🏷️ Basic Information

Make:

Chevrolet

Model:

Tracker

Model Variant:

Chevy Tracker

Year:

2004

Platform Code:

GM Theta (Shared with Suzuki Grand Vitara XL-7)

👋 Introduction

Vehicle Segment:

Compact SUV / Crossover

Target Demographic:

Individuals seeking an affordable, capable, and relatively fuel-efficient small SUV for light off-roading, commuting, and general utility.

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra (early models), Mitsubishi Outlander.

Vehicle Highlights:

Available 4WD/AWD, compact size with surprising interior space, robust mechanicals shared with Suzuki, generally good value proposition.

Manual Value Proposition:

Empowers owners to perform a wide range of maintenance and repair tasks, saving significant costs associated with dealership or independent mechanic services. Provides step-by-step guidance with visuals.

📋 Manual Details

Primary Coverage:

Complete Service and Repair Procedures

Model Coverage:

All Models, Engines, Trim Levels, and Transmission Types

Estimated Page Count:

Likely 1000+ pages (typical for comprehensive workshop manuals)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Powertrain:

Engine Mechanical, Engine Fuel, Engine Cooling, Engine Lubrication, Engine Ignition, Emissions Control, Exhaust System

Drivetrain:

Transmission (Automatic & Manual), Transfer Case, Drive Axles, CV Joints, Driveshafts

Chassis:

Suspension (Front & Rear), Steering System, Brakes (Hydraulic & Parking), Wheels & Tires

Electrical:

Battery, Charging System, Starting System, Lighting System, Instrumentation, Body Control Modules, Powertrain Control Modules (PCM), ABS System, Airbag System, Audio System, HVAC Controls

Body:

Body Structure, Exterior Trim, Doors, Hood, Liftgate, Interior Trim, Seats, Glass, HVAC System

Maintenance:

Scheduled Maintenance Intervals, Fluid Changes (Oil, Coolant, Brake, Transmission, Differential), Filter Replacements, Lubrication Points

Diagnostics:

Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Symptom-Based Diagnostics, Electrical Schematics and Wiring Diagrams

Repair:

Component Removal and Installation, Major Component Overhaul (Engine, Transmission), System Repairs (Brakes, Suspension, Steering, Electrical)

Technical Specifications:

Torque Specifications, Tolerances, Alignment Data, Diagnostic Specifications

Body Repair:

Panel replacement, dent repair, glass replacement, bumper repair, door mechanism repair.

Interior Repair:

Seat repair/replacement, dashboard removal, center console disassembly, carpet replacement, headliner repair.

Lighting System Repair:

Headlight, taillight, turn signal bulb replacement, wiring harness troubleshooting for lighting circuits.

HVAC System Repair:

Heater core replacement, A/C compressor replacement, blower motor service, refrigerant recharge procedures, ductwork repair.

Wheel Tire Service:

Tire inspection, rotation, balancing, wheel alignment procedures, wheel bearing replacement.

Depth:

Comprehensive (from basic fluid changes to full engine and transmission rebuilds)

📊 Manual Specifications

Format:

PDF

Compatibility:

All PC & MAC Computers, Tablets, Smartphones

Required Software:

Adobe Reader (Free Download)

Printability:

Printable (Individual pages, chapters, or entire manual)

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

J20A (Commonly used)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

2.0 Liters (1998 cc)

Bore X Stroke:

84.0 mm x 90.0 mm

Compression Ratio:

9.5:1

Fuel Induction:

Multi-point Fuel Injection (MPI)

Horsepower:

Approx. 127 hp @ 5500-6000 RPM (Varies slightly by market/tune)

Torque:

Approx. 134 lb-ft @ 3000-4000 RPM (Varies slightly by market/tune)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approx. 15.1 gallons (57 Liters)

ECM Type:

GM Powertrain Control Module (PCM)

🔧 Transmission

Transmission Type Std:

5-Speed Manual

Transmission Type Opt:

4-Speed Automatic

Drivetrain Options:

