1991 Chevrolet Cavalier
Recalls, consumer complaints and crash ratings from NHTSA
Recalls3
Fuel system, gasolineMay 19, 2006, Campaign 06E043000
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.
Risk
THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
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).
Seat beltsJan 10, 1992, Campaign 92V003000
THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208.
Risk
THE SEAT OCCUPANT FACES INCREASED RISK OF INJURY IN THEEVENT OF A SUDDEN STOP OR ACCIDENT.
Remedy
INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES.
StructureBody, door, hinge and attachmentsSep 23, 1991, Campaign 91V165000
FRONT DOOR INTERLOCK STRIKER MAY FAIL, CAUSING DOOR FRAME COLLAPSE AND INSUFFICIENT STRENGTH FOR THE SHOULDER BELT ANCHORAGE.
Risk
THE DOOR FRAME WOULD COLLAPSE. VEHICLE DOES NOT COMPLYWITH FMVSS 210.
Remedy
REPLACE THE PASSIVE RESTRAINT INTERLOCK STRIKER STUDS ON FRONT DOORS.
All recalls issued for this model year. To see whether any are still unrepaired on a specific vehicle, check its VIN at NHTSA.
Recent complaints74 total
Most reported, across all 74 complaints
- Electrical system26%
- Engine and engine cooling14%
- Service brakes, hydraulic12%
Seat beltsCrash1 injured1 deathFiled Feb 4, 2005
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
Incident Jan 21, 2005
Engine and engine cooling, structureFiled Jan 15, 2004
THE FIRST PROBLEM I HAVE ENCOUNTERED IS THE POOR BODY OF THE CAR. THE PANELS BELOW THE CAR HAVE COMPLETELY DIMINISHED. ANYTHING REMAINING OF THEM IS EITHER ROTTING AND RUSTING AWAY, OR HAS PAINT REMOVED FROM THEM. THE PAINT IS ALSO COMING OUT OF THE FRONT PLASTIC BUMPER AND FROM THE FRONT HOOD OF THE CAR. SOME RUST IS ALSO APPEARING AT THE SIDES. WHEN I STEP INTO THE HIGHWAY AT THE SPEED OF A MINIMUM 100 KM/H, THIS TRASH IS ANYTHING BUT QUIET. APART FROM THE ENGINE, WHICH IS NOW BROKEN, THE GASKETS OR WHATEVER KEEPS THE AIR OUT DOESN'T KEEP IT OUT. INSTEAD, SOME AIR COMES IN AND THUS MAKING THAT NOISE; LIKE HAVING YOUR WINDOWS OPEN AND GETTING ALL THAT NOISE OF THE AIR. IT'S NO DIFFERENT WHEN CLOSED. THE RUBBER SEAL OF THE DOORS IS EXTREMELY POOR IN THIS REGARD. MY SECOND PROBLEM HAS BEEN THE ENGINE. MY ENGINE'S MOTOR IS BROKEN DOWN. NO MECHANIC CAN FIX IT. I TRIED TO GO THROUGH CHEVROLET AND ONE OF THEIR LOCAL DEALERSHIPS. BUT JUST THE COST OF REFURBISHING MY ENGINE WOULD APROXIMATILY ADD UP TO $2,500 (MIGHT AS WELL BUY A NEW CAR INSTEAD!).
Incident Sep 15, 2003
WheelsFiled Dec 10, 2003
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
Incident Sep 24, 2003
Fuel system, otherFiled Aug 25, 2003
WHILE DRIVING DOWN 25-35MPH VEHICLE STALLED OUT AND DIED WITHOUT WARNING. DEALER REPLACED FUEL PUMP FILTER. *AK
Incident Aug 25, 2003
TiresFiled Aug 25, 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
Incident Sep 1, 2002
Seat belts, seatsFiled Feb 24, 2001
BACK SEAT IS NOT CONNECTED TO THE CAR AND REAR SEAT BELTS ARE MISSING.
