🏷️ 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 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: PDF 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...