1991 CHEVROLET CAVALIER

3 recalls, 77 complaints - 3 TSBs

FUEL SYSTEM, GASOLINE

Defect Description

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 CE... Read more

Consequence

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).

88,303 vehicles affected

Manufacturer: HONEYWELL INTERNATIONAL, INC.

SEAT BELTS

Defect Description

THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208.

Consequence

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.

347,866 vehicles affected

Manufacturer: GENERAL MOTORS CORP.

STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS

Defect Description

FRONT DOOR INTERLOCK STRIKER MAY FAIL, CAUSING DOOR FRAME COLLAPSE AND INSUFFICIENT STRENGTH FOR THE SHOULDER BELT ANCHORAGE.

Consequence

THE DOOR FRAME WOULD COLLAPSE. VEHICLE DOES NOT COMPLYWITH FMVSS 210.

Remedy

REPLACE THE PASSIVE RESTRAINT INTERLOCK STRIKER STUDS ON FRONT DOORS.

41,718 vehicles affected

Manufacturer: GENERAL MOTORS CORP.

Complaint Statistics

77 total complaints 8 crashes 6 fires 5 injuries 6 deaths

Top Reported Components

Component	Complaints
ENGINE AND ENGINE COOLING:ENGINE	6
SEATS	5
VISIBILITY:WINDSHIELD WIPER/WASHER	4
ELECTRICAL SYSTEM:IGNITION	3
ELECTRICAL SYSTEM:IGNITION:SWITCH	3
STEERING:LINKAGES	2
ELECTRICAL SYSTEM:WIRING	2
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS	2
ELECTRICAL SYSTEM:HORN	2
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP	2

Incident date: Jan 21, 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 I... Read more

Crash 1 injured 1 deaths

Incident date: Sep 15, 2003

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 TH... Read more

Incident date: Sep 15, 2003

Incident date: Sep 24, 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 date: Sep 1, 2002

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. T... Read more

Incident date: Aug 25, 2003

WHILE DRIVING DOWN 25-35MPH VEHICLE STALLED OUT AND DIED WITHOUT WARNING. DEALER REPLACED FUEL PUMP FILTER. *AK

Incident date: Feb 16, 2001

BACK SEAT IS NOT CONNECTED TO THE CAR AND REAR SEAT BELTS ARE MISSING.

Incident date: Feb 16, 2001

BACK SEAT IS NOT CONNECTED TO THE CAR AND REAR SEAT BELTS ARE MISSING.

Incident date: Aug 10, 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 MAN... Read more

Incident date: Mar 28, 1998

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... Read more

Crash 2 injured 3 deaths

WHILE DRIVING A PIN WITHIN THE TILT STEERING WHEEL CAME LOOSE,NEARLY CAUSING LOSS OF STEERING CONTROL. PLEASE GIVE ANY FURTHER DETAILS. *AK

STARTER WAS REPLACED, AND DID NOT FIT PROPERLY IN THE VEHICLE, CAUSING THE STARTER TO COM ELOOSE/ SHAKE. BOLTS NEED TO BE REPLACED. *AK

WINDSHIELD WIPERS WILL QUIT DURING OPERATION, CAUSING POOR VISIBILITY. *AK

Incident date: Aug 17, 1991

WHILE TRAVELING THE BRAKES WOULD MAKE A LOUD NOISE. DEALER AND MANUFACTURER HAVE BEEN CONTACTED. PLEASE PROVIDE FURTHER INFORMANTION. *AK

Incident date: May 28, 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 date: Jul 23, 1998

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 MEC... Read more

Incident date: Jul 23, 1998

Incident date: Dec 15, 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... Read more

Crash

Incident date: Dec 15, 1998

Crash

DEFECTIVE FAN MOTOR MELTED WHICH COULD CAUSE A FIRE. *AK

OIL PAN FAILED.

ALTERNATOR FAILED.

WINDSHIELD WIPERS FAIL WITHOUT ADDING PRESSURE TO THE IGNITION SWITCH, ONLY OPERATE WHEN HOLDING IGNITION SWITCH.

Incident date: Sep 17, 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

Crash 1 deaths

Incident date: Jul 3, 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.

Fire

STARTER AND FLYWHEEL BECOME NOISY AND THE VEHICLE WILL NOT START.

Incident date: Oct 15, 1996

DRIVER'S SEAT FRAME WELD BROKE. *AK

Incident date: Dec 12, 1996

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 PROB... Read more

Incident date: Jun 1, 1997

PROM FAILURE.

Incident date: Mar 1, 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 date: Nov 24, 1995

VALVE COVER GASKET FAILED,CAUSING OIL LEAK.

Incident date: Nov 24, 1995

TRANSMISSION MOUNT FAILED.

Incident date: Nov 24, 1995

FRONT AND REAR ENGINE MOUNTS FAILED.

Incident date: Nov 24, 1995

BELT TENSIONER FAILED.

Incident date: Apr 1, 1994

HEAD GASKETS LEAK.

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

Fire

Incident date: Aug 1, 1996

AIR CONDITIONER FAILED.

Incident date: Jun 1, 1996

TRANSMISSION LOCKED INTO GEAR, CAUSING VEHICLE TO STALL.

Incident date: Nov 1, 1996

ELECTRICAL SHORT IN STEERING COLUMN, CAUSING RADIO AND WINDSHIELD WIPERS TO BECOME INOPERATIVE.

Incident date: Nov 1, 1996

ELECTRICAL SHORT IN STEERING COLUMN, CAUSING RADIO AND WINDSHIELD WIPERS TO BECOME INOPERATIVE.

Incident date: Nov 1, 1996

ELECTRICAL SHORT IN STEERING COLUMN, CAUSING RADIO AND WINDSHIELD WIPERS TO BECOME INOPERATIVE.

