20 Most Recent 1991 Pontiac Sunbird Questions & Answers

No access, the fuel tank must be removed to get the fuel pump module out.

1991 Pontiac... | Answered on Jul 13, 2017

PAN GASKET.. "fused"...

That IS interesting ... I guess you should count yourself
lucky IF the previous owner was NOT into EPOXY...
(your challenge will be cleaning or REPLACING those anomalies... back into a useable/serviceable state)

I'm a pure AMATEUR mechanic ... As far as N00-b

Asking questions is a GREAT START...

Haynes is okay... but if you plan on keeping this
I highly recommend you attempt to find FACTORY
workshop... or "professional" grade MANUALS...

Even sets... Like MOTORS Repair Manuals
will give excellent detail...

For you... the really GREAT news is: "Grand Am' GAUGES share in the same VINTAGE ("91 & '92)...

FREE TSBs (& wiring diagrams) ,
That I found in a brief look... number up to 28 on your

(twenty eight...
( "Fluctuations" are specifically mentioned))...
You won't "SEE" anything because there are mass-storage device software updates involved...

Contact references are given inside for DEALER TECHNICIANS to contact Harco Industries, attention Bob Early... and gives both a 513 prefix number
(Englewood, OH) and a toll-free 800-523-0203..

Estimated Update time was 0.2 hours in 1992

Free TSBs & drawings at BBB Industries (below)
Registration is required (BECAUSE these are
Real PROPRIEARY documents.

I hope this information at least encourages your interest..

On-Board-Diagnostic (standards)
Keep in mind that STANDARDIZED OBD... had not yet been achieved in 1992... Which will pretty much assures there are COMMUNITIES of INTEREST out there
that have ALREADY (I would think) come together... to share information.

If not... you have that OPTION...!

(I've always admired those Sunbirds)....

As far as N00B... Just be aware you should use tubing wrenches... on tubes, anti-seize compounds on dissimilar metal fasteners... Liquid Wrench on all dirty and old bolts.. Six point sockets ruin less bolts...

(fusing things is not a GREAT IDEA... Especially when you are the mechanic who you will be following... My
'66 Austin (big) Healey came out to California from Illinois in 1970... but not before SOMEBODY used pliers on a couple of obvious spots... Since then it has been pampered pretty well (including DOT 5 Castrol Brake Fluid).

Summary... use the right tool for the job...
(pliers & vise-grips are generally ALWAYS NOT the ""RIGHT-TOOLS")...

The very first things you want to check are the coolant and brakes... IMMEDIATE FLUID Change-out..

The only exotic tool you need to flush the brakes is a couple of cans of FRESH FLUID... and a friends foot to press & release on command.

Good luck with your new treasures
(I still have 4 out of production cars...
(three roadsters))... endless hours of entertainment!!)

Use AMAZON & eBay when looking for those SPECIAL parts... and get yourself some EXTRA gauge clusters... (soon

BBB Industries Premium Alternators Starters Power Steering Products

1991 Pontiac... | Answered on Mar 03, 2017

Hi Betty:
Just about all coolant reservoirs are connected to the top of the radiator at the filler neck, right under where the cap is located. There will be a stub that the rubber hose slides over. It is usually secured by a spring-type clip.
When the engine heats up, excess fluid is pused through the hose to the reservoir.
When the engine cools off, fluid is sucked back into the radiator through the tube.
Hope this helps.

1991 Pontiac... | Answered on Dec 30, 2015

1991 Pontiac Sunbird

One piece trim panel is used on styles with standard trim. The custom trim has an upper metal trim panel. The one piece trim hangs over the door inner panel across the top and is secured by clips down the sides and across the bottom. It is retained by screws located in the areas of the top front of the panel assembly.

Remove all door inside handles.

Removing a window crank handle (with a retaining clip inside the handle) without a special tool can be a problem. An alternative method is to take a clean shop towel and wedge it between the window crank handle and the door panel. Move it up, while pulling it from left to right, as in a sawing motion working the clean shop towel until the retaining clip comes free.

Remove the door inside locking rod knob.
Unfasten the screws inserted through the door armrest and pull the handle assembly into the door inner panel or armrest hanger support bracket.
On styles with remote control mirrors assemblies, disengage the end of the mirror control cable from the bezel on the standard trim, or from the upper trim panel on the custom trim. On custom trim, remove the upper trim panel.
On styles with power window or door lock controls located in the door trim panel, disconnect the wire harnesses at the switch assemblies. On the four door sedan and the two door hatchback, remove the switch cover by pushing down at the switch area and pulling down at the bottom of the cover. The switch and base may be removed from the trim with the cover removed.
Remove the remote control handle bezel screws.
Unfasten the screws used to hold the armrest to the inner panel.
Remove the screws and plastic retainers from the perimeter of the door trim using tool BT-7323A or equivalent and a screwdriver. To remove the trim panel, push the trim panel upward and outboard to disengage from the door inner panel at the beltline.
On styles with an insulator pad fastened to the door inner panel, use tool J-21104 or equivalent to remove the fasteners and the insulator pad.
On styles with the water defector held in place by fasteners, use tool BT-7323A or equivalent to remove the fasteners and the water deflector.
On styles with the armrest bracket riveted to the inner panel and installed over the water deflector, drill out the armrest bracket rivets using a 3 / 16 in. (5mm) drill bit.

Tilt the front edge of the glass downward to locate the glass in the door.
Apply pressure rearward and snap the glass rear guide into the rear run channel.
Lower the glass to about 3 in. (76mm) above the beltline and install the widow regulator roller to sash channel.
Run the glass to the full up position.
Place the front glass retainer in position and install the bolts.
Check the window to make sure it operates correctly, then install the remaining trim parts.

1991 Pontiac... | Answered on Jul 24, 2015

you can see if you can get a used one from the auto wreckers. repair a broken one is not advisable.

1991 Pontiac... | Answered on Jul 12, 2015


1991 Pontiac... | Answered on Jun 17, 2015

Probably not, but there is a very good chance that it will break the folding mechanism in one or more places.
I have installed tops for over 40 years and have seen that happen several times. It can happen even at speeds as low as 25 MPH.

Karl #aoksales

1991 Pontiac... | Answered on Jun 10, 2015

that will be the fuel pump you hear probably . quite possably the ecm has failed

1991 Pontiac... | Answered on Mar 17, 2015

What motor? Fuse is located in a different place on the 4cyl. vs. the V6. The four cylinder fuse is in the fuse box under the dash. The V6 engine the fuse is in a in line fuse holder next to the fuel pump relay under the hood, diverside rear at the firewall, there may be a plastic cover on the relay and fuse.

1991 Pontiac... | Answered on Sep 04, 2014

One of the power amps is probably shot in the radio. A trip to the salvage yard should get you a used one for little money.

Good Luck.. ...

1991 Pontiac... | Answered on Dec 05, 2013

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