1991 Chevrolet Cavalier recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-20. Recalls apply to specific VINs — run your VIN to confirm.
3 safety recalls, most serious first
1. Fuel system
What's wrong, in plain English: Fuel lines, tank or pump. Fuel problems usually mean a leak, and leaks mean fire risk. 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 C…
What could happen: 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.
The fix: 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).
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 CAVALIER.
- Book a repair at any authorized Chevrolet dealer. Quote NHTSA campaign 06E043000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-800-890-2075.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: FUEL SYSTEM, GASOLINE
Summary: 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).
Notes: THIS RECALL ONLY PERTAINS TO AFTERMARKET FRAM FUEL FILTERS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE VEHICLES LISTED. CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.
2. Body / structure
What's wrong, in plain English: Body panels, frame, doors, hood, trunk or latches. FRONT DOOR INTERLOCK STRIKER MAY FAIL, CAUSING DOOR FRAME COLLAPSE AND INSUFFICIENT STRENGTH FOR THE SHOULDER BELT ANCHORAGE.
What could happen: THE DOOR FRAME WOULD COLLAPSE. VEHICLE DOES NOT COMPLYWITH FMVSS 210.
The fix: REPLACE THE PASSIVE RESTRAINT INTERLOCK STRIKER STUDS ON FRONT DOORS.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 CAVALIER.
- Book a repair at any authorized Chevrolet dealer. Quote NHTSA campaign 91V165000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS
Summary: 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.
Notes: SYSTEM: SEAT BELT ANCHORAGE; FMVSS 210.VEHICLE DESCRIPTION: PASSENGER VEHICLES.
3. Seat belts
What's wrong, in plain English: Seat belts may not hold you in a crash. THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208.
What could happen: THE SEAT OCCUPANT FACES INCREASED RISK OF INJURY IN THEEVENT OF A SUDDEN STOP OR ACCIDENT.
The fix: INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1991 CAVALIER.
- Book a repair at any authorized Chevrolet dealer. Quote NHTSA campaign 92V003000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: SEAT BELTS
Summary: 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.
Notes: SYSTEM: SAFETY BELTS; FMVSS 208.DESCRIPTION OF VEHICLES: PASSENGER VEHICLES; 1991 GM "J" AND "W" MODEL CARS.
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- Compact car fire extinguisher
- 1991 Chevrolet Cavalier owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Electrical system (19), Engine (10), Brakes (9), Hydraulic (9), Seats (8).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (8)
02/04/2005 · Seat belts · crash
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…
01/15/2004 · Engine
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 STE…
12/10/2003 · Wheels / tires
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
08/25/2003 · Fuel system
WHILE DRIVING DOWN 25-35MPH VEHICLE STALLED OUT AND DIED WITHOUT WARNING. DEALER REPLACED FUEL PUMP FILTER. *AK
08/25/2003 · Wheels / tires
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 O…
02/24/2001 · Seat belts
BACK SEAT IS NOT CONNECTED TO THE CAR AND REAR SEAT BELTS ARE MISSING.
09/28/2000 · Visibility (wipers / glass)
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
08/15/2000 · Visibility (wipers / glass)
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.