2004 Chevrolet Cavalier Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet Cavalier covers the coupe and the sedan in Base, LS and LS Sport trim, with two 2.2L inline-fours of 134 cubic inches to tell apart: a naturally aspirated twin-cam that could be built to run gasoline or a gasoline and LPG bi-fuel mix, and a naturally aspirated overhead-valve engine on gasoline alone. Valve train work, timing service and fuel system diagnosis differ between the two, and the manual carries specifications, torque values and wiring diagrams for both installations.

Engines covered

• 2.2L inline-four (134 cu in) — DOHC, naturally aspirated, gasoline or bi-fuel gasoline/LPG
• 2.2L inline-four (134 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 2-door coupe
• 4-door sedan

Trims covered

• Base
• LS
• LS Sport

Known issues on the 2004 Cavalier. Two recalls appear federally. One concerns the rear passenger-side belt, fitted with the wrong nut and bolt at its upper anchorage; in a severe crash that anchorage can pull loose and the belt no longer holds the occupant as it should. The other covers a replacement intermediate steering shaft with a weld that can break, taking steering control with it. Of 330 owner complaints, 166 are electrical, far ahead of 21 on the power train and 18 on visibility. Belt anchorage torque, steering column service and the body electrical diagnostics behind that cluster are all specified here.