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1991 Chevrolet Cavalier Service and Repair Manual

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$16.99
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🏷️ Basic Information Identification Make: Chevrolet Model: Cavalier Year: 1991 Codes Platform: J-Body 👋 Introduction Market Position Segment: Compact car, economy car Competitive Analysis Competitors: Ford Escort, Honda Civic, Toyota...
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斯库: 568833
1991 Chevrolet Cavalier Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Cavalier
Year:
1991
Codes
Platform:
J-Body
👋 Introduction
Market Position
Segment:
Compact car, economy car
Competitive Analysis
Competitors:
Ford Escort, Honda Civic, Toyota Corolla, Nissan Sentra
Key Features
Selling Points:
Affordability, fuel efficiency, variety of body styles, accessible maintenance
Manual Value
Value Proposition:
Provides dealership-level repair and maintenance information, empowering owners and independent mechanics
📋 Manual Details
Coverage Areas
Models Covered:
All 1991 Chevrolet Cavalier models (coupe, sedan, hatchback, convertible)
Repair Scope:
Comprehensive A-Z repairs
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Printed Book
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine performance diagnostics, engine overhaul
Transmission:
Manual transmission, automatic transmission (including 3T40, 4T60), clutch, drive axles, differentials
Brakes:
Front disc brakes, rear drum brakes, ABS (Anti-lock Braking System) if equipped, parking brake
Electrical:
Wiring diagrams, charging system, starting system, lighting, instrumentation, power windows, power door locks, accessories, fuse box, relays
Suspension Steering:
Front and rear suspension components, struts, shock absorbers, steering system, power steering, wheel alignment
Body Chassis:
Body construction, doors, windows, bumpers, interior trim, frame, exhaust system
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant handling (R12)
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, pressure regulator
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, hangers
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups
Repair:
Engine repair, transmission overhaul, brake system repair, suspension replacement, electrical component diagnosis and repair
Troubleshooting:
Diagnostic charts, common problems and solutions, symptom-based troubleshooting guides
Diagnostics:
On-board diagnostics (OBD-I) relevant to 1991 systems, sensor testing, actuator testing
Timing Belt Chain:
Timing belt replacement for 2.0L engines, timing chain for Quad 4 engines (if applicable)
Wheel Bearing Replacement:
Front and rear wheel bearing service and replacement
Radiator Replacement:
Radiator and associated cooling system hose replacement
Technical Depth
Depth:
Detailed procedures, specifications, torque values, diagnostic charts, wiring diagrams, overhaul instructions
Engine Rebuild:
Detailed instructions for engine disassembly, inspection, and reassembly, including piston ring and bearing replacement
Wiring Diagrams Completeness:
Full vehicle wiring diagrams with component identification and wire colors for all major electrical systems
📊 Manual Specifications
File Format
Format:
Printed book (potentially scanned to PDF for digital sales)
Print Quality
Quality:
Original manufacturer quality (clear text, legible diagrams)
Binding Type
Binding:
Perfect bound or stitched
Paper Type
Paper:
Durable paper stock suitable for workshop use
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.0L (VIN Code 3), 2.3L Quad 4 (VIN Code E), 2.3L Quad 4 HO (VIN Code G), 3.1L V6 (VIN Code T)
Performance
2.0L Hp:
Approx. 96 hp
2.3L Quad 4 Hp:
Approx. 150 hp
3.1L V6 Hp:
Approx. 130 hp
Fuel System
Fuel Delivery:
Multi-port fuel injection (MPFI)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) on Quad 4 engines, conventional distributor on 2.0L and 3.1L V6
Emissions
Emissions Controls:
Catalytic converter, EGR (Exhaust Gas Recirculation), PCV (Positive Crankcase Ventilation)
🔧 Transmission
Standard
Standard Transmission:
5-speed manual (Getrag F20/F23 variants)
Optional
Optional Transmission:
3-speed automatic (THM-3T40), 4-speed automatic (4T60)
Features
Drive Axles:
Front-wheel drive
Fluid Requirements
3T40 Fluid Type:
Dexron-III Automatic Transmission Fluid (ATF)
4T60 Fluid Type:
Dexron-II/III Automatic Transmission Fluid (ATF)
📐 Dimensions
Exterior
Wheelbase:
101.2 inches (2570 mm)
Length Coupe:
176.5 inches (4483 mm)
Width:
67.1 inches (1704 mm)
Weights
Curb Weight Approx:
2600-2900 lbs (1179-1315 kg) depending on body style and engine
Gvwr Approx:
3500-3800 lbs (1588-1724 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
3 out of 5 stars (for Coupe/Hatchback)
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on front wheels
Passive Features
Airbags:
Driver-side airbag standard on most models, passenger airbag optional
Seatbelts:
Front and rear seat belts
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette player, optional CD player
Controls:
Manual HVAC controls, analogue gauges
Driver Assistance
Cruise Control:
Optional
Anti Theft:
Basic ignition immobilizer and steering wheel lock
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions
Spark Plug Replacement:
Approx. 30,000-60,000 miles (48,000-96,000 km), refer to manual for specific engine
Coolant Flush:
Every 2 years or 30,000 miles (48,000 km)
Fluid Specifications
Engine Oil Recommendation:
API SG or SH, SAE 5W-30 or 10W-30 (refer to specific engine and climate)
Coolant Type:
Ethylene Glycol based, 50/50 mix with distilled water
Brake Fluid Type:
DOT 3
Known Issues
Common Problems:
Engine mounts, cooling system leaks (radiator, hoses), EGR valve issues, power steering pump leaks, window regulator failures, interior trim wear
Electrical Gremlins:
Flickering dash lights, intermittent wiper operation due to aging wiring and connectors
Part Numbers Example
Oil Filter Part Example:
AC-Delco PF2, Fram PH5, Wix 51085 (verify for specific engine)
📚 Vehicle History
Brand Heritage
Chevrolet Legacy:
Chevrolet has a long history of producing affordable and practical vehicles for the masses.
Model Evolution
Cavalier Generation:
This 1991 model is part of the second generation (1988-1994) of the Chevrolet Cavalier, built on the J-Body platform.
Production
Manufacturing Locations:
United States (e.g., Lordstown, Ohio)
Production Years:
1981-2005 (multiple generations)
🏆 Awards & Recognition
Recognitions
Historical Awards:
While specific awards for the 1991 model are scarce, the Cavalier consistently ranked as one of the best-selling compact cars in North America for its price point.
Ratings
Consumer Reports:
Consumer Reports generally rated the Cavalier as average to below average in reliability and performance compared to some Japanese competitors of the era.
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