1991 Chevrolet Cavalier: problems, recalls and reliability
3 recalls and 55 owner complaints on record; the weakest area is electrical system (25% of complaints).
Data updated weekly · latest recall May 2006
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 55 owner complaints filed with NHTSA for this exact model year.
“My son lost control of a 1991 chevrolet cavalier and was ejected after he was forced off the road. When entering the median, his car was skidding broadside and eventually rolled over three times. As the car rolled, the driver side door opened which defeated the ability of the seat belt to hold him inside because the seat belt design had the shoulder harness anchored to the top of the door/window frame and the lap belt anchored to the bottom of the door. *jb”Owner report · Seat Belts · Jan 2005
“While tightening up the lug nuts on the wheel, pieces of metal sheared off and dropped small pieces of metal on the ground. *ak the lug nuts in question were newly purchased. Part#254 abn 10.9 manufactured by r+b inc. *scc *jb”Owner report · Wheels · Sep 2003
“No one was injured. I was driving to work and had almost got there when I heard a bang on the side of the car and saw the tread fly off back behind from my drivers side front tire. Tire stayed aired up as I got off the interstate i80, and pulled in the parking lot. I got out to examine the damage. The ground effects on my drivers side were hanging by like one screw. The tire was still aired up but there was no tread left on the tire. It ripped half of my front bumper off dented my front quarter panel and drivers door and ground effects were destroyed. Firestone ,p205/60r15 90s m+s firehawk ss10 my car 1991 chevrolet, z24 cavalier. *ak”Owner report · Tires · Sep 2002
Show 7 more owner reports
“The rear window of this vehicle blew out as one large piece (with gasket material) and shattered into numerous pieces upon road impact. I suspect that this is very unusual and should be documented with the manufacture & other organizations. Also, if a problem exist with this vehicle, maybe the manufacturer will replace the part.”Owner report · Visibility · Aug 2000
“Consumer was driving at 35 mph on the interstate when he suffered a heart attack. Vehicle flipped over the gurdrail. The consumer's air bag driver side did not deploy, and consumer was killed in the accident. *ak”Owner report · Air Bags · Sep 1998
“I purchased this vehicle for a teenage driver. I have spent well over $l,000 to bring it up to speed - fuel filter, oil & air filters, serpentine belt radiator ignition switch (key & tumbler), tires, front brake pads, front brake rotors, rear brake shoes. It will soon need a new muffler, and my mechanic now informs me that the cylinder head gasket is leaking. He said he sees quite a few of cavaliers with this problem and wonders if there is a silent recall that could help me with the possible $600.00 cost to repair. *ak”Owner report · Engine And Engine Cooling · Jul 1998
“Driver's side wiring harness caught on fire. The electrical system remained functioning and the engine continued to run. The vehicle was burned from the back of the dash foreward. Front suspension melted and the front brakes fused into one piece.”Owner report · Electrical System · Jul 1998
“Seat belt guide loops on passenger side are cracked. Noticed recall on website (#92v003000). Called dealer & manufacturer & was told by both vehicle was not included in recall. Owner would need to pay for repairs. *ak”Owner report · Seat Belts · May 1998
“While driving experienced driver's seat track and anchor failure, seat brackets cracked/broke on both sides, causing seat to move/rock rearward, as a result, foot came off pedal and vehicle stalled out. *ak”Owner report · Seats · Mar 1997
“The starter has been replaced twice, once in december of 96, in february of 97 at 70,000 miles. Because the overrun clutch burns out, the starter is being replaced again for the third time for the same reason at 89,000 miles. The flywheel has also been replaced in january of 97 because of this problem. *ak”Owner report · Electrical System · Dec 1996
When filing, owners marked a crash in 7 of these complaints and injuries in 5 - self-reported to NHTSA, not verified accident statistics.
Recalls - 3 campaigns
FRONT DOOR INTERLOCK STRIKER MAY FAIL, CAUSING DOOR FRAME COLLAPSE AND INSUFFICIENT STRENGTH FOR THE SHOULDER BELT ANCHORAGE.
Remedy: REPLACE THE PASSIVE RESTRAINT INTERLOCK STRIKER STUDS ON FRONT DOORS.
CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER HOUSING MANUFACTURED FROM OCTOBER 18, 2005, THROUGH MARCH 21, 2006, SOLD FOR USE ON THE VEHICLES LISTED ABOVE AND ON CERTAIN SCHOOL BUSES. (TO SEE THE SCHOOL BUS ENGINE SIZES, CLICK ON "DOCUMENT SEARCH" AND THEN "BUS APPLICATIONS"). THE CONNECTOR ON THE FUEL FILTER WAS NOT MANUFACTURED TO HONEYWELL'S SPECIFICATION. AS A RESULT, THE O-RING MAY NOT SEAT CORRECTLY ON THE FUEL LINE.
Remedy: HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT FRAM CUSTOMER SERVICE AT 1-800-890-2075 (OPTION 1).
THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208.
Remedy: INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES.
How other years compare
Check your exact Cavalier by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 1991 Chevrolet Cavalier reliable?
NHTSA has 55 owner complaints and 3 recall campaigns on record for the 1991 Chevrolet Cavalier. The most complained-about area is electrical system (25% of complaints).
At what mileage do 1991 Chevrolet Cavalier problems usually appear?
Half of the complaints that mention mileage were filed at 112,000 miles or less.
Does the 1991 Chevrolet Cavalier have open recalls?
3 recall campaigns have been issued, the latest concerning structure:body:door:hinge and attachments. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.