2004 Chevrolet Tracker RWDFACTORY OEM SERVICE PROCEDURE

Removal Procedure

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
    2. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  2. Disconnect the negative battery cable.
  3. Disconnect the fuel vapor hose (3) from the fuel vapor pipe at the engine compartment.
  4. Disconnect the fuel return hose (4) from the fuel return pipe at the engine compartment.
  5. Disconnect the fuel feed hose (1) from the fuel feed pipe at the engine compartment.
  6. Disconnect the retaining clamp (2) from the fuel pipes.
    7. CAUTION: Refer to Vehicle Lifting Caution in Cautions and Notices.
  7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    8. Fig 1: View Of Fuel Vapor, Fuel Return & Fuel Feed Hoses
    GM410880Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the fuel return hose (1) from the fuel return pipe by the fuel tank.
  9. Disconnect the fuel vapor hose (2) from the fuel vapor pipe by the fuel tank.
  10. Disconnect the fuel feed outlet hose from the fuel filter.
  11. Disconnect the retaining clamps that secure the fuel pipes to the vehicle chassis.
  12. Remove the fuel tank. Refer to Fuel Tank Replacement .
  13. Remove the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  14. Remove the upper control arm from the right side of the rear suspension. Refer to Rear Axle Upper Control Arm Replacement in Rear Suspension.
  15. Disconnect the front driveshaft from the front differential.
  16. Remove the two post catalyst oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Position 2 .
  17. Remove the front exhaust pipe. Refer to Front Pipe Replacement (2.0L) in Engine Exhaust.
  18. Remove the center support bolts for the rear driveshaft (vehicles with two piece driveshafts only), and shift the center support to the left side.
  19. Remove the fuel lines.
    20. Fig 2: View Of Hoses & Clamps
    GM410904Courtesy 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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