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1996 Chevrolet Cavalier

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 1996 Cavalier.

Body PASSENGER CAR

The 1996 Chevrolet Cavalier is categorized as a passenger car requiring 4.5 quarts of 5W-30 API oil for engine maintenance. Owner records for this specific year capture 604 total complaints, identifying Engine & Engine Cooling as the top complaint area among 13 recalls. The model's covered years extend from 1990 to 2005, with complaint volumes ranging from a low of 63 to a high of 705 in 2003. Consequently, the 1996 Cavalier represents a period of significant reported issues that defines the vehicle's reliability profile for researchers.

Model year2024 2023 2021 2020 2019 2005 2004 2003 1996

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.5 qtOEM · verified

Engine oil type5W-30 APIOEM · verified

Lug nut torque100 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 75 · 525 CCA battery, OE oil filter 12731172. Note the factory fuel filter and front wiper blades are now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 75 · 525 CCAOEM · verified

Tire sizeBASE P185/75R14OEM · verified

Wheel / rim6-JJ inOEM · verified

OE service part numbers OEM · verified

Engine oil filter	12731172 alt 12731175
Engine air filter	24577608
Fuel filter	25121293 discontinued
Spark plug	19158037 alt 19301807
Front wiper blades	22711469 discontinued · alt 22711468
Serpentine belt	88984195 alt 24575312
Thermostat	24577288 alt 24577299

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length	180.3 in
Overall width	68.5 in
Overall height	53.9 in
Wheelbase	104.3 in
Curb weight	2837 lb
Track (front / rear)	57.5 / 56.7 in

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Cavalier of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

8.3 sec0–60 mph (tested)quickest 8.30 sec — 1996 LS Sedan

Year	Trim / engine	0–60	¼ mile	HP	Drivetrain
1996	LS Sedan 2.4L I-4	8.30 sec	16.10 sec	150 hp	FWD
1995	LS Sedan 2.2L I-4	10.10 sec	17.30 sec	120 hp	FWD
1990	Z24 Coupe 3.1L V6	8.40 sec	16.40 sec	140 hp	FWD
2003	LS Sport Coupe 2.2L I-4	7.90 sec	16.10 sec	140 hp	FWD

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.5 qt of 5W-30 API engine oil, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs. The firing order is 1-3-4-2.

Lubricants & capacities

Brake Fluid	DOT 3
Engine Oil	5W-30 · API
Engine Oil Capacity	4.5 qt
Engine Oil	5W-30 · API
Engine Oil Capacity	5 qt
Power Steering Fluid	USE GM PART NO. 1052884 OR EQUIVALENT

Engine torques

Crankshaft Position (CKP) Sensor Bolt(s)	6 ft-lbs
Camshaft Position (CMP) Sensor Bolt(s)	7.5 ft-lbs
Crankshaft Position (CKP) Sensor Bolt(s)	7.4 ft-lbs
Camshaft Position (CMP) Sensor Bolt(s)	7.4 ft-lbs
Camshaft Sprocket and/or Gear Bolt(s)	77 ft-lbs
Camshaft Sprocket and/or Gear Bolt(s)	52 ft-lbs
Crankshaft Pulley and/or Damper Bolts	77 code H ft-lbs
Crankshaft Pulley and/or Damper Bolts	129 ft-lbs, 90 degrees ft-lbs

Chassis torques

Lug Nuts	100 ft-lbs
Front Wheel Hub	185 ft-lbs

Ignition

Cylinder Firing Order	1-3-4-2
Ignition Coil Secondary Resistance	5000-8000 ohms
Ignition Coil Secondary Resistance	5000-8000 ohms
Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.060 in
Spark Plug Torque	13.0 ft-lbs
Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.043 in

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	1.50 lbs
Oil Group	PAG
Oil Type	GM part number 12345923 or equivalent.
Oil Capacity	9.00 oz
Standard BCI Group Number	75
Standard BCI Cranking Performance	525 cca
Standard BCI Group Number	75

Service checks

Pressure Test	15; Do not exceed 20 psi.
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	185-205 °F
Pressure Test	15, Pressure should not exceed 20 psi.
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	188-206 °F
Fuel Pump Pressure Minimum	47.0 psi
Key ON Engine OFF (KOEO)	40.5-47

Brakes

Torque Caliper to Bracket	38 ft-lbs
Torque to Knuckle	100 ft-lbs
Minimum Pad Thickness	Front: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation	0.0005 in
Rotor Runout Limit	0.003 in
Rotor Nominal Thickness From	0.796 in
Rotor Nominal Thickness To	0.796 in
Rotor Minimum Machining	0.751 in

