🏷️ Basic Information

Make:

Chevrolet

Model:

Tracker

Year:

2004

Platform Code:

GM M Platform (Second Generation)

👋 Introduction

Market Position:

The Chevrolet Tracker, particularly in its second generation (introduced for the 2001 model year), was positioned as an affordable and practical compact SUV/crossover, often favored for its relatively fuel-efficient operation and maneuverability in urban environments. It shared its platform with the Suzuki Vitara/Grand Vitara, reflecting a strategic partnership.

Key Competitors 2004:

Competed with vehicles like the Ford Escape, Honda CR-V, Toyota RAV4, Nissan Xterra, and Kia Sportage.

Manual Value Proposition:

This manual offers dealership-level, vehicle-specific repair and maintenance information, providing technicians and owners with the exact data used in authorized service centers, thereby enabling accurate diagnostics, efficient repairs, and proper upkeep.

📋 Manual Details

Systems Covered:

Engine, Fuel System, Emission Control, Intake/Exhaust/Cooling, Lube, Ignition, Starting/Charging, Automatic Transmission, Clutch, Manual Transmission, Transfer Case, Drive Shaft, Differential, Axle, Suspension, Steering, Brakes, Parking Brake, Air Conditioning, Supplemental Restraint System (SRS), Seat Belts, Engine Immobilizer, Cruise Control, Wiper/Washer, Door Locks, Meter/Audio/Visual, Horn, Windshield/Glass/Mirrors, Instrument Panel, Seats, Engine Hood/Doors, Exterior/Interior, Electrical, Multiplex/CAN Communication

Estimated Page Count:

Extensive (typical for dealership-level service manuals, likely 1000+ pages)

Manual Type:

Factory Service and Repair Manual

Language:

English

Format:

Digital (PDF)

Printability:

Yes, all pages are printable, allowing users to create hard copies of specific sections for use in the workshop.

Zoom Capability:

Yes, PDF format allows for zooming in on diagrams and illustrations for greater detail.

📖 Manual Coverage

Engine Mechanical:

Detailed coverage of engine disassembly, assembly, timing, valve train, lubrication system, cooling system, and internal component specifications.

Fuel And Emission Control:

Comprehensive information on fuel injection systems, fuel pump, injectors, evaporative emission control (EVAP), and catalytic converter diagnostics.

Powertrain Control:

In-depth analysis of engine control module (ECM) functions, sensor inputs, actuator outputs, and diagnostic trouble codes (DTCs).

Transmission Drivetrain:

Includes detailed procedures for automatic and manual transmission service, clutch replacement, transfer case operation, drive shaft balancing, and differential overhaul.

Suspension Steering Brakes:

Covers suspension component replacement (shocks, struts, control arms), power steering system diagnostics, brake system overhaul (pads, rotors, calipers, ABS), and parking brake adjustment.

Electrical Diagnostics:

Extensive wiring schematics, fuse and relay locations, diagnostic procedures for various electrical circuits, and component testing for systems like lighting, power windows, and audio.

Body And Interior:

Procedures for body panel alignment, door and hinge adjustments, interior trim removal and installation, seat repair, and glass replacement.

HVAC Safety Systems:

Detailed diagnostics for air conditioning systems, refrigerant handling, supplemental restraint system (SRS) component replacement and calibration, and seat belt mechanisms.

Vehicle Identification Numbers:

The manual will likely include VIN decoding information and specific component identification numbers.

Wheel Alignment Specifications:

Includes necessary alignment angles (camber, caster, toe) and procedures.

Tire Pressure Specifications:

Recommended tire pressures for front and rear tires, along with load ratings.

Wheel Bolt Pattern:

Standard bolt pattern for the 2004 Tracker is typically 5x114.3mm (5x4.5 inches).

Maintenance Procedures:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacements, and spark plug service.

Diagnostic Procedures:

Step-by-step troubleshooting guides for identifying and resolving common and uncommon vehicle issues using diagnostic tools and methodologies.

Repair Procedures:

Complete, illustrated instructions for disassembling, repairing, and reassembling virtually every component of the vehicle.

Installation Procedures:

Guidance on installing aftermarket parts or replacing major components with new or remanufactured units.

Wiring Schematics Interpretation:

Detailed explanation of how to read and utilize the provided wiring diagrams for accurate electrical troubleshooting.

Troubleshooting Charts:

Comprehensive flowcharts and charts for diagnosing specific symptoms and fault conditions.

Technical Depth:

Factory-level, covering everything from basic maintenance to complex system diagnostics and complete component overhauls, suitable for professional technicians and advanced DIYers.

Torque Specifications:

Precise torque values for all critical fasteners, essential for proper assembly and preventing component damage.

Diagnostic Trouble Codes:

Detailed explanations of Diagnostic Trouble Codes (DTCs), their meanings, and the procedures to diagnose and clear them.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Searchable Text:

Yes, PDF format typically allows for text searching, enabling quick retrieval of specific topics or components.

