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2004 Pontiac Sunfire

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Sunfire.

Body PASSENGER CARTransmission Automatic 4-spd

The 2004 Pontiac Sunfire is a passenger car paired with a 4-speed automatic transmission and an engine requiring 5 quarts of 5W-30 API oil, returning EPA figures of 21 city, 31 highway, and 25 combined mpg. With 32 total owner complaints and 2 recalls on record, this model year ranks among the quieter entries in the Sunfire's 1991–2005 complaint history — far below the 1996 peak of 237 complaints — though the electrical system stands out as the area where owners most frequently reported trouble. That relatively low complaint volume places the 2004 near the tail end of the platform's run as one of its more settled years, suggesting that most major issues had been addressed by the time production was winding down.

Model year2005 2004 2003 2002 2001 2000 1999 1998 1997

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 economy21/31/25 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 Note the factory fuel filter and front wiper blades are now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known.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 filter	12580255 alt 12605566
Engine air filter	24577608
Fuel filter	25121293 discontinued
Spark plug	12681663
Battery	88861746 alt 88865311
Front wiper blades	22711469 discontinued · alt 22711468
Serpentine belt	12634322 alt 12634320
Thermostat	12622410 alt 03522676

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

Transmission

Automatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length	185 in
Overall width	68.5 in
Overall height	53.1 in
Wheelbase	103.9 in
Curb weight	2771 lb
Track (front / rear)	57.5 / 56.7 in
Weight distribution (front / rear)	63/37

Ratings & economy EPA / vPIC

EPA city / highway / combined	21 / 31 / 25 mpg
Drivetrain	Front-Wheel Drive
Passenger volume	92 cu ft
Cargo volume	13 cu ft
Recommended fuel	Regular 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

Automatic Transmission Fluid	ATF
Automatic Transmission Fluid Capacity	7
Brake Fluid	DOT 3
Engine Coolant	DEX-COOL OR EQUIVALENT
Engine Oil	5W-30 · API
Engine Oil Capacity	5 qt
Manual Transmission Fluid	ATF
Manual Transmission Fluid Capacity	3.6

Engine torques

Intake Manifold to Engine Bolts	7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	9 ft-lbs
Engine Oil Pan Drain Plug	18.0 ft-lbs
Engine Valve Cover Bolts	7.4 ft-lbs

Chassis torques

Lug Nuts	100 ft-lbs
Front Wheel Hub	144 ft-lbs

Ignition

Spark Plug Manufacturer	AC Delco
Spark Plug Gap	0.042 in
Spark Plug Torque	15.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	1.50 lbs
Oil Group	PAG
Oil Type	46
Oil Capacity	5.00 oz
Standard BCI Group Number	75
Standard BCI Cranking Performance	525 cca

Service checks

Pressure Test	15, Pressure should not exceed 20 psi.
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	185-205 °F
Fuel Pump Pressure Minimum	60.0 psi
Key ON Engine OFF (KOEO)	50-60.0
RPM	40-57 @ Idle rpm
Injector Primary Resistance	11-14 na ohms
Engine Compression	100

Brakes

Torque to Knuckle	100 ft-lbs
Minimum Pad Thickness	Front: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation	0.001 in
Rotor Runout Limit	0.002 in
Rotor Nominal Thickness From	0.796 in
Rotor Nominal Thickness To	0.796 in
Rotor Minimum Machining	0.739 in
Rotor Discard at or Under	0.736 in

Multi-step torque procedures OEM · verified

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages

74 ft. lbs., step 2: 75

74 ft. lbs

Cylinder Head — tightening sequence 3 stages

1	22 ft. lbs.	22 ft. lbs
2	155 degrees.	155 degrees
3	26

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 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate) · Underbody (inspect)
Every 30,000 mi	Engine Air Filter Element (replace)
Every 100,000 mi	Spark Plug Wires (inspect) · Spark Plugs (replace)
At 150,000 mi	Accessory 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 2004 Pontiac Sunfire sits at the lowest point of a long downward trend in federal complaints across its generation, dropping to just 32 complaints compared to the generation's peak of 237 in 1996. This represents a notable decline from the 85 complaints in 2003 and favorably outperforms the following 2005 model year, which saw complaints more than double to 68. For the 2004 model specifically, the Electrical System is the primary concern with 11 reported issues, though the data does not specify the root cause, followed by Structure and Exterior Lighting with 3 reports each. Positioned at the mature end of the product lifecycle with 461 technical service bulletins and zero federal investigations, the 2004 model reflects a thoroughly debugged platform where most early-generation defects had already been addressed. Given its historically low complaint volume and favorable position within the generation's reliability arc, the 2004 Sunfire is a comparatively strong used purchase, provided you have the electrical system specifically inspected for unspecified faults.

Open recalls

NHTSA campaigns

461

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

Owner complaints

3 involved a crash · 1 a fire

Owner complaints by model year NHTSA · this generation & adjacent

’91 ’94 ’95 ’96 ’97 ’98 ’99 ’00 ’01 ’02 ’03’04’05

Owner complaints filed with NHTSA, by component

All 32 complaints on record, top 8 components.

Electrical System11

Structure3

Exterior Lighting3

Unknown Or Other2

Engine & Engine Cooling2

Engine & Engine Cooling,Electrical System2

Electrical System,Vehicle Speed Control,Engine1

Steering,Electrical System,Service Brakes1

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.

04V300000Seat Belts:Rear/OtherReported 23/06/2004

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. Remedy: DEALERS ARE TO INSPECT THE SAFETY BELT ANCHORAGE AND INSTALL A NEW NUT AND BOLT, IF NECESSARY. THE RECALL BEGAN ON AUGUST 23, 2004. OWNERS SHOULD CONTACT CHEVROLET AT…

Technical service bulletins NHTSA · verified

Showing 5 of 461 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
PIP5601C	2025-07-18	Unknown Or Other	This PI communicates the requirement to provide a pico file to receive diagnostic…
23-NA-001	2025-03-28	Electrical System	This service bulletin provides information for dealers/technicians on OnStar Module 2G…
PIP5358D	2025-02-19	Unknown Or Other	This Preliminary Information communication provides information to the technician about…
PIP4723J	2024-10-25	Electrical System	This Preliminary Information communicates to the dealer the process for downloading or…
PIT5099H	2024-09-12	Unknown Or Other	This 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.

Group 75 battery Vehicles taking 5 qt Engine oil filter 12580255 Engine air filter 24577608 Fuel filter 25121293 Spark plug 12681663

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 2004 Sunfire take?

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

Does the 2004 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 / 31 highway / 25 combined mpg.