Problems owners report
Complaints filed with NHTSA about the 2004 Chevrolet Cavalier, by the system named in each complaint. One complaint can name several.
- Electrical system185
- Vehicle speed control27
- Power train23
- Visibility23
- Steering16
- Air bags15
- Engine and engine cooling15
- Service brakes, hydraulic13
- Unknown or other13
- Structure13
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 19 injuries and 1 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 57 2004 Cavalier vehicles were involved in crashes on US public roads in which someone died; 53 people died inside them, and 15 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Chevrolet Cavalier failed the safety check 2.93% of the time — 33% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 103,691 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Fuel consumption
Official Canadian test results for 4 variants: combined 9.2–10.0 L/100 km (about 24–26 mpg US), CO₂ 189–223 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Cavalier · Compact · Regular gasoline | 10.8 | 7.2 | 9.2 |
| Cavalier Bi-Fuel · Compact · Regular gasoline | 11.0 | 8.0 | 9.6 |
| Cavalier · Compact · Regular gasoline | 11.2 | 7.9 | 9.7 |
| Cavalier Bi-Fuel · Compact · Natural gas | 11.6 | 8.0 | 10.0 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
1 Transport Canada recall for the 2004 Chevrolet Cavalier.
| 2004211 6 Jul 2004 | Seats And Restraints Certain vehicles do not comply with the requirements of CMVSS 209 - Seat Belt Assemblies, and CMVSS 210 - Seat Belt Assembly Anchorages. On some of these vehic… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, 'SEAT BELT ASSEMBLY ANCHORAGES.' THE PASSENGER-SIDE REAR SAFETY BELT MAY HAVE BEEN INSTALLED WITH AN INCORRECT NUT AND BOLT.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Chevrolet told its dealers about the 2004 Chevrolet Cavalier: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 618086 | CONCERNS WITH CLUNK NOISE FROM FRONT OF VEHICLE TURNING MANEUVER / STEERING WHEEL ROTATION.*JB (LUBRICATE OR REPLACE INTERMEDIATE SHAFT AS APPROPRIATE). UPDATED 10/05/07. *NJ UPDATED 4/1/08. *NJ UPDATED 7/1/2008 *PE |
| 11009156 | This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update. |
| 11007744 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 11007743 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 11007208 | This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection. |
| 11006621 | Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers. |
| 11006421 | GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return. |
| 11004761 | This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 11004557 | This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim. |
| 11002312 | This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information. |
| 11000576 | This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process. |
| 10252735 | This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish. |
| 10252163 | XM Audio Traffic And Travel Link Availability And Operation. |
| 10251890 | This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 10250775 | This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system. |
| 10249980 | This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Mot |
| 10249590 | This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim. |
| 10249579 | This PI bulletin advises the technician on the proper way to install the pistons in an engine. |
| 10249011 | This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage. |
| 10248444 | Vehicle Recalls |
| 10247780 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 10247681 | Information On Requests To Add OnStar Bluetooth Option. |
| 10247552 | This service bulletin provides information on Concerns or Questions Regarding Installation of Dealer Installed Accessories. |
| 10246952 | Programming And Activation Of Replacement OnStar Modules. |
| 10246951 | Programming And Activation Of Replacement OnStar Modules. |
NHTSA manufacturer communications (public domain)