2002 Pontiac Sunfire Service and Repair Manual

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Factory-Grade Data

2002 Pontiac Sunfire 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

  • SE Coupe 2-Door
  • SE Sedan 4-Door
  • GT Coupe 2-Door
  • Base Coupe 2-Door

Engines covered

  • 2.2L 2190CC 134Cu. In. l4 GAS OHV Naturally Aspirated
  • 2.2L 2198CC 134Cu. In. l4 GAS DOHC Naturally Aspirated
  • 2.4L 2392CC 146Cu. In. l4 GAS DOHC 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

2002 Pontiac Sunfire Recalls & Complaints

NHTSA #08E06300017/10/2008Component: STEERING

DORMAN PRODUCTS IS RECALLING 3,900 INTERMEDIATE STEERING SHAFTS DORMAN PART NOS. 425-151, 425-152, AND 425-153, (SOLD UNDER DORMAN'S "OE SOLUTIONS" BRAND NAME), BALKAMP #'S 7-3057, 7-3058, 7-3059 (SOL

Consequence

IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGAN ON OCTOB

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11014455

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the

TSB #11009156

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and

TSB #11007744

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi

TSB #11007743

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11004557

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.

TSB #11002312

This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.

Showing the 8 most recent of 421 technical service bulletins on file with NHTSA.

20040115Component: STEERINGCrash reported1 injured1 fatalities

MY SON WAS DRIVING HOME THE NIGHT BEFORE HIS WEDDING, WAS NOT DRUNK ACCORDING TO THE CORONER. THE POLICE REPORT SAID HE MUST HAVE WENT OFF THE ROAD, OVERCORRECTED AND BEGAN SPINNING AND ROLLING.THE CA

20040115Component: AIR BAGSCrash reported1 injured1 fatalities

MY SON WAS DRIVING HOME THE NIGHT BEFORE HIS WEDDING, WAS NOT DRUNK ACCORDING TO THE CORONER. THE POLICE REPORT SAID HE MUST HAVE WENT OFF THE ROAD, OVERCORRECTED AND BEGAN SPINNING AND ROLLING.THE CA

20081122Component: SERVICE BRAKES, HYDRAULICCrash reported1 injured

ON NOVEMBER 12, 2008 I WAS IN AN AUTO ACCIDENT. I WAS DRIVING MY 2002 PONTIAC SUNFIRE THAT I HAD PURCHASED ON OCTOBER 28, 2008. AS THE CAR AHEAD OF ME BEGAN TO BRAKE I BEGAN TO BRAKE AS WELL. HOWEV

20080824Component: TIRESCrash reported1 injured

I WAS DRIVING ON HIGHWAY 270-STATE ROUTE 3, AND WAS DRIVING WITH THE FLOW OF TRAFFIC! WENT TO CHANGE LANES FROM LEFT TO RIGHT! STARTED MERGING INTO MY CHANGING LANE WHEN I NOTICED A CAR SPEEDING INTO

20071231Component: SERVICE BRAKES, HYDRAULICCrash reported1 injured

TL*THE CONTACT OWNS A 2002 PONTIAC SUNFIRE. WHILE DRIVING BETWEEN 35-40 MPH, THE BRAKES FAILED. THE VEHICLE STRUCK AND DESTROYED THE REAR BUMPER OF THE PRECEDING VEHICLE. THE CONTACT'S VEHICLE WAS

Showing the 5 most serious of 128 complaints filed with NHTSA.

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