1996 Chevrolet Cavalier Service and Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Cavalier Year: 1996 Product Type: Service and Repair Manual 👋 Introduction Market Position Segment: Compact Car Target Demographic: Budget-conscious buyers, first-time car owners,...

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Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Cavalier

Year:

Product Type:

Service and Repair Manual

👋 Introduction

Market Position

Segment:

Compact Car

Target Demographic:

Budget-conscious buyers, first-time car owners, commuters.

Competitive Analysis

Key Competitors:

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

Key Features

Vehicle Philosophy:

Affordable, reliable transportation with a focus on practicality and fuel efficiency.

Appeal:

Wide availability, common parts, and a relatively simple mechanical design for ease of maintenance.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z

Specificity:

Vehicle Specific (Not Generic)

Target Audience:

Dealership Technicians, DIY Mechanics

Page Count

Estimated Pages:

1500-2000

Manual Type

Type:

Factory Service Manual

Language

Language:

English

Format

Format:

Printed Book

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, inspection, repair, and reassembly of all engine variants, including diagnostics, timing, and lubrication systems.

Engine Variants Covered:

2.2L DOHC L4 (V6 replacement), 2.4L DOHC DOHC L4 (GT/Z34 models), 3.1L OHV V6 (optional).

Fuel System:

Fuel injection systems (CPI, MPFI), fuel pumps, pressure regulators, injectors, and emissions controls.

Transmission:

Manual (Getrag 282) and Automatic (4T40-E) transmissions: overhaul, diagnostics, fluid specifications, and shift control systems.

Drivetrain:

Front-wheel drive system, CV axles, half-shafts, differential, and wheel bearings.

Suspension:

Front MacPherson struts, rear torsion beam or independent suspension (depending on model): alignment, component replacement, shocks, springs, and bushings.

Steering:

Power steering system, steering rack/gearbox, tie rods, and steering column components.

Brakes:

Front disc brakes (Vented/Solid depending on model), rear drum or disc brakes, ABS system (Bosch 2S or Teves Mk. 2): component replacement, bleeding, diagnostics, and parking brake.

Electrical System:

Battery, charging system (alternator), starting system (starter), ignition system (coil packs, plugs), lighting, horn, wipers, and power accessories.

Climate Control:

HVAC system: A/C compressor, refrigerant, blower motor, heater core, and control modules.

Body And Frame:

Body panel removal and installation, interior trim, bumpers, doors, windows, and glass replacement.

Chassis Electrical:

Instrument cluster, diagnostic port (OBD-II), sensors, relays, fuses, and wiring diagrams.

Procedures Included

Maintenance:

Scheduled maintenance procedures, oil changes, filter replacements, fluid checks and top-offs, tune-ups, and inspections.

Repair:

Detailed step-by-step repair procedures for all major components and systems, including engine rebuilds, transmission overhauls, and brake system repairs.

Troubleshooting:

Comprehensive diagnostic flowcharts, symptom-based troubleshooting guides, and common problem identification for all vehicle systems.

Diagnostics:

OBD-II code interpretation, specific diagnostic tests for various components, and advanced diagnostic strategies.

Specifications:

Torque specifications for fasteners, alignment specifications, fluid capacities, and wear limits.

Technical Depth

Depth:

Complete rebuild procedures, in-depth component diagnostics, and detailed electrical schematics.

📊 Manual Specifications

File Format

File Type:

Physical Book

Print Quality

Quality:

High-resolution print on durable paper, with clear diagrams and illustrations.

Binding Type

Binding:

Staple-bound or perfect bound, designed for workshop use.

Paper Type

Paper:

Matte finish paper to reduce glare in shop environments.

⚙️ Engine Specifications

Primary Engine

Engine 1 Code:

Engine 1 Description:

2.4L DOHC L4 (Twin Cam)

Engine 1 Displacement:

2398 cc

Engine 1 Horsepower:

150 hp @ 5600 rpm

Engine 1 Torque:

155 lb-ft @ 4400 rpm

Optional Engine

Engine 2 Code:

Engine 2 Description:

3.1L OHV V6

Engine 2 Displacement:

3135 cc

Engine 2 Horsepower:

160 hp @ 5200 rpm

Engine 2 Torque:

185 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Multi-Port Fuel Injection (MPFI) for 2.4L, Sequential Central Port Injection (SCPI) for 3.1L V6.