Incident Feb 16, 2001
VisibilityFiled Sep 28, 2000
WINDSHIELD WIPERS WORK INTERMITTENTLY; THIS COULD RESULT IN INOPERATIVE WINDSHIELD WIPERS AND REDUCED DRIVER'S VISIBILITY, INCREASING THE RISK OF A VEHICLE CRASH. *AK CAUSED BY BAD WIPER PRINTED CIRCUIT BOARDS THAT ARE LOCATED IN A SEALED COMPARTMENT, IT GETS DAMAGED BY WATER. *YH
Incident Apr 23, 2000
VisibilityFiled Aug 15, 2000
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.
Incident Aug 10, 2000
SteeringCrash2 injured3 deathsFiled Feb 13, 2000
AN '88 BLUE DODGE VAN (VIN 2B6GB113Y3JK56747)CRASHED INTO MY LITTLE GIRLS CAR THE 1991 CAVALIER. EXPERT RECONSTRUCTIONIST (TX DEPT. OF PUBLIC SAFETY) BLAME MY LITTLE GIRL FOR HAVING RAN THE STOP SIGN AND HITTING THE VAN, CAUSING AN INDIRECT DEATH OF THREE AND THE DIRECT DEATH WAS AN ABANDON UTILITY POLE. I DO NOT BELIEVE THAT IF THE CAR WAS TO HIT THE VAN IT WOULD HAVE CAUSED SO MUCH DAMAGE. MY DAUGHTER STATES THAT SHE CAME TO A COMPLETE STOP AND PROCEEDED ENTERING THE INTERSECTION AT 6 MPH. HOW CAN A SMALL CAR DO SO MUCH DAMAGE EVEN IF IT WAS TO HAVE RUNNED THE STOP SIGN. I BELIEVE THAT THE VAN HIT THE CAR CAUSING THE ROOF OF THE CAVALIER TO COLLAPSE AND DOING IRREPAIRABLE DAMAGE TO MY LITTLE GIRLS FRIEND. MY LITTLE GIRL HAD MULTIPLE CONTURSIONS TO THE HEAD WHEN THE ROOF CAVED IN AND HER ANKLE HAD THREE FRACTURES ON HER LEFT ANKLE. THERE WAS EVIDENCE IN THE DRIVER SIDE THAT THE BOTTOM SIDE OF THE DOOR WAS PINGED INWARD AND THE ROOF OVER HER HEAD WAS CAVED IN. LUCKILY THE TWO GIRLS SURVIVED. EVEN THOUGH ONE IS A VEGETABLE MY LITTLE GIRL IS NOT THE SAME AND HER YOUTH HAS BEEN STOLEN BY THIS ACCIDENT. SHE HAS RECURRING NIGHTMARES AND A BRAIN CONTUSSION THAT MIGHT NOT GO AWAY UNTIL ALL THE PRESSURE HAS BEEN RELIEVED AND THAT IS GOING TO TAKE TIME. WHY DID THE ROOF COLLAPSE INJURING BOTH OCCUPANTS WHO WERE WEARING SEATBELTS? WHY DID THEY HAVE TO USE THE JAWS-OF-LIFE TO RESCUE BOTH GIRLS? *AK
Incident Mar 28, 1998
SteeringFiled Oct 26, 1999
WHILE DRIVING A PIN WITHIN THE TILT STEERING WHEEL CAME LOOSE,NEARLY CAUSING LOSS OF STEERING CONTROL. PLEASE GIVE ANY FURTHER DETAILS. *AK
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Service brakes, hydraulicFiled Sep 30, 1999
ANTI LOCK BRAKES ARE HARD TO STOP AND LOCK UP TOO. YH
Service brakes, hydraulicFiled Sep 30, 1999
ANTI LOCK BRAKES ARE HARD TO STOP AND LOCK UP TOO. YH
Electrical systemFiled Sep 27, 1999
STARTER WAS REPLACED, AND DID NOT FIT PROPERLY IN THE VEHICLE, CAUSING THE STARTER TO COM ELOOSE/ SHAKE. BOLTS NEED TO BE REPLACED. *AK
VisibilityFiled Sep 22, 1999
WINDSHIELD WIPERS WILL QUIT DURING OPERATION, CAUSING POOR VISIBILITY. *AK
Service brakes, hydraulicFiled Jul 22, 1999
WHILE TRAVELING THE BRAKES WOULD MAKE A LOUD NOISE. DEALER AND MANUFACTURER HAVE BEEN CONTACTED. PLEASE PROVIDE FURTHER INFORMANTION. *AK
