1991 Saturn SL Service and Repair Manual

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Factory-Grade Data

1991 Saturn SL service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • Base Sedan 4-Door

Engines covered

  • 1.9L 116Cu. In. l4 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Saturn SL Recalls & Complaints

NHTSA #93V13200010/08/1993Component: ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR

THE GENERATOR ELECTRICAL WIRING IS NOT PROTECTED AGAINST EXCESSIVE CURRENT FLOW WHICH MAY BE CAUSED BY AN ELECTRICAL SHORT CIRCUIT IN THE GENERATOR.

Consequence

SHOULD AN ELECTRICAL SHORT CIRCUIT OCCUR IN THEGENERATOR, THE GENERATOR WIRING HARNESS WOULD EXPERIE

Remedy

THE GENERATOR WIRING HARNESS WILL BE REPLACED WITH ONE THAT WILL OPEN AS A FUSE WOULD UNDER CERTAIN

TSB #10233362

This service bulletin revision provides a repair procedure to Remove Debris from Evaporator Case, Disinfect evaporator or Apply Cooling coil coating and install blower motor control module to correct a customer concern of A/C Odor at start-

TSB #10246631

Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules

20001103Component: SEAT BELTSCrash reported2 injured1 fatalities

RESTRAINT SYSTEM ANALYSIS WAS PERFORMED BY CHP-CENTRAL DIVISION MAIT. THE ANALYSIS INDICATED THE RESTRAINT FAILED AT THE LATCH PLATE CONNECTION TO THE MOTORIZED GUIDE PLATE. THIS REPORT IS BEING FIL

19970306Component: SEAT BELTS:FRONT:BUCKLE ASSEMBLYCrash reported1 injured

VEHICLE INVOLVED IN A REAR END CRASH GOING ABOUT (20-25) MPH AND THE AIR BAG DID NOT DEPLOY. ALSO THE SHOULDER HARNESS DID NOT LOCK. VEHICLE IS BEING REPAIRED. *AK

19970306Component: AIR BAGSCrash reported1 injured

VEHICLE INVOLVED IN A REAR END CRASH GOING ABOUT (20-25) MPH AND THE AIR BAG DID NOT DEPLOY. ALSO THE SHOULDER HARNESS DID NOT LOCK. VEHICLE IS BEING REPAIRED. *AK

19991129Component: ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATORFire reported

NONE

19960502Component: SEATS1 injured

DRIVER'S SEAT BACK COLLAPSED DUE TO REAR IMPACT. *SD

Showing the 5 most serious of 31 complaints filed with NHTSA.

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