GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Tracker - 4WD 🢒 Engine 🢒 Engine Mechanical - 2.5L (LE8) 🢒 Engine Replacement

Tools Required

    • J 36854 Heavy Duty Automotive Engine Stand
    • J 35271 Fly Wheel Holder

Removal Procedure
  1. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls.

    2. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  2. Disconnect the negative battery cable.
  3. Remove the hood from the vehicle. Refer to Hood Replacement in Body Front End.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    5. Object Number: 479353 Size: SH
  5. Remove the front skid plate (5) from the vehicle, if equipped.
  6. Drain the engine oil.
  7. Drain the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    8. Object Number: 465595 Size: SH
  8. Remove the automatic transmission fluid cooler lines (1) from the radiator. Cap the open lines to prevent leakage.
  9. Lower the vehicle.
  10. Remove the radiator. Refer to Radiator Replacement in engine cooling

    11. Object Number: 648013 Size: SH
  11. Disconnect the accelerator cable (2).
  12. Disconnect the A/T throttle cable (1).

    13. Object Number: 464748 Size: SH

    Important: The vehicle should be supported on a hoist prior to removing the strut tower brace. This will facilitate removal and installation of the brace.

  13. Remove the 6 bolts and the strut tower brace. Refer to Front Suspension Support Brace Replacement in Front Suspension.

    14. Object Number: 648012 Size: SH
  14. Remove the 4 screws and the surge tank cover (1).
  15. Disconnect the intake air temperature (IAT) sensor connector.
  16. Remove the 4 nuts from the surge tank pipe (3).
  17. Remove the air cleaner upper case, the intake air hose, the intake air pipe (2) and the surge tank pipe (3) as an assembly.

    18. Object Number: 711377 Size: SH
  18. Remove the 1 bolt (1) and the engine oil level indicator and tube (2).
  19. Remove the 1 bolt and the transmission fluid level indicator and tube.
  20. Remove the ignition coil covers.

    21. Object Number: 648018 Size: SH
  21. Disconnect the injector wire connector (1).
  22. Disconnect the brake booster vacuum hose (2).

    23. Object Number: 648017 Size: SH
  23. Disconnect the following electrical connectors:
    24. • The camshaft position sensor (CMP)
    • The 6 ignition coils
    • The throttle position (TP) sensor (2)
    • The mass air flow (MAF) sensor (1)
    • The idle air control (IAC) valve (3)
    • The ground wires (5) from the surge tank
  24. Remove the clamp bracket (4)

    25. Object Number: 648007 Size: SH
  25. Disconnect the following electrical connectors:
    26. • The EVAP canister purge valve (4)
    • The exhaust gas recirculation (EGR) valve (5)
    • The oxygen sensor
    • The coolant temperature sensor
    • The generator wires
    • The starter wires
    • The oil pressure switch wire
    • The power steering pressure switch wire
    • The ground wire from the generator bracket
  26. Remove the clamp brackets (6)

    27. Object Number: 648002 Size: SH
  27. Disconnect the following hoses:
    28. • The heater hose (3) from the heater water pipe
    • The heater hose (5) from the water outlet cap
    • The EVAP canister hose from the canister pipe

    Object Number: 648007 Size: SH
  28. Remove the idle air control (IAC) valve (1).
  29. Remove the EVAP canister purge valve (4).

    30. Object Number: 648087 Size: SH
  30. Disconnect the fuel feed hose (1) from the fuel feed pipe.
  31. Disconnect the fuel return hose (2) from the fuel return pipe
  32. Remove the EVAP canister.
  33. Remove the 3 bolts and the power steering pump from its bracket and position aside.

    34. Object Number: 467823 Size: SH

    Important: Do not discharge the A/C system nor remove the refrigerant lines from the compressor.

