2002 Chevrolet Cavalier Service and Repair Manual

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Factory-Grade Data

2002 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

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

Engines covered

  • 2.2L 2190CC 134Cu. In. l4 GAS OHV Naturally Aspirated
  • 2.2L 2198CC 134Cu. In. l4 GAS DOHC Naturally Aspirated
  • 2.4L 2392CC 146Cu. In. l4 GAS DOHC Naturally Aspirated
  • 2.2L 2190CC 134Cu. In. l4 BI-FUEL OHV 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

2002 Chevrolet Cavalier Recalls & Complaints

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 #08E05000011/08/2008Component: EXTERIOR LIGHTING:HEADLIGHTS

K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FA

Consequence

WITHOUT THE AMBER SIDE REFLEX REFLECTORS, THE LIGHTING VISIBILITY MAY BE AFFECTED, POSSIBL

Remedy

K2 MOTOR WILL NOTIFY OWNERS AND OFFER A FULL REFUND. THE RECALL BEGAN ON DECEMEBER 17, 20

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 #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11014455

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the

TSB #11009156

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 #11007744

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi

TSB #11007743

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11006421

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal

TSB #11004761

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should

Showing the 8 most recent of 257 technical service bulletins on file with NHTSA.

20070803Component: AIR BAGSCrash reported5 injured

TL*THE CONTACT OWNS A 2002 CHEVROLET CAVALIER. WHILE DRIVING 17 MPH, THE ACCELERATOR PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. SHE DEPRESSED THE BRAKE PEDAL, BUT THE VEH

20070803Component: VEHICLE SPEED CONTROL:ACCELERATOR PEDALCrash reported5 injured

TL*THE CONTACT OWNS A 2002 CHEVROLET CAVALIER. WHILE DRIVING 17 MPH, THE ACCELERATOR PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. SHE DEPRESSED THE BRAKE PEDAL, BUT THE VEH

20061011Component: ELECTRICAL SYSTEM:IGNITION:SWITCHCrash reported4 injured

I HAVE A 2002 CHEVROLET CAVALIER AND I ALMOST HAD A BAD ACCIDENT WITH THIS CAR. THE IGNITION SWITCH AND WHEELS LOCKED UP ON ME AND I WAS STILL IN ONE PLACE AND A EIGHTEEN WHEELER R

20040803Component: SEATS:MID/REAR ASSEMBLYCrash reported3 injured

THIS VEHICLE WAS INVOLVED IN A COLLISIN IN WHICH ANOTHER VEHICLE HYDROPLANED HEAD-ON AND THEN ONTO THE REAR DRIVER SIDE OF THIS 4 DOOR CHEVROLET CAVALIER. MY DAUGHTER WAS IN HER

Showing the 4 most serious of 254 complaints filed with NHTSA.

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