Market Position:
The 2004 Chevrolet Cavalier was positioned as an affordable, compact car, often marketed towards younger drivers, first-time car buyers, and budget-conscious consumers seeking reliable transportation.
Competitive Analysis:
Competed directly with other compact cars of the era such as the Ford Focus, Honda Civic, Toyota Corolla, Nissan Sentra, and Hyundai Elantra. The Cavalier often differentiated itself with a lower price point and straightforward mechanicals.
Key Features:
Fuel efficiency, accessible pricing, and a range of body styles (coupe, sedan, convertible). The 2004 model represented the later years of the J-body platform, benefiting from incremental updates and refinement.
Systems Covered:
Engine mechanical, Engine performance, Fuel system, Exhaust system, Cooling system, Lubrication system, Ignition system, Starting system, Charging system, Transmission (automatic & manual), Drivetrain, Suspension, Steering, Brakes (ABS included), Wheels and Tires, Body (interior & exterior), HVAC system, Electrical system (wiring diagrams, components), Body control modules, Safety systems (airbags, seatbelts), Diagnostic procedures
Procedures Included:
Routine maintenance, Scheduled maintenance, Troubleshooting and diagnostics, Component removal and installation, Component repair and overhaul, Electrical system troubleshooting, Emission control system diagnosis, Brake system bleeding and service, Suspension alignment, Engine tune-up, Transmission service, Air conditioning service, Body repair, Interior trim removal and installation
Technical Depth:
Comprehensive: From basic fluid changes and inspections to advanced diagnostics, component rebuilds, and full system overhauls. Includes detailed specifications, torque values, diagnostic trouble codes (DTCs), and step-by-step repair instructions.
Diagnostic Trouble Codes:
Detailed listing and explanation of Diagnostic Trouble Codes (DTCs) with specific diagnostic flowcharts for troubleshooting.
Torque Specifications:
Comprehensive list of torque specifications for all critical fasteners across all systems (engine, chassis, body).
Wiring Diagrams:
Complete and detailed electrical wiring diagrams for all vehicle circuits, including component locations and wire colors.
๐ Manual Specifications
Print Quality:
High-resolution, printable pages with clear diagrams and text
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Searchable Text:
Yes, the PDF is text-searchable for quick information retrieval.
Navigation:
Bookmarked sections for easy navigation through different vehicle systems and procedures.
โ๏ธ Engine Specifications
Primary Engine:
2.2L ECOTEC DOHC 16-Valve Inline-4
Horsepower:
140 hp @ 5800 rpm
Torque:
150 lb-ft @ 4000 rpm
Fuel System:
Multi-port Fuel Injection (MPFI), Electronic Throttle Control (ETC)
Bore Stroke:
86 mm x 94.6 mm
Compression Ratio:
10.0:1
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Optional Engine:
2.4L ECOTEC DOHC 16-Valve Inline-4 (GT trim)
Optional Engine Code:
LE5
Optional Horsepower:
170 hp @ 6200 rpm
Optional Torque:
170 lb-ft @ 4800 rpm
Wheelbase:
104.3 inches (2649 mm)
Length:
177.0 inches (4496 mm)
Width:
67.9 inches (1725 mm)
Height:
54.9 inches (1395 mm) (Coupe)
Front Track:
57.5 inches (1460 mm)
Rear Track:
57.8 inches (1468 mm)
Trunk Capacity:
13.1 cu ft (370 L) (Sedan)
Curb Weight:
Approx. 2700-2850 lbs (1225-1293 kg) depending on body style and equipment
Gross Vehicle Weight Rating:
4000 lbs (1814 kg) (approx)
NHTSA Frontal Driver:
Good
NHTSA Frontal Passenger:
Good
NHTSA Side Driver:
Acceptable
NHTSA Side Rear Passenger:
Acceptable
Active Safety Features:
Anti-lock Braking System (ABS) (optional/standard depending on trim), Traction Control System (TCS) (optional)
Passive Safety Features:
Front airbags (driver and passenger), crumple zones, side-impact door beams, height-adjustable seat belts.
Infotainment Features:
Standard AM/FM stereo with CD player and 4 or 6 speakers. Optional premium audio systems, satellite radio integration was rare for this year.
Driver Assistance Features:
Limited driver assistance features typical for the era. Primarily ABS and optional Traction Control System (TCS). No advanced electronic driver aids like adaptive cruise control or lane keeping assist.
Connectivity Features:
Basic connectivity including power outlets. No Bluetooth or USB integration in standard factory units.
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months with synthetic oil, or 3,000 miles (5,000 km) or 3 months with conventional oil (refer to owner's manual for exact recommendation based on driving conditions).
Tire Rotation Interval:
Every 7,500 miles (12,000 km)
Engine Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection
Spark Plug Replacement:
Every 100,000 miles (160,000 km) for Ecotec engines (iridium type)
Engine Oil Type:
SAE 5W-30 (preferred for Ecotec engines, API certified)
Coolant Type:
GM Dex-Coolยฎ Extended Life Antifreeze/Coolant (50/50 mix with distilled water)
Power Steering Fluid Type:
GM Power Steering Fluid (or equivalent)
Known Issues:
Common issues include oil leaks from the valve cover gasket and oil pan gasket, front suspension component wear (ball joints, control arm bushings), exhaust manifold cracks (on some Ecotec engines), and potential HVAC blower motor resistor failure. Some earlier models experienced transmission issues, though later models and Ecotec engines generally saw improved reliability. The digital instrument cluster on some models could experience failure. Coolant leaks from the water pump or hoses were also not uncommon.
Brand Heritage:
Chevrolet, a division of General Motors, has a long history of producing a wide range of vehicles, from economy cars to trucks and performance automobiles. Founded in 1911, Chevrolet has consistently aimed to provide 'value for money' and accessible automotive solutions.
Model Evolution:
The Cavalier was introduced in 1982 as GM's response to the growing import compact car market and the need for fuel-efficient vehicles. It was built on GM's front-wheel-drive J-body platform. The third generation (2000-2005) saw significant updates to styling, interior, and the introduction of the Ecotec engine family, which improved performance and efficiency.
Production Years Global:
1982-2005
Production Location:
Primarily manufactured in Lordstown, Ohio, USA, and also in Mexico and South Korea for various markets.
