Chevrolet Tracker 1999-2004 Factory Service Workshop Repair Manual
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🏷️ Basic Information Identification Make: Chevrolet Model: Tracker Years Covered: 1999-2004 Codes Product Code: CHEV-TRK-9904-SRM 👋 Introduction Market Position Target Audience: Ideal for DIY enthusiasts, independent repair shops, and Chevrolet Tracker owners seeking to perform their own maintenance and repairs. Competitive Analysis Comparison: This factory-level manual provides more detail and accuracy than generic aftermarket guides, mirroring the information used by dealership technicians. Key Features Dealer Equivalent: This is the identical service manual used by Chevrolet dealership technicians, offering unparalleled accuracy and completeness. Comprehensive Coverage: Covers every aspect of vehicle service and repair, leaving no stone unturned for effective maintenance and troubleshooting. Diy Friendly: Explicitly designed to empower 'Do It Yourself' owners with the knowledge needed to service their vehicles. 📋 Manual Details Coverage Areas General Information: Included Engine Mechanical System: Included Engine Electrical System: Included Emission Control System: Included Fuel System: Included Clutch System: Included Manual Transaxle System: Included Automatic Transaxle System: Included Driveshaft And Axle: Included Suspension System: Included Steering System: Included Restraint System: Included Brake System: Included Body Interior And Exterior: Included Body Electrical System: Included Heating Ventilation Air Conditioning: Included Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Workshop Repair Manual Language Language: English Format Format: PDF Searchable: Yes Printable: Yes Indexed: Yes 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed coverage of engine disassembly, inspection, repair, and reassembly for all applicable engine variants. Engine Electrical: Comprehensive diagnostic procedures, wiring diagrams, component testing, and troubleshooting for ignition, starting, charging, and sensor systems. Emission Control: Information on emissions testing, control systems (EGR, EVAP, O2 sensors), and diagnostic trouble codes related to emissions. Fuel System: In-depth procedures for fuel pump, injectors, fuel pressure regulator, fuel tank, and lines servicing, including diagnostic strategies. Drivetrain: Covers clutch operation, manual transmission overhaul, automatic transmission diagnostics and repair, driveshaft U-joints, and axle bearing service. Suspension Steering: Detailed procedures for shock absorbers, struts, control arms, ball joints, tie rods, power steering system, and wheel alignment specifications. Brakes: Complete coverage of brake pad and rotor replacement, caliper overhaul, master cylinder service, ABS system diagnostics, and parking brake adjustments. Body And Interior: Instructions for interior trim removal, exterior panel replacement, door and window mechanisms, and basic bodywork repair. HVAC: Procedures for air conditioning system servicing, heater core replacement, blower motor troubleshooting, and climate control system diagnostics. Procedures Included Maintenance: Oil and filter changes, fluid level checks and replacements, spark plug replacement, air filter replacement, coolant flushes. Diagnostics: Troubleshooting guides for common problems, diagnostic trouble code interpretation, and component testing procedures. Repair Overhaul: Detailed step-by-step instructions for engine, transmission, brake caliper, suspension component, and starter motor overhauls. Replacement: Replacement of worn or failed components such as fuel pumps, water pumps, alternators, CV joints, and exhaust systems. Adjustment: Procedures for clutch pedal adjustment, parking brake adjustment, and wheel alignment. Technical Depth Depth: Covers everything from basic DIY maintenance to complex engine and transmission rebuilds, providing a comprehensive resource for all skill levels. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Quality: High-resolution scans ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options 99 02: 2.0L L4 DOHC (X20SE), 2.5L V6 DOHC (LB6) Engine Options 03 04: 2.0L L4 DOHC (X20SED), 2.5L V6 DOHC (LB6 - phased out), 3.2L V6 DOHC (1GZ - rare) Performance 2.0L Horsepower: Approx. 127-130 hp (varies by year/tune) 2.5L V6 Horsepower: Approx. 