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2004 Chevrolet Cavalier CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Air Bag System Precautions -> General Motors Corp. -> Disarming -> 1990 -> 1990-93 -> 1990-95 -> 1990-97 -> 1991 -> 1991-93 -> 1991-94 -> 1991-95 -> 1992-93 -> 1992-99 -> 1993-2002 -> 1993-94 -> 1993-98 -> 1994 -> 1994-2002 -> 1994-95 -> 1994-96 -> 1994-98 -> 1995-2002 -> 1995-96 -> 1995-97 -> 1995-98 -> 1995-99 -> 1996 -> 1996-2001 -> 1996-97 -> 1997 -> 1997-2002 -> 1997-98 -> 1997-99 -> 1998-2000 -> 1998-2002 -> 1998-99 -> 1999 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 2000-02 -> 2001-02 -> 2002 -> 2003 -> 2003-04 -> 2003-04 Except Malibu Maxx -> Achieva & Skylark -> Alero -> Astro & Safari -> Aurora -> Avalanche -> Aveo -> Aztek & Rendezvous -> Beretta & Corsica -> Blazer, Jimmy, Sonoma & S-10 -> Bonneville, Eighty-Eight, LeSabre, LSS, Ninety-Eight & Regency -> Bravada, Envoy, Rainier, SSR & TrailBlazer -> C/K Series -> Camaro & Firebird -> Canyon & Colorado -> Caprice, Custom Cruiser & Roadmaster -> Catera -> Cavalier & Sunfire -> Century -> Corvette -> Coupe -> CTS -> Cutlass -> Cutlass Ciera & Cruiser -> Cutlass Supreme -> DeVille -> Eldorado -> Escalade -> Express, G Series & Savana -> Fleetwood -> Grand Am -> Grand Prix & Intrigue -> Impala -> ION -> L-Series -> Light Trucks & Vans -> Lumina -> Lumina APV, Montana, Silhouette, Trans Sport & Venture -> Malibu -> Malibu Maxx -> Metro -> Monte Carlo -> Park Avenue -> Passenger Cars -> Prizm -> Reatta, Toronado & Trofeo -> Regal -> Riviera -> S-Series -> Sedan -> Seville -> Sierra & Silverado -> SRX -> Storm -> Suburban, Tahoe, Yukon & Yukon XL -> Tracker -> Vibe -> VUE -> XLR -> Zone 1 -> Zone 10 -> Zone 12 -> Zone 2 -> Zone 3 -> Zone 4 -> Zone 5 -> Zone 6 -> Zone 7 -> Zone 8 -> Zone 9 -> Zones 1 & 7 -> Zones 2 & 6 -> Zones 5 & 9 -> Zones 7 & 9
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
Passenger Cars
The Sensing and Diagnostic Module (SDM) can maintain enough voltage to cause air bag deployment for up to 10 minutes after the ignition is turned Off and the battery is disconnected. Servicing the Supplemental air bag (SIR) system during this period may result in accidental deployment and personal injury.
Achieva & Skylark
1994-96
- Ensure front wheels are in straight-ahead position.
- Turn ignition switch to LOCK position.
- Remove AIR BAG fuse from fuse block.
- On 1995 models, remove lefthand sound insulator panel to ac...
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Drum Brakes -> Cavalier, Cobalt, G5 & Sunfire -> Adjustments -> Parking Brake -> Service Brake
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
These brakes have self-adjusting shoe mechanisms that ensure proper lining-to-drum clearances at all times. The automatic adjusters operate only when the brakes are applied as the vehicle is moving rearward.
An initial adjustment is required after the brake shoes have been relined or replaced, or when the length of the adjusting screw has been changed during service operations.
Frequent usage of an automatic transmission forward range to halt reverse vehicle motion may prevent the automatic adjusters from functioning, thereby inducing low pedal heights. Should low pedal heights be enc...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Component Locations -> Skyhawk (1982-89), Cimarron, Beretta, Cavalier, Corsica, Firenza & 2000, Sunbird & Sunfire
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS
- Remove hub nut.
- Raise and support vehicle.
- Remove ball joint to steering knuckle nut.
- Break ball joint loose from steering knuckle.
- Push axle...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS
- Disconnect battery ground cable.
- Disconnect alternator electrical connectors.
- Rotate tensioner counterclockwise with suitable wrench and slide belt from alternator pulley.
- Release tensioner and...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
General Motors Corp./Saturn Cars -> Active Handling System Warning Lamp ->
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
This lamp should light for a approximately 6-8 seconds when the ignition is turned on as a bulb check. The lamp will also come on as the system is...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at inlet port using hose clamp pliers J 38185 or equivalent.
- Remove hose from inlet port.
- Raise and support vehicle.
- Reposition heater hose inlet clamp at heater core using hose clamp pliers J 38185 or equivalent.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to install.
...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
- Remove coolant reservoir.
- Rotate tensioner clockwise with a 15mm wrench ...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Chevrolet Cavalier AUTOMOBILES
Component location diagrams for most 2004 Chevrolet Cavalier cars and light trucks sold in the U.S. from 1990+.
Rearview Mirror Lamps Diagram for 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL Components on diagram: |
Dome Lamp And Sunroof Switch Diagram for 2004 Chevrolet Cavalier 2.2 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 Chevrolet Cavalier AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Chevrolet Cavalier cars and light trucks sold in the U.S.
2004 Chevrolet Cavalier 2.2 L4 GAS Wiring Diagram Components on diagram: |
2004 Chevrolet Cavalier 2.2 L4 BI-FUEL Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Chevrolet Cavalier AUTOMOBILES
OEM TSB listings for most 2004 Chevrolet Cavalier cars and light trucks sold in the U.S. from 1985+.
Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS Auto Systems: |
Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Chevrolet Cavalier AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Chevrolet Cavalier cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Chevrolet Cavalier cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Chevrolet Cavalier cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Chevrolet Cavalier cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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