Incident Aug 17, 1991
Service brakes, hydraulic, engine and engine cooling, electrical systemFiled Jan 21, 1999
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
Incident Jul 23, 1998
Steering, electrical systemCrashFiled Dec 20, 1998
STEERING STIFFENED/LOCKED AS DRIVER WAS PULLING INTO PARKING SPACE, CAUSING MINOR CONTACT WITH ADJACENT PARKED VEHICLE. FOLLOWING CONTACT, VEHICLE STOPPED AND STEERING WHEEL REALIGNED (WITH GREAT EFFORT) TO COMPLETE PARKING. AFTER PARKING, KEY COULD NOT BE REMOVED FROM IGNITION SWITCH, AND VEHICLE WOULD NOT CONTINUE RUNNING AFTER STARTING (ONLY 1-2 SECONDS). AFTER LOCAL CHEVROLET DEALERSHIP RETRIEVED VEHICLE, SERVICE REP STATED HE "KNEW WHAT HAPPENED" WHEN INCIDENT DESCRIBED AND VEHICLE IDENTIFIED AS '91 CAVALIER. IGNITION SWITCH ASSEMBLY REPLACED, NO PROBLEM SINCE. VEHICLE REPAIR COST $327; DAMAGE TO ADJACENT VEHICLE $450. I THINK THIS IGNITION SWITCH FAILURE MODE, INVOLVING STEERING WHEEL LOCKING, IS A DANGEROUS SAFETY DEFECT. AS A MINIMUM, I FEEL I SHOULD BE REIMBURSED FOR ALL REPAIR COSTS AND DAMAGES.
Incident Dec 15, 1998
Engine and engine coolingFiled Nov 13, 1998
DEFECTIVE FAN MOTOR MELTED WHICH COULD CAUSE A FIRE. *AK
StructureFiled Oct 10, 1998
PAINT PEELING OFF VEHICLE.
Air bagsCrash1 deathFiled Sep 25, 1998
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
Incident Sep 17, 1998
Electrical system, visibilityFiled Aug 26, 1998
WINDSHIELD WIPERS FAIL WITHOUT ADDING PRESSURE TO THE IGNITION SWITCH, ONLY OPERATE WHEN HOLDING IGNITION SWITCH.
Electrical systemFireFiled Aug 2, 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.
Incident Jul 3, 1998
Seat beltsFiled Jun 30, 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
Incident May 28, 1998
Service brakes, hydraulicFiled Jun 24, 1998
REAR DISK BRAKE CALIPERS FROZEN CAUSING FAILURE.
Engine and engine coolingFiled Jun 22, 1998
STARTER AND FLYWHEEL BECOME NOISY AND THE VEHICLE WILL NOT START.
Service brakes, hydraulicFiled Nov 5, 1997
BRAKE PEDAL GOES TO FLOOR.
Electrical systemFiled Oct 27, 1997
ALTERNATOR FAILED.
Engine and engine coolingFiled Oct 27, 1997
OIL PAN FAILED.
SeatsFiled Oct 21, 1997
DRIVER'S SEAT FRAME WELD BROKE. *AK
Incident Oct 15, 1996
Electrical systemFiled Sep 17, 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
Incident Dec 12, 1996
Electrical systemFiled Jun 9, 1997
PROM FAILURE.
Incident Jun 1, 1997
SeatsFiled Mar 26, 1997
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
Incident Mar 1, 1997
Engine and engine coolingFireFiled Mar 12, 1997
OWNER STATES THAT AFTER 45 MINUTES WHEN THE CAR WAS LEFT AFTER IT HAD BEEN DRIVEN VEHICE BLEW UP, CAUSING A MELT DOWN, FIRE DEPARTMENT WAS UNABLE TO DETERMINE THE CAUSE OF THE FIRE. *AK
Engine and engine coolingFiled Feb 26, 1997
VALVE COVER GASKET FAILED,CAUSING OIL LEAK.
