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Chevrolet Chevy Caprice Complete Workshop Service Repair Manual 1991

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🏷️ Basic Information Identification Make: Chevrolet Model: Caprice Year: 1991 Codes Platform: B-body Vehicle Identification Number Vin Decoder Basis: General Motors VIN system 👋 Introduction Market Position Segment: Full-size sedan, often used as police cruisers, fleet vehicles, and comfortable personal transport. Competitive Analysis Competitors: Ford Crown Victoria, Chrysler New Yorker, Dodge Monaco, Oldsmobile Custom Cruiser, Buick Roadmaster (on the B-body platform). Key Features Design Philosophy: Body-on-frame construction for durability, spacious interior, rear-wheel drive, V8 engine options. 📋 Manual Details Coverage Areas All Models Engines Trims Transmissions: True Page Count Estimated Page Count: Varies by specific edition, typically 1000+ pages for comprehensive factory service manuals. Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, fuel injection, ignition system, cooling system, lubrication system, exhaust system, emission controls. Transmission: Automatic transmission (e.g., 4L60/4L65E, 4L80E), manual transmission (if applicable), driveline, axles, driveshafts. Brakes: Front disc brakes, rear drum brakes (standard on most models), power brake booster, hydraulic system, parking brake. Suspension: Independent front suspension (short-long arm), solid rear axle, coil springs, shock absorbers, steering linkage. Steering: Power steering system, steering column, steering wheel, steering gear/rack. Electrical: Battery, charging system, starting system, lighting system, instrument cluster, wiring diagrams, body control modules, fuses, relays. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system operation, components, and servicing. Body: Body construction, exterior trim, interior trim, doors, windows, locks, seats, body panels, chassis components. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation. Repair: Component removal and installation, overhaul procedures, component repair. Diagnostics: Detailed diagnostic strategies for all major systems. Adjustments: Calibration and adjustment procedures for various components. Technical Depth Depth: Comprehensive from basic maintenance to advanced engine and transmission rebuilds, including detailed wiring schematics and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: High-resolution, fully printable; allows printing of individual pages, chapters, or the entire manual. Binding Type Binding Type: Digital (N/A for printed binding) Paper Type Paper Type: Digital (N/A for printed paper type) Software Requirements Required Software: Adobe Acrobat Reader (or compatible PDF viewer) Delivery Delivery Method: Instant Email Delivery upon payment confirmation ⚙️ Engine Specifications Primary Engine Engine Options: 5.0L (305 cu in) V8 (L03), 5.7L (350 cu in) V8 (L05 - often for police/heavy-duty applications), 4.3L V6 (VIN code 'X' - Less common for Caprice models, more for truck variants but possible). Performance Horsepower 5.0L V8: Approx. 170 hp @ 4000 rpm Torque 5.0L V8: Approx. 245 lb-ft @ 2400 rpm Horsepower 5.7L V8: Approx. 190-230 hp (depending on specific application, e.g., police package) Torque 5.7L V8: Approx. 300-340 lb-ft (depending on specific application) Fuel System Fuel Delivery: Throttle Body Injection (TBI) for 5.0L V8, Central Multi-Port Fuel Injection (CSFI/MPFI) for 5.7L V8 (Tunable Port Injection - TPI less common on standard Caprice, more on performance variants). Recommended Fuel: 87 Octane Unleaded (for 5.0L), 87-91 Octane Unleaded (for 5.7L depending on tune) 🔧 Transmission Standard Transmission Type: 4-speed automatic (e.g., THM700-R4 / 4L60) Optional Heavy Duty Transmission: 4-speed automatic (4L80-E for heavy-duty/police applications) Features Drivetrain: Rear-Wheel Drive (RWD) 📐 Dimensions Exterior Wheelbase: Approx. 116 inches Length: Approx. 204-207 inches Width: Approx. 71-72 inches Interior Passenger Volume: Very spacious, typically exceeding 110 cubic feet. Weights Curb Weight: Approx. 3700-4100 lbs (depending on engine and equipment) 🛡️ Safety Features Ratings Ntsa Crash Test Results: As per 1991 standards; frontal impact data available. Frontal impact rating was generally considered adequate for the era, but modern standards are significantly more stringent. Active Features Antilock Brakes: Available, typically on heavier duty or police models. Passive Features Airbags: Driver-side airbag standard for 1991 model year. Seatbelts: Front and rear seat belts, driver's side shoulder belt. 