Rear-Wheel Drive (RWD) / 4-Wheel Drive (4WD) with low range (on some models)

Manual Transmission Fluid:

GM Synchromesh or equivalent SAE 75W-90 GL-4 (Refer to manual for specific GM P/N)

Automatic Transmission Fluid:

Dexron-III / Dexron-VI (Refer to manual for specific GM P/N)

📐 Dimensions

Length:

Approx. 163.7 inches (4158 mm)

Width:

Approx. 66.7 inches (1694 mm)

Height:

Approx. 66.5 inches (1689 mm)

Wheelbase:

Approx. 98.4 inches (2500 mm)

Curb Weight:

Approx. 3000-3300 lbs (1360-1497 kg) depending on configuration

Gross Vehicle Weight Rating:

Approx. 4300-4500 lbs (1950-2041 kg)

🛡️ Safety Features

NHTSA Frontal Impact Driver:

4 Stars (for 2004 model year)

NHTSA Frontal Impact Passenger:

4 Stars (for 2004 model year)

NHTSA Side Impact Front Driver:

4 Stars (for 2004 model year)

NHTSA Side Impact Front Passenger:

4 Stars (for 2004 model year)

NHTSA Side Impact Rear Driver:

5 Stars (for 2004 model year)

NHTSA Side Impact Rear Passenger:

5 Stars (for 2004 model year)

ABS:

Standard on most models

Traction Control:

Available on some 4WD models

Airbags:

Frontal airbags standard. Side-impact airbags may be optional.

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player and up to 6 speakers. Auxiliary input may be available on higher trims.

Climate Control:

Manual HVAC controls, with optional automatic climate control on higher trims.

Cruise Control:

Standard on most models.

Onstar:

Available on select models.

🔧 Maintenance

Engine Oil Change:

Every 7,500 miles or 6 months (Synthetic Oil recommended), or 3,750 miles or 3 months (Conventional Oil or severe driving)

Engine Air Filter Replacement:

Every 15,000 - 30,000 miles (inspect more frequently)

Spark Plug Replacement:

Every 60,000 - 100,000 miles (depending on type, e.g., Iridium)

Transmission Fluid Change:

Automatic: Every 45,000 - 60,000 miles; Manual: Inspect periodically, change as needed or every 100,000 miles.

Engine Oil Specification:

SAE 5W-30 (API Service SG, SH, SJ, SL, SM, SN or ILSAC GF-3/GF-4 compliant)

Coolant Type:

GM P/N 12346290 (Orange, Dex-Cool) or equivalent OAT coolant

Brake Fluid Type:

DOT 3

Power Steering Fluid:

GM P/N 10503670 or equivalent Dexron-III ATF

Common Problems:

Catalytic converter issues, exhaust manifold leaks, minor electrical gremlins (window regulators, power locks), front suspension component wear (ball joints, tie rods), occasional power steering pump noise.

Rust Prone Areas:

Rear quarter panels, rocker panels, frame members (especially in rust-belt regions).

📚 Vehicle History

Chevrolet Legacy:

Chevrolet, a division of General Motors, has a long history in North America, known for a wide range of vehicles from trucks to sports cars.

Tracker Lineage:

The Tracker was originally a rebadged Suzuki Vitara, introduced in North America in the early 1990s. The 2004 model year represents the second generation, which became more sophisticated and shared the Theta platform with other GM and Suzuki vehicles.

Manufacturing Location:

Assembled in Ingersoll, Ontario, Canada (CAMI Automotive Inc.)

Production Span:

1989-2004 (First Gen), 2001-2004 (Second Gen under Chevrolet badge in North America)

🏆 Awards & Recognition

Typical Market Perception:

Often regarded as a value-oriented, capable compact SUV with respectable off-road potential for its class when equipped with 4WD. Praised for affordability and utility.

IIHS Status:

The Insurance Institute for Highway Safety (IIHS) ratings vary by year and specific test. The 2004 model generally performed moderately in frontal and side impact tests.