Chevy Cavalier 2002 Service Manual
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The Chevrolet Cavalier was a compact automobile produced from 1982 to 2005. Built on the company's, the Cavalier produced the highest sales in 1984. T he Cavalier replaced the, which was available as a 2-door, a 3-door and a 3-door (using the same body as the discontinued wagon, the model it replaced). The inexpensive was retained even as sales declined, and was formally replaced by even smaller.
Both previous platforms had rear-drive layouts while the new design followed the front wheel drive trend, as in the and. And also introduced new front drive compacts.
The largely successful mission of capturing the bulk of domestic compact sales would fall on the Cavalier's 2-door, 4-door and 4-door, the relatively short-lived 3-door (which replaced the Monza Sport 2-door hatchback) and, in later years, a 2-door. The small Cavalier even helped fill in lagging sales of the (a replacement). The Cavalier first went on sale in early 1981 as a 1982 model with front-wheel-drive, a choice of two carbureted four-cylinder engines, and 2 and 4-door sedan, hatchback, and station wagon body styles. Convertibles were added in 1983, initial production totaling less than 1000. 1983 Cavaliers offered, and a became available in 1985. The 1984 models received a mild facelift featuring quad headlights.
The Cavalier was largely identical to the. Before the brand was officially introduced in in 1992, Cavaliers sold there featured Sunbird body panels, as opposed to US-spec Cavalier panels. From 1993 on, the sibling marques were both offered, much in the same way as in the United States. The Cavalier was restyled in 1988.
The two door hatchback was dropped, while the coupe, sedan, wagon and convertible carried over. The sedan and wagon were unchanged from the doors back, while the coupe's exterior was completely redesigned. This resulted in different trunk designs for the coupe and sedan. Suzuki Ts 50 Workshop Manual. Three trim levels were available in 1988: VL, RS, and Z24. The convertible was only available as a Z24. The VL and RS came standard with the engine, now upgraded to throttle-body injection, or TBI, producing 90 hp (67 kW), while the producing 125 hp (93 kW) was optional on the RS and standard on the Z24.
With all trims, 5-speed manual transmission was standard, and a 3-speed automatic was optional, however the vast majority of sedans and wagons had a 3-speed automatic. An electronic dashboard was available with the RS and Z24 trims. 1991–1994 Cavalier wagon In 1989, the was redesigned to be adjustable, as well as the addition of 3-point for the rear outboard seats.
The optional V6 was retooled to 130 hp. In 1990, the base engine was enlarged to a, and power increased to 95 horsepower (71 kW).
The optional V6 engine was also upgraded to the and 140 horsepower. The convertible was dropped from availability to prevent internal competition with a planned. However, the Beretta convertible was shelved at the eleventh hour, before a 1990 Cavalier convertible could be prepared. 1993–1994 Cavalier coupe The Cavalier got a more extensive restyling in 1991 that involved a new hood, bumpers, headlights, taillights, wheel covers and a redesigned interior, however with the body style remaining unchanged. Most notably, the cooling system was redesigned to draw air from the bumper, giving it a -style bumper and grille-less nose. The new bumpers were unpainted, with the option to have them colored grey, black or white; the latter only available on white-colored models.
The Z24 eschewed this for a color keyed body kit. Z24 models also gained the options for a height adjustable driver's seat and a CD player. The platform and trim lines were carried over, while the convertible was brought back mid-year in the RS trim only with the V6 standard. In 1992, the 2.2 L standard engine adopted, or MPFI to improve output to 110 horsepower (82 kW), however unlike the SFI version of the 2.2L in the Chevrolet Corsica. The convertible was now available in both RS and Z24 trims, with the V6 standard in the Z24 and optional with the RS.
Were added as a standard feature, as had managed to develop a low-cost system. Power locks were also standard, and were designed to automatically lock when the car is shifted out of park, or if the car is traveling at least 8 miles per hour in manual transmission equipped models. 1993 brought minimal changes to the Cavalier line. The convertibles receive a glass rear window, allowing rear window defrost as an option. Also, General Motors received a new grille for the final time in this Chevrolet Cavalier's generation. 1994 Cavalier Z24 Convertible 1994 models were also carryovers, as a new model of Cavalier was in development. The VL trim was dropped on the wagon, while the was now the SFI version borrowed from the Corsica, which delivered an output of 120 horsepower.
Additional changes included a slightly redesigned climate control interface and the power locking system being again redesigned: the doors would still lock automatically when put into gear, but they would also unlock automatically when the ignition was switched off. The Cavalier received its first total redesign in 1995, with expanded dimensions and more modern styling, taking minor design cues from the 4th Generation Chevrolet Camaro. Some of the basic styling cues remained however, such as the coupes' dipped beltline, and the black bumpers on some Base model cars. Coupe, sedan, and convertible options were offered, however the wagon model was replaced by an LS Sedan for the third generation. All available engines were. The option for a, which had been available in the first and second generation, was replaced by a new 4-Cylinder of similar power outputs.
Base and RS models still retained the 2.2L Pushrod L4, however the Cavalier Z24 received a new engine in 1996, the 2.4 liter DOHC, the first DOHC engine ever used in a Cavalier. This engine produced 150 hp (112 kW) and 155 lbft (210 Nm) of torque and was used until 2002. In 2000, the car gained a minor facelift, lost the 'CHEVROLET' text badge at the trunklid and gained a new 'CAVALIER' badge along with new 'five spoke' hubcaps. The 2.4L engine came mated standard with the 5-speed on the Z24 models, or with the optional 4-Speed automatic on both the Z24 and the LS Models. The Z24 only came in 2-door coupe models until 2000 and featured a sport-tuned suspension, 16-inch tires, alloy wheels and improved interior electronics. Aesthetically little changed from the other models other than a ground effects kit and taller rear spoiler.
In 2000 a 4-door Z24 Sedan debuted, featuring the same mechanics but having a less sporty body. The Z24 trim also received several other upgrades including a wider front sway bar and FE2 Sports Suspension for better handling characteristics, and less aggressive ABS anti-lock braking system. In 2001, the 3-speed automatic was dropped from the base models equipped with the 2.2L, and the 4-speed Automatic became standard. In 2003 the 2.2L OHV L4 was dropped from the entire Cavalier line, and the Cavalier Z24 was dropped and replaced by the LS Sport line, which featured the new L61 motors (140 hp (104 kW) and 150 lbft (200 Nm) torque). These engines improved fuel economy, featuring the same displacement as the GM 122 Pushrod Engine (2.2L OHV), while maintaining most of the power of the older LD9 motors. The new Ecotec motors remained in the entire Cavalier line-up up until 2005 when the Chevrolet Cavalier was replaced by the.
A GM Eaton M45 Supercharger kit was also offered for the Z24 trim as well. The supercharger kit was developed and tested by General Motors and could only be installed at a GM dealer.
This upgrade increased performance considerably due to a pressure of 4.7 PSI which in turn added approximately 40 hp (30 kW) and 40 lbft (54 Nm) of torque increase; raising the Z24's ratings to approximately 190 hp (142 kW) and 195 lbft (264 Nm) of torque. As part of a wider effort to avoid additional restrictions on exports to the US, the third generation model was briefly sold in by under an agreement with GM, as the as in return for the. Aside from the fact that it was, the Toyota Cavalier also featured a leather-wrapped shift knob, steering wheel and park brake lever, wider front fenders, for Japanese regulations, power folding side mirrors, side lights on the front fenders, and carpeting on the inside of the trunk lid.
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