Chevrolet Chevy Tracker 1999-2004 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Chevrolet Model: Tracker Generation: Second Generation Model Years: 1999-2004 👋 Introduction Market Position Vehicle Segment: Compact SUV / Crossover Competitive Analysis Key Competitors: Jeep Wrangler, Toyota RAV4, Honda CR-V, Ford EcoSport, Nissan Xterra (depending on specific configurations and markets). Key Features Vehicle Type: Body-on-frame SUV with available 4WD, known for its ruggedness and off-road capability. 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive service, repair, and troubleshooting for Chevrolet Tracker 1999-2004 models. Page Count Estimated Pages: Hundreds (exact number not specified, but described as 'hundreds of pages'). Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, rebuild procedures, cylinder head, block, pistons, crankshaft, camshafts, timing components. Engine Management: Fuel injection system, ignition system, emission controls, engine control module (ECM) diagnostics and repair. Transmission Manual: Manual transmission overhaul, clutch system, shift linkage, gears, bearings, seals. Transmission Automatic: Automatic transmission overhaul, torque converter, valve body, planetary gear sets, seals, fluid service. Drivetrain: Driveshafts, universal joints, differential, axle shafts, hub bearings. Suspension: Front and rear suspension components, shock absorbers, struts, coil springs, control arms, ball joints, bushings, steering knuckles. Steering: Power steering system, steering column, steering gear or rack and pinion, tie rods, power steering pump and hoses. Brakes: Brake system hydraulics, front and rear disc/drum brakes, parking brake system, ABS (if equipped), brake fluid specifications. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, wiring diagrams, fuses, relays. Body And Chassis: Body construction, interior trim, exterior panels, doors, glass, hinges, latches, chassis frame, rust prevention. Heating And Air Conditioning: HVAC system components, refrigerant handling, blower motor, heater core, evaporator, compressor, climate control diagnostics. Restraint Systems: Airbag system (SRS) operation, diagnostic codes, seat belt mechanisms. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement. Troubleshooting: Diagnostic charts, symptom-based troubleshooting for all major systems, diagnostic trouble codes (DTCs) and their meanings. Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment for virtually all vehicle systems. Component Rebuild: Detailed procedures for overhauling engines, transmissions, and other major components. Wiring Diagrams: Comprehensive and detailed electrical wiring schematics for all vehicle circuits. Technical Depth Depth Of Information: Extremely detailed, covering from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics. Diagnostics: Advanced diagnostic procedures, including the use of scan tools and interpreting sensor data. Specifications And Tolerances: Precise torque specifications, measurements, clearances, and tolerances for all critical components. 📊 Manual Specifications File Format File Type: PDF Print Quality Printable: Yes, individual pages or the entire manual can be printed. Binding Type Digital Binding: Not applicable (digital download). Paper Type Digital Paper Type: Not applicable (digital download). Usability Multi Device Compatibility: Usable on unlimited computers, tablets, and smartphones. Licensing Licensing Terms: Full manual, no expiry, no renewal fees, for life. ⚙️ Engine Specifications Primary Engine Engine Type 1: 2.0L 16-valve DOHC I4 (J20A) Performance 1 Horsepower 1: Approx. 127 hp @ 6000 rpm (varies slightly by year/spec) Torque 1: Approx. 134 lb-ft @ 3000 rpm (varies slightly by year/spec) Fuel System 1 Fuel Delivery 1: Multi-point Fuel Injection (MPI) Primary Engine 2 Engine Type 2: 2.5L 24-valve DOHC V6 (H25A) Performance 2 Horsepower 2: Approx. 155 hp @ 6000 rpm (varies slightly by year/spec) Torque 2: Approx. 152 lb-ft @ 3500 rpm (varies slightly by year/spec) Fuel System 2 Fuel Delivery 2: Multi-point Fuel Injection (MPI) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission Features Drivetrain Options: Rear-Wheel Drive (RWD), 4-Wheel Drive (4WD) with available low-range gearing. 📐 Dimensions Exterior Length Length: Approximately 160-165 inches (depending on configuration). Exterior Width Width: Approximately 66.5 inches. Exterior Height Height: Approximately 65.5-67.5 inches (depending on configuration). Wheelbase Wheelbase: Approximately 97.5 inches. Weights Curb Weight: Approximately 2,800 - 3,200 lbs (depending on engine and drivetrain). 🛡️ Safety Features Ratings NHTSA Ratings: Information not readily available for specific model years, but typically rated for its class at the time. Active Features Active Safety: Anti-lock Braking System (ABS) - often optional or standard on higher trims. Passive Features Passive Safety Airbags: Driver and passenger front airbags. Passive Safety Seatbelts: Front and rear seat belts. 💡 Technology Features Infotainment Infotainment System: Basic AM/FM/CD or cassette player, with optional premium sound systems. Limited integration compared to modern vehicles. Driver Assistance Driver Assistance Features: Minimal by modern standards. Primarily focused on standard safety features and basic vehicle operation. Connectivity Connectivity Options: No factory Bluetooth or USB connectivity. Aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change Oil Change Interval: Every 3,000-5,000 miles or 3-6 months (consult manual for specific engine/oil type). Service Intervals Filters Air Filter Replacement: Every 15,000-30,000 miles or as needed based on driving conditions. Service Intervals Spark Plugs Spark...
