2002 Chevrolet Cavalier / Pontiac Sunfire Service Manual

Wiring diagrams, specifications, and repair sequences for Chevrolet Cavalier and Pontiac Sunfire models from 1995 through 2001. Includes PN 6F7-38016.

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Document Details

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Document Number / Seller:
27874 / Jennifer Mason
File Size:
71.01 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Car
Last updated / verified
May 13, 2025

Models Covered & Key Technical Specifications

Chevrolet Cavalier, Pontiac Sunfire (6F7–38016) — 1995–2001 Chevrolet Cavalier / Pontiac Sunfire (6F7–38016) — 1995–2001 Service Manual | Series Toolkit

  • Designated System Capacity: For engine lubricant, 3.7 L (4.0 US qt) establishes the initial fluid volume Protocol.
  • Nominal Component Specification: For spark plug gap, 0.7–0.8 mm (0.050 in) determines the correct electrode spacing Architecture.
  • Technical Rating Standard: For generator output, 14V/105A 420W signifies the electrical power delivery Norms.
  • Standard Measurement Bounds: The cylinder head bolts require 46 Ft–lbs for the initial torque specification Logic.
  • Principal Installation Component: For wheel lug nuts, 100 Ft–lbs (140 Nm) are specified for secure assembly Bounds.
  • Key Operational Parameters: The optimal operating temperature range for coolant is 60/40 ratio; it yields consistent performance Topology.

Professional Workshop Service Manual & Technical Specifications

Essential Diagnostic Electrical Manual: Chevrolet Cavalier, Pontiac Sunfire (1995–2001) (360 P.) | Service Standards Service-Catalog

Asset-ID: Chevrolet Cavalier, Pontiac Sunfire (6F7-38016) // Calibration-Scope: Car / Automotive Logic // Asset-ID: 1995-2001. Technical-details.

Engine Chapters Address

  • Engine mechanical specifications
  • Engine electrical systems
  • Fuel system
  • Emissions and engine control systems

Service Manual: Chevrolet Cavalier, Pontiac Sunfire (1995–2001)

This manual provides comprehensive information for servicing and repairing Chevrolet Cavalier and Pontiac Sunfire models produced between 1995 and 2001. It covers all aspects of vehicle maintenance, from routine tune-ups to complex engine overhauls.

Reference data is included for:

Engine mechanical specifications, including detailed component dimensions and torque values. The manual documents torque specifications for cylinder head bolts and wheel lug nuts to ensure proper service interval reliability.

This manual covers:

Engine electrical systems, including ignition, starting, and charging systems, with detailed troubleshooting guides and wiring diagrams.

Diagnostic procedures are covered for:

Fuel system components, including fuel pump, injectors, and fuel pressure regulator, with specific diagnostic steps and repair procedures.

Wiring diagrams are provided for:

Emissions and engine control systems, detailing the function of sensors, actuators, and control modules for accurate diagnosis.

Fuel system procedures are documented for:

Air intake and exhaust systems, detailing removal, installation, and adjustment procedures for optimal engine performance.

FAQ

What **essential** testing parameters are documented for the ignition system? keyboard_arrow_down

15 psi is the recommended pressure for coolant reservoir cap when checking the system. For spark plug gap, 0.7–0.8 mm (0.050 in) is specified.

Check the **correct** diagnostic procedures for the engine oil. keyboard_arrow_down

When checking the engine oil, it should be at the "FULL" mark on the dipstick when the engine is warm and has been shut off for 15 minutes. The periodic change requires 2.8 L (3.0 US qt).

What does the **documented** fluid capacity requirements state for engine coolant? keyboard_arrow_down

2.2L variants require 11.1 quarts (10.5 L) and 2.4L variants require 10.1 to 11.5 quarts framework. The coolant should be a 60/40 ratio of silicate-free ethylene glycol.

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I found this manual incredibly detailed and easy to follow. The support team was very helpful when I had questions about the download process!
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This manual has everything I needed to get my Cavalier back on the road. The download was smooth and the customer service was quick to respond to my queries!