Chevrolet Cavalier, Pontiac Sunfire Repair Manual 1995-2005

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Chevy Cavalier, Pontiac Sunfire Repair Manual 1995-2005
Chevy Cavalier, Pontiac Sunfire Repair Manual 1995-2005
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Item Description

This Haynes DIY repair manual covers Chevrolet Cavalier and Pontiac Sunfire, all models, 1995-2005, four-door sedans and two-door coupes.

Book Excerpt: 1995-2005 Chevrolet Cavalier, Pontiac Sunfire Repair Manual


This part of Chapter 2 is devoted to in vehicle repair procedures for the 2.2L DOHC (Double Overhead Camshaft), engine. All information concerning engine removal and installation and engine block overhaul can be found in Part D of this Chapter.

This engine is equipped with a single timing chain to drive the camshafts. The balance shaft chain drives the two balance shafts and the water pump sprocket. The balance shaft chain is mounted directly behind the camshaft timing chain.

The specifications included in this Part of Chapter 2 apply only to the procedures contained in this Part. Information concerning engine removal and overhaul or replacement can be found in Chapter2 Part D.

Repair operations possible with the engine in the vehicle

Many major repair operations can be accomplished without removing the engine from the vehicle.

Clean the engine compartment and the exterior of the engine with some type of pressure washer before any work is done. A clean engine will make the job easier and will help keep dirt out of the internal areas of the engine.

Depending on the components involved, it may be helpful to remove the hood to improve access to the engine as repairs are performed (refer to Chapter 11 if necessary). Cover the fenders to prevent damage to the paint. Special pads are available, but an old bedspread or blanket will also work.



Refer to illustration 9.2

Note: The hood is somewhat awkward to remove and install; at least two people should perform this procedure.

  1. Open the hood, then place blankets or pads over the fenders and cowl area of the body and paint as the hood is lifted off.

  2. Make marks or scribe a line around the hood hinge to ensure proper alignment during installation (see illustration).

  3. Disconnect any cables or wires that will interfere with removal.

  4. With an assistant supporting the weight of the hood, remove the hinge-to-hood bolts and lift off the hood.

  5. Installation is the reverse of removal. Align the hinge bolts with the marks made in Step 2.


    Refer to illustrations9.10a, 9.10b, 9.10c, 9.10d and 9.11

  6. Fore-and-aft and side-to-side adjustment of the hood is done by moving the hinge plate slot after loosening the bolts or nuts.

  7. Scribe a line around the entire hinge plate so you can determine the amount of movement.

  8. Loosen the bolts or nuts and move the hood into correct alignment. Move it only a little at a time. Tighten the hinge bolts and carefully lower the hood to check the position.

  9. If necessary after installation, the entire hood latch assembly can be adjusted up-and-down as well as from side-to-side on the radiator support so the hood closes securely and flush with the fenders. First, remove the hood latch cover (see illustrations).

    To make adjustments, scribe a line or mark around the hood latch to provide a reference point (see illustration), then loosen the latch retaining bolts (see illustration) and reposition the latch assembly, as necessary. Following adjustment, retighten the mounting bolts.

Subject: 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Chevrolet Cavalier, Pontiac Sunfire service, maintenance, repair. ISBN-10: 1563928140 | ISBN-13: 9781563928147 | Haynes 38016

  • Publisher: Haynes Manuals
  • Pages: 288 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.25 x 10.75 inches
  • ISBN: 978-1-56392-814-7
  • Years: 1995 - 2005
Table of Contents
TABLE of CONTENTS: Introductory pages
About this manual | Introduction to the Chevrolet Cavalier and Pontiac Sunfire | Vehicle identification numbers | Buying parts | Maintenance techniques, tools and working facilities | Jacking and towing | Booster battery (jump) starting | Automotive chemicals and lubricants | Conversion factors | Fraction/decimal/millimeter equivalents | Safety first! | Troubleshooting
  • Tune-up and routine maintenance
  • Overhead valve (OHV) engine
  • 2.3L and 2.4L overhead camshaft (OHC) engines
  • 2.2L overhead camshaft (OHC) engine
  • General engine overhaul procedures
  • Cooling heating and air conditioning systems
  • Fuel and exhaust systems
  • Engine electrical systems
  • Emissions and engine control systems
  • Manual transaxle
  • Automatic transaxle
  • Clutch and driveaxles
  • Brakes
  • Suspension and steering systems
  • Body
  • Chassis electrical system
  • Wiring diagrams
Questions & Answers about Chevy Cavalier, Pontiac Sunfire Repair Manual 1995-2005

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Customer Reviews


Tom verified customerJanuary 1, 2016
Very thorough and clear
Haynes has always been the best manual. I have had one for all of my vehicles.
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Ree Andress verified customerNovember 2, 2014
Chevy Cavalier
Fast and easy experience. Just what I wanted. Thanks.
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Chevrolet Cavalier, Pontiac Sunfire Repair Manual 1995-2005
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