1991 Chevrolet Cavalier Problems
- Complaints
- 55filed with NHTSA
- Median mileage
- 112,000miles, 3 complaints with mileage
- Recalls
- 2campaigns on record
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 20 mpgcombined, 3.1L 6-cyl FWD · 18 city / 25 hwy
Sources: NHTSA records for the 1991 Chevrolet Cavalier (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error
What owners report
Owners of this model year most often report electrical faults, followed by seat, seat-belt and seat-mount failures. The electrical complaints range from starter and ignition trouble to intermittent lighting loss and a wiring fire, with some describing gradual wear and others sudden failures. Mileage is rarely recorded in these reports, so the complaints do not point to a clear mileage range.
- Electrical system
Electrical faults: starter, ignition, lights and wiring
- 12 complaints (22%)
- typically at 5.6 yrs old
- 6 mention a crash, fire or injury
- filed 1995–1999
Owners describe starters that wear out and need repeated replacement, and a new starter that did not fit properly and shook loose. Other complaints describe intermittent electrical failures, in which the dash and rear lights stop working and a headlight goes out suddenly, which complaints attribute to a short. Some complaints also describe a wiring harness that caught fire behind the dash, and a key that could not be removed after parking, with the dealer replacing the ignition switch assembly. Mileage is not recorded in these complaints, and they describe problems while driving, at startup, and after parking.
What to check: Ask whether the starter, ignition switch and wiring have been inspected or replaced, and test the dash and rear lights at night with the engine running. Check the wiring behind the dash and the starter mounting bolts for burnt insulation or looseness.
2 excerpts from owner complaints in NHTSA records
“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.”
NHTSA complaint #816414, filed 1997-09“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.”
NHTSA complaint #538970, filed 1998-08 - Seats
Seat mounts, seatbacks and seat belt parts failing
- 9 complaints (16%)
- typically at 6.0 yrs old
- 3 mention a crash, fire or injury
- filed 1996–2005
Owners describe seat tracks, anchors and mounts that break, letting the seat shift while driving, and a seatback that gave way in a crash. Other complaints describe cracked seat-belt guide loops, a plastic cover on a buckle that came off and made it harder to buckle properly, and a belt anchored to the door frame that did not keep the driver inside when the door opened in a rollover. According to complaints, the dealer and the manufacturer said the vehicle was not included in the recall for the guide loops, so the owner would need to pay for repairs. Mileage is not recorded in these complaints, and some describe the failure while the vehicle was in motion or in a crash.
Recall 92V003000Recall 91V165000
What to check: Check that the seat locks firmly on its tracks and that the belt guide loops and buckle covers are intact. Ask whether the related seat-belt and door recall work was completed, using the vehicle identification number to check its recall status.
2 excerpts from owner complaints in NHTSA records
“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.”
NHTSA complaint #10109852, filed 2005-02“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.”
NHTSA complaint #510846, filed 1996-11
Buying note. Anyone considering this model year may want a pre-purchase inspection that covers the starting and lighting circuits, the seat mounts and seat belts, and whether any recall work was done.
Summary written with AI from a sample of 24 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.
NHTSA recorded 55 consumer complaints for the 1991 Chevrolet Cavalier. 3 of the complaints include a mileage, and 0% of those were filed for vehicles with under 50,000 miles; the median is 112,000 miles. Of all complaints, 7 involved a crash, 6 a fire, 5 an injury, 6 a death, according to the filers. NHTSA lists 2 recall campaigns and 0 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Electrical system17 31%
- Engine cooling8 15%
- Seats7 13%
- Brakes5 9.1%
- Seat belts5 9.1%
- Steering5 9.1%
- Equipment2 3.6%
- Fuel system2 3.6%
Also reported: Vehicle speed control (2), Air bags (1), Exterior lighting (1), Latches, locks and linkages (1), Other or unknown (1), Body and structure (1), Tires (1), Wheels (1).
Example complaints
Electrical system: “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.”
NHTSA complaint #701195, filed 1999-01Engine cooling: “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. …”
NHTSA complaint #10071378, filed 2004-01, 90,000 milesSeats: “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.”
NHTSA complaint #809481, filed 1997-03Mileage when problems were reported
0% of the 3 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 90,000 and 115,000 miles.
Complaints by year filed
Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Crash test ratings
NHTSA's 5-Star Safety Ratings for the 1991 Chevrolet Cavalier. Frontal results are shown driver / passenger; rollover shows the star rating and NHTSA's estimated risk of rolling over in a single-vehicle crash.
| Version | Overall | Frontal | Side | Side pole | Rollover |
|---|---|---|---|---|---|
| Cavalier · sedan | not rated | 4 / 5 | — | — | — |
Ratings before the 2011 model year come from an older, less demanding test and are not comparable with ratings for 2011 and later.
Source: NHTSA New Car Assessment Program (5-Star Safety Ratings), nhtsa.gov/ratings.