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 2 stages

1	long bolts 46 ft. lbs.; short bolts 43 ft. lbs.	46 ft. lbs
2	90

Cylinder Head — tightening sequence 2 stages

1	bolts 1-8	40 ft. lbs
2	turn 90

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 100,000 mi; coolant every 100,000 mi. The big-interval services (every 100,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

At 7,500 mi	Tire & Wheel Assembly (rotate)
Every 7,500 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Parking Brake Cable (lubricate) · Shift Linkage (inspect) · Steering Linkage (inspect) · Suspension System (inspect)
Every 15,000 mi	Tire & Wheel Assembly (rotate)
Every 30,000 mi	EGR System (inspect) · Engine Air Filter Element (replace) · Engine Breather Filter (replace) · Fuel Line (inspect) · Fuel Tank (inspect) · Fuel Tank Filler Cap (inspect)
Every 60,000 mi	Accessory Drive Belt (inspect)
Every 100,000 mi	Engine Coolant System (drain, flush & refill) · Spark Plug Wires (inspect) · Spark Plugs (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 1996 Chevrolet Cavalier marks a peak in complaints (604) and recalls (13) within its generation, reflecting a sharp escalation from the prior year (356 complaints, 9 recalls) and continuing a rising trend from 1992 onward. This year sits at the apex of reliability concerns, with complaint volumes nearly doubling those of 1994 and far exceeding the subsequent decline seen in 1998–2002. Notably, engine and electrical system complaints dominate, alongside persistent airbag and brake issues, while crash-related complaints (58) and fire reports (10) underscore broader safety concerns. The recall surge aligns with heightened investigations (4) and technical service bulletins (109), suggesting systemic rather than isolated defects. While 1997 mirrors this pattern, the 1996 model year’s combination of record-high complaints and recalls signals elevated risk. **Concrete takeaway: Avoid the 1996 Cavalier unless thorough service records and pre-purchase inspection confirm critical systems—particularly engine, electrical, and airbags—have been addressed.**

Open recalls

NHTSA campaigns

109

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

604

Owner complaints

58 involved a crash · 10 a fire

Owner complaints by model year NHTSA · this generation & adjacent

’90 ’91 ’92 ’93 ’94 ’95’96’97 ’98 ’99 ’00 ’01 ’02 ’03 ’04 ’05

Owner complaints filed with NHTSA, by component

All 604 complaints on record, top 8 components.

Engine & Engine Cooling106

Electrical System74

Air Bags65

Service Brakes, Hydraulic43

Power Train43

Steering42

Visibility24

Unknown Or Other17

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 13 campaigns on record for this vehicle.

06E049000Exterior LightingReported 24/05/2006

CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH… Remedy: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.

08E063000SteeringReported 17/10/2008

DORMAN PRODUCTS IS RECALLING 3,900 INTERMEDIATE STEERING SHAFTS DORMAN PART NOS. 425-151, 425-152, AND 425-153, (SOLD UNDER DORMAN'S "OE SOLUTIONS" BRAND NAME), BALKAMP #'S 7-3057, 7-3058, 7-3059 (SOLD UNDER THE "NAPA"… Remedy: DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 16, 2008. OWNERS MAY CONTACT DORMAN TOLL FREE AT 1-800-523-2492.

Technical service bulletins NHTSA · verified

Showing 5 of 109 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
17-NA-073	2023-02-21	Equipment	This warranty administration bulletin provides information regarding the field action…
PIP4723F	2022-01-14	Service Brakes, Hydraulic	This Preliminary Information communicates to the dealer the process for downloading or…
PIP4723D	2020-01-31	Electrical System	This Preliminary Information communicates to the dealer the process for downloading or…
19NA273	2019-12-02	Electrical System	This informational bulletin provides information for dealers/technicians on Procedures to…
PIC4696E	2019-11-22	Equipment	This Preliminary Information communication provides information to the technician on how…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific Cavalier. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 75 battery Vehicles taking 4.5 qt Engine oil filter 12731172 Engine air filter 24577608 Fuel filter 25121293 Spark plug 19158037

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 1996 Cavalier take?

4.5 qt of 5W-30 API, per the factory manual.

Does the 1996 Cavalier have open recalls?

NHTSA lists 13 recall campaign(s) for this model year. Check your specific vehicle by VIN.