2004 Chevrolet Tracker RWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install a new throttle body gasket (1) onto the intake collector (2).
    2. Fig 1: View Of Intake Collector & New Throttle Body Gasket
    GM675831Courtesy of GENERAL MOTORS CORP.
  2. Connect the breather hose (2) to the throttle body (3).
  3. Install the throttle body (3) onto the intake collector (1).
  4. Slide the intake collector (1) forward and attach to the intake manifold.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Secure the intake collector to the intake manifold with the 2 bolts and 4 nuts.

    Tighten:  Tighten the fasteners to 23 N.m (16 lb ft).

  6. Secure the throttle body to the intake collector with the 2 nuts and 2 bolts.

    Tighten:  Tighten the fasteners to 12 N.m (8.5 lb ft).

    7. Fig 2: View Of Intake Collector Throttle Body & Breather Hose
    GM675802Courtesy of GENERAL MOTORS CORP.
  7. Connect the accelerator control cable to the throttle body. Rotate the throttle lever (1) to WOT and insert the cable end into the slot (2).
  8. Connect the transmission throttle valve cable to the throttle lever.
  9. Adjust the transmission throttle valve cable as necessary. Refer to TV Cable Adjustment in Automatic Transmission.
  10. Adjust the accelerator control cable as necessary. Refer to Accelerator Cable Adjustment .
    11. Fig 3: View Of Throttle Lever & Throttle Lever Slot
    GM720512Courtesy of GENERAL MOTORS CORP.
  11. Connect the two coolant hoses (1, 3) to the throttle body (2).
  12. Connect the IAC air hose to the throttle body.
  13. Connect the TP sensor electrical connector.
  14. Connect the MAF sensor electrical connector.
    15. Fig 4: View Of Coolant Hoses & Throttle Body
    GM675822Courtesy of GENERAL MOTORS CORP.
  15. Connect the intake air inlet duct (4) to the throttle body.
  16. Secure the inlet duct with the hose clamp.
  17. Connect the intake surge tank (3) to the intake manifold.
  18. Secure the intake surge tank with four nuts (1).

    Tighten:  Tighten the nuts to 23 N.m (16 lb ft).

    19. Fig 5: View Of Air Inlet Ducts, Engine Surge Tank, Nuts & Fasteners
    GM674983Courtesy of GENERAL MOTORS CORP.
  19. Install the engine surge tank cover (1) and secure with the four fasteners.
    20. Fig 6: Identifying Top Of Engine Components
    GM648012Courtesy of GENERAL MOTORS CORP.
  20. Install the front suspension brace (1). Refer to Front Suspension Support Brace Replacement in Front Suspension.
  21. Refill the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
    22. Fig 7: View Of Front Suspension Support Brace
    GM674310Courtesy 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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