What are the most common Pontiac Sunfire problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 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 2004 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.

Pontiac · Known Issues

2004 Pontiac Sunfire Problems: 1 Known Issue

2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated August 2026

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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 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.

2004 Pontiac Sunfire Problems: 1 Known Issue

All 1 Known Issue

2002-2005 Pontiac Sunfire: Sunfire 2.2L Ecotec (L61) Head Gasket / Head Crack#

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Frequently Asked Questions

What are the most common Pontiac Sunfire problems?

Is the Pontiac Sunfire reliable?

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

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