💡 Technology Features Infotainment Audio System: AM/FM stereo radio, cassette player, optional CD player, basic speaker configurations. Driver Assistance Cruise Control: Available as an option. Connectivity Onboard Diagnostics: OBDI (On-Board Diagnostics I) system; requires specific diagnostic tools for reading fault codes, different from modern OBDII. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000 to 5,000 miles, or as specified by the manual based on driving conditions. Transmission Fluid Change Interval: Every 30,000 to 60,000 miles, depending on driving conditions and transmission type. Spark Plug Replacement: Refer to manual; typically 30,000 to 100,000 miles depending on spark plug type (e.g., copper vs. platinum/iridium). Fluid Specifications Engine Oil: API SG or SH certified, SAE 5W-30 or 10W-30 recommended (check manual for specific weight based on climate). Coolant: GM-specification engine coolant (typically green ethylene glycol based, 50/50 mix with distilled water). Transmission Fluid: Dexron II or Dexron III ATF (Automatic Transmission Fluid). Brake Fluid: DOT 3 brake fluid. Known Issues Common Problems: TBI fuel injector clogging, intake manifold gasket leaks (especially on L03), rear...
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Chevrolet Chevy Caprice Complete Workshop Service Repair Manual 1991
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Caprice
Year:
1991
Codes
Platform:
B-body
Vehicle Identification Number Vin Decoder Basis:
General Motors VIN system
👋 Introduction
Market Position
Segment:
Full-size sedan, often used as police cruisers, fleet vehicles, and comfortable personal transport.
Competitive Analysis
Competitors:
Ford Crown Victoria, Chrysler New Yorker, Dodge Monaco, Oldsmobile Custom Cruiser, Buick Roadmaster (on the B-body platform).
Key Features
Design Philosophy:
Body-on-frame construction for durability, spacious interior, rear-wheel drive, V8 engine options.
📋 Manual Details
Coverage Areas
All Models Engines Trims Transmissions:
True
Page Count
Estimated Page Count:
Varies by specific edition, typically 1000+ pages for comprehensive factory service manuals.
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, fuel injection, ignition system, cooling system, lubrication system, exhaust system, emission controls.
Transmission:
Automatic transmission (e.g., 4L60/4L65E, 4L80E), manual transmission (if applicable), driveline, axles, driveshafts.
Brakes:
Front disc brakes, rear drum brakes (standard on most models), power brake booster, hydraulic system, parking brake.
Suspension:
Independent front suspension (short-long arm), solid rear axle, coil springs, shock absorbers, steering linkage.
Steering:
Power steering system, steering column, steering wheel, steering gear/rack.
Electrical:
Battery, charging system, starting system, lighting system, instrument cluster, wiring diagrams, body control modules, fuses, relays.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system operation, components, and servicing.
Body:
Body construction, exterior trim, interior trim, doors, windows, locks, seats, body panels, chassis components.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections.
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation.
Repair:
Component removal and installation, overhaul procedures, component repair.
Diagnostics:
Detailed diagnostic strategies for all major systems.
Adjustments:
Calibration and adjustment procedures for various components.
Technical Depth
Depth:
Comprehensive from basic maintenance to advanced engine and transmission rebuilds, including detailed wiring schematics and diagnostic flowcharts.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
High-resolution, fully printable; allows printing of individual pages, chapters, or the entire manual.
Binding Type
Binding Type:
Digital (N/A for printed binding)
Paper Type
Paper Type:
Digital (N/A for printed paper type)
Software Requirements
Required Software:
Adobe Acrobat Reader (or compatible PDF viewer)
Delivery
Delivery Method:
Instant Email Delivery upon payment confirmation
⚙️ Engine Specifications
Primary Engine
Engine Options:
5.0L (305 cu in) V8 (L03), 5.7L (350 cu in) V8 (L05 - often for police/heavy-duty applications), 4.3L V6 (VIN code 'X' - Less common for Caprice models, more for truck variants but possible).
