Chevrolet Chevy Tracker Complete Workshop Service Repair Manual 2002
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🏷️ Basic Information Identification Make: Chevrolet Model: Chevy Tracker Year: 2002 Generation Generation: Second Generation (1998-2005) Codes Platform: GM M Platform (shared with Suzuki Vitara) 👋 Introduction Market Position Segment: Compact SUV / Crossover Target Audience: DIY enthusiasts, independent repair shops, owners seeking to maintain their vehicles affordably. Competitive Analysis Key Competitors 2002: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester Key Features Value Proposition: Cost savings through self-repair, comprehensive coverage for all model variants, ease of use with step-by-step instructions. Manual Advantage: Empowers owners with the knowledge and procedures previously only available to professional technicians. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service, Repair, and Maintenance Procedures Secondary Coverage: Troubleshooting, Diagnostics, Electrical Schematics, Specifications Page Count Estimated Page Count: 1500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Delivery Format: Downloadable (PDF) Accessibility: Printable, Tablet/Smartphone Compatible 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system Drivetrain: Transmission (automatic & manual), Transfer case, Drive shafts, Axles, Differentials, CV joints Chassis: Steering system, Suspension system (front & rear), Brakes system (hydraulic & parking), Wheels and tires Electrical: Battery, Charging system, Starting system, Lighting system, Instrumentation, Wiper/Washer system, Power windows/locks, Audio system, HVAC controls, SRS (Airbag) system Body And Frame: Body panels, Doors, Hood, Liftgate, Bumpers, Interior trim, Seats, Glass, Chassis frame diagnostics and repair Procedures Included Maintenance: Scheduled maintenance, Oil change, Filter replacement, Fluid checks and changes, Spark plug replacement, Belt inspection and replacement Diagnostics: Troubleshooting guides for common symptoms, Diagnostic trouble codes (DTCs) interpretation, Component testing procedures Repair: Engine overhaul, Transmission rebuild, Brake component replacement, Suspension component replacement, Electrical component repair, Body panel repair Installation: Component installation (e.g., brakes, steering parts), Accessory installation guidance Specifications: Torque specifications, Clearances, Fluid capacities, Electrical resistance values, Diagnostic parameters Technical Depth Depth: Comprehensive A-Z coverage, from basic fluid checks to complete engine and transmission overhauls. Detail Level: Step-by-step instructions with accompanying diagrams and photographic illustrations. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Resolution: High-resolution scans ensuring clear text and images. Readability: Designed for clear reading on various screen sizes and for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: G16A (1.6L Inline-4 SOHC) Engine Code Optional: J20A (2.0L Inline-4 DOHC) Performance Horsepower 1.6L: 97 hp @ 5,400 rpm Torque 1.6L: 95 lb-ft @ 3,400 rpm Horsepower 2.0L: 127 hp @ 6,000 rpm Torque 2.0L: 134 lb-ft @ 3,000 rpm Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Optional Transmission Type Optional: 4-Speed Automatic Features Drivetrain Options: Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD) with low range 📐 Dimensions Exterior Wheelbase: 98.4 inches Length: 163.4 inches Width: 66.7 inches Height: 65.9 inches Weights Curb Weight Min: 2700 lbs Curb Weight Max: 3100 lbs 🛡️ Safety Features Ratings NHTSA Rollover Resistance Score: 3 out of 5 stars (for 4WD models) Active Features ABS: Available (Anti-lock Braking System) Passive Features Airbags: Driver and front passenger airbags Rollover Protection: Reinforced body structure, particularly in the roof and pillars. 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player (optional), 4-speaker system typical. Display: Basic digital clock/display for radio. Driver Assistance Cruise Control: Available on higher trim levels. Connectivity Connectivity Options: Basic, limited to audio system connectivity; no Bluetooth or USB standard. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 6 months (recommended). Air Filter Replacement: Every 15,000-30,000 miles or as needed based on driving conditions. Spark Plug Replacement: Every 60,000-100,000 miles depending on plug type (iridium recommended). Fluid Specifications Engine Oil Type: SAE 5W-30 (API Service SG, SH, SJ or higher) Engine Oil Capacity: 4.3 quarts (4.1 L) with filter for 1.6L; 4.8 quarts (4.5 L) with filter for 2.0L Transmission Fluid Type Auto: Dexron III/VI Automatic Transmission Fluid Transmission Fluid Type Manual: GL-4 Gear Oil (e.g., 75W-90) Coolant Type: Ethylene Glycol based, 50/50 mix with distilled water (GM specific colors may apply) Brake Fluid Type: DOT 3 Known Issues Common Complaints 1.6L: Occasional exhaust manifold cracks, weak valve stem seals leading to oil consumption. Common Complaints 2.0L: Rear main seal leaks, timing chain noise on higher mileage units. Common Complaints Drivetrain: CV joint boot wear, differential seal leaks, transfer case chain stretch. Common Complaints Chassis: Worn front suspension bushings and ball joints, rear shock absorber leaks. Common Complaints Electrical: Power window motor failure, alternator issues, corroded grounds. 📚 Vehicle History Brand Heritage Chevrolet SUV Lineage: Part of Chevrolet's expanding SUV and crossover offerings aimed at versatility and utility. Model Evolution Second Generation Design: Introduced a more modern, rounded styling compared to the first generation, with improved interior and safety features. Platform Sharing: Leveraged the robust platform...