Print Quality:

High-resolution, suitable for printing individual pages or sections with clear text and sharp diagrams/illustrations.

Illustration Quality:

High-quality, clear diagrams, illustrations, and schematics are a hallmark of factory service manuals.

Binding Type:

N/A (Digital PDF, user prints as needed)

Paper Type:

N/A (Digital PDF, user prints on desired paper)

Software Requirements:

Adobe Acrobat Reader (or compatible PDF viewer), WinZip (or compatible archive utility)

Operating System Compatibility:

Windows (Vista32/64, XP, ME, 98, NT, 2000) and macOS

⚙️ Engine Specifications

Engine Options 2004:

2.0L DOHC 16-valve inline-4 (J20A), and 2.5L DOHC 24-valve V6 (H25A) for higher trims.

2.0L Engine Performance:

Approx. 127 hp @ 6000 rpm, 134 lb-ft @ 3000 rpm (figures may vary slightly by region/specific tuning).

2.5L V6 Engine Performance:

Approx. 155 hp @ 6200 rpm, 160 lb-ft @ 4200 rpm (figures may vary slightly by region/specific tuning).

Fuel Delivery:

Electronic Fuel Injection (EFI)

Oil Capacity 2.0L Engine:

Approximately 4.5 US quarts (4.3 liters) with filter change. Specific oil type and viscosity grade (e.g., 5W-30) will be detailed in the manual.

Coolant Capacity:

Approximately 6.3 US quarts (6.0 liters) for 2.0L, 7.4 US quarts (7.0 liters) for 2.5L V6. Requires specific coolant type (e.g., Dex-Cool or equivalent).

🔧 Transmission

Standard Transmission:

5-speed manual transmission (for 2.0L engine).

Optional Transmission:

4-speed automatic transmission (available for both 2.0L and 2.5L V6 engines).

Drivetrain Options:

Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations. 4WD systems typically feature a 2-speed transfer case with part-time engagement.

📐 Dimensions

Wheelbase:

Approximately 103.2 inches (2621 mm)

Overall Length:

Approximately 169.1 inches (4300 mm)

Overall Width:

Approximately 66.7 inches (1694 mm)

Overall Height:

Approximately 66.1 inches (1679 mm)

Curb Weight:

Varies by configuration, typically ranging from 3000-3400 lbs (1361-1542 kg).

🛡️ Safety Features

NHTSA Front Impact Rating:

The 2004 Tracker received 4-star ratings for the driver and front passenger in frontal impact tests from the NHTSA.

Antilock Brakes:

Available ABS (Anti-lock Braking System) on all four wheels.

Airbags:

Standard front driver and passenger airbags. Side-impact airbags were optional on some trims.

Seat Belts:

All seating positions equipped with three-point seat belts. Pretensioners and load limiters for front occupants.

💡 Technology Features

Audio System:

Base models typically featured an AM/FM stereo with CD player. Higher trims may have offered premium sound systems with more speakers and auxiliary inputs.

Cruise Control:

Cruise control was available as an option or standard on higher trim levels.

Multiplex Can Communication:

The manual covers the multiplex/CAN communication systems, indicating the vehicle utilizes networked electronic modules for various functions, crucial for modern diagnostic procedures.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions. The manual will specify the exact interval based on GM's recommendations and the type of oil used.

Tire Rotation Interval:

Recommended every 5,000-7,500 miles (8,000-12,000 km) to ensure even wear.

Spark Plug Replacement Interval:

For the 2.0L engine, typically around 100,000 miles (160,000 km) if using iridium or platinum-tipped plugs. The manual will provide specific part numbers and intervals.

Engine Oil Specification:

The manual will specify the SAE viscosity grade (e.g., 5W-30) and API service classification (e.g., API SN or newer) required for optimal engine performance and protection.

Transmission Fluid Automatic:

Dexron-VI or equivalent automatic transmission fluid (ATF) is typically recommended. Capacity and change intervals will be detailed.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid is generally specified for most GM vehicles of this era.

Common Wear Items:

Typical wear items include brake pads and rotors, tires, suspension bushings, and exhaust components. The manual will guide on inspecting and replacing these.

Potential Engine Issues:

Some owners have reported oil consumption on higher-mileage engines, potential issues with oxygen sensors, and occasional ignition coil failures. The manual will provide diagnostic steps.

📚 Vehicle History

Chevrolet SUV Lineage:

Chevrolet's entry into the compact SUV market was a strategic move to capture a growing segment. The Tracker nameplate has a long history, originally derived from the Suzuki Vitara and sold under various GM brands globally.

Second Generation Tracker Introduction:

The second generation of the Chevrolet Tracker (which this manual covers) was a significant redesign introduced for the 2001 model year. It featured a unibody construction, a move away from the body-on-frame design of its predecessor, offering improved on-road comfort and handling.

Manufacturing Location:

The Chevrolet Tracker was primarily manufactured in Ingersoll, Ontario, Canada, by CAMI Automotive, a joint venture between General Motors and Suzuki.