1991 Chevrolet Cavalier Service and Repair Manual

This factory service and repair manual for the 1991 Chevrolet Cavalier begins where the work does, with identification. Three gasoline engines were available, a naturally aspirated 2.8L overhead-valve V6 of 173 cubic inches, a naturally aspirated 3.1L overhead-valve V6 of 189 cubic inches and a naturally aspirated 2.2L overhead-valve inline-four of 134 cubic inches, in four bodies and four trims. Sedan, convertible, coupe and wagon shells carry Base, RS, VL and Z24 equipment, and the wiring diagrams, torque specifications and diagnostic tables are broken out accordingly.

Engines covered

• 2.8L V6 (173 cu in) — OHV, naturally aspirated, gasoline
• 3.1L V6 (189 cu in) — OHV, naturally aspirated, gasoline
• 2.2L inline-four (134 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 4-door sedan
• 2-door convertible
• 2-door coupe
• 4-door wagon

Trims covered

• Base
• RS
• VL
• Z24

Known issues on the 1991 Cavalier. Three recalls are recorded. Two of them touch the front door and the belt it carries: the door interlock striker can fail so that the frame collapses and no longer supports the shoulder belt anchorage, and the shoulder belt guide loops in the front doors may be cracked, which reduces the restraint's hold in a sudden stop. The third is a replacement fuel filter that can leak where it connects. Owners have logged 74 complaints, 17 electrical and nine each on engine cooling and the service brakes; door structure, belt anchorage and brake hydraulics are all covered here.