1991 Pontiac Sunbird Service and Repair Manual

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Factory-Grade Data

1991 Pontiac Sunbird service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • Value Leader Sedan 4-Door
  • LE Sedan 4-Door
  • SE Coupe 2-Door
  • Value Leader Coupe 2-Door
  • GT Coupe 2-Door
  • LE Convertible 2-Door
  • LE Coupe 2-Door

Engines covered

  • 2.0L 122Cu. In. l4 GAS SOHC Naturally Aspirated
  • 3.1L 189Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Pontiac Sunbird Recalls & Complaints

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONF

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE S

TSB #10246631

Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules

TSB #615073

SOME V6 ENGINES MAY, ON A VERY INFREQUENT BASIS, HAVE AN OIL ODOR CONDITION THAT IS GENERALLY ENCOUNTERED AFTER THE ENGINE'S OIL HAS BEEN CHANGED.TYPICALLY THE ODOR LASTS APPROXIMATELY 1000 MILES AFTER THE CHANGE OF OIL AND THEN DOES NOT RE

TSB #613590

INFORMATION REGARDING SNOW INTRUSION INTO REAR DRUM BRAKE ASSEMBLIES. **MR

TSB #37840

BUZZING SOUND WHEN REAR DEFOGGER IS ON. *TW

TSB #37843

CRUNCH NOISE FROM RIGHT SIDE DASH AREA WHEN TURNING STEERING WHEEL. *TW

19970220Component: SEAT BELTS:FRONT:BUCKLE ASSEMBLYCrash reported1 injured

VEHICLE WAS INVOLVED IN AN ACCIDENT, SEAT BELT BUCKLE BROKE DURING ACCIDENT. *AK

19961021Component: SEAT BELTS:FRONT:WEBBINGCrash reported1 injured

SHOULDER PORTION OF SEAT/LAP BELT FAILED TO RESTRAIN UPPER PORTION OF OWNER'S BODY, ALLOWING CONTACT WITH STEERING WHEEL. *AK

19950828Component: SEAT BELTSCrash reported1 injured

DRIVERS HEAD HIT SEAT BELT MOLDING WHEN STRUCK ON SIDE. VEHICLE EQUIPPED AUTOMATIC SEAT BELTS WITH SEPARATE LAP. PLEASE DESCRIBE DETAILS. TT

19980609Component: VEHICLE SPEED CONTROL:ACCELERATOR PEDALCrash reported

WHEN STARTING THE CAR THE ENGINE REVVED AND THE ACCELERATOR PEDAL JAMMED WHILE IN REVERSE AND THE CAR HIT ANOTHER VEHICLE. NO INJURIES. DEALER HAS THE VEHICLE NOW. *AK

19960205Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPERCrash reported

DRIVERS SIDE FRONT CALIPERS WORE OUT, CAUSING ACCIDENT. TT

Showing the 5 most serious of 30 complaints filed with NHTSA.

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