2004 Chevrolet Tracker RWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Raise the fuel tank with a hydraulic jack to within approximately 31 cm (12 in) of the vehicle underbody.
  2. Connect the electrical connector (2) to the fuel tank sender assembly.
  3. Connect the electrical connector to the fuel tank pressure sensor.
  4. Connect the fuel tank breather hose to the fuel tank.
  5. Raise the fuel tank all the way to the vehicle chassis.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Secure the fuel tank to the vehicle chassis with the 2 straps (1) and the 4 bolts (2).

    Tighten:  Tighten the strap bolts to 35 N.m (26 lb ft).

    7. Fig 1: View Of Fuel Tank Straps & Bolts
    GM479567Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel tank shield to the vehicle chassis.
  8. Secure the fuel tank shield to the vehicle chassis with the 4 bolts (3).

    Tighten:  Tighten the bolts to 35 N.m (26 lb ft).

    9. Fig 2: Removing/Installing Oil pan
    GM55178Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel vapor hose (2) to the fuel vapor pipe.
  10. Connect the fuel return hose (1) to the fuel return pipe.
  11. Install the fuel filler hose to the fuel tank.
  12. Connect the vapor hose from the EVAP canister to the fuel tank.
  13. Connect the vapor hose from the EVAP canister air filter to the fuel tank.
    14. Fig 3: View Of Hoses & Clamps
    GM410904Courtesy of GENERAL MOTORS CORP.
  14. Connect the fuel feed inlet hose (2) to the fuel filter (1).
  15. Lower the vehicle.
  16. Refill the fuel tank.
  17. Inspect for fuel leaks.
  18. Connect the negative battery cable.
  19. Start the engine.
  20. Inspect for fuel leaks and repair as necessary.
    21. Fig 4: Locating Fuel filter
    GM410875Courtesy 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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