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2002 Pontiac Sunfire CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Pontiac REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 Pontiac Sunfire car and truck
repair procedures including Pontiac engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Pontiac Sunfire automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2002 Pontiac Sunfire AUTOMOBILES
Air Bag System Precautions -> General Motors Corp. -> Disarming -> 1990 -> 1990-93 -> 1990-95 -> 1990-97 -> 1991 -> 1991-93 -> 1991-94 -> 1991-95 -> 1992-93 -> 1992-99 -> 1993-2002 -> 1993-94 -> 1993-98 -> 1994 -> 1994-2002 -> 1994-95 -> 1994-96 -> 1994-98 -> 1995-2002 -> 1995-96 -> 1995-97 -> 1995-98 -> 1995-99 -> 1996 -> 1996-2001 -> 1996-97 -> 1997 -> 1997-2002 -> 1997-98 -> 1997-99 -> 1998-2000 -> 1998-2002 -> 1998-99 -> 1999 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 2000-02 -> 2001-02 -> 2002 -> 2003 -> 2003-04 -> 2003-04 Except Malibu Maxx -> Achieva & Skylark -> Alero -> Astro & Safari -> Aurora -> Avalanche -> Aveo -> Aztek & Rendezvous -> Beretta & Corsica -> Blazer, Jimmy, Sonoma & S-10 -> Bonneville, Eighty-Eight, LeSabre, LSS, Ninety-Eight & Regency -> Bravada, Envoy, Rainier, SSR & TrailBlazer -> C/K Series -> Camaro & Firebird -> Canyon & Colorado -> Caprice, Custom Cruiser & Roadmaster -> Catera -> Cavalier & Sunfire -> Century -> Corvette -> Coupe -> CTS -> Cutlass -> Cutlass Ciera & Cruiser -> Cutlass Supreme -> DeVille -> Eldorado -> Escalade -> Express, G Series & Savana -> Fleetwood -> Grand Am -> Grand Prix & Intrigue -> Impala -> ION -> L-Series -> Light Trucks & Vans -> Lumina -> Lumina APV, Montana, Silhouette, Trans Sport & Venture -> Malibu -> Malibu Maxx -> Metro -> Monte Carlo -> Park Avenue -> Passenger Cars -> Prizm -> Reatta, Toronado & Trofeo -> Regal -> Riviera -> S-Series -> Sedan -> Seville -> Sierra & Silverado -> SRX -> Storm -> Suburban, Tahoe, Yukon & Yukon XL -> Tracker -> Vibe -> VUE -> XLR -> Zone 1 -> Zone 10 -> Zone 12 -> Zone 2 -> Zone 3 -> Zone 4 -> Zone 5 -> Zone 6 -> Zone 7 -> Zone 8 -> Zone 9 -> Zones 1 & 7 -> Zones 2 & 6 -> Zones 5 & 9 -> Zones 7 & 9
Vehicle: 2002 Pontiac Sunfire 2.4 L4 GAS
Passenger Cars
The Sensing and Diagnostic Module (SDM) can maintain enough voltage to cause air bag deployment for up to 10 minutes after the ignition is turned Off and the battery is disconnected. Servicing the Supplemental air bag (SIR) system during this period may result in accidental deployment and personal injury.
Achieva & Skylark
1994-96
- Ensure front wheels are in straight-ahead position.
- Turn ignition switch to LOCK position.
- Remove AIR BAG fuse from fuse block.
- On 1995 models, remove lefthand sound insulator panel to ac...
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BRAKE SERVICE PROCEDURES FOR 2002 Pontiac Sunfire AUTOMOBILES
Disc Brakes -> AC-Delco Single Piston Front Disc Brake -> Troubleshooting -> Brake Roughness
Vehicle: 2002 Pontiac Sunfire 2.4 L4 GAS
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in disc thickness. If roughness or vibration is encountered during highway operation or if pedal pulsation is experienced at low speeds, the disc may have excessive thickness variation. To inspect for this condition, measure the disc at 12 points with a micrometer at a radius approximately one inch from edge of disc. If thickness measurements vary by more than ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Pontiac Sunfire AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Component Locations -> Skyhawk (1982-89), Cimarron, Beretta, Cavalier, Corsica, Firenza & 2000, Sunbird & Sunfire
Vehicle: 2002 Pontiac Sunfire 2.2 L4 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Pontiac Sunfire AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2002 Pontiac Sunfire 2.2 L4 GAS
- Disconnect negative battery cable.