  34. Remove the 3 bolts (1) and the A/C compressor, if equipped, from its bracket and position aside.
  35. Remove the 4 bolts and the A/C compressor bracket, if equipped. Refer to Compressor Mounting Bracket Replacement in HVAC Systems Manual.
  36. Remove the lower steering shaft assembly. Refer to Lower Steering Shaft Assembly Replacement in Steering Wheel and Column.
  37. Raise the vehicle
  38. Remove the front axle housing, 4WD only. Refer to Front Axle Housing Replacement in Front Drive Axle.
  39. Remove the front exhaust pipe. Refer to Front Pipe Replacement in Engine Exhaust.
  40. Remove the exhaust manifold bracket from the transmission.
  41. Remove the transmission fluid hose clamps from the engine mounting bracket.
  42. Remove the flywheel cover.

    43. Object Number: 648084 Size: SH
  43. Remove the torque converter bolts on automatic transmission equipped vehicles. Use a screwdriver in order to lock the flywheel.
  44. Remove the 2 bolts and the starting motor. Refer to Starter Motor Replacement in Engine Electrical.
  45. Lower the vehicle.
  46. Support the transmission.

    47. Object Number: 648081 Size: SH
  47. Remove the 4 bolts and 2 nuts that fasten the transmission to the cylinder block.
  48. Install an engine hoist to the engine.

    49. Object Number: 648079 Size: SH
  49. Remove the 2 nuts from the top side of the engine mounts.

    50. Important: Before lifting the engine, ensure that all of the hoses, pipes, electrical wires and cables are disconnected from the engine and positioned aside.

  50. Remove the engine assembly from the vehicle by sliding the assembly toward the front side of the engine compartment. Carefully lift the engine assembly from the vehicle verifying clearance on all sides.

Installation Procedure
  1. Install the engine hoist.
  2. Remove the engine assembly from the J 36854 .

    3. Notice: Apply the proper amount of the sealant to the fastener when assembling this component. Excessive use of the sealant can prohibit the component from being assembled properly or allow the fastener to loosen. A component or fastener that is not assembled properly can loosen or fall off leading to extensive engine damage.

  3. Align the flywheel-to-engine marks and install the flywheel (3).

    4. Object Number: 470436 Size: SH
  4. Apply GM P/N 12345493 (Canadian P/N 10953488), or the equivalent, to the flywheel retaining bolt threads.

    5. Object Number: 477523 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  5. Install the flywheel retaining bolts to the crankshaft. Use the J 35271 to lock the flywheel.

    6. Tighten
    Cross tighten the 8 flywheel retaining bolts to 70 N·m (51 lb ft).

  6. Install the engine assembly. Lower the engine into the front of the engine compartment while ensuring clearance on all sides, slide the assembly rearward.

    7. Object Number: 648079 Size: SH
  7. Install the engine mount nuts.

    8. Tighten
    Tighten engine mount nuts to 50 N·m (37 lb ft).

  8. Remove the engine hoist.

    9. Object Number: 648081 Size: SH
  9. Install the 4 bolts and 2 nuts that fasten the transmission to the cylinder block.

    10. Tighten
    Tighten the bolt and nuts to 80 N·m (58 lb ft).

  10. Raise the vehicle.

    11. Object Number: 648084 Size: SH
  11. Install the torque converter bolts. Use a screwdriver in order to lock the flywheel.

    12. Tighten
    Tighten the torque converter bolts to 65 N·m (47 lb ft).

  12. Install the flywheel cover.
  13. Install the starting motor. Refer to Starter Motor Replacement in Engine Electrical.
  14. Install the transmission fluid hose clamps to the engine mounting bracket.
  15. Install the exhaust manifold bracket to the transmission.
  16. Install the front exhaust pipe. Refer to Front Pipe Replacement in Engine Exhaust.
  17. Install the front axle housing, 4WD only. Refer to Front Axle Housing Replacement in Front Drive Axle.
  18. Install the lower steering shaft assembly. Refer to Lower Steering Shaft Assembly Replacement in Steering Wheel and Column.
  19. Install the 4 bolts and the A/C compressor bracket, if equipped. Refer to Compressor Mounting Bracket Replacement in HVAC Systems Manual.

    20. Tighten
    Tighten the compressor bracket bolts to 55 N·m (40 lb ft).


    Object Number: 467823 Size: SH
  20. Install the A/C compressor, if equipped. Secure with the 3 bolts (1).

