2004 Pontiac Sunfire TSBs
117 Sunfire Technical Service Bulletins
Technical Service Bulletins, or TSBs for short, are notifications made directly by Pontiac to help automotive technicians diagnose and repair commonly reported Sunfire problems. Interested in how this information is collected? Read more about TSBs.
Recent 2004 Sunfire TSBs
STEERING
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Description: CONCERNS WITH CLUNK NOISE FROM FRONT OF VEHICLE TURNING MANEUVER / STEERING WHEEL ROTATION.*JB (LUBRICATE OR REPLACE INTERMEDIATE SHAFT AS APPROPRIATE). UPDATED 10/05/07. *NJ UPDATED 4/1/08. *NJ UPDATED 7/1/2008 *PE
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Description: RELEASE OF STEERING GEAR STUB SHAFT BEARING KIT FOR SERVICE. *TT UPDATED 08-15-07. *KB UPDATED 10/09/07. *NJ
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Description: CLUNK FELT/NOISE HEARD FROM STEERING COLUMN, STEERING GEAR AND/OR FRONT OF VEHICLE DURING TURNING MANEUVER AND/OR STEERING WHEEL ROTATION. *TT
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Description: CLUNK NOISE FROM FRONT OF VEHICLE DURING TURNING MANEUVER/STEERING WHEEL ROTATION. *TT *NM
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Description: MOMENTARY REDUCTION OF POWER STEERING PS ASSIST ON INITIAL START UP WITH LOW AMBIENT TEMPERATURES. THIS SERVICE BULLETIN REPLACES 030232001A. *EH
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Description: SOME CUSTOMERS MAY COMMENT ON A CLUNK TYPE NOISE COMING FROM THE FRONT OF THE VEHICLE DURING A TURNING MANEUVER. *TT
STEERING:COLUMN
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Description: CLUNK FELT/NOISE HEARD FROM STEERING COLUMN, STEERING GEAR AND/OR FRONT OF VEHICLE DURING TURNING MANEUVER AND/OR STEERING WHEEL ROTATION (LUBRICATE INTERMEDIATE SHAFT [I-SHAFT]). *NJ
STEERING:HYDRAULIC POWER ASSIST SYSTEM
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Description: MOMENTARY REDUCTION ON POWER STEERING (P/S) ASSIST ON INITIAL START UP WITH LOW AMBIENT TEMPERATURES. *TT
SUSPENSION
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Description: SQUEAKING NOISE IN FRONT END ON TURNS. *TT
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Description: CHANGES TO LABOR TIME GUIDE RELATING TO FRONT SUSPENSION LABOR OPERATIONS COMPONENTS. *EH
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Description: WHEEL SQUEAK ON VEHICLES WITH 14 AND 15 INCH WHEEL COVERS. *TT
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Description: FRONT SUSPENSION NOISE ON TURNS. *EH
SUSPENSION:FRONT
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Description: SQUEAK OR RUB TYPE NOISE ON TURNS COMING FROM THE FRONT SUSPENSION AS IF IT IS COMING FROM THE SHOCK ABSORBER OR THE TOP MOUNT. *TT
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Description: FRONT SUSPENSION STEER NOISE SMOOTH ROAD TURNS. *MR
SERVICE BRAKES, HYDRAULIC
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Description: CAR ISSUES - FIX IT RIGHT THE FIRST TIME (NEW ISSUES IN BOLD). TO INCLUDE 2006 AND 2007 MODELS. GM. TECH LINK. *TT
SERVICE BRAKES, HYDRAULIC:ANTILOCK:ABS WARNING LIGHT
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Description: ANTI-LOCK BRAKE SYSTEM (ABS) WARNING LIGHT ON, TRACTION OFF WARNING LIGHT ON, DIAGNOSTIC TROUBLE CODES (DTCS) C1223 AND C1225 SET. *TT
SERVICE BRAKES, AIR
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Description: ABS PUMP RUNNING WHEN NOT NEEDED. *NJ
SERVICE BRAKES, AIR:ANTILOCK:WHEEL SPEED SENSOR
