The 2004 Chevrolet Cavalier represents the third generation of this compact car, known for its affordability and fuel efficiency. Positioned as a practical choice for budget-conscious consumers and first-time car buyers, the Cavalier offered a straightforward driving experience and a range of body styles. Powered by the 2.2L Ecotec DOHC 16-Valve Inline-4 engine, it delivered a balance of performance and economy, competing effectively in the compact car segment with its accessible pricing and dependable, if unexciting, engineering. This comprehensive service and repair manual provides full vehicle repair and service coverage for the 2004 Chevrolet Cavalier. It details everything from routine and scheduled maintenance to advanced troubleshooting and component repair, covering all major vehicle systems including the engine, transmission, brakes, suspension, and electrical systems. With detailed specifications, torque values, diagnostic trouble codes, and clear, step-by-step instructions supported by extensive wiring diagrams, this manual is an essential resource for owners and technicians seeking to maintain, diagnose, and repair the vehicle. 🏷️ Basic Information Identification Make: Chevrolet Model: Cavalier Year: 2004 Codes Vin Model Code: 1G5 Generation Generation: Third Generation (J-Body Platform) Generation Years: 2000-2005 👋 Introduction Market Position 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 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 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. 📋 Manual Details Coverage Areas Coverage Areas: Full vehicle repair and service Page Count Page Count: Estimated 2000+ pages (comprehensive digital format) Manual Type Manual Type: Service and Repair Manual Software Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered 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 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 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. Diagnostics Diagnostic Trouble Codes: Detailed listing and explanation of Diagnostic Trouble Codes (DTCs) with specific diagnostic flowcharts for troubleshooting. Torque Specifications Torque Specifications: Comprehensive list of torque specifications for all critical fasteners across all systems (engine, chassis, body). Wiring Diagrams Wiring Diagrams: Complete and detailed electrical wiring diagrams for all vehicle circuits, including component locations and wire colors. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, printable pages with clear diagrams and text Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Yes, the PDF is text-searchable for quick information retrieval. Navigation Navigation: Bookmarked sections for easy navigation through different vehicle systems and procedures. ⚙️ Engine Specifications Primary Engine Primary Engine: 2.2L ECOTEC DOHC 16-Valve Inline-4 Primary Engine Details Engine Code: L61 Performance Horsepower: 140 hp @ 5800 rpm Torque: 150 lb-ft @ 4000 rpm Fuel System Fuel System: Multi-port Fuel Injection (MPFI), Electronic Throttle Control (ETC) Bore Stroke Bore Stroke: 86 mm x 94.6 mm Compression Ratio Compression Ratio: 10.0:1 Fuel Type Fuel Type: Unleaded gasoline, 87 octane (minimum) Displacement Displacement: 2198 cc Optional Engine Optional Engine: 2.4L ECOTEC DOHC 16-Valve Inline-4 (GT trim) Optional Engine Details Optional Engine Code: LE5 Optional Performance Optional Horsepower: 170 hp @ 6200 rpm Optional Torque: 170 lb-ft @ 4800 rpm 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission: 4-speed Automatic (4T40-E / 4T45-E) Features Transmission Features: Electronically controlled automatic transmission with overdrive, lock-up torque converter. Fluid Type Transmission Fluid Type: Dexron VI Automatic Transmission Fluid (ATF) or equivalent (check specific manual for exact specification) 📐 Dimensions Exterior 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) Cargo Trunk Capacity: 13.1 cu ft (370 L) (Sedan) Weights Curb Weight: Approx. 2700-2850 lbs (1225-1293 kg) depending on body style and equipment Gross Vehicle Weight Rating: 4000 lbs (1814 kg) (approx) 🛡️ Safety...