Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chevrolet Cavalier owners, lightly cleaned up (personal details are redacted by NHTSA).
Dt: while driving the contact's vehicle was involved in an accident due to a possible medical condition. The vehicle caught on fire immediately upon impact. The vehicle was deemed a total loss from the insurance company. A representative from the manufacturer inspected the vehicle and was unable to determine the cause of the fire due to the extensive damage. The solid fuel lines were intact as well as the gasoline tank. Updated 02/26/06.
My 2004 Chevy Cavalier has suffered a number of defects since its purchase. While they did not result in any collisions or injuries, they easily could have. At 10,211 miles (8/31/2004) the water pump failed; luckily, this was covered under warranty, and the pump, along with several seals and gaskets were replaced. At 29,522 miles (5/23/2005), white smoke began billowing out of the exhaust. Multi Chevrolet in union, nj discovered that a cylinder head was defective, the head gaskets were cracked, and the timing chain needed to be replaced. These repairs were again covered by the warranty at 48,241 miles (6/9/2006), the instrument cluster and a suspension beam failed. Luckily, we had purchased an extended warranty, and the repairs were again covered. Finally, at 74,000 miles (5/10/10), the vehicle suffered catastrophic engine failure. …
Idle miss while auto is in gear (automatic). Initial occurrence 15000-20000 miles. Started when at a stop light you could feel the miss it was every 30-45 seconds. No check engine light associated with problem. Has gotten worse, still no check engine light. Now it stalls and you can watch the tachometer drop 25-50 RPM. Took it to the dealership under extended warranty @ 512010 miles. Dealership said it was #2 cylinder misfire. Changed ignition module & coil pack. I picked it up and drive it 1.5 miles and it was the same. Took it back and they swapped injectors with another cylinder and spark plugs, changed fuel filter. Picked it up again. Same problem. Dealership said they cannot fix it until there is a check engine light, even though problem could be duplicated every time car was taken back to the dealership. …
The car has a major wiring or electrical problem, but its not detected by mechanics. I have a temp gauge that is all over the place, sometimes it even touches the far bottom right side of the control panel. The speedometer is no longer working, driving or parked I am going -3 miles an hour. The rpms work when they feel like it which is rarely. The only gauge working is the gas. In addition to this, the car cuts off while driving. All of this has been for the last year and a half and continues to date. I have been in mid-left turn on major intersections of los angeles and it just died. I commute on the 110 fwy and it has just died, always while I am accelerating never parked. Then in a few seconds you crank the key and your off and running again. It is so scary because it is so unpredictable. I have received speeding tickets not knowing my speed and mechanic cant find the problem. …
2004 Cavalier, 2.2l dohc, 5-speed manual transmission. While driving at 60 MPH vehicle felt as if cruise control was engaged. Rpms would not fall off as fast as usual when foot taken off gas, and when I depressed the clutch (which was just replaced last week due to another known issue that Chevy refuses to recall) rpms went above 4,000. Tapped gas pedal thinking maybe it was stuck and it only revved higher and did not come down on its own. Rpms continued to climb as I came to a stop, around 6,000 by the time I pulled over. Shut the car off and immediately back on, no problems for the rest of the trip home (another 8 miles). I cannot risk my car revving at 6,000 rpms in stop and go traffic which I'm in every weekday and I can't shut it off and turn it back on to fix the problem, so I have to find out what causes it and fix it asap. Thanks for another spendy repair, Chevy.
A strong fuel odor entered the inside of the vehicle when the vents were used. This odor caused nausea and headaches to any one riding in the vehicle. At any temperature, the vehicle took a very long time to crank up. Also, while driving at 50 MPH, the vehicle suddenly decelerated and bogged down. The vehicle would eventually pick up speed and act as if nothing ever happened. These problems occurred eight times. There was rattle in the drivers side door panel due to the regulator, there was also an intermittent noise on the passenger side rear, the vehicle would not start due to the power train control module, the engine was hard to start at times and was unable to be duplicated, the engine would lose power, the driver door made a rubbing noise, the floor area was buckling, and the A/C displayed a burning smell.
Tl contact owns a 2004 Chevrolet Cavalier. While driving 5 MPH, the engine intermittently stalled. The failure occurred while making a turn in first gear. The RPM decreased to 400 RPM and there was a loss of power steering. When the vehicle stalled, the contact released his foot from the clutch and the motor increased the RPM's automatically. When the key was turned in the ignition, the vehicle failed to start intermittently until approximately ten attempts. While driving 55 MPH, the speedometer displayed 30 MPH. When the gas tank was full, the fuel gauge would display half a tank. The temperature gauge also malfunctioned. The vehicle would not overheat, but the gauge would read hot. The dealer was unable to diagnose or repair the failures. The failure mileage was 24,000 and current mileage was 37,500.
With less than 100 miles on the car it began to rev up on its own. It has been to the dealer on 9 different occasions. They even installed an on board computer and were able to see the problem that occurs. The mechanic says he believes it is a glitch in the computer and is unable to fix it. It has now begun to accelerate on its own while driving, and the only thing you can do is push in the clutch and hope the engine blows up. This is now a real safety issue. GM refuses to do anything to correct this problem. We filed a lemon law case with them and they said they are unable to do anything.
Car will accelerate on it's own usually occurs while slowing down or while making a turn pressing the brake hard slows the car but it continues to apply power what stops the engine from continuing to accelerate is to push the clutch in, at the moment the engine will accelerate to 6500 RPM then return to normal like it is completing some cycle. It is very dangerous in the winter. We have expected a recall but nothing. I can guarantee a lawsuit if my wife and kids are injured. This is a true case of sudden acceleration that the feds can investigate.
Tl* the contact owns a 2004 Chevrolet Cavalier. The contact stated that while driving 60 MPH, the vehicle stalled and no warning lamp illuminated. The vehicle was taken to a local shop, who diagnosed that the timing chain guide bolts broke. As a result, the cylinder head, oil pump, and transmission were damaged. The manufacturer was made aware of the failure and did not offer any assistance. The vehicle was not repaired. The failure and current mileages were 80,000.
Engine complaints in other Cavalier years
Frequently asked questions
How common are engine problems on the 2004 Chevrolet Cavalier?
NHTSA has 22 complaints about the engine & cooling of the 2004 Chevrolet Cavalier, 7% of the model year's 330 complaints. The component named most often is engine (7 mentions).
Is there a recall for 2004 Chevrolet Cavalier engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Chevrolet Cavalier, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Chevrolet Cavalier engine problems start?
Half of the complaints with a recorded mileage happened before about 51,000 miles, and 33% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 1 fire and 1 injury to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.