2004 Chevrolet Tracker 4WDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install the fuel pipes (1) to the frame of the vehicle chassis.
  2. Secure the fuel pipes (1) with the retaining clamps (2).
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the rear driveshaft center support.

    Tighten:  Tighten the center support fasteners to 68 N.m (50 lb ft).

  4. Install the front exhaust pipe. Refer to Front Pipe Replacement (2.0L) in Engine Exhaust.
  5. Install the two post catalyst oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Position 2 .
  6. Connect the front driveshaft to the front differential.
  7. Install the right rear upper control arm. Refer to Rear Axle Upper Control Arm Replacement in Rear Suspension.
  8. Install the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  9. Install the fuel tank. Refer to Fuel Tank Replacement .
    10. Fig 1: View Of Fuel Pipes & Retaining Clamps
    GM55191Courtesy of GENERAL MOTORS CORP.
  10. Connect the fuel return hose (1) to the fuel return pipe by the fuel tank.
  11. Connect the fuel vapor hose (2) to the fuel vapor pipe by the fuel tank.
  12. Connect the fuel feed outlet hose at the fuel filter.
    13. Fig 2: View Of Hoses & Clamps
    GM410904Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel vapor hose (3) to the fuel vapor pipe at the engine compartment.
  14. Connect the fuel return hose (4) to the fuel return pipe at the engine compartment.
  15. Connect the fuel feed hose (1) to the fuel feed pipe at the engine compartment.
  16. Connect the retaining clamp (2) to the fuel pipes.
    17. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  17. Connect the negative battery cable.
    18. Fig 3: View Of Fuel Vapor, Fuel Return & Fuel Feed Hoses
    GM410880Courtesy of GENERAL MOTORS CORP.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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