2004 Chevrolet Tracker RWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install the EGR valve with a new gasket to the intake collector.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Secure the EGR valve to the intake collector with the two retaining bolts.

    Tighten:  Tighten the bolts to 23 N.m (17 lb ft).

  3. Install the intake collector and the throttle body assembly to the intake manifold. Refer to Throttle Body Assembly Replacement .
  4. Install the exhaust gas recirculation (EGR) pipe (4).
  5. Connect the following hoses:
    • The PCV hose to the cylinder head cover (9)
    • The breather hose to the throttle body (6)
    • The EVAP canister purge valve hose (1)
    • The water hose (8)
    • The heater hoses (3, 5)
  6. Connect the following electrical connectors:
    • The manifold absolute pressure (MAP) sensor
    • The EVAP canister purge valve (1)
    • The exhaust gas recirculation (EGR) valve (2)
    7. Fig 1: Identifying Engine Components
    GM648002Courtesy of GENERAL MOTORS CORP.
  7. Install the clamp bracket (4) to intake collector.
  8. Install the ground terminal (5) to intake collector.
  9. Connect the following electrical connectors:
    • The throttle position (TP) sensor (2)
    • The mass air flow (MAF) sensor (1)
    • The idle air control (IAC) valve (3)
    10. Fig 2: Identifying TPS, MAF & IAC Connectors
    GM648017Courtesy of GENERAL MOTORS CORP.
  10. Install the engine surge tank cover (1) and secure with the four fasteners.
    11. Fig 3: Identifying Top Of Engine Components
    GM648012Courtesy of GENERAL MOTORS CORP.
  11. Install the front suspension brace (1). Refer to Front Suspension Support Brace Replacement in Front Suspension.
  12. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  13. Connect the negative battery cable.

    Tighten:  Tighten the bolt to 8 N.m (72 lb in).

    14. Fig 4: View Of Front Suspension Support Brace
    GM674310Courtesy of GENERAL MOTORS CORP.
Chapter Navigation
Return to Chapter: Exhaust Gas Recirculation (EGR) Valve Replacement
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.