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Description: VEHICLES MAY SET ANYONE OR A COMBINATION OF FRONT-WHEEL SPEED SENSOR ANTI-LOCK BRAKE SYSTEM CODES AS INTERMITTENT OR HARD FAILURES. GM VOICEMAIL EXPRESS. *TT
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Description: ANTI-LOCK BRAKING SYSTEM (ABS) FRONT WHEEL SPEED CODES - JUMPER HARNESS. *TT
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Description: ABS FRONT WHEEL SPEED CODES - JUMPER HARNESS. *TT
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Description: TECH 2 DISPLAYS ASTERISK FOR THE LEFT FRONT WHEEL SPEED SENSOR. *TT
ENGINE AND ENGINE COOLING
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Description: HIGHER THAN EXPECTED OIL CONSUMPTION BLUE SMOKE ON ACCELERATION. *EH
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Description: ENGINE FAILURE DUE TO WATER INGESTION HYDRO LOCK. *EH
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Description: ENGINE IDLE FLARE WHEN THE CLUTCH IS DEPRESSED. ALSO LOW SPEED ENGINE DECEL STALL WHEN COMING TO A STOP. GM TECH LINK. *TT
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Description: NEW CYLINDER BORE LINER REPLACEMENT PROCEDURE. THIS SERVICE BULLETIN REPLACES 030601018A. *EH
ENGINE AND ENGINE COOLING:ENGINE
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Description: GM: THERE MAY BE NOISE COMING FROM THE CYLINDER HEAD, BECAUSE OF LOW OIL PRESSURE WHICH IS CAUSED BY DEBRIS. *RM
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Description: MULTIPLE DRIVEABILITY SYMPTOMS OF LONG OR HARD STARTS, CHUGGLE, ROUGH IDLE AND LIGHT OR INTERMITTENT MISFIRE DUE TO CLOGGED FUEL INJECTORS. *TT
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Description: VEHICLE HESITATES, NO START, LACK OF POWER, LOW FUEL PRESSURE. *TT
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Description: ENGINE IDLE FLAIR WHEN CLUTCH DEPRESSED OR DECEL STALL. *TT
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Description: INTERMITTENT IDLE CONCERNS. *TT
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Description: ENGINE MISFIRE DUE TO INJECTOR FRETTING CORROSION. *TT
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Description: STALL, HESITATION, STUMBLE WITH NO DIAGNOSTIC TROUBLE CODES (DTCS). *TT
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Description: GUIDELINES FOR CYLINDER BORE LINER/PISTON SLEEVE REPLACEMENT ON THE L4 ECOTEC ENGINE. *TT
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Description: ENGINE STALL HESITATION STUMBLE WITH NO DIAGNOSTIC TROUBLE CODES (DTCS). *TT
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Description: EXCESSIVE OIL CONSUMPTION ON THE 2.2L L61 ECOTEC ENGINE. *TT
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Description: ENGINE MISFIRE POSSIBLE DIAGNOSTIC TROUBLE CODES (DTCS) P0300 - P0304. *TT
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Description: SERVICE ENGINE SOON/CHECK ENGINE LIGHT ILLUMINATED, MISFIRE OR ROUGHNESS, DIAGNOSTIC TROUBLE CODE (DTC) P0300 SET. *TT
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Description: SERVICE ENGINE SOON (SES) LIGHT AND SEVERE ENGINE MISFIRE ON CYLINDERS 1 AND 4 OR CYLINDERS 2 AND 3. *TT UPDATED 08-15-07. *KB
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Description: LOW OIL PRESSURE - INSPECT OIL FILTER FOR DAMAGE. *KB UPDATED 10/18/07. *NJ
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Description: INFORMATION ON TRANSFERRING ORIGINAL FUEL RAIL TO GOODWRENCH ENGINE. *AK
ENGINE AND ENGINE COOLING:COOLING SYSTEM
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Description: COOLANT LOSE, EVIDENCE FLUID ON THE GARAGE FLOOR, ETC., OR COOLANT WARNING LIGHT COMING ON. *TT