    21. Tighten
    Tighten the compressor mounting bolts to 23 N·m (17 lb ft).

  21. Install the power steering pump to its bracket. Secure with the 3 bolts.

    22. Tighten
    Tighten the power steering pump mounting bolts to 25 N·m (19 lb ft).

  22. Install the power steering pump drive belt. Refer to Drive Belt Replacement - Air Conditioning Compressor and Power Steering
  23. Install the EVAP canister.

    24. Object Number: 648087 Size: SH
  24. Connect the fuel return hose (2) to the fuel return pipe
  25. Connect the fuel feed hose (1) to the fuel feed pipe.

    26. Object Number: 648007 Size: SH
  26. Install the EVAP canister purge valve (4).
  27. Install the idle air control (IAC) valve (1).

    28. Object Number: 648002 Size: SH
  28. Connect the following hoses:
    29. • The EVAP canister hose to the canister pipe
    • The heater hose (5) to the water outlet cap
    • The heater hose (3) to the heater water pipe

    Object Number: 648007 Size: SH
  29. Connect the following electrical connectors:
    30. • The EVAP canister purge valve (4)
    • The exhaust gas recirculation (EGR) valve (5)
    • The oxygen sensor
    • The coolant temperature sensor
    • The generator wires
    • The starter wires
    • The oil pressure switch wire
    • The power steering pressure switch wire
    • The ground wire to the generator bracket
  30. Install the clamp brackets (6)

    31. Object Number: 648017 Size: SH
  31. Connect the following electrical connectors:
    32. • The camshaft position sensor (CMP)
    • The 6 ignition coils
    • The throttle position (TP) sensor (2)
    • The mass air flow (MAF) sensor (1)
    • The idle air control (IAC) valve (3)
    • The ground wires (5) to the surge tank
  32. Install the clamp bracket (4)

    33. Object Number: 648018 Size: SH
  33. Connect the injector wire connector (1).
  34. Connect the brake booster vacuum hose (2).

    35. Object Number: 711377 Size: SH
  35. Install the engine oil level indicator and tube (2). Secure with the bolt (1).

    36. Tighten
    Tighten the oil level indicator tube bolt to 11 N·m (8 lb ft).

  36. Install the transmission fluid level indicator and tube. Secure with the 1 bolt.

    37. Tighten
    Tighten the transmission fluid level indicator tube bolt to 11 N·m (8 lb ft).

  37. Install the ignition coil covers.

    38. Object Number: 648012 Size: SH
  38. Install the air cleaner upper case, the intake air hose, the intake air pipe (2) and the surge tank pipe (3) as an assembly to the throttle body and intake manifold.
  39. Install the 4 nuts to the surge tank pipe (3).

    40. Tighten
    Tighten the surge tank pipe nuts to 12 N·m (8.5 lb ft).

  40. Connect the intake air temperature (IAT) sensor connector.
  41. Install the surge tank cover (1).

    42. Object Number: 464748 Size: SH
  42. Install the strut tower brace. Secure with the 6 bolts.

    43. Tighten
    Tighten the strut tower brace bolts to 50 N·m (37 lb ft).


    Object Number: 648013 Size: SH
  43. Connect the A/T throttle cable (1).
  44. Connect the accelerator cable (2).
  45. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
  46. Install the upper radiator hose.

    47. Object Number: 465595 Size: SH
  47. Install the automatic transmission fluid cooler lines (1) to the radiator.
  48. Install the lower radiator hose.

    49. Object Number: 479353 Size: SH
  49. Install the front skid plate (5) to the vehicle, if equipped. Secure the front skid plate with the 4 bolts.

    50. Tighten
    Tighten the front skid plate bolts to 55 N·m (40 lb ft).


    Object Number: 648671 Size: SH
  50. Install the engine oil drain plug (3) with a new gasket.

    51. Tighten
    Tighten the engine oil drain plug to 35 N·m (26 lb ft).

  51. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  52. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  53. Fill the automatic transmission fluid as necessary. Refer to Transmission Fluid Check in Automatic Transmission.
  54. Connect the negative battery cable.
  55. Run the engine and inspect for the following:
    56. • Engine oil leaks
    • Transmission fluid leaks
    • Engine coolant leaks
    • Fuel leaks