18 of the 77 complaints about the 1991 Chevrolet Cavalier are about the electrical system — 23% of everything reported for this model year.
18
Complaints
1
Crashes
5
Fires
0
Injuries
Filed with NHTSA, in their own words.
ELECTRICAL SYSTEM:STARTER ASSEMBLY
STARTER WAS REPLACED, AND DID NOT FIT PROPERLY IN THE VEHICLE, CAUSING THE STARTER TO COM ELOOSE/ SHAKE. BOLTS NEED TO BE REPLACED.
NHTSA complaint #848793 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:IGNITION:SWITCH
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 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:IGNITION
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.
NHTSA complaint #701480 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR
ALTERNATOR FAILED.
NHTSA complaint #604563 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:IGNITION:SWITCH
WINDSHIELD WIPERS FAIL WITHOUT ADDING PRESSURE TO THE IGNITION SWITCH, ONLY OPERATE WHEN HOLDING IGNITION SWITCH.
NHTSA complaint #539379 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:WIRING
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 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:STARTER ASSEMBLY
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 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:IGNITION:MODULE
PROM FAILURE.
NHTSA complaint #518256 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:IGNITION
ENGINE COMPARTMENT FIRE, PE93-090, THE VEHICLE WAS IN MOTION AND THE VEHICLE CUT OFF AND CAUGHT ON FIRE IN THE ENGINE.
NHTSA complaint #801969 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
THE WIRING UNDER THE HOOD OVERHEATED AND CAUGHT ON FIRE.
NHTSA complaint #986748 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS
WHILE DRIVING, EXPERIENCED INTERMITTENT FAILURE, INTIALLY DASH AND REAR LIGHTS WERE INOPERATIVE, ALSO DRIVING AT NIGHT HEADLIGHT WENT OUT DUE TO SHORT.
NHTSA complaint #980108 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH
WHILE DRIVING EXPERIENCED INTERMITTENT FAILURE, INITIALLY DASH AND REAR LIGHTS WERE INOPERATIVE, ALSO DRIVING AT NIGHT HEADLIGHT SUDDENLY WENT OUT DUE TO SHORT
NHTSA complaint #980271 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:HORN
VEHICLE HORN CAME OFF THE STEERING WHEEL, CAUSED LOSS OF STEERING.
NHTSA complaint #979832 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:HORN
VEHICLE HORN CAME OFF THE STEERING WHEEL, CAUSED LOSS OF STEERING.
NHTSA complaint #979832 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
ENGINE COMPARTMENT FIRE AN ELECTRICAL SHORT IN THE HARNESS. TT
NHTSA complaint #977133 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:IGNITION:SWITCH
THE WINDSHEILD WIPER STOPPED WORK AND THE IGNITION SWITCH WAS REPLACED. TT
NHTSA complaint #970603 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:WIRING
ELECTRICAL SHORT CIRCUIT, CAUSING THE WIRING HARNESS TO CATCH FIRE. TT
NHTSA complaint #959281 — an unverified report by a vehicle owner.
ELECTRICAL SYSTEM:IGNITION
DISTRIBUTOR BECOMES WET AND FAILS. TT
NHTSA complaint #958216 — an unverified report by a vehicle owner.