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Description: THIS VME MESSAGE IS A WATER PUMP REPLACEMENT DUE TO A KNOWN CAM DRIVELINE. SOME CUSTOMERS MAY QUESTION ABOUT WHINE NOISE COMING FROM THE FRONT ENGINE AREA. *TT
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
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Description: EXCESSIVE OIL CONSUMPTION AND/OR BLACK/BLUE SMOKE FROM THE EXHAUST. *TT
FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:FUEL RAIL
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Description: INFORMATION ON TRANSFERRING ORIGINAL FUEL RAIL TO GOODWRENCH ENGINE. *AK
FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:INJECTORS
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Description: CAR ISSUES - FIX IT RIGHT THE FIRST TIME (NEW ISSUES IN BOLD). TO INCLUDE 2006 AND 2007 MODELS. GM. TECH LINK. *TT
FUEL SYSTEM, OTHER
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Description: CRANK NO START, LOW OR NO FUEL PRESSURE. *TT
POWER TRAIN
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Description: 4T40E, 4T45E CHANGE IN APPEARANCE OF FORWARD, SECOND AND REVERSE CLUTCH WAVE PLATE. *TT
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Description: CLUNK NOISE FROM FRONT END DURING LOW SPEED TURNS OR MANEUVERS. *TT
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Description: TRANSMISSION SLIPS IN 4TH GEAR, STUCK IN 2ND GEAR OR SES/TCS LIGHT ILLUMINATED, DIAGNOSTIC TROUBLE CODES (DTCS) P0753, P0758, P1860, C1223, C1224 OR C1275 MAY BE SET. *TT
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Description: 2004 MODEL YEAR CHANGES FOR 4T40E AND 4T45E TRANSMISSIONS. *TT
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Description: 4T40E OR 4T45E WILL NOT SHIFT NO DIAGNOSTIC TROUBLE CODES. *TT
POWER TRAIN:CLUTCH ASSEMBLY
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Description: GRINDING/RATTLE NOISE WITH CLUTCH FULLY DISENGAGED. *TT
POWER TRAIN:CLUTCH ASSEMBLY:PEDAL/LINKAGE
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Description: CLUTCH PEDAL STAYS TO FLOOR. *TT
POWER TRAIN:MANUAL TRANSMISSION
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Description: GRIND NOISE FROM MANUAL TRANSMISSION WHEN CLUTCH IS RELEASED. *TT
POWER TRAIN:AUTOMATIC TRANSMISSION
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Description: INFORMATION ON 4T40-E (MN4) AND 4T45-E (MN5) FRONT WHEEL DRIVE AUTOMATIC TRANSMISSION VALVE BODY RECONDITIONING, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, HARSH SHIFTS, SLIPS, NO DRIVE, NO REVERSE. *NJ
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Description: TRANSAXLE OR TRANSMISSION SLIPS, WON'T SHIFT, NO REVERSE, 2ND, 3RD OR OVERDRIVE, ERRATIC SHIFTS. *TT
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Description: CLUNK NOISE FROM FRONT END DURING LOW SPEED TURNS OR MANEUVERS. THIS SERVICE BULLETIN REPLACES 030729005A. *EH
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Description: IF DEALERSHIP HAS A TRANSMISSION AXLE SEAL LEAK AND YOUR LOCATION IS WITHIN TWO HOURS DRIVING TIME OF DETROIT OR WINDSOR, PLEASE CALL THE WINDSOR LAB DUE FOR ENGINEERING WOULD LIKE TO EXAMINE THE VEHICLE PRIOR TO THE REPAIR OF THE LEAK. GM
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Description: AUTOMATIC TRANSMISSION POOR ACCELERATION, PERFORMANCE. *TT
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Description: M86/M94 TRANSMISSION INFORMATION TO DISASSEMBLE THIRD FOURTH AND FIFTH GEAR. *AK
