Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

2004 Chevrolet Tracker RWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

Install the EGR pipe (5) with a new upper gasket (2) to the intake collector (1).

NOTE: Refer to Fastener Notice in Cautions and Notices.

Secure the EGR pipe (5) to the intake collector (1) with the 2 fasteners.
Tighten: Tighten the fasteners to 15 N.m (11 lb ft).
Install the EGR pipe (5) with a new gasket (3) to the exhaust manifold (4).
Secure the EGR pipe (5) to the exhaust manifold with the 2 fasteners.
Tighten: Tighten the fasteners to 15 N.m (11 lb ft).
Install the fastener to the EGR pipe bracket.
Tighten: Tighten the fastener to 10 N.m (88 lb in).
Start the engine and check for exhaust leaks.
Repair as necessary.

Fig 1: View Of EGR Pipe, Intake Collector, Bank 2 Exhaust Manifold, Upper & Lower Gasket

Courtesy 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.