The 1991 Chevrolet Cavalier, built on the versatile J-Body platform, represented a practical and affordable option within the compact car segment of its time. Known for its efficient packaging and focus on fuel economy, this model offered a comfortable ride and competed effectively against other popular vehicles like the Ford Escort and Honda Civic. Chevrolet, with its long-standing heritage dating back to 1911, aimed to provide reliable transportation, and the Cavalier exemplified this commitment with its accessible design and straightforward engineering, making it a popular choice for a wide range of drivers. This comprehensive Service and Repair Manual in English provides detailed information for the maintenance and repair of your 1991 Chevrolet Cavalier. It covers all major systems, including engine variants (2.2L L4 and 3.1L V6), manual and automatic transmissions, braking systems, the complete electrical system, suspension, steering, cooling, fuel, exhaust, HVAC, and body/interior components. You will find step-by-step instructions for routine maintenance, troubleshooting common issues, in-depth diagnostics, and complete rebuild procedures. This manual is an essential resource for owners, technicians, and mechanics seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ 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...