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Description: VEHICLE WILL NOT MOVE IN EITHER DIRECTION. TRANSMISSION MAY SHOW OVER FULL. P90 4T40E 4T45E NO MOVEMENT DRIVE OR REVERSE. CONVERTER MAY BE EMPTY OF FLUID. *TT
ELECTRICAL SYSTEM
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Description: GENERAL MOTORS CORP: SPECIAL COVERAGE ADJUSTMENT; ANALOG ONSTAR DEACTIVATION. *PE UPDATED 2/17/09. *PE
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Description: SIR LIGHT ON, DIAGNOSTIC TROUBLE CODE B0036. *TT
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Description: SIR LIGHT ON AND A DIAGNOSTIC TROUBLE CODE B0036. *TT
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Description: 2003-2004 GENERATION 5 ONSTAR STEERING WHEEL CONTROL FUNCTION EXPLANATION. SIT BULLETIN 1416474. *TT
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Description: SIR LIGHT ON AND A DIAGNOSTIC TROUBLE CODE (DTC) B0036. *TT
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Description: DIAGNOSTIC TROUBLE CODES (DTCS) P0716, P0717. *TT
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Description: FALSE CODE B3785. SERVICE VME. *TT
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Description: THIS SERVICE VME MESSAGE CONCERNS A NUMBER OF VEHICLES EXPERIENCING INPUT SPEED SENSOR CODES P0716 AND 717. GM VOICEMAIL LOG. *TT
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Description: THE BODY CONTROL MODULE (BCM) MAY SET A FALSE CODE OF B3785. GM VOICEMAIL LOG. *TT
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
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Description: HESITATION ON ACCELERATION AFTER INTERNAL ENGINE REPAIRS - CHECK INJECTOR HARNESS ORIENTATION. *TT
ELECTRICAL SYSTEM:IGNITION
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Description: THE PURPOSE OF THIS MESSAGE IS TO PROVIDE INFORMATION ABOUT A NEW PRODUCT EMISSION RECALL. THE RECALL NUMBER OF 03042. THIS RECALL IS FOR VEHICLES IN DEALER INVENTORY ONLY. SOME OF THESE VEHICLES MAY HAVE BEEN BUILT WITH SPARKPLUGS THAT
ELECTRICAL SYSTEM: SOFTWARE
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Description: GENERAL MOTORS CORP: SPECIAL COVERAGE ADJUSTMENT; ANALOG ONSTAR DEACTIVATION. *PE UPDATED 2/17/09. *PE
VISIBILITY
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Description: CAR ISSUES - FIX IT RIGHT THE FIRST TIME (NEW ISSUES IN BOLD). TO INCLUDE 2006 AND 2007 MODELS. GM. TECH LINK. *TT
VISIBILITY:SUN ROOF ASSEMBLY
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Description: SUNROOF WILL NOT OPEN OR CLOSE COMPLETELY DUE TO THE SUNROOF MOTOR. *TT
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Description: SUNROOF SUPPLEMENTAL INFORMATION TO 03-08-67-009.*MR
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Description: JAMMED SUNROOF THAT WILL NOT OPEN OR A CLOSE COMPLETELY. GM VOICEMAIL LOG. *TT
VISIBILITY:REARVIEW MIRRORS/DEVICES:EXTERIOR
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Description: LEFT OUTSIDE BREAKAWAY MIRROR INOPERATIVE. *TT UPDATE. *TT
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Description: MIRROR VIBRATES AT HIGHWAY SPEEDS. *TT
VISIBILITY:DEFROSTER/DEFOGGER SYSTEM:WINDSHIELD:BLOWER
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Description: CAR ISSUES - FIX IT RIGHT THE FIRST TIME (NEW ISSUES IN BOLD). TO INCLUDE 2006 AND 2007 MODELS. GM. TECH LINK. *TT
VISIBILITY:DEFROSTER/DEFOGGER SYSTEM:WINDSHIELD:HEATER CORE
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Description: BINDING MODE VALVE-HVAC. *SC
SEAT BELTS
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Description: GM: THERE ARE SEAT BELT PROBLEMS: DIFFICULTY LATCHING AND UNLATCHING BUCKLE. BUCKLE RELEASE BUTTON IS STICKING. SEAT BELT WARNING LIGHT ILLUMINATED. LIKELY CAUSED BY STICKY BEVERAGES THAT ARE SPILLED INTO THE BUCKLE ASSEMBLY. *RM
