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Pontiac · Known Issues

2002 Pontiac Sunfire Problems: 1 Known Issue

2002 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Pontiac Sunfire has 1 documented issue, with 1 rated critical. The most serious is Sunfire 2.2L Ecotec (L61) Head Gasket / Head Crack ($1,000-$2,500 repair). Across all issues with published estimates, repair costs range from $1,000 to $2,500. DIY maintenance guides at au7o.io.

In This Article

  • Sunfire Engine1
  • Recalls4
  • FAQ
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In This Article

  • Engine1
  • Recalls4
  • FAQ

All 1 Known Issue

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ALL YEARS2005200420032002

On the 2002-2005 Pontiac Sunfire 2.2L L61 Ecotec, the first-generation 2.2L Ecotec L61 in 2002-2005 Sunfire (and Cobalt, Cavalier, Saturn Ion) is prone to head gasket failure and cylinder head cracking — particularly if overheated once. Aluminum head warps easily. Often presents as bubbles in coolant reservoir, white smoke, and overheating.

This issue also affects: Buick Lucerne, Cadillac CT5, Cadillac DeVille

Common Symptoms

  • white smoke
  • overheating
  • bubbles in coolant
  • milky oil
  • rough idle after warm-up

How to Fix

Pressure-test cooling system to confirm. Head gasket replacement ~$1,000-$1,800 — but ALWAYS have the head pressure-tested and resurfaced (~$150-$250 machine shop) since cracking is so common. If head is cracked, a used head is often the most economical replacement ($200-$400 from yard). Driving while overheating destroys the head; tow it.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Fel-Pro HS 26223 PT-1 cylinder-head gasket set

    2002-2005 Pontiac Sunfire 2.2L DOHC Ecotec L61; head bolts are not included and the listing requires TCS46041. Fitment/availability: Fourteen in stock and add-to-cart live at review

    PartsGeek
  • Replacement 698-001 fourteen-piece L61 head-bolt set

    2002-2005 Pontiac Sunfire 2.2L DOHC Ecotec L61; includes ten long and four short bolts and interchanges with ES72196/HB32201. Not ES72170.

    PartsGeek
  • Fel-Pro TCS 46041 timing-cover gasket set

    2002-2005 Pontiac Sunfire 2.2L L61; verify production details and contents against the removed timing-cover seals.

    Newparts.com

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$1,000 - $2,500

Research This Issue

GoogleRedditYouTubeNHTSA
Manually Verified
Medium Confidence
NHTSA Recalls4 recalls

STEERING

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" BRAND NAME), AND PLATINUM PARTS #'S 2425151, 2425152, AND 2425153 MANUFACTURED DURING THE MONTH OF SEPTEMBER 2007. THESE REPLACEMENT STEERING SHAFTS CAN BE USED ON THE VEHICLES LISTED ABOVE. THE WELD CONNECTING THE INNER TUBE TO THE OUTER TUBE MAY BE DEFECTIVE.

Campaign #08E06300017/10/2008

FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY:PRESSURE RELIEF DEVICES

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 REGULATORS (UPR) WERE PRODUCED WITHOUT AN O'RING AND RETAINER.

Campaign #07E02100012/03/2007

SEAT BELTS:REAR/OTHER

CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, 'SEAT BELT ASSEMBLY ANCHORAGES.' THE PASSENGER-SIDE REAR SAFETY BELT MAY HAVE BEEN INSTALLED WITH AN INCORRECT NUT AND BOLT.

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Frequently Asked Questions

What are the most common Pontiac Sunfire problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Pontiac Sunfire has 1 documented issue. The documented issue is: Sunfire 2.2L Ecotec (L61) Head Gasket / Head Crack. Of these, 1 is rated critical and should be addressed promptly.

Is the Pontiac Sunfire reliable?

The 2002 Pontiac Sunfire has 1 known issue compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: Sunfire 2.2L Ecotec (L61) Head Gasket / Head Crack. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Pontiac Sunfire problems?

Repair costs for known Pontiac Sunfire issues range from $1,000 to $2,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Sunfire 2.2L Ecotec (L61) Head Gasket / Head Crack, typically costs $1,000-$2,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2002-2005 Pontiac Sunfire Sunfire 2.2L Ecotec (L61) Head Gasket / Head Crack?

The first-generation 2.2L Ecotec L61 in 2002-2005 Sunfire (and Cobalt, Cavalier, Saturn Ion) is prone to head gasket failure and cylinder head cracking — particularly if overheated once. Aluminum head warps easily. Often presents as bubbles in coolant reservoir, white smoke, and… Repairs typically run $1,000-$2,500. Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

Campaign #04V30000023/06/2004

EXTERIOR LIGHTING:TURN SIGNAL

ON CERTAIN PASSENGER VEHICLES, THE REAR LAMPS THAT PROVIDE STOP AND TURN SIGNALS AND TAIL LAMP FUNCTIONS STOP WORKING BECAUSE OF INADEQUATE CONTACT BETWEEN THE BULB AND SOCKET. IN ADDITION, IF ONE BULBS WERE TO BECOME INOPERATIVE WHILE THE VEHICLE WAS OPERATING IN CRUISE CONTROL, THE CRUISE CONTROL WOULD DISENGAGE WHEN THE REMAINING BULB WAS ACTIVATED. IF BOTH LAMPS WERE TO BECOME INOPERATIVE, THE CRUISE CONTROL WOULD NOT ENGAGE.

Campaign #04V52400001/11/2004

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