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.
CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, 'SEAT BELT ASSEMBLY ANCHORAGES.' THE PASSENGER-SIDE REAR SAFETY BELT MAY HAVE BEEN IN
IN A SEVERE CRASH, THE UPPER SEAT BELT ANCHORAGE MAY SEPARATE. THE EFFECTIVENESS OF THE S
DEALERS ARE TO INSPECT THE SAFETY BELT ANCHORAGE AND INSTALL A NEW NUT AND BOLT, IF NECESS
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,
IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.
DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGA
This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the
This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and
This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi
This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi
This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed fo
Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo
Showing the 8 most recent of 239 technical service bulletins on file with NHTSA.
DT: WHILE DRIVING THE CONTACT'S VEHICLE WAS INVOLVED IN AN ACCIDENT DUE TO A POSSIBLE MEDICAL CONDITION. THE VEHICLE CAUGHT ON FIRE IMMEDIATELY UPON IMPACT. THE VEHICLE WAS DEEM
DT: WHILE DRIVING THE CONTACT'S VEHICLE WAS INVOLVED IN AN ACCIDENT DUE TO A POSSIBLE MEDICAL CONDITION. THE VEHICLE CAUGHT ON FIRE IMMEDIATELY UPON IMPACT. THE VEHICLE WAS DEEM
MY 2004 CHEVY CAVALIER 2.2L BASE/SEDAN IS WELL MAINTAINED. THREE MONTHS AFTER THE PURCHASE THE FUEL PUMP STOPPED WORKING. REPLACED BY DEALERSHIP UNDER WARRANTY. A YEAR LATER THE F
TL*THE CONTACT OWNS A 2004 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE DRIVERS SEAT MALFUNCTIONED AND THE AIR BAG DID NOT DEPLOY WHEN A TRUCK CRASHED INTO HER VEHICLE FROM THE
Showing the 4 most serious of 428 complaints filed with NHTSA.