SEAT BELTS:FRONT:RETRACTOR
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Description: INCORRECT PASSENGER SIDE REAR SEATBELT RETRACTOR WELD NUTS AND BOLT ATTACHMENT FASTENERS. THE SHEER STRENGTH OF THE INCORRECT FASTENER, WHICH WAS USED IN ERROR, IS BELOW THE SHEER FORCE REQUIRED BY FEDERAL MOTOR VEHICLE SAFETY STANDARDS 20
SEAT BELTS:FRONT:WARNING LIGHT/DEVICES
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Description: GM: THERE ARE SEAT BELT PROBLEMS: DIFFICULTY LATCHING AND UNLATCHING BUCKLE. BUCKLE RELEASE BUTTON IS STICKING. SEAT BELT WARNING LIGHT ILLUMINATED. LIKELY CAUSED BY STICKY BEVERAGES THAT ARE SPILLED INTO THE BUCKLE ASSEMBLY. *RM
SEAT BELTS:REAR
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Description: THE PASSENGER SIDE REAR SAFETY BELT MAY HAVE BEEN INSTALLED WITH AN INCORRECT NUT AND BOLT. NON-COMPLIANCE RECALL 04056. GM ADMINISTRATIVE MESSAGE. *TT
STRUCTURE
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Description: RIGHT FRONT SPEAKER RATTLE. *SC
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Description: SCREW MISSING FROM THE A-PILLAR CEILING STRIP FRONT DOOR AUXILIARY. *TT
STRUCTURE:BODY
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Description: LEFT DOOR MOLDING BINDS ON THE FENDER CLADDING. *TT
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Description: RIGHT FRONT SPEAKER RATTLE. *TT
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Description: RATTLE OR BUZZ FROM THE RIGHT FRONT SPEAKER. *TT
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Description: CARPET WET ON DRIVER'S SIDE. *TT
STRUCTURE:BODY:DOOR
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Description: LEFT FRONT DOOR MOLDING BINDS ON FENDER WHEN OPENING. *TT
VEHICLE SPEED CONTROL
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Description: HIGH IDLE WHEN CLUTCH IS DEPRESSED. *SC
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Description: SUPPLEMENT TO 05-06-01-003A - WRONG THROTTLE GASKET PART NUMBER. *TT
VEHICLE SPEED CONTROL:CRUISE CONTROL
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Description: CRUISE CONTROL SHUTS OFF WHEN THE HAZARDS ARE SWITCHED ON. *TT
EQUIPMENT
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Description: INFORMATION ON UPGRADING CERTAIN ONSTAR GENERATION 5 ANALOG/DIGITAL-READY SYSTEMS TO ONSTAR GENERATION 6 DUAL-MODE (ANALOG/DIGITAL). *TT
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Description: 99 THROUGH 05 YEAR VEHICLES, EQUIPPED WITH THREE-BUTTON ONSTAR SYSTEMS. *TT
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Description: 02-05 ONSTAR EQUIPPED VEHICLES EMITTING BEEPING NOISE BEFORE CONNECTING TO ONSTAR. *TT
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Description: CLARIFICATION OF SERVICE BULLETIN 02-08-44-012. CERTAIN STEPS IN THE SERVICE BULLETIN TO DISABLE OR ENABLE THE REMOTE KEYLESS ENTRY RADIO PERSONALIZATION FEATURE HAS BEEN DELETED IN THE TECH 2 SOFTWARE. CONCERN WILL BE UPDATED IN JULY REL
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Description: GENERATION 5 ONSTAR STEERING WHEEL CONTROL FUNCTION. *TT
EQUIPMENT:ELECTRICAL
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Description: BUICK\CADILLAC\CHEVROLET\GMC\HUMMER\OLDSMOBILE\PONTIAC\SAAB\SATURN SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. SPECIAL COVERAGE ADJUSTMENT-ANALOG ONSTAR DEACTIVATION. FCC RULED IN 2002 WIRELESS CARRIERS WOULD NO LONGER R
EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.
