🏷️ 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...