️ Basic Information

Make:

Chevrolet

Model:

Cavalier

Year:

2002

Market:

North America

Platform:

J-body

👋 Introduction

Positioning:

The 2002 Chevrolet Cavalier was positioned as a value-oriented compact car, appealing to a broad range of buyers seeking affordability, fuel efficiency, and practical transportation. It competed directly with other popular models in its segment.

Competitors:

Key competitors for the 2002 Cavalier included the Ford Focus, Honda Civic, Toyota Corolla, Nissan Sentra, and Mitsubishi Eclipse/Galant.

Features:

Fuel efficiency, comfortable ride for its class, available in coupe, sedan, and wagon body styles, relatively low cost of ownership, simple and straightforward mechanicals.

Value Proposition:

This manual is an indispensable resource for owners and technicians seeking accurate, vehicle-specific repair and maintenance information, replacing generic advice with authoritative, factory-level procedures.

Accuracy:

Emphasizes that this is not generic information but the exact manual used by dealership technicians, ensuring the highest level of accuracy and completeness for all service operations.

📋 Manual Details

Coverage:

All Models and All Repairs A-Z

Page Count:

Varies (Typically 800-1200 pages for a comprehensive service manual of this era)

Type:

Service and Repair Manual

Language:

English

Format:

Printed (typically spiral-bound or case-bound for durability in a workshop environment)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, valve train, piston and connecting rod, crankshaft and main bearings, lubrication system, cooling system, fuel system (carburetor/injection), intake and exhaust systems.

Engine Electrical:

Ignition system, starting system, charging system, ECM (Engine Control Module) and sensors, emissions control systems.

Transmission Manual:

Clutch, manual transmission operation and repair (disassembly, inspection, reassembly), shift linkage.

Transmission Automatic:

Automatic transmission operation and repair (disassembly, inspection, reassembly), torque converter, transmission control module (TCM), hydraulic circuits.

Drivetrain:

Front wheel drive axles, CV joints, drive shafts, differential.

Suspension:

Front suspension (struts, control arms, ball joints, bushings), rear suspension (torsion beam axle, shocks), alignment specifications.

Steering:

Steering gear, power steering system (pump, hoses, reservoir), steering column, wheel alignment.

Brakes:

Front and rear disc/drum brake systems, hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), parking brake, ABS (Anti-lock Braking System).

Electrical Body:

Lighting system, interior and exterior lamps, instrument panel, gauges, warning indicators, horn, wipers and washers, power windows and locks, mirrors, audio system, HVAC controls, body control module (BCM).

Body And Frame:

Body construction, panels, doors, hood, trunk lid, bumpers, glass, interior trim, chassis components.

Heating Ventilation And Air Conditioning HVAC:

HVAC system components, refrigerant, operation, diagnosis and repair.

Maintenance:

Oil changes, filter replacements, fluid level checks and top-offs, belt inspections and replacement, spark plug replacement, air filter replacement.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, electrical circuit tracing, DTC (Diagnostic Trouble Code) interpretation and resolution.

Repair:

Component removal and installation (engine, transmission, suspension parts, brake components, electrical modules), overhaul procedures, body panel repair and replacement.

Diagnostics:

On-board diagnostics (OBD-II), scan tool usage, sensor testing, actuator testing, circuit continuity and resistance testing.

Specifications:

Torque specifications for all fasteners, clearance measurements, fluid capacities, electrical resistance values, pressure test specifications.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, grounds, and circuit tracing guides.

Depth:

Complete vehicle service and repair, ranging from basic scheduled maintenance and fluid changes to complex engine and transmission overhauls, advanced electrical diagnostics, and bodywork.

📊 Manual Specifications

Quality:

High-resolution text and diagrams for clarity. (If digital, typically searchable PDF).

Quality:

Professional printing with clear text, legible diagrams, and durable paper stock suitable for workshop use.

Type:

Likely spiral-bound or case-bound to lay flat for ease of use during repairs.

Type:

Durable, possibly coated paper stock to resist grease and dirt in a workshop environment.

⚙️ Engine Specifications

Engine Code 1:

2.2L ECOTEC DOHC L4 (Optional for 2002, becoming standard later)

Engine Code 2:

2.2L OHV L4 (LD9)

Engine Code 3:

2.4L DOHC L4 (Twin Cam) (Less common in 2002 models)

2.2L OHV (Ld9) Horsepower:

115 hp @ 5000 rpm

2.2L OHV (Ld9) Torque:

130 lb-ft @ 3600 rpm

2.2L Ecotec Horsepower:

140 hp @ 5800 rpm

2.2L Ecotec Torque:

150 lb-ft @ 4000 rpm

Fuel Delivery:

Multi-Port Fuel Injection (MPFI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Oil Capacity:

4.0 US quarts (3.8 L) with filter (for 2.2L OHV and ECOTEC engines, verify with manual)

Oil Specification:

API SM or SN, ILSAC GF-4 or GF-5, SAE 5W-30 viscosity (refer to manual for exact spec based on temperature range)

Coolant Capacity:

Approximately 7.0 US quarts (6.6 L) (verify with manual)

Coolant Type:

GM-specific orange or Dex-Cool antifreeze (50/50 mix with distilled water)

🔧 Transmission

Transmission Type Standard:

5-speed Manual Transmission (M82 or Getrag F23 depending on engine)

Transmission Type Optional:

4-speed Automatic Transmission (4T40-E)

Automatic Transmission Fluid Capacity:

Approximately 6.5 US quarts (6.2 L) for initial fill (dry fill higher, verify with manual)

Automatic Transmission Fluid Type:

Dexron-VI ATF (or Dexron III/Mercon equivalent, verify with manual)

Manual Transmission Fluid Capacity:

Approximately 2.0 US quarts (1.9 L) (verify with manual)

Manual Transmission Fluid Type:

SAE 75W-90 GL-4 or GL-5 gear oil (verify with manual)

📐 Dimensions

Length:

177.7 inches (4514 mm) for Sedan/Coupe

Width:

67.4 inches (1712 mm)

Height:

55.0 inches (1397 mm) for Coupe, 54.8 inches (1392 mm) for Sedan

Wheelbase:

101.3 inches (2573 mm)

Front Headroom:

Approx. 38.0 inches (965 mm)

Rear Headroom:

Approx. 37.0 inches (940 mm)

Trunk Volume:

Approx. 12.8 cubic feet (362 L)

Curb Weight:

Approx. 2700-2900 lbs (1225-1315 kg) depending on body style and equipment.

Wheel Bolt Pattern:

5 x 100 mm (5 x 3.94 inches)

Wheel Size:

14-inch or 15-inch wheels standard, optional 16-inch

Tire Size:

185/70R14 or 195/60R15 standard (verify with specific trim/option)

🛡️ Safety Features

NHTSA Driver Front Impact:

Good (for 2002 model year, based on available data, may vary)

NHTSA Passenger Front Impact:

Good (for 2002 model year, based on available data, may vary)

IIHS Side Impact:

Acceptable (for comparable models/years, verify specific 2002 Cavalier ratings)

ABS:

Optional Anti-lock Braking System (ABS) on front wheels, optional on all four wheels on some trims.

Airbags:

Driver and front passenger airbags standard.

Seat Belts:

Three-point seat belts for all occupants, pretensioners for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system may be present depending on specific manufacturing date/options.

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with CD player or cassette tape, optional premium audio systems with more speakers.

Climate Control:

Manual climate control with A/C is standard or optional. Automatic climate control was not typically available on this model.

ABS:

Optional Anti-lock Braking System (ABS).

Onboard Diagnostics:

OBD-II (On-Board Diagnostics, Second Generation) compliant for emissions and engine management diagnostics.

Cruise Control:

Optional cruise control.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, using synthetic oil can extend this to 5,000-7,500 miles (8,000-12,000 km) or 6-12 months. (Always consult manual for specific conditions).

Air Filter Replacement Interval:

Every 15,000-30,000 miles (24,000-48,000 km) or annually, or sooner if driving in dusty conditions.

Spark Plug Replacement Interval:

2.2L OHV: ~60,000 miles. ECOTEC: ~100,000 miles (using long-life plugs, verify with manual).

Transmission Fluid Change Interval Automatic:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years. (Often overlooked, critical for longevity).

Transmission Fluid Change Interval Manual:

Every 50,000-75,000 miles (80,000-120,000 km) or 4-5 years.

Coolant Flush Interval:

Every 50,000 miles (80,000 km) or 5 years, using the correct coolant type.

Brake Fluid Type:

DOT 3 or DOT 4 Brake Fluid (verify specific requirement in manual).

Power Steering Fluid Type:

GM Power Steering Fluid or Dexron-VI ATF (verify with manual).

Common Issues Engine:

Oil leaks (valve cover gasket, rear main seal), coolant leaks (heater core, hose failures), ignition coil failure, intake manifold gasket leaks (on some engines), ECOTEC oil consumption (early models).

Common Issues Transmission:

Automatic transmission internal seal failures leading to slipping or delayed engagement, torque converter shudder.

Common Issues Suspension:

Worn control arm bushings, ball joints, and tie rod ends leading to steering looseness and premature tire wear. Sagging rear springs.

Common Issues Electrical:

Window regulator failures, power lock actuator failures, instrument cluster issues, headlamp switch failure, alternator failures.

Common Issues HVAC:

Blend door actuator failure, blower motor resistor failure, AC compressor clutch issues.

📚 Vehicle History

Chevrolet Heritage:

Chevrolet, founded in 1911, is one of America's most iconic and enduring automotive brands, known for producing a wide range of vehicles from economy cars to heavy-duty trucks.

Cavalier Generations:

The 2002 Cavalier belongs to the third generation of the Cavalier (1995-2005), which was a significant redesign from its predecessors, focusing on improved styling, safety, and refinement.

Third Generation Updates:

This generation saw the introduction of the ECOTEC engine family, enhanced safety features, and updated styling cues over its production run. The 2002 model year generally received minor refinements.

Production Location:

North American assembly plants, including Lordstown, Ohio.

Sales Figures Trend:

The Cavalier was a strong seller in its segment for many years, though sales began to decline in the early 2000s as the compact car market evolved and competitors introduced more compelling products.

🏆 Awards & Recognition

Segment Awards:

While specific awards for the 2002 model are less prominent than later generations or competitors, the Cavalier consistently ranked as one of the best-selling vehicles in the compact segment for many years.

Consumer Reports General Perception:

Generally perceived as an affordable and functional vehicle, though often rated below class leaders in areas like refinement, driving dynamics, and long-term reliability.

Emissions Certification:

Meets EPA emissions standards for its model year.