1996 Chevrolet Cavalier Service and Repair Manual
This factory service and repair manual for the 1996 Chevrolet Cavalier deals with two inline-fours and three body shells. The engines are a naturally aspirated 2.2L overhead-valve unit of 134 cubic inches and a naturally aspirated 2.4L twin-cam of 146 cubic inches, both on gasoline; the shells are a sedan, a coupe and a convertible, sold in Base, LS and Z24 form. Pushrod and overhead-cam service diverge sharply at the cylinder head, and this manual keeps the timing, valve and head procedures for the two engines in separate sequences.
Engines covered
- 2.2L inline-four (134 cu in) — OHV, naturally aspirated, gasoline
- 2.4L inline-four (146 cu in) — DOHC, naturally aspirated, gasoline
Body styles covered
- 4-door sedan
- 2-door coupe
- 2-door convertible
Trims covered
- Base
- LS
- Z24
Known issues on the 1996 Cavalier. Eight recalls stand federally. One concerns the power rack, where uncrimped bearing retainer tabs let ball bearings escape and the pinion shaft ride up, so the wheel goes heavy as if the assist had failed. Another covers an ignition switch that can melt internally under a long crank and later set the column alight. A replacement fuel pump module with vent and return tubes reversed can make the engine idle rough, stall, or leak fuel from the canister. Five more involve replacement lamps missing reflectors, and a steering shaft. Of 604 complaints, 118 are on engine cooling, 80 electrical and 69 on air bags.
VEHICLE DESCRIPTION: PASSENGER VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S SENSING AND DIAGNOSTIC MODULE, AN INADVERTENT AIR BAG DEPLOYMENT COULD OCCUR IN A LOW S
AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED OCCUPANTS WHO ARE T
DEALERS WILL RECALIBRATE THE AIR BAG SENSING AND DIAGNOSTIC MODULE.
DORMAN PRODUCTS IS RECALLING 3,900 INTERMEDIATE STEERING SHAFTS DORMAN PART NOS. 425-151, 425-152, AND 425-153, (SOLD UNDER DORMAN'S "OE SOLUTIONS" BRAND NAME), BALKAMP #'S 7-3057,
IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.
DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGA
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM
This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and
This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and
This informational bulletin provides information for dealers/technicians on Procedures to Unlock Delco Radio with Theftlock.
Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
ABS PUMP RUNNING WHEN NOT NEEDED. *NJ
VEHICLE WILL NOT MOVE IN EITHER DIRECTION. TRANSMISSION MAY SHOW OVER FULL. P90 4T40E 4T45E NO MOVEMENT DRIVE OR REVERSE. CONVERTER MAY BE EMPTY OF FLUID. *TT
4T40E OR 4T45E WILL NOT SHIFT NO DIAGNOSTIC TROUBLE CODES. *TT
Showing the 8 most recent of 74 technical service bulletins on file with NHTSA.
SUDDEN ACCELERATION, CAUSING ACCIDENT/INJURIES.
TL* THE CONTACT OWNED A 1996 CHEVROLET CAVALIER. WHILE THE CONTACT WAS MAKING A U TURN, ANOTHER VEHICLE CRASHED INTO THE DRIVER SIDE OF THE VEHICLE. THE AIR BAGS DID NOT DEPLOY. A
POWER STEERING FAILED ON 2 SEPARATE OCCASIONS. HAD PROBLEM FIXED FIRST TIME DEALER WANTS TO TOTAL VEHICLE SECOND TIME. GM DID NOT OWN UP TO THE PROBLEM. SAID CAR DID NOT FALL UNDER
WHILE DRIVING AT ABOUT 50 MPH CONSUMER HAD TO SLAM ON BRAKES AND THE SEATBELT DID NOT PROPERLY RESTRAIN. THE LITTLE PIECES OF THE BELT BUCKLE FELL OFF IN THE ACCIDENT. *AK
Showing the 4 most serious of 748 complaints filed with NHTSA.
