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    Chevrolet Tracker 1999-2004 Service Repair Manual

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    The Chevrolet Tracker, produced from 1999 to 2004, represents the second generation of this compact SUV, built on the GM M Platform. Known for its affordability, maneuverability in urban environments,...
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    Art.-Nr: 104801
    The Chevrolet Tracker, produced from 1999 to 2004, represents the second generation of this compact SUV, built on the GM M Platform. Known for its affordability, maneuverability in urban environments, and the availability of a four-wheel-drive system, the Tracker offered practical cargo space and relatively simple mechanics, making it a competitive option in its segment. Its engineering quality and reliability were designed to provide dependable service for everyday use and light off-road adventures. This comprehensive factory service manual is designed to assist owners, independent repair shops, and professional mechanics in maintaining and repairing the Chevrolet Tracker. It covers a wide array of systems, including detailed procedures for powertrain components, chassis, body, and electrical systems. The manual provides in-depth guidance on scheduled maintenance, repair and rebuild processes, and diagnostic troubleshooting, complete with hundreds of illustrations and wiring diagrams to ensure accurate and efficient service.
    🏷️ Basic Information
    Identification
    Make:
    Chevrolet
    Model:
    Tracker
    Years Covered:
    1999-2004
    Generation
    Generation Designation:
    Second Generation (GM M Platform)
    Codes
    Platform Code:
    GM M Platform
    👋 Introduction
    Market Position
    Segment:
    Compact SUV / Sport Utility Vehicle
    Competitive Analysis
    Key Competitors:
    Honda CR-V, Toyota RAV4, Ford Escape, Jeep Wrangler (though more focused on off-road capability), Suzuki Vitara/Sidekick.
    Key Features
    Vehicle Strengths:
    Affordability, compact size for urban maneuverability, available 4x4 (4WD) system, practical cargo space for its class, relatively simple mechanicals.
    Manual Benefit:
    Empowers owners to perform maintenance and repairs themselves, saving money and ensuring proper vehicle upkeep.
    📋 Manual Details
    Coverage Areas
    Market Focus:
    North America (USA, Canada)
    Page Count
    Estimated Page Count:
    Varies by specific manual edition, but typically comprehensive over 1000 pages.
    Manual Type
    Type:
    Factory Service Manual (FSM) / Workshop Manual
    Target Audience:
    DIY Enthusiasts, Independent Repair Shops, Professional Mechanics.
    Language
    Language:
    English
    Format
    Format:
    Digital Download (PDF)
    📖 Manual Coverage
    Systems Covered
    Powertrain:
    Engine mechanical, fuel system, lubrication, cooling, emission controls, exhaust system, ignition system, starting and charging system, automatic transmission, manual transmission, clutch, transfer case, drive shafts, differentials, axles, suspension (front and rear), brakes (hydraulic and parking), steering.
    Chassis And Body:
    Body and frame, exterior trim, interior trim, HVAC system, power steering, climate control, supplemental restraint system (SRS), seat belts, windshield wipers and washers, door locks, power windows, mirrors, instrument panel, audio/visual systems, horn.
    Electrical And Diagnostics:
    Wiring diagrams, electrical schematics, diagnostic procedures, troubleshooting guides, multiplex communication systems, engine immobilizer, cruise control.
    Body And Interior:
    Includes procedures for door panel removal, seat adjustment mechanisms, instrument cluster replacement, airbag system servicing (with safety precautions), and HVAC component access.
    Procedures Included
    Maintenance:
    Scheduled maintenance, fluid changes, filter replacements, lubrication, inspection procedures.
    Repair And Rebuild:
    Complete disassembly and reassembly of major components (engine, transmission, differentials, brakes, steering), component replacement, body repair, interior system repair.
    Diagnostics:
    Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs), electrical system diagnostics, fuel system diagnostics, engine performance diagnostics.
    Troubleshooting Electrical System:
    Yes, includes detailed wiring diagrams and troubleshooting trees for diagnosing electrical faults.
    Tire And Wheel Service:
    Includes tire pressure recommendations, wheel torque specifications, and basic alignment procedures/specifications.
    Technical Depth
    Depth:
    Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, detailed electrical diagnostics, and bodywork.
    Diagnostic Tools Guidance:
    Provides guidance on using scan tools for OBD-II diagnostics and troubleshooting specific system faults.
    Diagrams And Illustrations:
    Hundreds of detailed illustrations, drawings, and photos, including exploded views and wiring diagrams.
    📊 Manual Specifications
    File Format
    Format:
    PDF
    Print Quality
    Printability:
    Yes, all pages are printable.
