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Chevrolet Spark 2004 Service Repair Workshop Manual

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Basic Information Identification Make: Chevrolet Model: Spark Year: 2004 Generation Generation Designation: First Generation (M100/M150) Codes Platform Code: M100/M150 Introduction Market Position Target Audience: Owner with basic mechanical skills, independent...
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Chevrolet Spark 2004 Service Repair Workshop Manual
Basic Information
Identification
Make: Chevrolet
Model: Spark
Year: 2004
Generation
Generation Designation: First Generation (M100/M150)
Codes
Platform Code: M100/M150
Introduction
Market Position
Target Audience: Owner with basic mechanical skills, independent auto service professionals, and dealerships.
Competitive Analysis
Value Proposition: Provides dealer-level repair information at a fraction of the cost, enabling significant savings on maintenance and repairs.
Key Features
Content Uniqueness: Vehicle-specific, not generic; includes step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications.
Ease Of Use: Accurate, clear, and concise text combined with illustrations facilitates safe and easy servicing for users with basic mechanical knowledge.
Preparation: Empowers owners to be informed and knowledgeable when discussing repairs with technicians, or to perform simple repairs themselves.
Manual Details
Coverage Areas
Primary Coverage: Full Service, Repair, Diagnostics, Troubleshooting, Maintenance
Geographic Coverage: Global (developed for technicians worldwide)
Page Count
Estimated Page Count: High (Detailed content suggests significant page volume, typical of comprehensive workshop manuals)
Manual Type
Type: Service Repair Workshop Manual
Language
Language: English
Format
File Format: PDF Download
Manual Coverage
Systems Covered
Engine Mechanical: Complete coverage including disassembly, assembly, specifications, and torque values.
Engine Electrical: Wiring diagrams, component testing, diagnostic procedures for ignition, starting, charging systems.
Emission Control: Details on emission control devices, diagnosis of related malfunctions, and system operation.
Fuel System: Injection system, fuel pump, injectors, fuel pressure, diagnosis, and repair.
Clutch System: Clutch operation, hydraulic system, disc, pressure plate, release bearing diagnosis and replacement.
Manual Transaxle: Gearbox overhaul, component replacement, lubrication, and troubleshooting.
Automatic Transaxle: Transmission operation, hydraulic control, component diagnosis, fluid service, and adjustments.
Driveshaft And Axle: CV joints, drive axles, mounting and lubrication procedures.
Suspension System: Front and rear suspension components, shock absorbers, springs, alignment specifications.
Steering System: Power steering system, steering rack, tie rods, alignment, and troubleshooting.
Restraint System: Airbag system operation, diagnosis, and replacement procedures; seat belt mechanisms.
Brake System: Disc and drum brakes, hydraulic system, ABS (if equipped), bleeding procedures, component replacement.
Body Interior Exterior: Panel replacement, trim removal, door mechanisms, upholstery, glass replacement.
Body Electrical: Lighting, wipers, power windows, central locking, audio system, body control modules.
HVAC System: Air conditioning system, heater core, ventilation, blower motor, refrigerant handling.
Procedures Included
Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication points.
Troubleshooting: Step-by-step diagnostic trees for common and complex issues.
Repair: Detailed repair instructions for all major mechanical and electrical components.
Diagnostics: Procedures for using diagnostic tools and interpreting fault codes.
Wiring Schematics: Comprehensive and detailed wiring diagrams for all vehicle systems.
Technical Depth
Depth: Expert level, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed specifications, procedures, and diagnostic aids.
Manual Specifications
File Format
File Type: PDF
Print Quality
Printability: Yes, all pages are printable for workshop use.
Binding Type
Binding: Digital (N/A for PDF, but printable pages offer flexibility)
Paper Type
Paper Recommendation: Recommended for printing on durable paper for garage/workshop environments.
Engine Specifications
Primary Engine
Engine Type: Inline 3-cylinder, naturally aspirated gasoline engine
Displacement: 0.8L (796 cc) and 1.0L (995 cc) variants were common in this generation.
Bore X Stroke: Refer to manual for specific engine variant (e.g., 0.8L F8CV: 68.5 mm x 72.0 mm)
Compression Ratio: Refer to manual for specific engine variant (e.g., 0.8L: 9.1:1)
Performance
Horsepower: Approx. 52-60 hp for 0.8L, 66 hp for 1.0L (exact figures depend on engine variant and market).
