2004 Chevrolet Cavalier Service and Repair Manual

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Factory-Grade Data

2004 Chevrolet Cavalier service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • LS Sport Coupe 2-Door
  • Base Sedan 4-Door
  • LS Coupe 2-Door
  • LS Sedan 4-Door
  • Base Coupe 2-Door
  • LS Sport Sedan 4-Door

Engines covered

  • 2.2L 2198CC 134Cu. In. l4 GAS DOHC Naturally Aspirated
  • 2.2L 2190CC 134Cu. In. l4 GAS OHV Naturally Aspirated
  • 2.2L 2198CC 134Cu. In. l4 BI-FUEL DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Chevrolet Cavalier Recalls & Complaints

NHTSA #04V30000023/06/2004Component: SEAT BELTS:REAR/OTHER

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

Consequence

IN A SEVERE CRASH, THE UPPER SEAT BELT ANCHORAGE MAY SEPARATE. THE EFFECTIVENESS OF THE S

Remedy

DEALERS ARE TO INSPECT THE SAFETY BELT ANCHORAGE AND INSTALL A NEW NUT AND BOLT, IF NECESS

NHTSA #08E06300017/10/2008Component: STEERING

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,

Consequence

IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGA

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11017252

This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.

TSB #11014455

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

TSB #11009156

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

TSB #11007744

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

TSB #11007743

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

TSB #11007208

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

TSB #11006621

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.

20051116Component: ELECTRICAL SYSTEMCrash reportedFire reported1 injured

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

20051116Component: ENGINE AND ENGINE COOLINGCrash reportedFire reported1 injured

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

20090808Component: FUEL SYSTEM, GASOLINECrash reported3 injured

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

20100217Component: AIR BAGSCrash reported2 injured

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.

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