177-180 hp Torque Figures: Detailed torque specifications for all engine fasteners provided in the manual. Fuel System Injection Type: Multi-port Fuel Injection (MPFI) Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Transmission Options: 5-Speed Manual Transmission, 4-Speed Automatic Transmission Optional Drivetrain Layout: Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations. Features Manual Transaxle Coverage: Detailed overhaul procedures, clutch replacement, shift linkage adjustment, and common failure point diagnosis. Automatic Transaxle Coverage: Includes transmission fluid service, filter replacement, solenoid testing, torque converter service, and rebuild procedures. 📐 Dimensions Exterior Wheelbase: Approx. 98.6 inches (2504 mm) Length: Approx. 165.3 inches (4198 mm) Width: Approx. 66.9 inches (1700 mm) Height: Approx. 63.5 inches (1613 mm) Weights Curb Weight: Varies by configuration, typically 3,000 - 3,400 lbs (1360 - 1542 kg) 🛡️ Safety Features Ratings NHTSA Ratings: Specific NHTSA ratings for this model year range should be verified; the manual covers relevant safety systems. Active Features ABS: Anti-lock Braking System (ABS) diagnostics and repair procedures are covered. Passive Features Airbags: Frontal airbag system servicing, component location, and SRS warning light troubleshooting. Seat Belts: Information on seat belt operation and inspection. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM stereo with CD player or cassette player options. Manual covers basic system diagnostics and speaker replacement. Driver Assistance ABS System: Details on the operation and troubleshooting of the Anti-lock Braking System are provided. Connectivity Wiring Diagrams: Comprehensive...
Ideal for DIY enthusiasts, independent repair shops, and Chevrolet Tracker owners seeking to perform their own maintenance and repairs.
Competitive Analysis
Comparison:
This factory-level manual provides more detail and accuracy than generic aftermarket guides, mirroring the information used by dealership technicians.
Key Features
Dealer Equivalent:
This is the identical service manual used by Chevrolet dealership technicians, offering unparalleled accuracy and completeness.
Comprehensive Coverage:
Covers every aspect of vehicle service and repair, leaving no stone unturned for effective maintenance and troubleshooting.
Diy Friendly:
Explicitly designed to empower 'Do It Yourself' owners with the knowledge needed to service their vehicles.
📋 Manual Details
Coverage Areas
General Information:
Included
Engine Mechanical System:
Included
Engine Electrical System:
Included
Emission Control System:
Included
Fuel System:
Included
Clutch System:
Included
Manual Transaxle System:
Included
Automatic Transaxle System:
Included
Driveshaft And Axle:
Included
Suspension System:
Included
Steering System:
Included
Restraint System:
Included
Brake System:
Included
Body Interior And Exterior:
Included
Body Electrical System:
Included
Heating Ventilation Air Conditioning:
Included
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Workshop Repair Manual
Language
Language:
English
Format
Format:
PDF
Searchable:
Yes
Printable:
Yes
Indexed:
Yes
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed coverage of engine disassembly, inspection, repair, and reassembly for all applicable engine variants.
Engine Electrical:
Comprehensive diagnostic procedures, wiring diagrams, component testing, and troubleshooting for ignition, starting, charging, and sensor systems.
Emission Control:
Information on emissions testing, control systems (EGR, EVAP, O2 sensors), and diagnostic trouble codes related to emissions.
Fuel System:
In-depth procedures for fuel pump, injectors, fuel pressure regulator, fuel tank, and lines servicing, including diagnostic strategies.
Drivetrain:
Covers clutch operation, manual transmission overhaul, automatic transmission diagnostics and repair, driveshaft U-joints, and axle bearing service.
Suspension Steering:
Detailed procedures for shock absorbers, struts, control arms, ball joints, tie rods, power steering system, and wheel alignment specifications.
Brakes:
Complete coverage of brake pad and rotor replacement, caliper overhaul, master cylinder service, ABS system diagnostics, and parking brake adjustments.
Body And Interior:
Instructions for interior trim removal, exterior panel replacement, door and window mechanisms, and basic bodywork repair.
HVAC:
Procedures for air conditioning system servicing, heater core replacement, blower motor troubleshooting, and climate control system diagnostics.
Procedures Included
Maintenance:
Oil and filter changes, fluid level checks and replacements, spark plug replacement, air filter replacement, coolant flushes.
