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2004 Chevrolet Cavalier CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- 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
Manual Air Conditioning & Heater System Diagnosis & Testing -> Cavalier & Sunfire -> Air Conditioning System Troubleshooting
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
If an air conditioning system fault is suspected, inspect the following conditions:
- Outer surfaces of radiator and condenser cores to ensure air flow is not blocked by dirt, leaves or other foreign material.
- Restrictions or kinks in condenser core, hoses or tubes.
- Blower motor operation.
- Refrig...
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Drum Brakes -> Cavalier, Cobalt, G5 & Sunfire -> Tightening Specifications
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Filter Replacement -> Except Aveo, Chevette 1.8L Diesel, Corvette, GTO, LaCrosse, Malibu (2004-06) & Malibu Maxx, Vibe, XLR, 2004-05 Corvette & 1998-2002 Metro & Prizm
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the v...
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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 -> Check Engine Or Service Now Soon Engine Indicator Lamps (Gasoline Engines w/Electronic Engine Controls Or EFI) -> Except LeMans, Metro, Prizm, Storm & Vibe
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS
The Check Engine lamp should light when the ignition is turned On. When the engine is started, the lamp should go off. If the lamp remains on for 10 seconds or constantly after the engine is started, the self diagnosis system has detected a fault condition and has stored a code in the system Electronic Control Module (ECM) or Powertrain Control Module (PCM). After diagnosis and repair, the ECM memory can be cleared of codes as follows:
On models except Cadillac with DEFI, remove the ECM/PCM fuse or disconnect the battery ground cable for approximately 30...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from cylinder head using hose clamp pliers J 38185 or equivalent.
- Remove radiator outlet hose from cylinder head.
- Raise and suitably support vehicle.
- Reposition hose clamp from surge tank pipe using hose clamp pliers J 38185 or equivalent.
- Remove radiator outlet hose from surge tank pipe.
- Reposition hose clamp from radiator using hose clamp pliers J 38185 or equivalent.
- Remove...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS
- 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+.
Cooling Fans Diagram for 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL Components on diagram: |
Fuse Block - Underhood 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 GAS 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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