    Binding Type
    Binding:
    N/A (Digital Download)
    Paper Type
    Paper Type:
    N/A (Digital Download)
    ⚙️ Engine Specifications
    Primary Engine
    Engine Displacement And Type:
    2.0L DOHC Inline-4 (J20A)
    Performance
    Horsepower Range:
    Approximately 127-135 hp @ 6000 rpm (depending on year and specific configuration)
    Torque Range:
    Approximately 134-137 lb-ft @ 3000-3200 rpm
    Fuel System
    Fuel Delivery:
    Electronic Multi-Point Fuel Injection (MPI)
    Engine Code
    Engine Code:
    J20A
    Engine Variants
    Engine Option 2 0L:
    2.0L Suzuki J20A DOHC 16-valve inline-4
    Engine Option 2 5L:
    2.5L DOHC V6 (For select markets/trims)
    Engine Option V6:
    2.5L V6 (155 hp @ 6000 rpm, 153 lb-ft @ 4000 rpm) - less common, primarily for North American market, often associated with the Grand Vitara platform.
    🔧 Transmission
    Standard
    Transmission Type Std:
    5-Speed Manual
    Optional
    Transmission Type Opt:
    4-Speed Automatic
    Features
    Drivetrain Options:
    Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD) with selectable or full-time options.
    📐 Dimensions
    Exterior
    Length:
    Approx. 165.5 inches
    Width:
    Approx. 66.7 inches
    Height:
    Approx. 64.6 inches
    Wheelbase:
    Approx. 97.2 inches
    Weights
    Curb Weight:
    Approx. 2,800 - 3,200 lbs (depending on configuration)
    🛡️ Safety Features
    Ratings
    NHTSA Rollover Resistance Rating:
    3-star (for 4WD models, as rated by NHTSA for certain years within the range).
    Active Features
    ABS:
    Available (often standard on higher trims or later models)
    Passive Features
    Airbags:
    Driver and front passenger airbags
    Seat Belts:
    Front and rear seat belts
    💡 Technology Features
    Infotainment
    Audio System:
    Factory AM/FM/CD player, often with optional cassette player or premium speaker system.
    Driver Assistance
    Cruise Control:
    Available on most trims.
    Connectivity
    Power Accessories:
    Power windows, power door locks, power mirrors often available on higher trims.
    🔧 Maintenance
    Service Intervals
    Oil Change Interval:
    Typically every 3,000 to 5,000 miles or 3-6 months, depending on driving conditions and oil type used.
    Engine Coolant Flush:
    Every 30,000 to 50,000 miles or 2-3 years.
    Transmission Fluid Change:
    Automatic: Every 30,000 to 50,000 miles. Manual: Inspect periodically, change as needed or at higher mileage intervals (e.g., 60,000 miles).
    Fluid Specifications
    Engine Oil Type:
    API Service SM or higher, SAE 5W-30 or 5W-40 (refer to manual for exact specification based on climate).
    Coolant Type:
    GM DEX-COOL® or equivalent (Orange/Pink OAT coolant), typically a 50/50 mix with distilled water.
    Transmission Fluid Automatic:
    ATF Type T-IV or equivalent (Dexron III/VI may be acceptable depending on specific ATF type and manufacturer recommendation).
    Brake Fluid Type:
    DOT 3 or DOT 4 brake fluid.
    Power Steering Fluid Type:
    GM Power Steering Fluid or equivalent DEXRON®-III ATF.
    Known Issues
    Common Problems Engine:
    Occasional oil leaks, catalytic converter failure, ignition coil issues, minor cooling system leaks.
    Common Problems Suspension Steering:
    Worn ball joints, tie rod ends, and bushings due to its lightweight SUV design and potential off-road use. Steering rack leaks can occur.
    Common Problems Electrical:
    Window regulator failures, power lock actuator issues, interior light failures, occasional sensor failures (e.g., ABS sensor).
    Common Problems Drivetrain:
    U-joint wear in 4WD models, differential seals leaking.
    📚 Vehicle History
    Brand Heritage
    Chevrolet Brand History:
    Founded by Louis Chevrolet and Billy Durant in 1911, General Motors' flagship brand, known for a wide range of vehicles from economical sedans to performance trucks and sports cars.
    Model Evolution
    Tracker Origin:
    The Chevrolet Tracker (North American market) was a rebadged version of the Suzuki Vitara/Sidekick, produced as part of a joint venture between GM and Suzuki. This second generation continued that relationship.
    Tracker Name Usage:
    The 'Tracker' name was used by GM for various rebadged Suzuki SUVs globally, including in the US and Canada.
    Production
    Manufacturing Locations:
    Primarily manufactured in Ingersoll, Ontario, Canada (by CAMI Automotive) and Japan (for Suzuki-sourced components/models).
    🏆 Awards & Recognition
    Recognitions
    General Market Perception:
    Generally regarded as a practical, no-frills compact SUV offering good value for its price point, particularly for those needing light off-road capability or all-wheel drive.
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