Tracker 2000-2004

Engine

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Removal & Installation



1.6L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system and engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Strut tower bar, if equipped
     
    Cooling fan and shroud
     
    Heater hoses
     
    Radiator hoses
     
    Bypass hose
     
    Radiator
     
    Air intake tube
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Exhaust Gas Recirculation (EGR) valve and temperature sensor
     
    EGR vacuum valve connector
     
    EGR bypass valve connector
     
    Idle Air Control (IAC) valve hoses and connector
     
    Fuel lines
     
    Main engine control wiring harness connectors at the firewall
     
    Throttle Position (TP) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Temperature gauge sender connector
     
    A/C temperature switch, if equipped
     
    Injector harness connectors
     
    Alternator wiring connectors
     
    Manifold Absolute Pressure (MAP) sensor connector and vacuum line
     
    Brake booster vacuum line
     
    Evaporative Emission (EVAP) canister and hoses
     
    Distributor, if equipped
     
    Front skidplate, if equipped
     
    Power steering hoses
     
    A/C compressor, if equipped
     
    Flywheel access cover
     
    Torque converter, if equipped
     
    Clutch cable, if equipped
     
    Transmission cooler lines, if equipped
     
    Exhaust front pipe
     
    Starter motor
     
    Transmission flange fasteners and support the transmission
     
    Left and right engine mounts
     
    Engine
     

  8.  

To install:

  1. Install or connect the following:

    Engine. Tighten the mount bolts to 40 ft. lbs. (54 Nm).
     
    Transmission flange fasteners. Tighten them to 62 ft. lbs. (85 Nm).
     
    Starter motor
     
    Exhaust front pipe
     
    Transmission cooler lines, if equipped
     
    Clutch cable, if equipped
     
    Torque converter, if equipped. Tighten the bolts to 40 ft. lbs. (54 Nm).
     
    Flywheel access cover
     
    A/C compressor, if equipped
     
    Power steering hoses
     
    Front skidplate, if equipped
     
    Distributor, if equipped
     
    EVAP canister and hoses
     
    Brake booster vacuum line
     
    MAP sensor connector and vacuum line
     
    Alternator wiring connectors
     
    Injector harness connectors
     
    A/C temperature switch, if equipped
     
    Temperature gauge sender connector
     
    ECT sensor connector
     
    HO 2 S sensor connectors
     
    TP sensor connector
     
    Main engine control wiring harness connectors at the firewall
     
    Fuel lines
     
    IAC valve hoses and connector
     
    EGR bypass valve connector
     
    EGR vacuum valve connector
     
    EGR valve and temperature sensor
     
    PCV valve and hose
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Air intake tube
     
    Radiator
     
    Bypass hose
     
    Radiator hoses
     
    Heater hoses
     
    Cooling fan and shroud
     
    Strut tower bar, if equipped
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

2.0L And 2.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Heater hoses
     
    Radiator hoses
     
    Cooling fan and shroud
     
    Radiator overflow tank
     
    Radiator
     
    Accelerator cable
     
    Transmission cable, if equipped
     
    Strut tower bar, if equipped
     
    Air intake assembly
     
    Engine oil dipstick tube
     
    Transmission oil dipstick tube, if equipped
     
    Ignition coil covers
     
    Ignition coil connectors
     
    Injector connectors
     
    Camshaft Position (CMP) sensor connector
     
    Crankshaft Position (CKP) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve
     
    Intake manifold ground cable
     
    Evaporative Emission (EVAP) canister purge valve
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Alternator wiring connectors
     
    Oil pressure gauge sender connector
     
    Power Steering Pressure (PSP) switch connector
     
    Alternator bracket ground cable
     
    Brake booster vacuum line
     
    Tank pressure control vacuum valve hose
     
    Fuel lines
     
    EVAP canister
     
    Power steering pump
     
    A/C compressor
     
    Steering shaft lower assembly
     
    Front differential housing, if equipped
     
    Exhaust front pipe and bracket
     
    Transmission oil cooler lines, if equipped
     
    Transmission stiffener brackets, if equipped
     
    Flywheel access cover
     
    Torque converter, if equipped
     
    Starter motor
     
    Transmission flange fasteners and support the transmission
     
    Left and right engine mounts
     
    Engine
     

  10.  

To install:

  1. Install or connect the following:

    Engine
     
    Left and right engine mounts. Tighten the nuts to 36 ft. lbs. (50 Nm).
     
    Transmission flange fasteners. Tighten them to 58 ft. lbs. (80 Nm).
     
    Starter motor
     
    Torque converter. Tighten the bolts to 47 ft. lbs. (65 Nm).
     
    Flywheel access cover
     
    Transmission stiffener brackets. Tighten the bolts to 36 ft. lbs. (50 Nm).
     
    Transmission oil cooler lines, if equipped
     
    Exhaust front pipe and bracket
     
    Front differential housing, if equipped
     
    Steering shaft lower assembly
     
    A/C compressor
     
    Power steering pump
     
    EVAP canister
     
    Fuel lines
     
    Tank pressure control vacuum valve hose
     
    Brake booster vacuum line
     
    Alternator bracket ground cable
     
    PSP switch connector
     
    Oil pressure gauge sender connector
     
    Alternator wiring connectors
     
    ECT sensor connector
     
    HO 2 S sensor connectors
     
    EGR valve connector
     
    EVAP canister purge valve
     
    Intake manifold ground cable
     
    IAC valve
     
    MAF sensor connector
     
    TP sensor connector
     
    CKP sensor connector
     
    CMP sensor connector
     
    Injector connectors
     
    Ignition coil connectors
     
    Ignition coil covers
     
    Transmission oil dipstick tube, if equipped
     
    Engine oil dipstick tube
     
    Air intake assembly
     
    Strut tower bar, if equipped
     
    Transmission cable, if equipped
     
    Accelerator cable
     
    Radiator
     
    Radiator overflow tank
     
    Cooling fan and shroud
     
    Radiator hoses
     
    Heater hoses
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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