PontiacSunfire2003Overview/pontiac/sunfire/2003/base/

2003 Pontiac Sunfire

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2003 Sunfire.

Body PASSENGER CARTransmission Automatic 4-spd

The 2003 Pontiac Sunfire is a passenger car equipped with an automatic four-speed transmission and a 5-quart oil capacity calling for 5W-30 API viscosity, with EPA ratings of 21 mpg city, 30 mpg highway, and 25 mpg combined. Positioned in the latter half of the nameplate's 1991-2005 production span, this model year accumulated 85 total owner complaints. That volume falls well below the 237 complaints marking the 1996 high point but exceeds the single complaint logged for 1991, with two recalls on record and exterior lighting standing as the top complaint area.

Model year200520042003200220012000199919981997

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5 qtOEM · verified
Engine oil type5W-30 APIOEM · verified
Lug nut torque100 ft-lbsOEM · verified
EPA fuel economy21/30/25 mpgEPA · 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 12580255. Note the factory fuel filter and front wiper blades are now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known.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 size1SC:P205-55R16OEM · verified

OE service part numbers OEM · verified

Engine oil filter12580255 alt 12605566
Engine air filter24577608
Fuel filter25121293 discontinued
Spark plug12681663
Battery88861746 alt 88865311
Front wiper blades22711468 discontinued · alt 22711469
Serpentine belt12634322 alt 12634320
Thermostat12622410 alt 24422922

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length185 in
Overall width68.5 in
Overall height53.1 in
Wheelbase103.9 in
Curb weight2771 lb
Track (front / rear)57.5 / 56.7 in
Weight distribution (front / rear)63/37

Ratings & economy EPA / vPIC

EPA city / highway / combined21 / 30 / 25 mpg
DrivetrainFront-Wheel Drive
Passenger volume92 cu ft
Cargo volume13 cu ft
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5 qt of 5W-30 API engine oil, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs, the oil drain plug to 18.0 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 Capacity5 qt
Power Steering FluidATF

Engine torques

Intake Manifold to Engine Bolts7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts9 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs
Engine Valve Cover Bolts7.4 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs
Front Wheel Hub144 ft-lbs

Ignition

Spark Plug ManufacturerAC Delco
Spark Plug Gap0.042 in
Spark Plug Torque15.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.50 lbs
Oil GroupPAG
Oil Type46
Oil Capacity5.00 oz
Standard BCI Group Number75
Standard BCI Cranking Performance525 cca

Service checks

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)50-60.0
RPM40-57 @ Idle rpm
Injector Primary Resistance11-14 na ohms
Engine Compression100

Brakes

Torque to Knuckle100 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 From0.796 in
Rotor Nominal Thickness To0.796 in
Rotor Minimum Machining0.739 in
Rotor Discard at or Under0.736 in

Multi-step torque procedures OEM · verified

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
174 ft. lbs., step 2: 7574 ft. lbs
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 100,000 miSpark Plug Wires (inspect) · Spark Plugs (replace)
At 150,000 miAccessory Drive Belt (inspect) · Engine 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 2003 Pontiac Sunfire sits in the mature, declining tail of this generation's complaint arc, which peaked dramatically in 1995–1997 with 225–237 complaints and 9–10 recalls annually before steadily tapering off. By 2003, complaints had settled to 85 — closely tracking 2001 (78) and 2002 (91) — while recalls held at a low and stable 2, matching both 2002 and 2004. However, investigations ticked up to 2 from zero the prior year, a modest but notable shift that breaks an otherwise quiet pattern. The top complaint areas — Exterior Lighting (16) and Electrical System (14) — dominate the profile, with 5 crash complaints and 2 fire complaints recorded; the federal data does not specify root causes for any of these. Meanwhile, TSBs continued their relentless climb from 375 in 2000 to 471 in 2003, indicating GM was still actively issuing technical service updates well into the generation's twilight. Taken together, the 2003 model year represents a relatively settled point in the Sunfire's lifecycle — complaint and recall volumes are low by historical standards — but the investigation uptick and persistent electrical/lighting complaints warrant a pre-purchase inspection focused on those systems; assuming that checks out, 2003 is a reasonable used buy within this generation.

2
Open recalls
NHTSA campaigns
471
Service bulletins
Manufacturer communications
2
ODI investigations
Office of Defects Investigation
85
Owner complaints
5 involved a crash · 2 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 85 complaints on record, top 8 components.

Exterior Lighting16
Electrical System14
Engine & Engine Cooling6
Service Brakes, Hydraulic6
Air Bags,Seat Belts2
Electrical System,Exterior Lighting2
Power Train2
Fuel System, Gasoline2

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.

04V524000Exterior Lighting:Turn SignalReported 01/11/2004

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… Remedy: DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY GREASE OR REPLACE THEM IF NECESSARY. THE RECALL BEGAN ON JANUARY 18, 2005. OWNERS SHOULD CONTACT CHEVROLET AT…

Technical service bulletins NHTSA · verified

Showing 5 of 471 bulletins on record with NHTSA.

BulletinDateComponentSummary
PIP5601C2025-07-18Unknown Or OtherThis PI communicates the requirement to provide a pico file to receive diagnostic…
23-NA-0012025-03-28Electrical SystemThis service bulletin provides information for dealers/technicians on OnStar Module 2G…
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…

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 2003 Sunfire take?

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

Does the 2003 Sunfire have open recalls?

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

What gas mileage does the Sunfire get?

EPA figures are 21 city / 30 highway / 25 combined mpg.