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Description: XM ERROR ON A RADIO DISPLAY. *TT
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Description: XM RADIO WAS WORKING PRIOR TO JULY 26, 2004 AND IT IS INOPERATIVE NOW. *JB
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Description: XM RAPID ACTIVATION UTILIZATION. *MR
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Description: XM RADIO MUST BE TUNED TO CHANNEL 1 THROUGH 66 DURING ACTIVATION ATTEMPT. 2004 CHEVROLET CANYON, GMC DENALI, GMC COLORADO ALSO INCLUDED. *TT
EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)
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Description: GENERAL MOTORS CORP: SPECIAL COVERAGE ADJUSTMENT; ANALOG ONSTAR DEACTIVATION. *PE UPDATED 2/17/09. *PE
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Description: ONSTAR CENTER UNABLE TO PERFORM REMOTE DIAGNOSTIC. (2004-2005 CHEVROLET YUKON, 2005 CHEVROLET TRAILBLAZER, 2002, 2003, 2005 BUICK RAINIER, 2005 CHEVROLET EXPRESS VAN, AND 2005 CADILLAC SEVILLE) *SC
EQUIPMENT:ELECTRICAL:AIR CONDITIONER
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Description: BINDING MODE VALVE-HVAC. *SC
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Description: HARD TO CHANGE HVAC MODE OR TEMPERATURE SETTINGS. *TT UPDATE. *AR
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Description: UNDERHOOD RATTLE OR GROWL NOISE WITH AIR CONDITIONER ON. *TT
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Description: HVAC MODE CONTROL HARD TO CHANGE SETTINGS. *TT
UNKNOWN OR OTHER
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Description: SOME CUSTOMERS MAY WANT TO TOW THEIR VEHICLE BEHIND ANOTHER VEHICLE WITH ALL FOUR TIRES ONT HE GROUND. THIS BULLETIN PROVIDES INFORMATION REGARDING RECREATIONAL (DINGHY) TOWING FOR CERTAIN VEHICLES INCLUDING 1988-2004 CHEVROLET AND GMC LI
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Description: PROGRAMMING ONSTAR MODULE FOR CANADIAN FRENCH VOICE RECOGNITION. *TT UPDATE. *TT UPDATED *EH
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Description: SERVICE ENGINE SOON LIGHT ON WITH DIAGNOSTIC TROUBLE CODES P0716 AND / OR P0717, P0730, P0753, P0758, P1860, P1887 OR OTHER MISCELLANEOUS TRANSMISSION TROUBLE CODES SET. *TT
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Description: SOME CUSTOMERS MAY WANT TO TOW THEIR VEHICLE BEHIND ANOTHER VEHICLE WITH ALL FOUR TIRES ONT HE GROUND. THIS BULLETIN PROVIDES INFORMATION REGARDING RECREATIONAL (DINGHY) TOWING FOR CERTAIN VEHICLES INCLUDING 1988-2004 CHEVROLET AND GMC LI
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Description: XM DEALER ASSISTANCE LINE INFORMATION. *TT
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Description: PARTS UPDATE - TIMING CHAIN TENSIONER DESIGN CHANGE. *KB