Tracker 2000-2004

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Disable the SIR by performing the following procedure:
    1. From the fuse box, located near the base of the steering column, remove the AIR BAG fuse.
    2.  
    3. Remove the steering wheel side cap, disconnect the Connector Positive Assurance (CPA) and the yellow 2-way driver-s inflator module connectors.
    4.  
    5. Pull the instrument panel compartment out by pushing the right-side and left-side stoppers (located on both sides) inward.
    6.  
    7. Disconnect the CPA and the yellow 4-way passenger-s inflator module connectors.
      NOTE
      With the AIR BAG fuse removed and the ignition switch turned ON, the AIR BAG warning light will be ON; this is normal operation and does not indicate a SIR system malfunction.

    8.  

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the instrument panel as follows:
    1. Remove the center console.
    2.  
    3. Remove the lower steering column cover by loosening the mounting screws.
    4.  
    5. Remove the glove box.
    6.  
    7. Detach the wiring harness connectors from the heater unit and the blower motor assembly.
    8.  
    9. Detach the wiring harness connectors from the ignition switch, contact coil and combination switch.
    10.  
    11. Open the hood.
    12.  
    13. Remove the steering column shaft joint bolt, then separate the steering column shaft from the lower steering shaft.
    14.  
    15. Loosen all of the steering column-to-firewall and instrument panel brace bolts.
    16.  
    17. If equipped, remove the shift (key) interlock cable screw. Disconnect the cable from the ignition switch.
    18.  
    19. Remove the steering column from the vehicle.
      WARNING
      Do not rest the steering column assembly on the steering wheel with the air bag module facing downward and the column vertical-personal injury may be the result.

    20.  
    21. Disconnect the speedometer cable from the speedometer, then remove the instrument cluster.
    22.  
    23. Remove the hood latch handle.
    24.  
    25. Remove the radio, the heater control panel and the heater control cables from the instrument panel.
    26.  
    27. Disconnect and label all wiring harness connectors from the instrument panel.
    28.  
    29. Remove the instrument panel mounting screws and bolts. Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly. Then, remove the upper cover plates and loosen the remaining mounting fasteners
    30.  
    31. Have an assistant help you carefully lift the instrument panel up and out of the vehicle. When separating the instrument panel from the firewall, ensure that all of the cables, wires and hoses are disconnected form the instrument panel.
    32.  

  8.  
  9. Remove the 2 bolts and the right-side instrument panel center support.
  10.  
  11. If equipped with air conditioning, remove the evaporator.
  12.  
  13. Remove the 2 screws securing the SIR harness clip on the Sensing and Diagnostic Module (SDM) bracket.
  14.  
  15. Disconnect the SDM electrical connector.
  16.  
  17. Remove the 4 screws and the SDM bracket from the vehicle.
  18.  
  19. Remove the speedometer cable and antenna cable (if equipped) from the heater case.
  20.  
  21. Remove the floor duct from the heater case.
  22.  
  23. If equipped with air conditioning, disconnect the electrical jumper harness for the air conditioning amplifier.
  24.  
  25. Remove the relay bracket screws and the relay bracket.
  26.  
  27. From the engine compartment, remove the 2 heater assembly-to-chassis nuts and the 2 bolts.
  28.  
  29. Remove the heater case from the vehicle.
  30.  
  31. Remove the dampers and linkages from the heater case.
  32.  
  33. Remove the heater core bracket screw and the bracket.
  34.  
  35. Remove the heater core from the heater case.

    Click image to see an enlarged view

    Fig. Disabling the air bag system



    Click image to see an enlarged view

    Fig. Exploded view of the heater case assembly and related components

  36.  

To install:

  1. Install the heater core to the heater case.
  2.  
  3. Install the heater core bracket and the bracket screw.
  4.  
  5. Install the dampers and linkages to the heater case.
  6.  
  7. Install the heater case to the vehicle.
  8.  
  9. In the engine compartment, install the 2 heater assembly-to-chassis nuts and the 2 bolts. Torque the nuts/bolts to 89 inch lbs. (10 Nm).
  10.  
  11. Install the relay bracket and the relay bracket screws.
  12.  
  13. If equipped with air conditioning, connect the electrical jumper harness for the air conditioning amplifier.
  14.  
  15. Install the floor duct to the heater case.
  16.  
  17. Install the speedometer cable and antenna cable (if equipped) to the heater case.
  18.  
  19. Install the SDM bracket and the 4 screws to the vehicle. Torque the screws to 49 inch lbs. (5.5 Nm).
  20.  
  21. Connect the SDM electrical connector.
  22.  
  23. Install the 2 screws securing the SIR harness clip on the Sensing and Diagnostic Module (SDM) bracket. Torque the screws to 49 inch lbs. (5.5 Nm)
  24.  
  25. If equipped with air conditioning, install the evaporator.
  26.  
  27. Install the 2 bolts and the right-side instrument panel center support.
  28.  
  29. Install the instrument panel as follows:
    1. Have an assistant help you position the instrument panel in the vehicle. When installing the instrument panel on the firewall, ensure that all of the cables, wires and hoses are routed properly.
    2.  
    3. Install and tighten the instrument panel mounting screws and bolts.
    4.  
    5. Reattach all wiring harness connectors to the instrument panel.
    6.  
    7. Install the radio, the heater control panel and the heater control cables. Be sure to adjust the heater control cables.
    8.  
    9. Install the hood latch handle.
    10.  
    11. Install the instrument cluster, then connect the cable to the speedometer.
    12.  
    13. Install the steering column in the vehicle.
    14.  
    15. If equipped, connect the cable from the ignition switch, then install the shift (key) interlock cable screw.
    16.  
    17. Install and tighten all of the steering column-to-firewall and instrument panel brace bolts to 221 inch lbs. (25 Nm).
    18.  
    19. Install and tighten the steering column shaft joint bolt to 221 inch lbs. (25 Nm).
    20.  
    21. Reattach the wiring harness connectors to the ignition switch, contact coil and combination switch.
    22.  
    23. Reattach the wiring harness connectors to the heater unit and the blower motor assembly.
    24.  
    25. Install the glove box.
    26.  
    27. Install the lower steering column cover.
    28.  
    29. Install the center console.
    30.  