Incident Nov 24, 1995
Engine and engine coolingFiled Feb 26, 1997
BELT TENSIONER FAILED.
Incident Nov 24, 1995
Engine and engine coolingFiled Feb 26, 1997
FRONT AND REAR ENGINE MOUNTS FAILED.
Incident Nov 24, 1995
Power trainFiled Feb 26, 1997
TRANSMISSION MOUNT FAILED.
Incident Nov 24, 1995
Engine and engine coolingFiled Jan 17, 1997
HEAD GASKETS LEAK.
Incident Apr 1, 1994
SeatsCrash1 deathFiled Nov 1, 1996
SON DRIVING ON SLIPPERY SNOW-COVERED ROAD WITH LITTLE STRREET LIGHTING, DRIVER LOST CONTROL, VEHICLE VEERED OFF ROAD AND STRUCK A TREE, DRIVER'S SEATBACK FAILED AND DRIVER WAS EJECTED BACKWARD THROUGH REAR WINDOW AND WAS KILLED. *AK
Incident Feb 14, 1996
Steering, visibility, equipmentFiled Nov 1, 1996
ELECTRICAL SHORT IN STEERING COLUMN, CAUSING RADIO AND WINDSHIELD WIPERS TO BECOME INOPERATIVE.
Incident Nov 1, 1996
Power trainFiled Nov 1, 1996
TRANSMISSION LOCKED INTO GEAR, CAUSING VEHICLE TO STALL.
Incident Jun 1, 1996
EquipmentFiled Nov 1, 1996
AIR CONDITIONER FAILED.
Incident Aug 1, 1996
Vehicle speed controlFiled Oct 16, 1996
WHILE IN STOP POSITION VEHICLE RPMS REVVED UP, THEN LURCHED FORWARD, FOR NO APPARENT REASON. *AK
Electrical systemFireFiled Sep 24, 1996
ENGINE COMPARTMENT FIRE, PE93-090, THE VEHICLE WAS IN MOTION AND THE VEHICLE CUT OFF AND CAUGHT ON FIRE IN THE ENGINE.*AK
Incident Aug 22, 1996
Seat beltsFiled Sep 11, 1996
THE PLASTIC PIECE THAT GOES OVER THE BUTTON ON THE FEMALE PART HAS COME OFF, MAKING IT EASY TO UNBUCKLE AND HARDER TO BUCKLE PROPERLY.*AK
SeatsFiled Aug 9, 1996
FAILURE ON THE DRIVER SIDE SEAT MOUNT THAT HOLDS THE SEAT IN PLACE IS BROKEN, CAUSING THE DRIVER SIDE SEAT TO MOVE. *AK
Incident Jul 18, 1996
Electrical systemFireFiled Jul 30, 1996
THE WIRING UNDER THE HOOD OVERHEATED AND CAUGHT ON FIRE. *AK
Incident Jun 29, 1996
SeatsFiled Jul 24, 1996
FAILURE ON THE DRIVER SIDE SEAT MOUNT THAT HOLDS THE SEAT IN PLACE IS BROKEN, CAUSING THE DRIVER SIDE SEAT TO MOVE. *AK
Incident Jul 18, 1996
Seats1 injuredFiled Jun 20, 1996
DRIVER'S SEAT BACK COLLAPSED DURING ACCIDENT/EJECTING DRIVER FROM VEHICLE. *SD
Incident Feb 14, 1996
Seat beltsFiled May 21, 1996
FAILURE ON THE FRONT DRIVER AND LEFT REAR SEAT BELT BUCKLE, SEAT BELT COMES OUT OF THE BUCKLE. *AK
Incident Jan 21, 1996
NHTSA crash ratings
1991 Chevrolet Cavalier 4-DR
- Front, driver
- 4 out of 5 stars
- Front, passenger
- 5 out of 5 stars
- Side, front seat
- Not Rated
- Side, rear seat
- Not Rated
- Rollover
- Not Rated
Rated under NHTSA's pre-2011 program, which scored each seat. These stars can't be compared with ratings from 2011 on.
Decode a 1991 Chevrolet Cavalier VIN
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