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2002 Chevrolet Cavalier

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Cavalier.

Body PASSENGER CAR

The 2002 Chevrolet Cavalier is a passenger car requiring 5 quarts of 5W-30 API engine oil, carrying a record of 210 total owner complaints and 5 recalls. While the electrical system is identified as the top complaint area, this model year's issue count remains well below the 705 complaints logged for the 2003 peak within the covered 1990-2005 history. Instead, the 2002 model sits between the historical extremes of the timeline, exceeding the 63 complaints from the 1990 low. This positioning indicates a reliability performance that avoids the highest volume of reported issues seen in the subsequent year while surpassing the figures from the start of the documented range.

Model year202420232021202020192005200420032002

Quick specs

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

Engine oil capacity5 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 · 600 CCA battery, OE oil filter 12731175. Note the factory fuel filter and front wiper blades are now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known.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 · 600 CCAOEM · verified
Tire sizeP195/70R14OEM · verified
Wheel / rim6-J inOEM · verified

OE service part numbers OEM · verified

Engine oil filter12731175 alt 12731172
Engine air filter24577608
Fuel filter25121293 discontinued
Spark plug19301812 alt 12681663
Front wiper blades22711469 discontinued · alt 22711468
Serpentine belt88984191 alt 12575450
Thermostat24577288 alt 12622410

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length182.7 in
Overall width68.5 in
Overall height52.8 in
Wheelbase103.9 in
Curb weight2619 lb
Track (front / rear)57.5 / 56.7 in
Weight distribution (front / rear)64/36

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.

7.9–10.1 sec0–60 mph (tested)quickest 7.90 sec — 2003 LS Sport Coupe
YearTrim / engine0–60¼ mileHPDrivetrain
2003LS Sport Coupe 2.2L I-47.90 sec16.10 sec140 hpFWD
1996LS Sedan 2.4L I-48.30 sec16.10 sec150 hpFWD
1995LS Sedan 2.2L I-410.10 sec17.30 sec120 hpFWD

Service quick specs OEM factory data

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

This engine holds 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. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Brake FluidDOT 3
Engine CoolantDEX-COOL OR EQUIVALENT
Engine Oil5W-30 · API
Engine Oil Capacity5 qt
Engine Oil5W-30 · API
Engine Oil Capacity5.0 qt
Engine Oil5W-30 · API
Engine Oil Capacity4.5 qt

Engine torques

Crankshaft Pulley and/or Damper Bolts77 code H ft-lbs
Crankshaft Pulley and/or Damper Bolts129 ft-lbs, 90 degrees ft-lbs
Intake Manifold to Engine BoltsBolts, nuts: 17 ft-lbs, studs: 8.8 ft-lbs
Exhaust Manifold to Cylinder Head Bolts9.6 ft-lbs
Intake Manifold to Engine Bolts7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts10 ft-lbs
Intake Manifold to Engine Bolts18 ft-lbs
Exhaust Manifold to Cylinder Head Bolts9.2 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs
Front Wheel Hub144 ft-lbs

Ignition

Cylinder Firing Order1-3-4-2
Spark Plug ManufacturerAC Delco
Spark Plug Gap0.060 in
Spark Plug Torque13.0 ft-lbs
Spark Plug ManufacturerAC Delco
Spark Plug Gap0.042 in
Spark Plug Torque15.0 ft-lbs
Spark Plug ManufacturerAC Delco

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.50 lbs
Oil GroupPAG
RefrigerantR134a
Refrigerant Capacity1.35 lbs
Oil GroupPAG
RefrigerantR134a
Refrigerant Capacity1.50 lbs

Service checks

Pressure Test15; Do not exceed 20 psi.
Radiator Cap Pressure Relief15 psi
Thermostat Opening Temperature185-205 °F
Pressure Test15, Pressure should not exceed 20 psi.
Radiator Cap Pressure Relief15 psi
Thermostat Opening Temperature188-206 °F
Fuel Pump Pressure Minimum60.0 psi
Key ON Engine OFF (KOEO)50-60

