The Chevrolet Cavalier, a compact car produced from 1982 to 2005, is known for its affordability and fuel efficiency. The 1996 model, built on the J-Body platform, offered a range of engine options including a 2.2L L4, a more powerful 2.4L DOHC L4, and a 3.1L V6. This generation featured a more rounded design compared to its predecessors. The Cavalier was a popular choice in the compact segment, competing with models like the Ford Escort, Honda Civic, and Toyota Corolla, and was a significant volume seller for Chevrolet, reflecting its value proposition for owners seeking practical transportation. This comprehensive factory service manual provides in-depth information for the 1996 Chevrolet Cavalier. It covers essential maintenance schedules, detailed troubleshooting guides, and technical specifications for all major systems, including the engine, transmission, drivetrain, suspension, steering, brakes, electrical system, and HVAC. The manual also includes repair procedures, diagnostic trouble codes, and wiring diagrams, making it an invaluable resource for owners and professional technicians alike. With over 1500 pages of detailed content, this manual ensures proper maintenance and repair, helping to preserve the longevity and performance of your vehicle. 🏷️ Basic Information Identification Make: Chevrolet Model: Cavalier Year: 1996 Codes Platform: J-Body 👋 Introduction Market Position Segment: Compact Car Target Audience: Owners seeking to perform their own maintenance and repairs, professional mechanics working on the Chevrolet Cavalier. Competitive Analysis Competitors: Ford Escort, Honda Civic, Toyota Corolla, Nissan Sentra. Key Features Value Proposition: Provides official factory-level repair information, enabling accurate diagnosis and repair, saving money on labor costs, and ensuring proper vehicle maintenance. 📋 Manual Details Coverage Areas Covered Sections: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body and Frame, Diagnostic Trouble Codes (DTCs), Maintenance Schedules, Troubleshooting Guides, Wiring Diagrams. Page Count Estimated Pages: 1500+ Manual Type Type: Official Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: 2.2L L4 (VIN 4), 2.4L DOHC L4 (VIN 8), 3.1L V6 (VIN T). Includes troubleshooting, diagnosis, repair, and overhaul procedures. Transmission: 4-speed Automatic (4T40-E), 5-speed Manual. Includes diagnosis, repair, and overhaul for both. Drivetrain: Front Wheel Drive (FWD), CV Axles, Differential, Clutch (Manual). Suspension Steering: Front MacPherson Struts, Rear Torsion Beam Axle, Power Steering System, Steering Column, Wheel Alignment Specifications. Brakes: Front Disc Brakes, Rear Drum Brakes, Anti-lock Braking System (ABS) (if equipped), Brake System Diagnosis and Repair. Electrical System: Battery, Charging System, Starting System, Ignition System, Lighting, Gauges, Instruments, Fuses, Relays, Body Control Modules, Powertrain Control Modules (PCM), Diagnostic Trouble Codes (DTCs), Wiring Diagrams for all systems. HVAC: Air Conditioning System, Heater, Ventilation, Blower Motor, Controls, Refrigerant Handling Procedures. Body Frame: Body Panels, Doors, Hood, Trunk, Glass, Interior Trim, Seats, Bumpers, Frame Repair (if applicable). Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Replenishments, Spark Plug Replacement, Belt Replacement, Tire Rotation, Brake Pad Replacement, Tune-up procedures. Repair: Complete engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical component diagnosis and repair, HVAC system repair, fuel system repair, exhaust system repair. Diagnostics Troubleshooting: Systematic troubleshooting charts, pinpoint tests for electrical issues, diagnostic trouble code (DTC) interpretation and resolution, common problem diagnosis. Technical Depth Depth: Comprehensive. Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed electrical system diagnostics and component-level repair. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF with clear text and images. Printable. Print Quality Readability: Excellent. Designed for clarity of text and diagrams, ensuring ease of use for mechanics and DIY enthusiasts. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine 2.2L L4: Engine Code: VIN 4 (2200). Features: Overhead Valves (OHV), Multi-Port Fuel Injection (MPFI). Approximate Horsepower: 115 hp @ 5200 rpm. Approximate Torque: 130 lb-ft @ 3200 rpm. 2.4L DOHc L4: Engine Code: VIN 8 (LD9). Features: Dual Overhead Camshafts (DOHC), Sequential Fuel Injection (SFI), Dual Counter-rotating Balance Shafts. Approximate Horsepower: 150 hp @ 6000 rpm. Approximate Torque: 155 lb-ft @ 4400 rpm. 3.1L V6: Engine Code: VIN T (3100 SFI). Features: Overhead Valves (OHV), Sequential Fuel Injection (SFI). Approximate Horsepower: 160 hp @ 5200 rpm. Approximate Torque: 185 lb-ft @ 3600 rpm. Performance Fuel Recommendation: Unleaded Regular (87 Octane) for 2.2L and 3.1L. Unleaded Premium (91 Octane) recommended for 2.4L DOHC for optimal performance. Fuel System Injection Type: Multi-Port Fuel Injection (MPFI) or Sequential Fuel Injection (SFI) depending on engine. Engine Oil Capacity 2.2L L4: 4.5 US quarts (4.3 L) with filter change. 2.4L L4: 4.5 US quarts (4.3 L) with filter change. 3.1L V6: 4.5 US quarts (4.3 L) with filter change. 🔧 Transmission Standard Transmission 1: 5-speed Manual (Getrag F23 or similar) - Standard on most models. Optional Transmission 2: 4-speed Automatic (4T40-E) - Optional. Features Automatic Transmission Fluid: Dexron III (or equivalent) is recommended. Capacity typically around 7-8...