2004 Pontiac Sunfire Service and Repair Manual

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Factory-Grade Data

2004 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

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

Engines covered

  • 2.2L 2198CC 134Cu. 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

2004 Pontiac Sunfire Recalls & Complaints

NHTSA #04V30000023/06/2004Component: SEAT BELTS:REAR/OTHER

CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, 'SEAT BELT ASSEMBLY ANCHORAGES.' THE PASSENGER-SIDE REAR SAFETY BELT MAY HAVE BEEN INSTALLED WITH AN INCO

Consequence

IN A SEVERE CRASH, THE UPPER SEAT BELT ANCHORAGE MAY SEPARATE. THE EFFECTIVENESS OF THE SEAT BELT C

Remedy

DEALERS ARE TO INSPECT THE SAFETY BELT ANCHORAGE AND INSTALL A NEW NUT AND BOLT, IF NECESSARY. THE

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 #11017252

This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.

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 #11007208

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed fo

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

Showing the 8 most recent of 461 technical service bulletins on file with NHTSA.

20050621Component: ELECTRONIC STABILITY CONTROL:AUTOMATIC (ASC)Crash reported1 injured

DT: THE FRONT OF THE VEHICLE FELL APART, LOST CONTROL OF THE VEHICLE .TRIED TO GET IT TO STRAIGTEN OUT., IT WAS LIKE THE VEHICLE WOULDN'T DO WHAT CONSUMER, WANTED IT TO DO AND THERE WAS NO IMPACT TO T

20111212Component: SERVICE BRAKES, HYDRAULICCrash reported

WHILE BRAKING THE BRAKE PEDAL WAS WORKING NORMALLY THEN SUDDENLY WENT SOFT. PUMPED BRAKES BUT PEDAL WENT TO FLOOR. CAUSED CAR TO CRASH INTO VEHICLE IN FRONT OF IT. FAILURE WAS CONSISTENT WITH EITHER

20080316Component: WHEELS:HUBCrash reported

THE ABS,TRAC AND SERVICE LIGHT CAME ON AFTER I HIT A DEER BECAUSE THE TRACTION CONTROL AND ABS WOULD NOT LET ME STOP FROM HITTING IT. I NOW HAVE THE PROBLEM WITH ABS TRACTION CONTROL AND SERVICE LIGHT

20080316Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reported

THE ABS,TRAC AND SERVICE LIGHT CAME ON AFTER I HIT A DEER BECAUSE THE TRACTION CONTROL AND ABS WOULD NOT LET ME STOP FROM HITTING IT. I NOW HAVE THE PROBLEM WITH ABS TRACTION CONTROL AND SERVICE LIGHT

20050220Component: ELECTRICAL SYSTEMFire reported

I WAS DRIVING MY NEW 2004 SUNFIRE THAT WAS JUST PURCHASED AT THE END OF AUGUST, WHEN I SAW A FLAME COME OUT FROM UNDER THE DASH NEAR MY FOOT. I SLAMMED ON THE BRAKES, THROUGH IT IN PARK AND JUMPED FR

Showing the 5 most serious of 41 complaints filed with NHTSA.

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