1991 Chevrolet Cavalier Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Chevrolet Model: Cavalier Year: 1991 Codes Platform: J-Body 👋 Introduction Market Position Positioning: The 1991 Chevrolet Cavalier was a significant player in the compact car...

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Mots clés: 1991 Car Cars Cavalier Chevrolet Misc

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Cavalier

Year:

Codes

Platform:

J-Body

👋 Introduction

Market Position

Positioning:

The 1991 Chevrolet Cavalier was a significant player in the compact car segment, known for its affordability and practicality. This era marked continued refinement of the J-body platform.

Competitive Analysis

Competitors:

Competed against vehicles like the Ford Escort, Honda Civic, Toyota Corolla, and Nissan Sentra.

Key Features

Design Philosophy:

Front-wheel drive, efficient packaging, and a focus on fuel economy and a comfortable ride.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Approximately 2000+ pages (typical for this era's comprehensive manuals)

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for on-the-go referencing in a workshop environment.

Digital Quality:

High-resolution scans of original factory documentation.

📖 Manual Coverage

Systems Covered

Engine:

All engine variants, including troubleshooting, diagnostics, repair procedures, overhaul, and component specifics.

Transmission:

Manual and automatic transmission systems, including diagnosis, repair, and fluid specifications.

Brakes:

Hydraulic brake systems, disc and drum brakes, parking brake, ABS (if equipped), bleeding procedures, component replacement.

Electrical:

Full electrical system coverage, including wiring diagrams, charging system, starting system, ignition system, lighting, accessories, and diagnostic procedures.

Suspension:

Front and rear suspension components, alignment specifications, shock absorbers, struts, bushings, and replacement procedures.

Steering:

Power steering system, steering gear, tie rods, linkages, and repair procedures.

Cooling System:

Radiator, water pump, thermostat, cooling fan, hoses, and coolant specifications and flushing procedures.

Fuel System:

Fuel tank, fuel pump, fuel injectors (throttle body injection or multi-port injection), fuel lines, and pressure testing.

Exhaust System:

Exhaust manifolds, catalytic converter, muffler, pipes, and diagnostic procedures.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, and repair.

Body And Interior:

Body panel removal/installation, door mechanisms, interior trim, seats, and body repair techniques.

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacements.

Troubleshooting:

Diagnostic charts and flowcharts for common problems, symptom-based troubleshooting.

Repair:

Step-by-step repair instructions for all major vehicle systems, including component removal, installation, and adjustment.

Diagnostics:

Detailed diagnostic procedures for electrical and mechanical systems, including use of test equipment.

Rebuilds:

Complete engine and transmission rebuild procedures, including specifications and torque values.

Technical Depth

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine and transmission overhauls, including electrical diagnostics.

⚙️ Engine Specifications

Primary Engine

Engine 1 Variant:

2.2L L4 OHV (VIN 4)

Engine 1 Displacement:

2198 cc (134 cu in)

Engine 1 Horsepower:

96 hp @ 4800 rpm

Engine 1 Torque:

125 lb-ft @ 2800 rpm

Optional Engine

Engine 2 Variant:

3.1L V6 OHV (VIN T)

Engine 2 Displacement:

3135 cc (191 cu in)

Engine 2 Horsepower:

140 hp @ 4800 rpm

Engine 2 Torque:

180 lb-ft @ 3600 rpm

Fuel System

Fuel Delivery:

Throttle Body Injection (TBI) for 2.2L, Multi-Port Fuel Injection (MPFI) for 3.1L V6.

Fuel Type:

Unleaded Gasoline

Performance

Compression Ratio 2.2L:

8.9:1

Compression Ratio 3.1L:

8.7:1

🔧 Transmission

Standard

Transmission Type 2.2L:

5-speed Manual

Optional

Transmission Type Optional:

3-speed Automatic (THM-125C)

Transmission Type V6 Optional:

4-speed Automatic (4T60)

Features

Clutch Type:

Dry, single plate, cable operated

Fluid Specifications

Automatic Transmission Fluid:

Dexron-III (or equivalent)

📐 Dimensions

Exterior

Wheelbase:

103.2 inches (2621 mm)

Length:

171.3 - 179.4 inches (4351 - 4557 mm) (depending on body style)

Width:

67.4 inches (1712 mm)

Height:

52.4 - 53.8 inches (1331 - 1367 mm) (depending on body style)

Weights

Curb Weight:

Approximately 2500 - 2700 lbs (1134 - 1225 kg)

Gross Vehicle Weight Rating:

Varies by configuration, typically around 3600 - 3800 lbs

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

Not rated for this specific year/model in all configurations, general safety was evolving.

Active Features

Braking System Type:

Front disc, rear drum standard; Optional rear ABS for V6 models.

Passive Features

Seatbelts:

Standard front 3-point seat belts, lap belts in rear.

Airbags:

Driver-side airbag became optional or standard on some trims by this year.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with cassette player, optional CD player on higher trims.

Instrument Cluster:

Analog gauges for speedometer, tachometer (optional), fuel, temperature, oil pressure; warning lamps.

Driver Assistance

Cruise Control:

Optional on most models.

Connectivity

Connectivity Features:

Limited by modern standards; primarily focused on basic vehicle operation and driver comfort.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles or 3 months, whichever comes first (under normal driving conditions).

Engine Coolant Flush:

Every 24,000 miles or 24 months.

Spark Plug Replacement 2.2L:

Approximately 30,000 miles.

Fluid Specifications

Engine Oil Type 2.2L:

API SG, SAE 5W-30 or 10W-30 (depending on climate).

Engine Oil Type 3.1L:

API SG, SAE 5W-30 or 10W-30 (depending on climate).

Engine Coolant Type:

Ethylene Glycol based, GM specification 1825M or equivalent (pre-mix 50/50).

Brake Fluid Type:

DOT 3

Known Issues

Common Issues 2.2L:

Head gasket leaks, intake manifold gasket leaks, timing chain wear, accessory belt tensioner issues.

Common Issues 3.1L:

Intake manifold gasket leaks (especially lower intake), valve cover gasket leaks, accessory drive belt noise.

Common Issues Transmission:

Torque converter shudder in automatic transmissions, clutch wear in manual transmissions.

Common Issues Electrical:

Faulty ignition switch, intermittent power to accessories, dashboard warning light malfunctions.

📚 Vehicle History

Brand Heritage

Chevrolet Legacy:

Chevrolet, founded in 1911, has a long history of producing reliable and accessible vehicles for the American market.

Model Evolution

J Body Platform:

The J-body platform, introduced in 1981, served various GM brands, with the Cavalier being a core model, evolving through multiple design updates to maintain market competitiveness.

Production

Manufacturing Locations:

Primarily produced in the United States and Canada.

Production Span:

The Cavalier was in production for multiple generations, with the 1991 model being part of the second generation (1988-1994).

🏆 Awards & Recognition

Recognitions

Market Perception:

The Cavalier was generally considered a good value for the money, appealing to budget-conscious buyers and often cited for its fuel efficiency and decent ride quality.

Ratings

Consumer Reports Historical:

Consumer Reports often highlighted its affordability and fuel economy, while also noting potential reliability concerns in certain areas common to GM vehicles of this era.