IllustrationSTARTER WAS REPLACED, AND DID NOT FIT PROPERLY IN THE VEHICLE, CAUSING THE STARTER TO COM ELOOSE/ SHAKE. BOLTS NEED TO BE REPLACED. *AK
1991 Chevrolet Cavalier
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 1991 Chevrolet Cavalier do not stand out strongly from the model-year median of 140.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cavalier years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 3 of 55 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Electrical System. Review the 17 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Seats. Review the 7 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
7 crash reports6 fire reports4 injury reports
Electrical System complaints
17 reportsI 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 …
Read full complaint
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
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 AF…
Read full complaint
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.
WINDSHIELD WIPERS FAIL WITHOUT ADDING PRESSURE TO THE IGNITION SWITCH, ONLY OPERATE WHEN HOLDING IGNITION SWITCH.
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.
ALTERNATOR FAILED.
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
PROM FAILURE.
ENGINE COMPARTMENT FIRE, PE93-090, THE VEHICLE WAS IN MOTION AND THE VEHICLE CUT OFF AND CAUGHT ON FIRE IN THE ENGINE.*AK
THE WIRING UNDER THE HOOD OVERHEATED AND CAUGHT ON FIRE. *AK
Official recalls
292V003000 · Seat Belts
Jan 10, 1992
THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208.
Consequence & remedy
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.
91V165000 · Structure:body:door:hinge And Attachments
Sep 23, 1991
FRONT DOOR INTERLOCK STRIKER MAY FAIL, CAUSING DOOR FRAME COLLAPSE AND INSUFFICIENT STRENGTH FOR THE SHOULDER BELT ANCHORAGE.
Consequence & remedy
Consequence: THE DOOR FRAME WOULD COLLAPSE. VEHICLE DOES NOT COMPLYWITH FMVSS 210.
Remedy: REPLACE THE PASSIVE RESTRAINT INTERLOCK STRIKER STUDS ON FRONT DOORS.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
2PE93090 · Engine Compartment Fires
Opened Oct 8, 1993 · Closed Feb 28, 1994
Status: closed (inferred from source dates) · Engine And Engine Cooling
There is no summary currently available
EA92024 · Sticking Throttle
Opened Jun 26, 1992 · Closed Jan 31, 1994
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available