🏷️ Basic Information Identification Make: Chevrolet Model: Tracker Year: 2004 Codes Platform Code: GM M Platform (Second Generation) 👋 Introduction Market Position 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. Competitive Analysis Key Competitors 2004: Competed with vehicles like the Ford Escape, Honda CR-V, Toyota RAV4, Nissan Xterra, and Kia Sportage. Key Features 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 Coverage Areas 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 Page Count Estimated Page Count: Extensive (typical for dealership-level service manuals, likely 1000+ pages) Manual Type Manual Type: Factory Service and Repair Manual Language Language: English Format 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 Systems Covered 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). Procedures Included 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 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 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 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 Binding Type: N/A (Digital PDF, user prints as needed) Paper Type Paper Type: N/A (Digital PDF, user prints on desired paper) Software Requirements Software Requirements: Adobe Acrobat Reader (or compatible PDF viewer), WinZip (or compatible archive utility) Compatibility Operating System Compatibility: Windows (Vista32/64, XP, ME, 98, NT, 2000) and macOS ⚙️ Engine Specifications Primary Engine Engine Options 2004: 2.0L DOHC 16-valve inline-4 (J20A), and 2.5L DOHC 24-valve V6 (H25A) for higher...
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.
Competitive Analysis
Key Competitors 2004:
Competed with vehicles like the Ford Escape, Honda CR-V, Toyota RAV4, Nissan Xterra, and Kia Sportage.
Key Features
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.
Extensive (typical for dealership-level service manuals, likely 1000+ pages)
Manual Type
Manual Type:
Factory Service and Repair Manual
Language
Language:
English
Format
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
Systems Covered
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).
Procedures Included
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
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
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
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.
Windows (Vista32/64, XP, ME, 98, NT, 2000) and macOS
⚙️ Engine Specifications
Primary Engine
Engine Options 2004:
2.0L DOHC 16-valve inline-4 (J20A), and 2.5L DOHC 24-valve V6 (H25A) for higher trims.
Performance
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 System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Lubrication
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.
Cooling
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
Standard Transmission:
5-speed manual transmission (for 2.0L engine).
Optional
Optional Transmission:
4-speed automatic transmission (available for both 2.0L and 2.5L V6 engines).
Features
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
Exterior
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)
Weights
Curb Weight:
Varies by configuration, typically ranging from 3000-3400 lbs (1361-1542 kg).
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
The 2004 Tracker received 4-star ratings for the driver and front passenger in frontal impact tests from the NHTSA.
Active Features
Antilock Brakes:
Available ABS (Anti-lock Braking System) on all four wheels.
Passive Features
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
Infotainment
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.
Driver Assistance
Cruise Control:
Cruise control was available as an option or standard on higher trim levels.
Connectivity
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
Service Intervals
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.
Fluid Specifications
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.
Known Issues
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
Brand Heritage
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.
Model Evolution
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.
Production
Manufacturing Location:
The Chevrolet Tracker was primarily manufactured in Ingersoll, Ontario, Canada, by CAMI Automotive, a joint venture between General Motors and Suzuki.