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2003 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
A/C & HEATER SERVICE PROCEDURES FOR 2003 Pontiac Sunfire AUTOMOBILES
Component Replacement & Adjustment -> Cavalier & Sunfire -> Blower Motor, Replace
Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS
- Disconnect blower motor electrical connectors.
- Remove sound insulator panels.
- Remo...
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BRAKE SERVICE PROCEDURES FOR 2003 Pontiac Sunfire AUTOMOBILES
Power Brake Units -> Description -> AC-Delco Single Diaphragm Type -> AC-Delco Tandem Diaphragm Type -> Toyota/GM Single Diaphragm Type
Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS
AC-Delco Tandem Diaphragm Type
This unit utilizes a vacuum power chamber, consisting of a front and rear shell, housing divider, front and rear diaphragm, plate assemblies, hydraulic pushrod and a diaphragm return spring, Fig. .
In normal operating mode, with service brakes in released position, the booster operates with vacuum on both sides of its diaphragms. When brakes are applied, air at atmospheric pressure is admitted to one side of each diaphragm to provide power assist. When the service brake is released, atmospheric air is shut off from one side of each diaphragm. The air is ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Pontiac Sunfire AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Filter Replacement -> Except Aveo, Chevette 1.8L Diesel, Corvette, GTO, LaCrosse, Malibu (2004-06) & Malibu Maxx, Vibe, XLR, 2004-05 Corvette & 1998-2002 Metro & Prizm
Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the v...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Pontiac Sunfire AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2003 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 2003 Pontiac Sunfire AUTOMOBILES
Starter, Replace
Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS
- Disconnect battery ground cable.
- Remove air inlet duct to throttle body.
- Remove top starter bolt.
- Raise and support vehi...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2003 Pontiac Sunfire AUTOMOBILES
General Motors Corp./Saturn Cars -> Anti-Lock Warning Lamp ->
Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS
This lamp should light when the ignition is turned On. The lamp may light for as long as 30 seconds as a bulb and system inspection. If lamp remains lit or lights while operating the vehicle, a fault condition in the anti-lock brake system is indicated. When lamp is lit, turn ignition Off, then restart engine. If l...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Pontiac Sunfire AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS
Lower
- Disconnect negative battery cable.
- Drain cooling system into a suitable container.
- Reposition outlet hose clamp from cylinder head.
- Remove outlet hose from cylinder head.
- Raise and support vehicle.
- Reposition hose clamp from surge tank pipe.
- Remove radiator outlet hose from surge tank pipe.
- Reposition hose clamp from radiator.
- Remove radia...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Pontiac Sunfire AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS
- Remove coolant reservoir.
- Rotate tensioner clockwise with a 15mm wrench ...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Pontiac Sunfire AUTOMOBILES
Component location diagrams for most 2003 Pontiac Sunfire cars and light trucks sold in the U.S. from 1990+.
Rear Compartment Diagram for 2003 Pontiac Sunfire 2.2 L4 GAS Components on diagram: |
Under the Left Side of the I/P Diagram for 2003 Pontiac Sunfire 2.2 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2003 Pontiac Sunfire AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Pontiac Sunfire cars and light trucks sold in the U.S.
2003 Pontiac Sunfire 2.2 L4 GAS Wiring Diagram Components on diagram: |
2003 Pontiac Sunfire 2.2 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Pontiac Sunfire AUTOMOBILES
OEM TSB listings for most 2003 Pontiac Sunfire cars and light trucks sold in the U.S. from 1985+.
Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS Auto Systems: |
Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2003 Pontiac Sunfire 2.2 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Pontiac Sunfire AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 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 2003 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 2003 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 2003 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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