Here's a general outline. This is not a substitute for a repair manual specific to your vehicle's year and engine. A repair manual will have detailed diagrams and specific torque specifications crucial for success.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Jack and jack stands (essential for safety)
* Wheel chocks
* Pry bar (possibly)
* Wire brush
* New starter motor
* Penetrating oil (like PB Blaster)
Steps:
1. Safety First: Disconnect the negative battery cable. Chock the rear wheels and safely raise the front of the car using a jack and secure it on jack stands.
2. Access the Starter: The location of the starter varies slightly depending on the engine (1.8L or 2.0L). Generally, it's located on the driver's side of the engine block, often near the bell housing (where the engine and transmission connect). You may need to remove some components for better access. This could include:
* Intake components: Possibly the air intake hose or parts of the air filter assembly.
* Exhaust components: Possibly a heat shield or portion of the exhaust system.
* Engine wiring harnesses: Carefully maneuver them out of the way. Label wires if you disconnect anything to ensure correct reassembly.
3. Disconnect the Starter:
* Battery Cable(s): Locate the large positive and smaller negative cables connected to the starter. Use a wrench to carefully loosen and remove the nuts securing them.
* Starter Solenoid Wire: There's a smaller wire connecting to the starter solenoid. Disconnect this as well.
4. Remove the Starter: The starter is typically held in place by one or two bolts. Use your sockets and wrenches to remove these bolts. Sometimes the starter is a tight fit and may require some gentle persuasion with a pry bar (use caution to avoid damaging surrounding parts).
5. Install the New Starter: Clean the mounting surface on the engine block with a wire brush to ensure a good connection. Install the new starter, aligning the mounting holes. Tighten the bolts to the manufacturer's specified torque (consult your repair manual).
6. Reconnect Everything: Reconnect the starter solenoid wire, then the battery cables. Reinstall any components you removed earlier.
7. Lower the Vehicle: Carefully lower the vehicle using the jack.
8. Reconnect the Battery: Reconnect the negative battery cable.
9. Test the Starter: Attempt to start the engine.
Important Considerations:
* Penetrating Oil: Before attempting to remove the bolts, spray penetrating oil on them to help loosen them. Let it sit for a while to work its magic.
* Torque Specifications: Use a torque wrench and tighten the starter mounting bolts to the correct specification. Over-tightening can damage the starter or engine block. Under-tightening can lead to failure.
* Repair Manual: A repair manual specific to your 1991 Chevrolet Cavalier is highly recommended. It will provide detailed diagrams, torque specifications, and other crucial information to make this repair successful.
This is a general guide; variations exist depending on the specific engine and modifications to your vehicle. If you're uncomfortable performing this repair, take your Cavalier to a qualified mechanic. Working on your car can be dangerous if you don't have the proper knowledge and tools.
