This manual covers the Chevrolet Cavalier and Pontiac Sunfire models produced between 1995 and 2001. These vehicles, built on the J-Body platform, were designed as practical and affordable compact cars, available as coupes, sedans, convertibles, and wagons (Cavalier only). They offered a range of engine options, from the efficient 2.2L OHV inline-four to more powerful 2.3L Quad 4 and 2.4L Twin Cam variants, as well as a 3.1L V6. Known for their straightforward mechanicals and value proposition, these cars served as dependable transportation for a wide array of drivers. This comprehensive factory service manual provides detailed information essential for the maintenance, diagnosis, and repair of your Chevrolet Cavalier or Pontiac Sunfire. It covers all major systems, including powertrain, chassis, and electrical components, with in-depth procedures for routine maintenance tasks, complex repairs, and troubleshooting common issues. With clear, step-by-step instructions, high-resolution diagrams, and technical specifications, this manual empowers owners and technicians to effectively service these vehicles, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Chevrolet Model: Sunfire Generation Cavalier Generation: 3rd Generation (1995-2005) Sunfire Generation: 1st Generation (1995-2005) Codes Cavalier Platform Code: J-Body Sunfire Platform Code: J-Body 👋 Introduction Market Position Vehicle Segment: Compact Car Target Audience: Budget-conscious consumers, first-time car buyers, economy-focused drivers Competitive Analysis Primary Competitors: Honda Civic, Toyota Corolla, Ford Focus, Dodge Neon, Nissan Sentra Key Features Value Proposition: Affordability, practicality, readily available parts, straightforward mechanicals Manual Value: Essential for DIY maintenance and repair, reduces reliance on expensive dealership services, aids in troubleshooting and diagnostics 📋 Manual Details Coverage Areas Covered Years: 1995, 1996, 1997, 1998, 1999, 2000, 2001 Covered Models: Chevrolet Cavalier, Pontiac Sunfire Covered Body Styles: Coupe, Sedan, Convertible, Wagon (Cavalier only) Page Count Estimated Page Count: 1500-2000+ Manual Type Manual Classification: Factory Service Manual / Repair Manual Language Language Content: English Format Delivery Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical (2.2L OHV, 2.3L Quad 4, 2.4L Twin Cam, 3.1L V6), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System Transmission: Manual Transmissions (Getrag 5-speed), Automatic Transmissions (4T40-E, 4T45-E) Chassis: Suspension (Front Struts, Rear Shock Absorbers, Control Arms), Steering System (Power Rack and Pinion), Brakes (Front Disc, Rear Drum/Disc), Wheel Bearing Replacement Electrical: Wiring Diagrams, Lighting, Ignition Switch, Power Distribution, Fuses and Relays, Charging System, Starting System, Body Control Modules, Instrument Cluster Body And Interior: Body Panels, Doors, Windows, Seats, HVAC System, Body Hardware, Trim Components, Convertible Top Systems (if applicable) Procedures Included Maintenance Procedures: Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Inspections and Replacement, Fluid Level Checks and Top-offs, Brake Pad Replacement, Tire Rotation Repair Procedures: Engine Overhaul/Rebuild, Transmission Removal and Installation, Brake System Service, Suspension Component Replacement, Electrical Component Diagnosis and Replacement, Fuel System Component Repair, Exhaust System Repair Diagnostics And Troubleshooting: Diagnostic Trouble Codes (DTCs), Engine Performance Issues, Transmission Shifting Problems, Electrical System Faults, HVAC System Malfunctions, ABS System Diagnosis Technical Depth Diagnostic Capabilities: Detailed diagnostic flowcharts, component testing procedures, wiring harness schematics, sensor data interpretation Rebuild Procedures: Comprehensive engine and transmission rebuild specifications, torque values, clearances, and assembly sequences Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures 📊 Manual Specifications File Format Digital File Type: PDF Searchability: Searchable text content for quick information retrieval Print Quality Image Clarity: High-resolution diagrams and illustrations for clarity Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Simulation: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Cavalier Sunfire 2.2L OHV Inline-4: 2.2L (2198cc) SOHC Inline-4, 115-125 hp, 130-135 lb-ft torque (variable by year/tune) Cavalier Sunfire 2.3L Quad 4 Inline-4: 2.3L (2319cc) DOHC Inline-4, 150-180 hp, 155-170 lb-ft torque (High Output versions available) Cavalier Sunfire 2.4L Twin Cam Inline-4: 2.4L (2392cc) DOHC Inline-4, 150-170 hp, 165-175 lb-ft torque (LD9 Engine) Cavalier Sunfire 3.1L V6: 3.1L (3135cc) OHV V6, 155-170 hp, 185-190 lb-ft torque (L82/LG7 Engines) Performance Acceleration 0 60 Mph: Approximately 8-11 seconds (depending on engine and transmission) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPFI) Recommended Fuel: 87 Octane Unleaded Gasoline (higher for Quad 4 High Output and performance variants) 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Transmission (Getrag F23) Optional Optional Transmission Type: 4-Speed Automatic Transmission (4T40-E / 4T45-E) Features Automatic Transmission Features: Electronically controlled, overdrive, torque converter lock-up Fluid Specifications Manual Transmission Fluid: GM Synchromesh Transmission Fluid or equivalent (e.g., Dexron III/VI, check manual for exact spec) Automatic Transmission Fluid: Dexron III or Dexron VI automatic transmission fluid (ATF) 📐 Dimensions Exterior Wheelbase: 104.3 inches (2649 mm) Overall Length: 177.9 - 179.5 inches (4519 - 4559 mm) (depending on model/year) Overall Width: 67.5 inches (1715 mm) Overall Height: 53.5 - 55.6 inches (1359 - 1412 mm) (depending on model/year) Wheel Bolt Pattern: 4 x 100mm (4.4 inches) Weights Curb Weight: Approximately 2700 - 3000 lbs (1225 - 1360 kg) (depending on engine and trim) 🛡️ Safety Features...