Performance
Horsepower 5.0L V8:
Approx. 170 hp @ 4000 rpm
Torque 5.0L V8:
Approx. 245 lb-ft @ 2400 rpm
Horsepower 5.7L V8:
Approx. 190-230 hp (depending on specific application, e.g., police package)
Torque 5.7L V8:
Approx. 300-340 lb-ft (depending on specific application)
Fuel System
Fuel Delivery:
Throttle Body Injection (TBI) for 5.0L V8, Central Multi-Port Fuel Injection (CSFI/MPFI) for 5.7L V8 (Tunable Port Injection - TPI less common on standard Caprice, more on performance variants).
Recommended Fuel:
87 Octane Unleaded (for 5.0L), 87-91 Octane Unleaded (for 5.7L depending on tune)
🔧 Transmission
Standard
Transmission Type:
4-speed automatic (e.g., THM700-R4 / 4L60)
Optional
Heavy Duty Transmission:
4-speed automatic (4L80-E for heavy-duty/police applications)
Features
Drivetrain:
Rear-Wheel Drive (RWD)
📐 Dimensions
Exterior
Wheelbase:
Approx. 116 inches
Length:
Approx. 204-207 inches
Width:
Approx. 71-72 inches
Interior
Passenger Volume:
Very spacious, typically exceeding 110 cubic feet.
Weights
Curb Weight:
Approx. 3700-4100 lbs (depending on engine and equipment)
🛡️ Safety Features
Ratings
Ntsa Crash Test Results:
As per 1991 standards; frontal impact data available. Frontal impact rating was generally considered adequate for the era, but modern standards are significantly more stringent.
Active Features
Antilock Brakes:
Available, typically on heavier duty or police models.
Passive Features
Airbags:
Driver-side airbag standard for 1991 model year.
Seatbelts:
Front and rear seat belts, driver's side shoulder belt.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo radio, cassette player, optional CD player, basic speaker configurations.
Driver Assistance
Cruise Control:
Available as an option.
Connectivity
Onboard Diagnostics:
OBDI (On-Board Diagnostics I) system; requires specific diagnostic tools for reading fault codes, different from modern OBDII.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 to 5,000 miles, or as specified by the manual based on driving conditions.
Transmission Fluid Change Interval:
Every 30,000 to 60,000 miles, depending on driving conditions and transmission type.
Spark Plug Replacement:
Refer to manual; typically 30,000 to 100,000 miles depending on spark plug type (e.g., copper vs. platinum/iridium).
Fluid Specifications
Engine Oil:
API SG or SH certified, SAE 5W-30 or 10W-30 recommended (check manual for specific weight based on climate).
Coolant:
GM-specification engine coolant (typically green ethylene glycol based, 50/50 mix with distilled water).
Transmission Fluid:
Dexron II or Dexron III ATF (Automatic Transmission Fluid).
Brake Fluid:
DOT 3 brake fluid.
Known Issues
Common Problems:
TBI fuel injector clogging, intake manifold gasket leaks (especially on L03), rear main seal leaks, aging rubber bushings in suspension, power window/lock issues, ABS sensor failures (if equipped).
📚 Vehicle History
Brand Heritage
Chevrolet Legacy:
Chevrolet has a long history of producing reliable and popular vehicles, particularly trucks and full-size sedans.
Model Evolution
Caprice Lineage:
The Caprice was Chevrolet's flagship full-size sedan from 1965 to 1996, known for its comfort and spaciousness. The 1991 model represents the facelifted fourth generation of the B-body platform.
Production
Manufacturing Locations:
Primarily Arlington, Texas; Baltimore, Maryland; Doraville, Georgia; and Janesville, Wisconsin.
🏆 Awards & Recognition
Recognitions
Police Pursuit Recognition:
The Caprice platform, particularly with the 5.7L engine and police package, was a staple for law enforcement agencies across North America for its durability and performance.
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