🏷️ Basic Information

Make:

Chevrolet

Model:

Caprice

Year:

1991

Platform:

B-body

👋 Introduction

Target Audience:

DIY enthusiasts, independent repair shops, and fleet maintenance technicians seeking in-depth factory-level repair information.

Value Proposition:

Provides the exact same, highly detailed, vehicle-specific information used by dealership technicians, offering a significant advantage over generic repair guides. Saves time and money by enabling owners to perform their own maintenance and repairs.

Digital Convenience:

Single, easy-to-use PDF manual with searchable text, eliminating the need to flip through multiple physical books. Printable pages for convenient use in a workshop environment.

Illustration Quality:

Includes detailed illustrations and diagrams to guide users through complex procedures, enhancing understanding and accuracy.

📋 Manual Details

Primary Coverage:

All 1991 Chevrolet Caprice models and all repairs A-Z

Estimated Page Count:

Extensive (as it is a complete service manual, typically 1000+ pages for this era and depth)

Type:

Factory Service and Repair Manual

Language:

English

Format:

Digital (PDF)

Compatibility:

Compatible with Windows Vista (32/64), XP, ME, 98, NT, 2000, and Mac operating systems.

Software Requirements:

Adobe PDF Reader and Winzip (free online).

📖 Manual Coverage

Powertrain:

Engine, Control System, Fuel Service, Emission Control, Intake/Exhaust/Cooling, Lube, Ignition, Starting/Charging, Automatic Transmission, Manual Transmission, Transfer Case/Propeller Shaft, Drive Shaft, Differential, Axle

Chassis:

Suspension, Tire & Wheel, Brake Control, Brakes, Parking Brake, Steering Column, Power Steering

Electrical And Body:

Air Conditioning, Supplemental Restraint System (Airbag), Seat Belts, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Locks, Meter/Audio/Visual, Horn, Windshield/Glass/Mirror, Instrument Panel, Seats, Engine Hood/Door, Exterior & Interior, Electrical Systems, Multiplex/CAN Communication

Body And Trim:

Interior and exterior trim components, door mechanisms, glass and mirrors, hood and trunk operation, seats, and instrument panel removal/installation.

Climate Control:

Air conditioning system service, refrigerant handling, component replacement, and operational checks.

Diagnostic Procedures:

Troubleshooting guides, diagnostic flowcharts, symptom-to-cause identification

Maintenance Procedures:

Scheduled maintenance, fluid changes, filter replacements, inspections

Repair Procedures:

Step-by-step repair instructions for all major and minor components, including complete disassembly and reassembly

Technical Data And Specs:

Torque specifications, clearance measurements, tolerances, diagnostic trouble codes (DTCs), wiring schematics, exploded views

Wiring Schematics:

Complete and detailed wiring diagrams for all electrical systems, crucial for diagnosing electrical faults.

Emissions Control:

Information on emission control systems, component testing, and diagnosis for compliance with emissions regulations.

Depth:

Comprehensive; covers everything from basic fluid checks to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs.

📊 Manual Specifications

Digital Format:

PDF

Printability:

Fully printable, allowing users to print specific pages or sections as needed. Image blow-up capability for detailed diagrams.

Digital Binding:

N/A (Digital file)

Digital Medium:

N/A (Digital file, typically delivered via download)

⚙️ Engine Specifications

Engine Options:

The 1991 Chevrolet Caprice was primarily offered with the 5.0L (305 cu in) V8 engine (VIN code E) and the 5.7L (350 cu in) V8 engine (VIN code 7), typically the L98 variant used in higher performance models or police packages.

5.0L V8 Horsepower:

Approximately 170 hp @ 4000 rpm (varies slightly by specific application/tune)

5.0L V8 Torque:

Approximately 255 lb-ft @ 2400 rpm (varies slightly by specific application/tune)

5.7L V8 Horsepower:

Approximately 225 hp @ 4000 rpm (L98 variant, often with throttle-body injection)

5.7L V8 Torque:

Approximately 330 lb-ft @ 2400 rpm (L98 variant)

Fuel Delivery:

Throttle Body Injection (TBI) for the 5.0L, and often Tuned Port Injection (TPI) or TBI for the 5.7L (L98) depending on trim/package.