Diagnostics:
Troubleshooting guides for common problems, diagnostic trouble code interpretation, and component testing procedures.
Repair Overhaul:
Detailed step-by-step instructions for engine, transmission, brake caliper, suspension component, and starter motor overhauls.
Replacement:
Replacement of worn or failed components such as fuel pumps, water pumps, alternators, CV joints, and exhaust systems.
Adjustment:
Procedures for clutch pedal adjustment, parking brake adjustment, and wheel alignment.
Technical Depth
Depth:
Covers everything from basic DIY maintenance to complex engine and transmission rebuilds, providing a comprehensive resource for all skill levels.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Quality:
High-resolution scans ensuring clarity of diagrams and text.
Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations.
Features
Manual Transaxle Coverage:
Detailed overhaul procedures, clutch replacement, shift linkage adjustment, and common failure point diagnosis.
Automatic Transaxle Coverage:
Includes transmission fluid service, filter replacement, solenoid testing, torque converter service, and rebuild procedures.
📐 Dimensions
Exterior
Wheelbase:
Approx. 98.6 inches (2504 mm)
Length:
Approx. 165.3 inches (4198 mm)
Width:
Approx. 66.9 inches (1700 mm)
Height:
Approx. 63.5 inches (1613 mm)
Weights
Curb Weight:
Varies by configuration, typically 3,000 - 3,400 lbs (1360 - 1542 kg)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Specific NHTSA ratings for this model year range should be verified; the manual covers relevant safety systems.
Active Features
ABS:
Anti-lock Braking System (ABS) diagnostics and repair procedures are covered.
Passive Features
Airbags:
Frontal airbag system servicing, component location, and SRS warning light troubleshooting.
Seat Belts:
Information on seat belt operation and inspection.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player or cassette player options. Manual covers basic system diagnostics and speaker replacement.
Driver Assistance
ABS System:
Details on the operation and troubleshooting of the Anti-lock Braking System are provided.
Connectivity
Wiring Diagrams:
Comprehensive electrical diagrams for all vehicle systems, crucial for diagnosing and repairing electronic components.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, depending on driving conditions. Refer to manual for specifics.
Transmission Fluid Interval:
Automatic: Every 50,000 - 60,000 miles (80,000 - 96,000 km). Manual: Inspect periodically.
Coolant Interval:
Initial change at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) or 5 years.
Fluid Specifications
Engine Oil Type:
API Service SG, SH, SJ or higher. Viscosity: SAE 5W-30 recommended for most climates (check manual for specific temperature ranges).
Automatic Transmission Fluid:
Dexron III/Mercon or equivalent.
Manual Transmission Fluid:
GL-4 Gear Oil, SAE 75W-90 or SAE 75W-85.
Coolant:
Ethylene Glycol based, 50/50 mix with distilled water. Orange or Dex-Cool compatible coolant may be specified.
Known Issues
Common Wear Items:
CV joints, tie rod ends, ball joints, catalytic converters (can be costly), power steering pumps.
Engine Performance:
Occasional issues with oxygen sensors, idle air control valves, and fuel injectors affecting performance and emissions.
Electrical Quirks:
Intermittent electrical issues related to body wiring harnesses and minor sensor failures can occur.
📚 Vehicle History
Brand Heritage
Chevrolet SUV Legacy:
Chevrolet has a long history of producing SUVs and trucks, with the Tracker representing a compact, car-based SUV offering.
Model Evolution
Tracker Platform:
The Chevrolet Tracker (this generation) is a rebadged version of the Suzuki Vitara/Grand Vitara, developed in partnership with Suzuki.
Production
Manufacturing Location:
Primarily manufactured by Suzuki in Japan and assembled in various global locations, including North America for some markets.
🏆 Awards & Recognition
Recognitions
Segment Popularity:
The Tracker was a popular choice in the compact SUV segment during its production years due to its affordability and capability.
Ratings
Owner Satisfaction:
Owner satisfaction varied, but the robust Suzuki-derived mechanicals generally provided good reliability when properly maintained, as detailed in this manual.