Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Pontiac Sunfire owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl contact owns a 1996 Pontiac Sunfire. Within a week of purchasing the vehicle, it began overheating. In addition, the headlights would remain illuminated when the vehicle was turned off, wiper fluid was leaking, and the muffler made a loud noise. The contact has not been able to reach the dealer since the vehicle was purchased. The failure mileage was 136,050. Updated 10/03/08 updated 10/06/08.
The vehicle was parked and the consumer noticed oil was leaking from underneath the vehicle. The consumer had taken the vehicle to the dealer for analysis and the mechanic noticed that the head gasket needed to be replaced due to deterioration. The vehicle had also been losing coolant for the past year and exhibited a coolant smell.
Head gasket on my 96 Pontiac Sunfire blew and caused my car to stall in traffic and almost caused an accident with my family aboard. My car went from 195 operating temp to 260 with in 1 minute. The car could have caught fire and caused tremendous injuries.
Engine runs hot at the very top of the gauge just before the over-heating mark on the gauge. Losing coolant. Car some times has trouble starting and back-fires. Water pump had to be replaced at 43,000 miles as it had a hole in it and was leaking. Oil leaks in several places, oil coming out of exhaust pipe, check engine light keeps coming on. Replaced gasket between the transmission and engine due leaks. Currently, the clutch sticks intermittently and I sometimes can't get the transmission to go into reverse. Had to replace high-pressure power steering pump due to leaks. Electrical system currently has a problem whereby I can't turn on the car alarm, the sensor alarms don't function right, drivers-side window only works intermittently and I've burned-out about 5 fues in six months. Driver's leather seats ripped at the sewed ribbing at around 15,000. …
-the horn on 1996 Pontiac Sunfire has quit working and been repaired three times. The people at the shop said that it was getting wet apparently everytime I went through water because of it being pointed downward. -the muffler has been fixed three times -there are more that I can not remeber right off hand -their is an electrical problem with the whole car. The light on the radio time and staion display has not worked since I bought it, the driver's rear door light has not come on, the passenger rear window lets down but will not let up when needed since right after I got the car, the lights in the dashboard go on and off without even being touched, while riding down the road, the widshield wipers will just come on without being turned on and then stop halfway down impairing vision, the passenger rear tail light blows all of the time, it has never stayed with a bulb that works, etc. …
Water pump leaking half gallon or more of fluid everyday, causing low coolant light to come on. Local dealer wanted 7 hours and $600.00 dollars or more to fix. Catalytic converter failed at accordian-like shock absorber at high speed. Was upset to learn that replacement part was dealer-only item and cost $420.00 dollars plus $40.00 dollar core charge. Wheel studs (three)on passenger side front wheel failed during highway trip in June of 1999. Two more failed during August of 2000. Have been told, could be overtightening issue, but have not had problem with remaining studs on other wheels. This could be very serious safety concern. Interior dome light has intermittent malfunction which causes light to remain lit indefinitely. Has happened several times. Had to turn light off by pulling dome light fuse or disconnecting battery each time.
The airbags have failed to deploy on two separate occasions and I have statements proving they should of. The fuel injectors damaged in the accident were fixed by newby auto 2 weeks later they were broken again they refused to redo them saying it wasn't the same one they fixed. They also refused to add an airbag check onto the estimate saying there wasnt enough damage to deploy them I have two other estimates totalling my car they refused to look at them and insisted it was OK and they would fix it unfortually they did not and it has had many problems since. Newby auto a Pontiac dealership was located in richfield utah at the time they had my car they are no longer in business in richfield.
At 72,000 miles the head gasket blew and the head was cracked. Only had the vehicle since February 1999. All previous recalls on vehicle were not handled by dealer before purchase. This information was discovered several months after purchase. Information obtained determined that GM recalled the quad 4 engine for previous vehicles 1992-93 due to the same problem with the engines. GMC refuses to accept blame. The repairs of the engine will cost $2,650.00 due to this problem.
Headlights go out intermittently while driving. This has been repaired numerous times, the problem is a splice in the wiring. The high beams were inoperative and the daytime running lights flashed while driving. The dealer replaced the instrument panel cluster. The vacuum actuator was sticking which caused the heater control not to blow on the setting selected. The mufflers hanger broke and the baffles were loose which caused rattling at idle.
I have constant problems with this vehicle. Major difficulty stopping when pavement is wet. My complet brake and rotors have been replaced on at least 3 occasions. I've also had problems with leaks, right rear window has been replaced. Problems with vibration when at a standstill, almost losing power. Smell of gas fumes. Problems with the transmission.
Engine complaints in other Sunfire years
Frequently asked questions
How common are engine problems on the 1996 Pontiac Sunfire?
NHTSA has 39 complaints about the engine & cooling of the 1996 Pontiac Sunfire, 19% of the model year's 201 complaints. The component named most often is engine (21 mentions).
Is there a recall for 1996 Pontiac Sunfire engine problems?
No. NHTSA lists no engine & cooling recall for the 1996 Pontiac Sunfire, though it has 7 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1996 Pontiac Sunfire engine problems start?
Half of the complaints with a recorded mileage happened before about 136,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.