Brakes

Torque to Knuckle100 ft-lbs
Torque Caliper to Bracket63 ft-lbs
Minimum Pad ThicknessFront: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation0.001 in
Rotor Runout Limit0.002 in
Rotor Nominal Thickness From0.786 in
Rotor Nominal Thickness To0.786 in
Rotor Minimum Machining0.751 in

Multi-step torque procedures OEM · verified

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
174 ft. lbs., step 2: 7574 ft. lbs
Cylinder Head — tightening sequence 2 stages
1long bolts 46 ft. lbs.; short bolts 43 ft. lbs.46 ft. lbs
290
Cylinder Head — tightening sequence 2 stages
122 ft. lbs.22 ft. lbs
2155 degrees155 degrees
126
Cylinder Head — tightening sequence 2 stages
1bolts 1-840 ft. lbs
2turn 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 at 150,000 mi. The big-interval services (at 150,000 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.

Every 7,500 miEngine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate) · Underbody (inspect)
Every 30,000 miEngine Air Filter Element (replace)
Every 60,000 miAccessory Drive Belt (inspect)
Every 100,000 miSpark Plug Wires (inspect) · Spark Plugs (replace)
At 150,000 miEngine Coolant System (drain, flush & refill)

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 2002 Chevrolet Cavalier marks a relative low point in complaints (210) within its generation, falling between the higher-volume years of 2000 (338) and 2003 (705), which saw a sharp spike in reported issues. Recalls dropped to five—below the double-digit figures of 1995–1998—while investigations ceased entirely, suggesting either resolved concerns or reduced severity of emerging problems. However, the 2002 model’s 456 TSBs indicate persistent, though likely addressable, technical quirks, particularly in the electrical system (22 complaints) and hydraulic brakes (19). Crash-related complaints (26) and fire reports (4) remain consistent with adjacent years, offering no red flags beyond the generation’s baseline. This year sits in a mid-cycle lull, avoiding the early recalls and late-stage complaint surge, but still reflects the Cavalier’s broader reliability challenges. **Takeaway:** The 2002 is a comparatively stable choice within the generation, but thorough pre-purchase inspection—especially of brakes and wiring—is essential.

5
Open recalls
NHTSA campaigns
456
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
210
Owner complaints
26 involved a crash · 4 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★★
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 210 complaints on record, top 8 components.

Electrical System22
Service Brakes, Hydraulic19
Engine & Engine Cooling14
Visibility13
Power Train11
Steering10
Exterior Lighting9
Fuel System, Gasoline9

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 5 campaigns on record for this vehicle.

08E050000Exterior Lighting:HeadlightsReported 11/08/2008

K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FAILS TO CONFORM WITH THE REQUIREMENTS OF… Remedy: K2 MOTOR WILL NOTIFY OWNERS AND OFFER A FULL REFUND. THE RECALL BEGAN ON DECEMEBER 17, 2008. OWNERS MAY CONTACT K2 MOTOR AT 1-909-839-2992.

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 456 bulletins on record with NHTSA.

BulletinDateComponentSummary
PIP5601C2025-07-18Unknown Or OtherThis PI communicates the requirement to provide a pico file to receive diagnostic…
PIP5358D2025-02-19Unknown Or OtherThis Preliminary Information communication provides information to the technician about…
PIP4723J2024-10-25Electrical SystemThis Preliminary Information communicates to the dealer the process for downloading or…
PIT5099H2024-09-12Unknown Or OtherThis Preliminary Information communication provides information to the technician about…
PIT5099H2024-09-12Unknown Or OtherThis Preliminary Information communication provides information to the technician about…

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 batteryVehicles taking 5 qtEngine oil filter 12731175Engine air filter 24577608Fuel filter 25121293Spark plug 19301812

Reference guides

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

Vehicle recalls & TSBsOBD-II trouble codesTorque specificationsMaintenance schedulesFluid capacities & specs

Frequently asked

How much oil does the 2002 Cavalier take?

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

Does the 2002 Cavalier have open recalls?

NHTSA lists 5 recall campaign(s) for this model year. Check your specific vehicle by VIN.