Fuel Type:

Unleaded Regular Gasoline (87 Octane)

Engine Maintenance

Spark Plugs:

ACDelco Iridium Part Number: 41-990 or equivalent

Engine Oil Capacity:

4.5 US Quarts (4.3 Liters) with filter for 2.4L; 4.5 US Quarts (4.3 Liters) for 3.1L.

Engine Oil Type:

SAE 5W-30 API Certified

🔧 Transmission

Standard

Transmission Type 1:

Getrag 282 5-Speed Manual

Optional

Transmission Type 2:

4T40-E 4-Speed Automatic

Features

Automatic Transmission Features:

Electronic control, lock-up torque converter.

Maintenance

Manual Transmission Fluid Type:

GM Synchromesh Manual Transmission Fluid or DEXRON-III

Automatic Transmission Fluid Type:

DEXRON-III (or DEXRON-VI)

Automatic Transmission Fluid Capacity:

6.0 US Quarts (5.7 Liters) for initial fill (consult manual for exact capacity based on torque converter drain).

📐 Dimensions

Exterior

Wheelbase:

101.3 inches (2573 mm)

Length:

174.5 inches (4432 mm)

Width:

67.5 inches (1715 mm)

Height:

53.8 inches (1367 mm) Coupe / 54.3 inches (1380 mm) Sedan

Weights

Curb Weight Min:

2700 lbs (1225 kg) approx.

Curb Weight Max:

3000 lbs (1361 kg) approx.

🛡️ Safety Features

Ratings

NHTSA Driver Side Impact Rating:

4 stars (1996 model year, frontal impact for driver - consult specific test data)

NHTSA Passenger Side Impact Rating:

4 stars (1996 model year, frontal impact for passenger - consult specific test data)

Active Features

Optional (Bosch 2S or Teves Mk. 2 systems)

Passive Features

Airbags:

Driver and Passenger front airbags

Seatbelts:

Front: 3-point retractable with pretensioners; Rear: 3-point retractable (outboard), lap belt (center).

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or optional CD player. Speaker configurations vary by trim level (e.g., 4-speaker standard, 6-speaker optional).

Driver Assistance

Cruise Control:

Available on most trim levels

Connectivity

Diagnostic Port:

OBD-II compliant diagnostic connector located under the dashboard for emissions and powertrain diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used.

Tire Rotation Interval:

Every 7,500 miles

Transmission Fluid Change Interval:

Every 30,000-50,000 miles (automatic); Every 50,000-60,000 miles (manual).

Coolant Change Interval:

Every 30,000 miles or 2 years

Spark Plug Replacement:

100,000 miles for iridium plugs (LD9 engine); 30,000-60,000 miles for conventional plugs (V6 engine).

Fluid Specifications

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

GM Power Steering Fluid or Dexron-III

Known Issues

Common Issue 1:

Intake manifold gasket leaks (especially on 3.1L V6)

Common Issue 2:

Head gasket failures on 2.4L LD9 engine (potential coolant leaks into cylinders)

Common Issue 3:

Premature wear of front suspension components (ball joints, tie rod ends)

Common Issue 4:

CV joint failures

Common Issue 5:

PCM (Powertrain Control Module) issues, leading to erratic engine performance.

Common Issue 6:

Oil leaks from valve cover gaskets and rear main seal.

📚 Vehicle History

Brand Heritage

Manufacturer:

General Motors (GM)

Model Evolution

Generation:

Third Generation (J-body platform)

Platform:

GM J-body platform

Design Updates 1996:

Facelifted model with new front and rear styling, updated interior, and improved safety features including standard airbags.

Production

Production Years:

1997-2005 (Fourth Generation, not covered by this manual)

Manufacturing Location:

Lordstown, Ohio, USA and other GM assembly plants.

🏆 Awards & Recognition

Recognitions

Safety Awards:

The 1996 Cavalier received good frontal impact ratings from the NHTSA, a testament to GM's advancements in passenger safety for the time.

Ratings

Fuel Economy Estimates:

EPA estimates ranged from 24 MPG city / 30 MPG highway for the 2.4L engine to 20 MPG city / 27 MPG highway for the 3.1L V6, depending on transmission and configuration.