Summary
The Pontiac Sunbird has 15 recalls spanning the 1977-1993 production run, with the most serious being a throttle cable defect on 1992-1993 four-cylinder models where water can freeze inside the cable conduit in cold weather, causing the throttle to stick open and the engine to stay at elevated speed when the driver lifts off the accelerator.
The final production years carry several other concerns as well. Also on 1992 models, the accelerator cable can be kinked during assembly, leading to a stiff pedal, a stuck throttle, or a snapped cable that eliminates throttle control entirely. A separate 1992 issue involves the secondary hood latch, which can be improperly installed or missing, leaving the hood held by only the primary latch; if that also fails to engage, the hood can fly up while driving. The 1993 model year has a compliance issue with the shoulder belt geometry on four-door models with manual seat adjusters, where the shoulder belt contact point falls outside the required zone when the seat is fully rearward. There is also a 1992 crankcase ventilation hose that can fail prematurely, causing excess emissions.
Going back to the early 1990s, 1991 models have a door frame striker stud that can fail in a crash, collapsing the door frame and reducing the shoulder belt's ability to restrain the occupant. The 1990 model year has a daytime running light module located near the battery that can overheat and start an engine compartment fire.
The late 1980s saw a pair of 1988 issues: a windshield bonding problem where poor adhesion can cause the glass to separate from the body in a frontal crash, and a rear lamp wiring harness with open or intermittent circuits that can cause backup lights or license plate lights to flash or go dark.
Earlier in the production run, 1985 models with the 2-liter engine have a plastic air cleaner cover that can come loose and fall onto the exhaust manifold, starting an engine compartment fire without warning. The 1980 model year has rear seat lap belt retractors that may not lock fully when buckled, leaving smaller occupants without adequate restraint in a crash. The 1979 model year carries two separate issues: a carburetor fuel hose on V6 engines that can be misrouted, contact the exhaust gas recirculation valve, rupture, and leak fuel near a heat source, and an oil pressure switch with an internal short that can cause the engine to start on its own when the ignition is switched to the on position, moving the vehicle if a gear is engaged. The earliest recall, covering the 1977 model year, involves front suspension movement that can deform the engine mount bracket until it contacts the steering linkage, making the steering wheel difficult to return to center after a sharp right turn.
