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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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- A/C & Heater Service
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- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Chevrolet Cavalier car and truck
repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
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A/C & HEATER SERVICE PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
General Service Domestic Vehicles -> 2003-04 -> Leak Test -> Electronic Leak Detectors -> Fluid Leak Detectors
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS
Testing the refrigerant system for leaks is one of the most important phases of troubleshooting. One or more of the methods outlined will prove useful in detecting leaks or checking connections if service work is performed. Before beginning any leak test, attach a manifold gauge set and note pressure. If little or no pressure is indicated, a partial charge must be installed. Check all connections, compressor head gasket, oil filler plug and compressor shaft seal for leaks.
For R-134a system an electronic type leak detector is recommended.
Electronic Leak Detectors
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
Disc Brakes -> AC-Delco Single Piston Front Disc Brake -> Brake System Bleed -> Bleed Sequence -> Manual -> Pressure
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS
Manual
Pressure bleeding is recommended for all hydraulic systems. However, if a pressure bleeder is unavailable, use the following procedure. Brake fluid damages painted surfaces. Immediately clean any spilled fluid.
- Remove vacuum reserve by pumping brakes several times with engine off.
- Fill master cylinder reservoir with clean brake fluid. Do not let reservoir fall below half full during bleeding procedure.
- If required, bleed master cylinder as follows:
- Loosen master cylinder forward brake line connection until fluid flows from reservoir, then tighten brake line.
- Have assistant t...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Filter Scheduled Maintenance -> 1980-06 Gasoline Engine Models Except Catera, LeMans (1988-93) Metro, Nova (1985-88), Saturn & Sprint -> Normal Service -> Severe Service
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS
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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
Starter, Replace
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL
- Disconnect battery ground cable.
- Remove wiring harness bracket nut from starter bolt.
- Raise and support vehicle.
- Remove flywheel inspection shield.
- Remove electrical c...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Cavalier AUTOMOBILES
General Motors Corp./Saturn Cars -> Reduce Engine Power Indicator Lamp ->
Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS
The Reduce Engine Power indicator lamp should light for a approximately 3 seconds when the ignition is turned on as a bulb check. If the warning lamp turns on during vehicle operation, a vehicl...
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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 GAS
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+.
 Crankshaft Position Sensor Diagram for 2004 Chevrolet Cavalier 2.2 L4 BI-FUELComponents on diagram: |
 ABS Components Diagram for 2004 Chevrolet Cavalier 2.2 L4 GASComponents 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 BI-FUEL Wiring DiagramComponents on diagram: |
 2004 Chevrolet Cavalier 2.2 L4 BI-FUEL Wiring DiagramComponents 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+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2004 Chevrolet Cavalier 2.2 L4 GAS Auto Systems: |
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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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