Fuel economy and running cost
EPA ratings for each 1991 Chevrolet Cavalier version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| Cavalier FWD | 2.2L 4-cyl | 5-speed manual | 21 | 32 | 25 | $2,700 |
| Cavalier FWD | 2.2L 4-cyl | 3-speed automatic | 21 | 29 | 24 | $2,800 |
| Cavalier FWD | 3.1L 6-cyl | 3-speed automatic | 18 | 25 | 20 | $3,350 |
| Cavalier FWD | 3.1L 6-cyl | 5-speed manual | 17 | 26 | 20 | $3,350 |
| Cavalier Convertible FWD | 3.1L 6-cyl | 3-speed automatic | 18 | 25 | 20 | $3,350 |
| Cavalier Convertible FWD | 3.1L 6-cyl | 5-speed manual | 17 | 26 | 20 | $3,350 |
| Cavalier Wagon FWD | 2.2L 4-cyl | 3-speed automatic | 21 | 28 | 24 | $2,800 |
| Cavalier Wagon FWD | 2.2L 4-cyl | 5-speed manual | 21 | 30 | 24 | $2,800 |
| Cavalier Wagon FWD | 3.1L 6-cyl | 3-speed automatic | 18 | 25 | 20 | $3,350 |
Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.
Recalls and investigations
- 92V003000Jan 10, 1992Seat beltsCovers: Chevrolet Cavalier 1991, Oldsmobile Cutlass 1991, Pontiac Grand Prix 1991 +3 more
The front door shoulder belt guide loops may be cracked and are not in compliance with fmvss 208.
- 91V165000Sep 23, 1991Structure › Body › Door › Hinge and attachmentsCovers: Chevrolet Cavalier 1991, Pontiac Sunbird 1991
Front door interlock striker may fail, causing door frame collapse and insufficient strength for the shoulder belt anchorage.
Recall details for the 1991 Chevrolet Cavalier → · Check a VIN at nhtsa.gov/recalls
NHTSA investigations
- PE93090Engine compartment firesClosed · Oct 8, 1993
Technical service bulletins
No technical service bulletins are on record for the 1991 Chevrolet Cavalier.
Other model years of the Chevrolet Cavalier
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2005 | 287 | 66,630 | 0 | — | 26 | Not compared (before 2008) | Stable |
| 2004 | 330 | 51,931 | 1 | — | 27 | Not compared (before 2008) | Falling |
| 2003 | 678 | 62,204 | 1 | — | 25 | Not compared (before 2008) | Falling |
| 2002 | 196 | 53,503 | 0 | — | 24 | Not compared (before 2008) | Stable |
| 2001 | 243 | 49,310 | 1 | — | 23 | Not compared (before 2008) | Stable |
| 2000 | 315 | 58,500 | 2 | — | 23 | Not compared (before 2008) | Rising |
| 1999 | 240 | 64,000 | 2 | — | 23 | Not compared (before 2008) | Stable |
| 1998 | 345 | 82,525 | 4 | — | 23 | Not compared (before 2008) | Stable |
| 1997 | 540 | 84,101 | 7 | — | 24 | Not compared (before 2008) | Stable |
| 1996 | 503 | 87,500 | 7 | — | 24 | Not compared (before 2008) | Stable |
| 1995 | 270 | 82,500 | 4 | — | 23 | Not compared (before 2008) | Stable |
| 1994 | 212 | 95,000 | 1 | — | 23 | Not compared (before 2008) | Stable |
| 1993 | 146 | 81,000 | 1 | — | 23 | Not compared (before 2008) | Stable |
| 1992 | 134 | 120,000 | 1 | — | 24 | Not compared (before 2008) | Stable |
| 1991 | 55 | 112,000 | 2 | — | 20 | Not compared (before 2008) | Stable |
| 1990 | 55 | 173,000 | 0 | — | 24 | Not compared (before 2008) | Stable |
| 1989 | 43 | 106,000 | 1 | — | 20 | Not compared (before 2008) | Stable |
| 1988 | 12 | 82,435 | 2 | — | 21 | — | Not enough data |
| 1987 | 24 | 86,394 | 2 | — | 24 | — | Stable |
| 1986 | 18 | 189,654 | 2 | — | 22 | — | Stable |
| 1984 | 8 | — | 2 | — | 25 | — | Not enough data |
All Chevrolet Cavalier model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 1991 Chevrolet Cavalier?
Owners of this model year most often report electrical faults, followed by seat, seat-belt and seat-mount failures. The issues reported most often: Electrical faults: starter, ignition, lights and wiring; Seat mounts, seatbacks and seat belt parts failing.
How many NHTSA complaints does the 1991 Chevrolet Cavalier have?
NHTSA recorded 55 consumer complaints for the 1991 Chevrolet Cavalier as of Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 1991 Chevrolet Cavalier is reported most often?
Electrical system is named most often, in 17 complaints (31% of the total), followed by engine cooling with 8.
Has the 1991 Chevrolet Cavalier been recalled?
NHTSA lists 2 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
What gas mileage does the 1991 Chevrolet Cavalier get?
The EPA rates the 1991 Chevrolet Cavalier (Cavalier, 3.1L 6-cyl) at 20 mpg combined, 18 city and 25 highway, with an estimated annual fuel cost of $3,350 at 15,000 miles a year. Other engine and drive versions are rated differently.
At what mileage are problems with the 1991 Chevrolet Cavalier reported?
Among the 3 complaints that include a mileage, the median is 112,000 miles and the middle half falls between 90,000 and 115,000 miles; 0% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Crash ratings are from NHTSA’s New Car Assessment Program. Fuel economy is from the EPA and DOE (fueleconomy.gov).
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.