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.