Incident date: Feb 14, 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

Crash 1 deaths

WHILE IN STOP POSITION VEHICLE RPMS REVVED UP, THEN LURCHED FORWARD, FOR NO APPARENT REASON. *AK

Incident date: Aug 22, 1996

ENGINE COMPARTMENT FIRE, PE93-090, THE VEHICLE WAS IN MOTION AND THE VEHICLE CUT OFF AND CAUGHT ON FIRE IN THE ENGINE.*AK

Fire

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

Showing 50 of 77 complaints.

EPA Fuel Economy, 1991 CHEVROLET CAVALIER

Trim / Engine	City MPG	Highway MPG	Combined MPG	Fuel Type	Annual Fuel Cost
2.2L 4-cyl, Automatic 3-spd (Front-Wheel Drive)	21.0	29.0	24.0	Regular	$2,550
2.2L 4-cyl, Manual 5-spd (Front-Wheel Drive)	21.0	32.0	25.0	Regular	$2,450
3.1L 6-cyl, Automatic 3-spd (Front-Wheel Drive)	18.0	25.0	20.0	Regular	$3,100
3.1L 6-cyl, Manual 5-spd (Front-Wheel Drive)	17.0	26.0	20.0	Regular	$3,100

CO2 Emissions: -1.0 g/mile (Subcompact Cars)

Source: U.S. Environmental Protection Agency (EPA). Actual fuel economy may vary based on driving conditions.

Technical Service Bulletins, 1991 CHEVROLET CAVALIER

3 manufacturer communications from 3 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
010000 STEERING	1
034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS	1
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	1

034000 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

INFORMATION REGARDING SNOW INTRUSION INTO REAR DRUM BRAKE ASSEMBLIES. **MR

061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

SOME V6 ENGINES MAY, ON A VERY INFREQUENT BASIS, HAVE AN OIL ODOR CONDITION THAT IS GENERALLY ENCOUNTERED AFTER THE ENGINE'S OIL HAS BEEN CHANGED.TYPICALLY THE ODOR LASTS APPROXIMATELY 1000 MILES AFTER THE CHANGE OF OIL AND THEN DOES NOT RE

010000 STEERING

CRUNCH NOISE FROM RIGHT SIDE DASH AREA WHEN TURNING STEERING WHEEL. *TW

NHTSA Safety Investigations, CHEVROLET CAVALIER

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

EA, Closed , Model Year: 2003

ENGINE STALLING - FUEL PUMP FAILURE

ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INC... Read more

PE, Closed , Model Year: 2003

FUEL PUMP FAILURE

AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET V... Read more

EA, Closed , Model Year: 2003

TURN SIGNAL MALFUNCTION

ON MAY 14, 2004 THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-043) BASED ON CONSUMER COMPLAINTS ALLEGING THAT THE BRAKE/TAIL TURN SIGNAL LAMPS WOULD NOT OPERATE PROPERLY WHEN EITHER THE TAIL LIGHTS WERE TURNED ON, THE BRAKE PEDAL WAS DEPRESSED, OR WHEN THE TURN SIGN... Read more

PE, Closed , Model Year: 2003

TURN SIGNAL MALFUNCTION

COMPLAINANTS ALLEGE THAT THE REAR TURN SIGNALS FAIL TO ILLUMINATE AND DO NOT PROVIDE A SIGNAL TO DRIVERS IN FOLLOWING VEHICLES.ODI HAS RECEIVED ONE REPORT OF A CRASH WHERE THE COMPLAINANT BRAKED AND ATTEMPTED TO MAKE A LEFT TURN AND THE FOLLOWING VEHICLE IMPACTED THE COMPLAINANT'S VEHICLE IN THE DRI... Read more

DP, Closed , Model Year: 1996

UNINTENDED VEHICLE ACCELERATION

ON SEPTEMBER 23, 2003, THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) RECEIVED A LETTER DATED SEPTEMBER 8, 2003 FROM MR. DONALD FRIEDMAN, PETITIONING THE AGENCY TO OPEN A DEFECT INVESTIGATION INTO UNINTENDED ACCELERATION INVOLVING [MODEL YEAR] 1996 AND 1997 GENERAL MOTORS J-CARS.IN SUPPO... Read more

EA, Closed , Model Year: 2000

ERRATIC FUEL GAUGE

ODI OPENED EA 02-028 TO REVIEW COMPLAINTS OF CONSUMERS REPORTING THAT THEIR FUEL GAUGE WAS INCORRECTLY DISPLAYING THE AMOUNT OF FUEL IN THE GAS TANK.THE FUEL GAUGE RECEIVES AN ELECTRICAL SIGNAL FROM A FUEL TANK SENDING SENSOR CIRCUIT CARD.A FLOAT ARM IN THE TANK MOVES ELECTRICAL CONTACTS THAT RUB AG... Read more

PE, Closed , Model Year: 2000

ENGINE STALL DUE TO FUEL STARVATION

ODI OPENED PE02-066 TO EVALUATE THE SCOPE AND CONSEQUENCE OF ENGINE POWER-LOSS DUE TO FUEL STARVATION INDUCED BY IN-TANK MODULAR FUEL PUMP STRAINER RESTRICTION.THE SUBJECT PUMPS USE AN EXTERNAL ?SOCK? STRAINER TO FILTER FUEL FLOWING TO THE PUMP INLET.THIS FILTER CAN SOMETIMES BECOME CLOGGED, RESULTI... Read more

PE, Closed , Model Year: 1995

FIRE IN STEERING COLUMN AREA

SQ, Closed , Model Year: 2000

ERRATIC FUEL GAUGE