- Raise and suitably support vehicle.
- Remove tire and wheel assembly.
- Place shop towels underneath outer joint to protect from any sharp edges.
- Insert a drift into caliper and rotor to prevent rotor from turning.
- Remove drive axle nut and washer.
- Remove lower ball joint from steering knuckle. If you remove right axle, turn wheel to left. If you remove left axle, turn wheel to right.
- Disconnect wheel speed sensor harness.
- Disconnect stabilizer link from low...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Pontiac Sunfire AUTOMOBILES
Alternator, Replace
Vehicle: 2002 Pontiac Sunfire 2.2 L4 GAS
- Disconnect battery ground cable.
- Disconnect alternator electrical connectors.
- Rotate tensioner clockwise with suitable wrench and slide belt from alternator pulley.
- Release tensioner and remove belt, usin...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Pontiac Sunfire AUTOMOBILES
General Motors Corp./Saturn Cars -> Check Fuel Cap Lamp ->
Vehicle: 2002 Pontiac Sunfire 2.4 L4 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the on position as a bulb check. If...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Pontiac Sunfire AUTOMOBILES
Radiator, Replace
Vehicle: 2002 Pontiac Sunfire 2.2 L4 GAS
- Drain cooling system into suitable container.
- Remove hood latch assembly.
- Remove righthand and lefthand headlamp assemblies.
- Remove radiator upper mount attaching bolts, then the mounts.
- Raise vehicle using suitable lift.
- Remove cooling fan mounting bolts, disconnect electrical connectors, then the cooling fan.
- Remove radiator outlet hose clamp from radiator using tool No. J381...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Pontiac Sunfire AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Pontiac Sunfire 2.2 L4 GAS
CLICK HERE TO GET FULL ACCESS TO 2002 Pontiac Sunfire SERPENTINE BELT SERVICE PROCEDURES
COMPONENT LOCATION DIAGRAMS FOR 2002 Pontiac Sunfire AUTOMOBILES
Component location diagrams for most 2002 Pontiac Sunfire cars and light trucks sold in the U.S. from 1990+.
 Below the Left Side of the I/P Near the Steering Column Diagram for 2002 Pontiac Sunfire 2.2 L4 GASComponents on diagram: |
 Master Window Switch Lead Diagram for 2002 Pontiac Sunfire 2.4 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 Pontiac Sunfire AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Pontiac Sunfire cars and light trucks sold in the U.S.
 2002 Pontiac Sunfire 2.4 L4 GAS Wiring DiagramComponents on diagram: |
 2002 Pontiac Sunfire 2.2 L4 GAS Wiring DiagramComponents on diagram: |
CLICK HERE TO GET FULL ACCESS TO 2002 Pontiac Sunfire WIRING DIAGRAMS!
TECHNICAL SERVICE BULLETINS FOR 2002 Pontiac Sunfire AUTOMOBILES
OEM TSB listings for most 2002 Pontiac Sunfire cars and light trucks sold in the U.S. from 1985+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2002 Pontiac Sunfire 2.2 L4 GAS Auto Systems: |
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2002 Pontiac Sunfire 2.2 L4 GAS Auto Systems: |
CLICK HERE TO GET FULL ACCESS TO 2002 Pontiac Sunfire TECHNICAL SERVICE BULLETINS!
COMPONENT/PARTS SPECIFICATIONS FOR 2002 Pontiac Sunfire AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 Pontiac Sunfire cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2002 Pontiac Sunfire cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2002 Pontiac Sunfire cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2002 Pontiac Sunfire cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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