2002 Chevrolet Cavalier / Pontiac Sunfire Service Manual

Technical Scope for the 1995–2001 Chevrolet Cavalier and Pontiac Sunfire

• Covers 1995–2001 Chevrolet Cavalier and Pontiac Sunfire variants including 2.2L OHV, 2.3L DOHC, and 2.4L DOHC configurations
• Third-party publication: Haynes Repair Manual P/N 38016, 2005 edition
• Includes 124 exploded-view diagrams, 28 wiring schematics, and 14 detailed engine torque-sequence tables
• File architecture allows for keyword-indexed PDF search across every technical chapter
• Accessible from your device as soon as the order is placed
• Laid out for standard letter and A4 printing
• This 2005 release provides the reference data necessary for servicing the 1995–2001 Chevrolet Cavalier and Pontiac Sunfire engine, chassis, and electrical systems in a unified format

Engine, Drivetrain, and Electrical Systems

This 1995–2001 Chevrolet Cavalier and Pontiac Sunfire service manual delivers technical documentation for vehicle maintenance, covering routine tune-ups, cooling system diagnostics, and major engine overhaul sequences. The content segments focus on internal combustion diagnostics, including timing chain procedures, valve train inspections, and fuel injection system analysis. Electrical system references include diagnostic methods for alternators, starter motors, and cooling fan circuits, supported by manufacturer-specified voltage and resistance thresholds. Lubrication schedules, fluid capacities, and torque-specification tables are provided for all major drivetrain components, including manual and automatic transaxle assemblies.

Specification Highlights

Technical data within the publication includes critical clearance and torque parameters necessary for component assembly. Cylinder head bolt torque values for the 1995–2001 Chevrolet Cavalier are specified at 46 Ft–lbs followed by a 90-degree angle-tightening stage. Intake manifold bolt sequences are documented for various engine years to prevent casting distortion. Coolant system operational data specifies a 15 psi pressure cap and a 50/50 ethylene glycol mix. Reference values for spark plug gaps, ranging from 0.040 to 0.060 inches depending on engine displacement, are how factory workshop documentation is structured. Spark plug torque is documented at 11 Ft–lbs for consistent installation bounds. Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions. An official Haynes OEM-based manual covering the 1995–2001 Chevrolet Cavalier and Pontiac Sunfire, documenting engine, chassis, electrical, and fuel-injection specifications for the 6F7-38016 series build.