VehicleVerdict

1991 Chevrolet Cavalier problems

Verdict · NHTSA data

A typical year for this model

The 1991 Chevrolet Cavalier sits mid-pack among Cavalier years: 77 NHTSA complaints against a model median of roughly 208, with 3 recalls and 2 closed investigations. Reports tied to this model year include 6 deaths and 5 injuries, per the complaint records themselves.

No single system dominates the record — complaints spread across electrical system (19), engine (12), and seats (8), which usually points to general build quality rather than one defect.

77

NHTSA complaints

3

Recalls

2

Investigations

8

Crash-involved

6

Fires reported

5

Injuries

6

Deaths

—

NCAP overall

How does 1991 compare to other Cavalier years?

Cavalier NHTSA complaints by model year, 1991 highlighted867 complaints1980: 0 complaints1981: 0 complaints1982: 1 complaints1983: 17 complaints1984: 10 complaints1985: 4 complaints1986: 21 complaints1987: 27 complaints1988: 14 complaints1989: 71 complaints1990: 70 complaints1991: 77 complaints1992: 178 complaints1993: 237 complaints1994: 310 complaints1995: 392 complaints1996: 748 complaints1997: 751 complaints1998: 473 complaints1999: 337 complaints2000: 447 complaints2001: 356 complaints2002: 254 complaints2003: 867 complaints2004: 428 complaints2005: 362 complaints
Cavalier NHTSA complaints by model year, 1991 highlighted. Red bars are years to avoid.

See all Cavalier years to avoid →

What are the most common 1991 Chevrolet Cavalier problems?

ComponentComplaintsShare
Electrical System1925%
Engine1216%
Seats810%
Steering56%
Visibility & Wipers56%
Brakes56%
Seat Belts56%
Transmission45%
Fuel System34%
Lighting23%
Speed Control23%
Tires & Wheels23%
Other11%
Climate Control (A/C & Heat)11%
Latches & Locks11%
Airbags11%
Body & Structure11%

Does the 1991 Chevrolet Cavalier have recalls?

3 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

06E043000Fuel SystemMay 19, 2006 · 88,303 units

Defect

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.

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).

92V003000Seat BeltsJanuary 10, 1992 · 347,866 units

Defect

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.

91V165000Body & StructureSeptember 23, 1991 · 41,718 units

Defect

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“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.”

Complaint filed with NHTSA · Electrical System · July 3, 1998 · fire

“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”

Complaint filed with NHTSA · Engine · fire

“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”

Complaint filed with NHTSA · Seats · February 14, 1996 · crash

“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…”

Complaint filed with NHTSA · Brakes · July 23, 1998

“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…”

Complaint filed with NHTSA · Visibility & Wipers · August 10, 2000

1991 Chevrolet Cavalier — common questions

Is the 1991 Chevrolet Cavalier reliable?

Its record is better than the model's norm: 77 NHTSA complaints, below the typical Cavalier year, with 3 recalls and no open investigations.

What are the most common 1991 Cavalier problems?

According to NHTSA complaint data, the leading problem areas are electrical system (19 complaints), engine (12 complaints), seats (8 complaints).

Does the 1991 Chevrolet Cavalier have recalls?

Yes — NHTSA lists 3 recall campaigns affecting the 1991 Chevrolet Cavalier. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 1991 Chevrolet Cavalier under NHTSA investigation?

NHTSA opened 2 investigations into this model year; all are now closed.

Which Chevrolet Cavalier years should you avoid?

Based on complaint rates and open investigations, the Cavalier years to avoid are 2003, 1997, 1996, 1998, 2000, 2004, 1995, 2005, 2001, 1999. The cleanest record among Cavalier years belongs to 1981.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.