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1996 Pontiac Sunfire

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 1996 Sunfire.

Body PASSENGER CAR

Classified as a passenger car requiring 4.5 quarts of 5W-30 API oil, the 1996 Pontiac Sunfire occupies a distinct position within the model's 1991-2005 history. This model year accumulated 237 total owner complaints across ten recalls, with the engine and engine cooling systems identified as the top complaint area. As the highest complaint year recorded, the 1996 Sunfire represents the peak of reported issues, standing in sharp contrast to the lowest complaint count of one recorded in 1991.

Model year2005 2004 2003 2002 2001 2000 1999 1998 1996

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.5 qtOEM · verified

Engine oil type5W-30 APIOEM · verified

Lug nut torque100 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 75 · 525 CCA battery, OE oil filter 12731172. Note the factory fuel filter and front wiper blades are now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 75 · 525 CCAOEM · verified

Tire sizeP195-70R14OEM · verified

Wheel / rim6-JJ inOEM · verified

OE service part numbers OEM · verified

Engine oil filter	12731172 alt 12731175
Engine air filter	24577608
Fuel filter	25121293 discontinued
Spark plug	19301805 alt 19301807
Front wiper blades	22711468 discontinued · alt 22711469
Serpentine belt	88984195 alt 24575312
Thermostat	24577118 alt 24577288

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length	181.9 in
Overall width	67.3 in
Overall height	53.9 in
Wheelbase	103.9 in
Curb weight	2873 lb
Track (front / rear)	57.1 / 56.7 in

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.5 qt of 5W-30 API engine oil. Torque lug nuts to 100 ft-lbs. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Engine Oil	5W-30 · API
Engine Oil Capacity	4.5 qt
Engine Oil	5W-30 · API
Engine Oil Capacity	4.5 qt

Engine torques

Crankshaft Position (CKP) Sensor Bolt(s)	6 ft-lbs
Camshaft Position (CMP) Sensor Bolt(s)	7.5 ft-lbs
Crankshaft Position (CKP) Sensor Bolt(s)	7.4 ft-lbs
Camshaft Position (CMP) Sensor Bolt(s)	7.4 ft-lbs
Camshaft Sprocket and/or Gear Bolt(s)	77 ft-lbs
Camshaft Sprocket and/or Gear Bolt(s)	52 ft-lbs
Crankshaft Pulley and/or Damper Bolts	77 ft-lbs
Crankshaft Pulley and/or Damper Bolts	129 ft-lbs

Chassis torques

Lug Nuts	100 ft-lbs
Front Wheel Hub	185 ft-lbs

Ignition

Ignition Coil Secondary Resistance	5,000-8,000 ohms
Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.040 in
Spark Plug Torque	13.0 ft-lbs
Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.060 in
Spark Plug Torque	13.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	1.50 lbs
Oil Group	PAG
Oil Type	GM part number 12345923 or equivalent.
Oil Capacity	8.00-9.00 oz
Standard BCI Group Number	75
Standard BCI Cranking Performance	525 cca
Standard BCI Group Number	75

Service checks

Pressure Test	15 psi
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	185-205 °F
Pressure Test	15, Pressure should not exceed 20 psi.
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	185-205 °F
Fuel Pump Pressure Minimum	47.0 psi
Key ON Engine OFF (KOEO)	40-47.0

Brakes

Torque Caliper to Bracket	38 ft-lbs
Torque to Knuckle	100 ft-lbs
Minimum Pad Thickness	Front: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation	0.0005 in
Rotor Runout Limit	0.003 in
Rotor Nominal Thickness From	0.786 in
Rotor Nominal Thickness To	0.786 in
Rotor Minimum Machining	0.751 in

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 3 stages

1	Bolts 1-8	40 ft. lbs
2	Bolts 9-10	30 ft. lbs
3	90 degrees.	90 degrees

Cylinder Head — tightening sequence 3 stages

1	Long bolts	46 ft. lbs
2	Short bolts	43 ft. lbs
3	90 degrees.	90 degrees

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 100,000 mi; coolant every 100,000 mi. The big-interval services (every 100,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

