Warning: Do not smoke or allow an open flame of any type when working on or near any fuel system related components. highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Caution: Prior to disconnecting fuel lines, fuel system pressure must be relieved to prevent accidental spray of fuel.
After battery has been disconnected and connected, some abnormal driveability symptoms may occur. vehicle may require to be driven while vehicle relearns its adaptive strategy.
On models equipped with fuel injected engines, relieve fuel system pressure.
On models equipped with metal collar quick disconnect connectors, GM tool No. J37088-A, or equivalent, will be required to disconnect connector. Prior to connecting connector, apply a few drops of clean motor oil to male pipe ends.
On models equipped with plastic collar quick disconnect connectors, squeeze connector plastic retainer release tabs to release connector. Prior to connecting connector, apply a few drops of clean motor oil to male pipe end.
On all models, after completing fuel filter installation, start engine and ensure no fuel leakage is present.
Fuel Filter Location
The fuel filter on a 2003 Pontiac Sunfire is located on the underside of the vehicle. It is mounted inline on the fuel line between the gas tank and the engine fuel rail. Toward the rear of the vehicle between the rear bumper and rear axle.
Fuel Filter Removal
- Before servicing the vehicle, refer to the precautions section.
- Relieve the fuel system pressure.
- Remove the fuel filter from the fuel line using a back-up wrench on the filter.
- Grasp the filter and nylon connection line fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within the fitting. Disconnect the quick-connect fitting from the fuel filter.
- Remove the fuel filter from the bracket.
Fuel Filter Installation
- Before installing a new filter, always apply a few drops of clean engine oil to the male tube end of the filter and to the fuel sending unit assembly connection. This will help ensure proper connection and prevent possible fuel leaks. During normal operation, the O-rings located in the female connector will swell and may prevent proper connection if not lubricated.
- Install the fuel filter in the mounting bracket.
- Connect the quick-connect fitting to the fuel filter using the following procedure:
- Apply a few drops of clean engine oil to the male ends of the filter and the fuel sender assembly.
- Push the connectors together to cause the retaining tabs/fingers to snap into place.
- Once installed, pull on both ends of each connection to be sure they are secure.
4. Install or connect the following:
- New O-ring
- Fuel filter. Torque the fitting to 20 ft. lbs. (27 Nm).
- Negative battery cable
5. Pressurize the fuel system and verify no leaks.