Diagnostic charts, symptom-based troubleshooting for all major systems, diagnostic trouble codes (DTCs) and their meanings.
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment for virtually all vehicle systems.
Component Rebuild:
Detailed procedures for overhauling engines, transmissions, and other major components.
Wiring Diagrams:
Comprehensive and detailed electrical wiring schematics for all vehicle circuits.
Technical Depth
Depth Of Information:
Extremely detailed, covering from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics.
Diagnostics:
Advanced diagnostic procedures, including the use of scan tools and interpreting sensor data.
Specifications And Tolerances:
Precise torque specifications, measurements, clearances, and tolerances for all critical components.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printable:
Yes, individual pages or the entire manual can be printed.
Binding Type
Digital Binding:
Not applicable (digital download).
Paper Type
Digital Paper Type:
Not applicable (digital download).
Usability
Multi Device Compatibility:
Usable on unlimited computers, tablets, and smartphones.
Licensing
Licensing Terms:
Full manual, no expiry, no renewal fees, for life.
⚙️ Engine Specifications
Primary Engine
Engine Type 1:
2.0L 16-valve DOHC I4 (J20A)
Performance 1
Horsepower 1:
Approx. 127 hp @ 6000 rpm (varies slightly by year/spec)
Torque 1:
Approx. 134 lb-ft @ 3000 rpm (varies slightly by year/spec)
Fuel System 1
Fuel Delivery 1:
Multi-point Fuel Injection (MPI)
Primary Engine 2
Engine Type 2:
2.5L 24-valve DOHC V6 (H25A)
Performance 2
Horsepower 2:
Approx. 155 hp @ 6000 rpm (varies slightly by year/spec)
Torque 2:
Approx. 152 lb-ft @ 3500 rpm (varies slightly by year/spec)
Fuel System 2
Fuel Delivery 2:
Multi-point Fuel Injection (MPI)
🔧 Transmission
Standard Transmission
Type Standard:
5-speed Manual Transmission
Optional Transmission
Type Optional:
4-speed Automatic Transmission
Features
Drivetrain Options:
Rear-Wheel Drive (RWD), 4-Wheel Drive (4WD) with available low-range gearing.
📐 Dimensions
Exterior Length
Length:
Approximately 160-165 inches (depending on configuration).
Exterior Width
Width:
Approximately 66.5 inches.
Exterior Height
Height:
Approximately 65.5-67.5 inches (depending on configuration).
Wheelbase
Wheelbase:
Approximately 97.5 inches.
Weights
Curb Weight:
Approximately 2,800 - 3,200 lbs (depending on engine and drivetrain).
🛡️ Safety Features
Ratings
NHTSA Ratings:
Information not readily available for specific model years, but typically rated for its class at the time.
Active Features
Active Safety:
Anti-lock Braking System (ABS) - often optional or standard on higher trims.
Passive Features
Passive Safety Airbags:
Driver and passenger front airbags.
Passive Safety Seatbelts:
Front and rear seat belts.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM/CD or cassette player, with optional premium sound systems. Limited integration compared to modern vehicles.
Driver Assistance
Driver Assistance Features:
Minimal by modern standards. Primarily focused on standard safety features and basic vehicle operation.
Connectivity
Connectivity Options:
No factory Bluetooth or USB connectivity. Aftermarket solutions are common.
🔧 Maintenance
Service Intervals Oil Change
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (consult manual for specific engine/oil type).
Service Intervals Filters
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on driving conditions.
Service Intervals Spark Plugs
Spark Plug Replacement:
Approximately every 60,000-100,000 miles depending on plug type (e.g., platinum or iridium).
Fluid Specifications Engine Oil
Engine Oil Viscosity:
Typically 5W-30 or 10W-30 (consult manual for specific recommendations).
Fluid Specifications Coolant
Coolant Type:
Ethylene glycol-based coolant (e.g., Dex-Cool or equivalent).
Fluid Specifications Brake Fluid
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (consult manual).
Fluid Specifications Transmission Atf
Automatic Transmission Fluid Type:
Dexron III or equivalent (consult manual).
Known Issues
Common Issue Rust:
Rusting of the frame, body panels, and exhaust system, especially in areas with road salt.
Common Issue Engine Mounts:
Degradation of engine and transmission mounts leading to vibration.
Common Issue Cv Joints:
Wear in front Constant Velocity (CV) joints, particularly on 4WD models.
Common Issue Ac Compressor:
AC compressor failures or leaks can occur with age.
📚 Vehicle History
Brand Heritage
Chevrolet Heritage:
Chevrolet is a long-standing American automotive division of General Motors, known for a wide range of vehicles from trucks to passenger cars, with a focus on value and accessibility.
Model Evolution
Tracker Evolution 2Nd Gen:
The second generation (1999-2004) marked a significant redesign, moving from the older Geo Tracker platform. It adopted a more modern, rounded styling and was offered with more powerful engine options. While still a capable compact SUV, it became more refined for on-road comfort.
Production
Original Manufacturing Origin:
Primarily manufactured in Japan by Suzuki (for GM) and later in North America.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific awards for the 1999-2004 Tracker are not widely publicized. Its reputation is more for utility and value in the compact SUV segment.
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