Torque: Approx. 72-76 Nm for 0.8L, 87 Nm for 1.0L (exact figures depend on engine variant and market).
Fuel System
Fuel Delivery: Electronic Multi-Port Fuel Injection (MPI)
Fuel Type: Unleaded Gasoline (Regular)
Ignition System: Distributorless Ignition System (DIS) or Coil-on-Plug (COP) depending on engine variant.
Engine Mechanical
Valvetrain: SOHC (Single Overhead Camshaft) with 2 valves per cylinder.
Engine Mounting: Front-wheel drive transverse engine layout.
Transmission
Standard
Transmission Type: 5-speed Manual Transaxle
Optional
Transmission Type: 4-speed Automatic Transaxle
Features
Clutch Type: Dry single plate (manual transmission)
Gear Ratios: Refer to manual for specific gear ratios for manual and automatic transmissions.
Fluid Specifications
Manual Transmission Fluid: API GL-4, SAE 75W-90 or 80W-90 (specific viscosity may vary based on ambient temperature and manufacturer recommendation).
Automatic Transmission Fluid: Dexron III or equivalent (refer to manual for exact specification).
Dimensions
Exterior
Length: Approx. 3410 mm (134.3 inches)
Width: Approx. 1495 mm (58.9 inches)
Height: Approx. 1415 mm (55.7 inches)
Wheelbase: Approx. 2345 mm (92.3 inches)
Weights
Curb Weight: Approx. 750-800 kg (1650-1760 lbs), varies by trim and transmission.
Gross Vehicle Weight Rating: Refer to vehicle's VIN plate or owner's manual.
Cargo
Cargo Volume: Small, hatchback utility. Specific volume figures not readily available without consulting a detailed spec sheet or manual.
Safety Features
Ratings
Crash Test Ratings: As a small city car from this era, early models may have had limited safety features and lower crash test scores compared to modern vehicles. Refer to specific market regulatory reports if available.
Active Features
Anti Lock Brakes: Optional on some trims/markets. Covered in manual if equipped.
Passive Features
Airbags: Driver and front passenger airbags standard. Side airbags may have been optional.
Seatbelts: Front and rear seatbelts, with pre-tensioners for front occupants (typically).
Technology Features
Infotainment
Audio System: Basic AM/FM radio with CD player (optional) and limited speaker configuration. Aux input availability may vary.
Driver Assistance
Traction Control: Likely not standard or available on this model year, but check manual if equipped.
Connectivity
Bluetooth: Rarely available on this model year; typically aftermarket installations.
Maintenance
Service Intervals
Oil Change Interval: Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions. Refer to manual for exact intervals.
Air Filter Replacement: Generally recommended every 15,000-30,000 miles (24,000-48,000 km) or annually.
Spark Plug Replacement: Typically around 30,000-60,000 miles (48,000-96,000 km), depending on spark plug type (copper vs. platinum/iridium).
Fluid Specifications
Engine Oil Type: API SN or SP, ILSAC GF-5 or GF-6, SAE 0W-20 or 5W-30 (Check manual for specific viscosity based on climate and engine variant).
Coolant Type: GM-specific orange coolant (or compatible silicate-free, long-life OAT coolant).
Brake Fluid Type: DOT 3 or DOT 4 (Refer to manual for exact specification).
Known Issues
Common Wear Items: Suspension components (bushings, ball joints), exhaust system, clutch wear (manual transmission), starter motor, alternator.
Engine Management: Potential for ignition coil issues, MAF sensor contamination, or oxygen sensor failures affecting fuel economy and emissions.
Vehicle History
Brand Heritage
Manufacturer Origin: Chevrolet is an American automotive division of General Motors (GM).
Model Evolution
Model Introduction Year: The Daewoo Matiz was redesigned and rebadged as the Chevrolet Spark for various markets starting around 2002-2003, with the 2004 model year falling into the early part of this generation.
Production
Production Locations: Originally designed by Daewoo (South Korea), production occurred in various GM facilities globally.
Awards & Recognition
Recognitions
Awards History: The original Daewoo Matiz received some recognition for its urban mobility and affordability in various markets prior to its Chevrolet rebadging. Specific awards for the 2004 Chevrolet Spark model year are not widely documented.
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