1996 Chevrolet Cavalier Service and Repair Manual

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Factory-Grade Data

1996 Chevrolet Cavalier service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Sedan 4-Door
  • LS Coupe 2-Door
  • Z24 Coupe 2-Door
  • LS Sedan 4-Door
  • Base Coupe 2-Door
  • LS Convertible 2-Door

Engines covered

  • 2.2L 2190CC 134Cu. In. l4 GAS OHV Naturally Aspirated
  • 2.4L 2392CC 146Cu. In. l4 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1996 Chevrolet Cavalier Recalls & Complaints

NHTSA #98V14600029/06/1998Component: 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

Consequence

AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED OCCUPANTS WHO ARE T

Remedy

DEALERS WILL RECALIBRATE THE AIR BAG SENSING AND DIAGNOSTIC MODULE.

NHTSA #08E06300017/10/2008Component: STEERING

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,

Consequence

IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGA

NHTSA #09E02500011/05/2009Component: EXTERIOR LIGHTING:HEADLIGHTS

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

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

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

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

TSB #10232287

This warranty administration bulletin provides information regarding the field action courtesy transportation policy.

TSB #10208027

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

TSB #10171318

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

TSB #10170494

This informational bulletin provides information for dealers/technicians on Procedures to Unlock Delco Radio with Theftlock.

TSB #10246631

Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules

TSB #10023171

ABS PUMP RUNNING WHEN NOT NEEDED. *NJ

TSB #10017096

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

TSB #10017086

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.

19961009Component: VEHICLE SPEED CONTROLCrash reported4 injured

SUDDEN ACCELERATION, CAUSING ACCIDENT/INJURIES.

20171128Component: AIR BAGSCrash reported2 injured

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

20021126Component: STEERING:RACK AND PINIONCrash reported2 injured

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

19991122Component: SEAT BELTS:FRONT:BUCKLE ASSEMBLYCrash reported2 injured

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.

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