Fuel Type:

Unleaded gasoline

ECM:

Engine Control Module (ECM) managing fuel injection, ignition timing, and emissions.

Diagnostics Interface:

OBD-I (On-Board Diagnostics - First Generation) compliance, with diagnostic connector and potential for code retrieval as detailed in the manual.

🔧 Transmission

Transmission Type:

4-speed automatic transmission (e.g., THM700-R4 / 4L60)

Optional Transmission:

While primarily automatic, some specific heavy-duty or police interceptor models might have had variations, though manual transmissions were not common for civilian Caprice models in this year.

Transmission Fluid:

Dexron-III (or equivalent)

📐 Dimensions

Wheelbase:

115.5 inches

Overall Length:

204.7 inches

Overall Width:

79.1 inches

Overall Height:

54.3 inches

Curb Weight:

Approx. 3,800 - 4,200 lbs (depending on engine and options)

Gross Vehicle Weight Rating Gvwr:

Typically around 5,000 - 5,300 lbs

🛡️ Safety Features

Crash Test Results:

Specific NHTSA ratings for the 1991 model may vary by year and test protocol; however, this era of Caprice offered robust body-on-frame construction. The manual would detail any available crashworthiness information.

Passive Restraints:

Seat belts (manual operation), padded interior surfaces, collapsible steering column.

Supplemental Restraint System:

Driver's side airbag was optional or standard on certain trims/packages for 1991. The manual covers its operation and service.

💡 Technology Features

Audio System:

Factory AM/FM stereo, often with cassette player. Optional premium sound systems were available. The manual covers speaker replacement, radio diagnostics, and antenna issues.

Cruise Control:

Available as an option, controlled via steering column stalk. The manual provides troubleshooting for speed sensor, vacuum/cable operation, and control module issues.

Multiplex Communication:

The manual lists 'Multiplex/CAN Communication', suggesting the presence of some early multiplexed wiring systems for certain functions, which the manual details troubleshooting for.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 miles or 3 months, using conventional oil. Synthetic options could extend intervals as specified in the manual.

Transmission Fluid Change Interval:

Recommended every 30,000-60,000 miles depending on driving conditions, with filter replacement.

Coolant Flush Interval:

Typically every 2 years or 30,000 miles.

Engine Oil Specification:

API Service SG or SH, SAE 5W-30 or 10W-30 (check manual for specific viscosity based on temperature).

Coolant Specification:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Specific type may be detailed in the manual.

Brake Fluid Specification:

DOT 3 brake fluid.

Power Steering Fluid:

GM Power Steering Fluid or Dexron-III/VI automatic transmission fluid.

Differential Fluid:

API GL-5, SAE 80W-90 gear oil.

Common Wear Items:

Due to age, common issues may include worn suspension components (bushings, ball joints), aging electrical connectors, fuel injector issues (TBI), and exhaust system wear. The manual provides diagnostic steps for these.

Cooling System Potential Issues:

Radiator leaks, thermostat failure, water pump leaks, and hose deterioration are common on vehicles of this age.

📚 Vehicle History

Chevrolet Legacy:

Chevrolet has a long history of producing large, comfortable, and powerful sedans, with the Caprice being a flagship model known for its rear-wheel-drive platform and spacious interiors.

Caprice Development:

The 1991 Caprice represented a significant styling update for the B-body platform, moving towards a more aerodynamic and rounded appearance compared to its predecessors. It maintained its RWD configuration and V8 engine dominance.

Manufacturing Location:

United States (e.g., Arlington, Texas Assembly Plant)

Production Years:

Caprice production spanned from 1965 to 1996 in North America.