2004 Chevrolet Tracker RWDFACTORY OEM SERVICE PROCEDURE

Removal Procedure

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
    3. CAUTION: Refer to Vehicle Lifting Caution in Cautions and Notices.
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Disconnect the fuel feed inlet hose (2) from the fuel filter (1).
    5. Fig 1: Locating Fuel filter
    GM410875Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the fuel vapor hose (2) from the fuel tank.
  6. Disconnect the fuel return hose (1) from the fuel tank.
  7. Disconnect the fuel filler hose from the fuel tank.
    8. Fig 2: View Of Hoses & Clamps
    GM410904Courtesy of GENERAL MOTORS CORP.
  8. Remove the 4 bolts (3) and the fuel tank shield (4) from the vehicle.
    9. Fig 3: Removing/Installing Oil pan
    GM55178Courtesy of GENERAL MOTORS CORP.
  9. Support the fuel tank with a hydraulic jack.
  10. Remove the 4 bolts (2) and the 2 fuel tank straps (1) from the vehicle.
  11. Lower the fuel tank approximately 31 cm (12 in) from the vehicle chassis.
    12. Fig 4: View Of Fuel Tank Straps & Bolts
    GM479567Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the electrical connector (2) of the fuel tank sender assembly.
  13. Disconnect the electrical connector (3) from the fuel tank pressure sensor.
  14. Disconnect the vapor hose to the EVAP canister.
  15. Disconnect the vapor hose to the EVAP canister air filter.
  16. Continue to lower the fuel tank until the tank can be removed from the vehicle.
    17. Fig 5: View Of Electrical Connectors
    GM55172Courtesy 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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