PontiacSunfire2002Overview/pontiac/sunfire/2002/base/

2002 Pontiac Sunfire

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Sunfire.

Body PASSENGER CAR

The 2002 Pontiac Sunfire is a passenger car requiring 4.5 quarts of engine oil at a 5W-30 API viscosity specification. As part of a model run spanning 1991 to 2005, the 2002 Sunfire accumulated 91 total owner complaints with the electrical system emerging as the primary concern, while two recalls were issued for the model year. This complaint tally places the 2002 well below the model's peak of 237 complaints recorded in 1996, though it remains distant from the remarkably low count of just one complaint logged in 1991, suggesting the platform had achieved measurable quality improvements over its worst years but had not yet reached the early reliability levels established at the model's launch.

Model year200520042003200220012000199919981997

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 12731175. Note the factory fuel filter and front wiper blades are now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known.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 filter12731175 alt 25322835
Engine air filter24577608
Fuel filter25121293 discontinued
Spark plug12681663 alt 19301811
Battery88861746 alt 88865311
Front wiper blades22711468 discontinued · alt 22711469
Serpentine belt12634322 alt 12634320
Thermostat24577118 alt 12622410

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length185 in
Overall width68.5 in
Overall height53.1 in
Wheelbase103.9 in
Curb weight2606 lb
Track (front / rear)57.5 / 56.7 in
Weight distribution (front / rear)65/35

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, DOT 3 brake fluid. 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

Brake FluidDOT 3
Engine CoolantDEX-COOL OR EQUIVALENT
Engine Oil5W-30 · API
Engine Oil Capacity4.5 qt
Engine Oil5W-30 · API
Engine Oil Capacity4.5 qt
Power Steering FluidATF

Engine torques

Crankshaft Pulley and/or Damper Bolts77 ft-lbs
Crankshaft Pulley and/or Damper Bolts74 ft-lbs
Crankshaft Pulley and/or Damper Bolts129 ft-lbs
Intake Manifold to Engine BoltsBolt and nuts: 17 ft-lbs, studs: 8.8 ft-lbs
Exhaust Manifold to Cylinder Head Bolts9.6 ft-lbs
Intake Manifold to Engine Bolts7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts9 ft-lbs
Intake Manifold to Engine Bolts18 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs
Front Wheel Hub144 ft-lbs

Ignition

Spark Plug ManufacturerAC Delco
Spark Plug Gap0.040 in
Spark Plug Torque13.0 ft-lbs
Spark Plug ManufacturerAC Delco
Spark Plug Gap0.042 in
Spark Plug Torque15.0 ft-lbs
Spark Plug ManufacturerAC Delco
Spark Plug Type41-942

Battery & A/C

RefrigerantR134a
Refrigerant Capacity2.2 L
Oil GroupPAG
Oil Type46
Oil Capacity2.2 L
Standard BCI Group Number75
Standard BCI Cranking Performance525 cca
Standard BCI Group Number75

Service checks

Pressure Test15 psi
Radiator Cap Pressure Relief15 psi
Thermostat Opening Temperature185-205 °F
Pressure Test15, Pressure should not exceed 20 psi.
Radiator Cap Pressure Relief15 psi
Thermostat Opening Temperature185-205 °F
Fuel Pump Pressure Minimum60.0 psi
Key ON Engine OFF (KOEO)53-59.0

Brakes

Torque to Knuckle100 ft-lbs
Torque Caliper to Bracket62 ft-lbs
Minimum Pad ThicknessFront: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation0.001 in
Rotor Runout Limit0.002 in
Rotor Nominal Thickness From0.786 in
Rotor Nominal Thickness To0.786 in
Rotor Minimum Machining0.751 in

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 3 stages
1Bolts 1-840 ft. lbs
2Bolts 9-1030 ft. lbs
390 degrees.90 degrees
Cylinder Head — tightening sequence 3 stages
1Long bolts46 ft. lbs
2Short bolts43 ft. lbs
390 degrees.90 degrees
Cylinder Head — tightening sequence 3 stages
122 ft. lbs.22 ft. lbs
2155 degrees.155 degrees
326

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 at 150,000 mi. The big-interval services (at 150,000 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.

Every 7,500 miEngine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate) · Underbody (inspect)
Every 30,000 miEngine Air Filter Element (replace)
Every 60,000 miAccessory Drive Belt (inspect)
Every 100,000 miSpark Plug Wires (inspect) · Spark Plugs (replace)
At 150,000 miEngine Coolant System (drain, flush & refill)

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 2002 Sunfire sits in the latter half of a generation that saw complaint volumes peak sharply in 1996–1997 at 237 and 225 respectively before declining steadily; by 2002 complaints had fallen to 91, with only two recalls and zero investigations, marking a clear improvement over the early high-water marks. However, Technical Service Bulletins tell a different story, climbing from 97 in 1995 to 432 in 2002 and continuing upward through 2005, indicating that while catastrophic failures became rarer, the manufacturer issued a growing stream of service directives — many likely addressing the electrical system (13 complaints), hydraulic brakes (10), visibility (7), and steering (6) that dominate the 2002 complaint profile. The data also records eight crash-related and three fire-related complaints for the year, though the records do not specify root causes for any of these categories. Compared with the adjacent 2001 (78 complaints, 379 TSBs) and 2003 (85 complaints, 471 TSBs), the 2002 model year shows a modest uptick in complaints but sits squarely in the low-recall, high-TSB phase of the lifecycle. For a buyer, this suggests a vehicle past the worst of its systemic defects but one that demands verification that all 432 TSBs — particularly those covering electrical and brake components — have been applied; if that service history is documented, 2002 represents a relatively sound choice within this generation.

2
Open recalls
NHTSA campaigns
432
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
91
Owner complaints
8 involved a crash · 3 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 91 complaints on record, top 8 components.

Electrical System13
Service Brakes, Hydraulic10
Visibility7
Steering6
Engine & Engine Cooling6
Exterior Lighting4
Air Bags4
Power Train3

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 2 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.

07E021000Fuel System, Other:Storage:Tank Assembly:Pressure Relief DevicesReported 12/03/2007

CERTAIN DELPHI FUEL PRESSURE REGULATORS, P/NOS. FP10020-11B1, FP10026-11B1, AND FP10027-11B1, SOLD AFTER JANUARY 9, 2007, AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES LISTED ABOVE. THE UNIVERSAL PRESSURE… Remedy: DELPHI WILL NOTIFY OWNERS AND REPLACE THE UPR FREE OF CHARGE. THE RECALL BEGAN ON APRIL 23, 2007. OWNERS CAN CONTACT DELPHI AT 877-411-8770.

Technical service bulletins NHTSA · verified

Showing 5 of 432 bulletins on record with NHTSA.

BulletinDateComponentSummary
PIP5601C2025-07-18Unknown Or OtherThis PI communicates the requirement to provide a pico file to receive diagnostic…
PIP5358D2025-02-19Unknown Or OtherThis Preliminary Information communication provides information to the technician about…
PIP4723J2024-10-25Electrical SystemThis Preliminary Information communicates to the dealer the process for downloading or…
PIT5099H2024-09-12Unknown Or OtherThis Preliminary Information communication provides information to the technician about…
PIT5099H2024-09-12Unknown Or OtherThis Preliminary Information communication provides information to the technician about…

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.

Reference guides

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

Frequently asked

How much oil does the 2002 Sunfire take?

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

Does the 2002 Sunfire have open recalls?

NHTSA lists 2 recall campaign(s) for this model year. Check your specific vehicle by VIN.