Comprehensive A-Z coverage, from basic fluid checks to complete engine and transmission overhauls.
Detail Level:
Step-by-step instructions with accompanying diagrams and photographic illustrations.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Resolution:
High-resolution scans ensuring clear text and images.
Readability:
Designed for clear reading on various screen sizes and for printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
G16A (1.6L Inline-4 SOHC)
Engine Code Optional:
J20A (2.0L Inline-4 DOHC)
Performance
Horsepower 1.6L:
97 hp @ 5,400 rpm
Torque 1.6L:
95 lb-ft @ 3,400 rpm
Horsepower 2.0L:
127 hp @ 6,000 rpm
Torque 2.0L:
134 lb-ft @ 3,000 rpm
Fuel System
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual
Optional
Transmission Type Optional:
4-Speed Automatic
Features
Drivetrain Options:
Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD) with low range
📐 Dimensions
Exterior
Wheelbase:
98.4 inches
Length:
163.4 inches
Width:
66.7 inches
Height:
65.9 inches
Weights
Curb Weight Min:
2700 lbs
Curb Weight Max:
3100 lbs
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance Score:
3 out of 5 stars (for 4WD models)
Active Features
ABS:
Available (Anti-lock Braking System)
Passive Features
Airbags:
Driver and front passenger airbags
Rollover Protection:
Reinforced body structure, particularly in the roof and pillars.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player (optional), 4-speaker system typical.
Display:
Basic digital clock/display for radio.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Connectivity Options:
Basic, limited to audio system connectivity; no Bluetooth or USB standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months (recommended).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
Every 60,000-100,000 miles depending on plug type (iridium recommended).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API Service SG, SH, SJ or higher)
Engine Oil Capacity:
4.3 quarts (4.1 L) with filter for 1.6L; 4.8 quarts (4.5 L) with filter for 2.0L
Transmission Fluid Type Auto:
Dexron III/VI Automatic Transmission Fluid
Transmission Fluid Type Manual:
GL-4 Gear Oil (e.g., 75W-90)
Coolant Type:
Ethylene Glycol based, 50/50 mix with distilled water (GM specific colors may apply)
Brake Fluid Type:
DOT 3
Known Issues
Common Complaints 1.6L:
Occasional exhaust manifold cracks, weak valve stem seals leading to oil consumption.
Common Complaints 2.0L:
Rear main seal leaks, timing chain noise on higher mileage units.
Common Complaints Drivetrain:
CV joint boot wear, differential seal leaks, transfer case chain stretch.
Common Complaints Chassis:
Worn front suspension bushings and ball joints, rear shock absorber leaks.
Common Complaints Electrical:
Power window motor failure, alternator issues, corroded grounds.
📚 Vehicle History
Brand Heritage
Chevrolet SUV Lineage:
Part of Chevrolet's expanding SUV and crossover offerings aimed at versatility and utility.
Model Evolution
Second Generation Design:
Introduced a more modern, rounded styling compared to the first generation, with improved interior and safety features.
Platform Sharing:
Leveraged the robust platform of the Suzuki Vitara, indicating a focus on capability and proven engineering.
Production
Manufacturing Location:
Ingersoll, Ontario, Canada (shared production with Suzuki)
🏆 Awards & Recognition
Recognitions
Award Mention:
While specific awards for the 2002 Tracker are not prominent, it was generally seen as a competent entry in the compact SUV segment, appreciated for its affordability and capability, especially in 4WD configurations.