At 7,500 mi	Tire & Wheel Assembly (rotate)
Every 7,500 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Parking Brake Cable (lubricate) · Shift Linkage (inspect) · Steering Linkage (inspect) · Suspension System (inspect)
Every 15,000 mi	Tire & Wheel Assembly (rotate)
Every 30,000 mi	EGR System (inspect) · Engine Air Filter Element (replace) · Engine Breather Filter (replace) · Fuel System (inspect)
Every 60,000 mi	Accessory Drive Belt (inspect)
Every 100,000 mi	Engine Coolant System (drain, flush & refill) · Spark Plug Wires (inspect) · Spark Plugs (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 1996 Pontiac Sunfire marks a pronounced peak in federal-reported issues within its generation, with 237 complaints—nearly double the 1995 total and the highest of any model year in the dataset. Recalls and investigations also surged to 10 and 3, respectively, reflecting systemic concerns that emerged as the platform matured, particularly in engine cooling, airbags, and electrical systems. This year falls at the crest of a reliability arc, where early build-quality problems (evident in the 1995 spike) were still being addressed, but before later refinements reduced complaints post-1998. The concentration of crash-related (30) and fire-related (11) complaints further underscores the year’s elevated risk profile. While Technical Service Bulletins (92) indicate GM’s efforts to mitigate issues, the data suggests 1996 is among the least desirable years to purchase, given its outsized share of unresolved and recurring problems. Buyers should prioritize later model years (1999 onward) where complaint rates decline significantly.

Open recalls

NHTSA campaigns

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

237

Owner complaints

30 involved a crash · 11 a fire

Owner complaints by model year NHTSA · this generation & adjacent

’91 ’94 ’95’96’97 ’98 ’99 ’00 ’01 ’02 ’03 ’04 ’05

Owner complaints filed with NHTSA, by component

All 237 complaints on record, top 8 components.

Engine & Engine Cooling34

Air Bags28

Electrical System28

Service Brakes, Hydraulic19

Power Train17

Steering16

Suspension8

Structure8

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 10 campaigns on record for this vehicle.

08E063000SteeringReported 17/10/2008

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 (SOLD UNDER THE "NAPA"… Remedy: DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 16, 2008. OWNERS MAY CONTACT DORMAN TOLL FREE AT 1-800-523-2492.

02V070000Electrical System:Ignition:SwitchReported 06/03/2002

ON CERTAIN PASSENGER VEHICLES. IF THE ENGINE FAILS TO START AND THE DRIVER HOLDS THE KEY IN THE "START" POSITION FOR AN EXTENDED PERIOD, HIGH CURRENT FLOWS THROUGH THE IGNITION SWITCH, AND SOMETIMES PRODUCES ENOUGH HEAT… Remedy: DEALERS WILL INSTALL A RELAY KIT IN THESE VEHICLES TO PREVENT HIGH CURRENT FROM FLOWING THROUGH THE IGNITION SWITCH. OWNER NOTIFICATION BEGAN MARCH 27, 2002. OWNERS WHO TAKE THEIR…

Technical service bulletins NHTSA · verified

Showing 5 of 92 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
PIP4723F	2022-01-14	Service Brakes, Hydraulic	This Preliminary Information communicates to the dealer the process for downloading or…
PIP4723D	2020-01-31	Electrical System	This Preliminary Information communicates to the dealer the process for downloading or…
19NA273	2019-12-02	Electrical System	This informational bulletin provides information for dealers/technicians on Procedures to…
PIC4696E	2019-11-22	Equipment	This Preliminary Information communication provides information to the technician on how…
17NA073	2019-09-18	Equipment	This warranty administration bulletin provides information regarding the field action…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific Sunfire. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 75 battery Vehicles taking 4.5 qt Engine oil filter 12731172 Engine air filter 24577608 Fuel filter 25121293 Spark plug 19301805

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 1996 Sunfire take?

4.5 qt of 5W-30 API, per the factory manual.

Does the 1996 Sunfire have open recalls?

NHTSA lists 10 recall campaign(s) for this model year. Check your specific vehicle by VIN.