  30.  
  31. Refill the cooling system.
  32.  
  33. Enable the SIR by performing the following procedure:
    1. Turn the ignition switch to LOCK and remove the key.
    2.  
    3. Connect the Connector Positive Assurance (CPA) and the yellow 4-way passenger-s inflator module connectors.
    4.  
    5. Close the instrument panel compartment.
    6.  
    7. Connect the Connector Positive Assurance (CPA) and the yellow 2-way driver Inflator module connectors and install the steering wheel side cap.
    8.  
    9. At the fuse box, located near the base of the steering column, install the AIR BAG fuse.

      Click image to see an enlarged view

      Fig. Enabling the air bag system

    10.  

  34.  
  35. Connect the negative battery cable.
  36.  
  37. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  38.  

  1. Disconnect the negative battery cable.
  2.  
  3. Disable the SIR by performing the following procedure:
    1. From the fuse box, located near the base of the steering column, remove the AIR BAG fuse.
    2.  
    3. Remove the steering wheel side cap, disconnect the Connector Positive Assurance (CPA) and the yellow 2-way driver-s inflator module connectors.
    4.  
    5. Pull the instrument panel compartment out by pushing the right-side and left-side stoppers (located on both sides) inward.
    6.  
    7. Disconnect the CPA and the yellow 4-way passenger-s inflator module connectors.
      NOTE
      With the AIR BAG fuse removed and the ignition switch turned ON, the AIR BAG warning light will be ON; this is normal operation and does not indicate a SIR system malfunction.

    8.  

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the instrument panel as follows:
    1. Remove the center console.
    2.  
    3. Remove the lower steering column cover by loosening the mounting screws.
    4.  
    5. Remove the glove box.
    6.  
    7. Detach the wiring harness connectors from the heater unit and the blower motor assembly.
    8.  
    9. Detach the wiring harness connectors from the ignition switch, contact coil and combination switch.
    10.  
    11. Open the hood.
    12.  
    13. Remove the steering column shaft joint bolt, then separate the steering column shaft from the lower steering shaft.
    14.  
    15. Loosen all of the steering column-to-firewall and instrument panel brace bolts.
    16.  
    17. If equipped, remove the shift (key) interlock cable screw. Disconnect the cable from the ignition switch.
    18.  
    19. Remove the steering column from the vehicle.
      WARNING
      Do not rest the steering column assembly on the steering wheel with the air bag module facing downward and the column vertical-personal injury may be the result.

    20.  
    21. Disconnect the speedometer cable from the speedometer, then remove the instrument cluster.
    22.  
    23. Remove the hood latch handle.
    24.  
    25. Remove the radio, the heater control panel and the heater control cables from the instrument panel.
    26.  
    27. Disconnect and label all wiring harness connectors from the instrument panel.
    28.  
    29. Remove the instrument panel mounting screws and bolts. Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly. Then, remove the upper cover plates and loosen the remaining mounting fasteners
    30.  
    31. Have an assistant help you carefully lift the instrument panel up and out of the vehicle. When separating the instrument panel from the firewall, ensure that all of the cables, wires and hoses are disconnected form the instrument panel.
    32.  

  8.  
  9. Remove the 2 bolts and the right-side instrument panel center support.
  10.  
  11. If equipped with air conditioning, remove the evaporator.
  12.  
  13. Remove the 2 screws securing the SIR harness clip on the Sensing and Diagnostic Module (SDM) bracket.
  14.  
  15. Disconnect the SDM electrical connector.
  16.  
  17. Remove the 4 screws and the SDM bracket from the vehicle.
  18.  
  19. Remove the speedometer cable and antenna cable (if equipped) from the heater case.
  20.  
  21. Remove the floor duct from the heater case.
  22.  
  23. If equipped with air conditioning, disconnect the electrical jumper harness for the air conditioning amplifier.
  24.  
  25. Remove the relay bracket screws and the relay bracket.
  26.  
  27. From the engine compartment, remove the 2 heater assembly-to-chassis nuts and the 2 bolts.
  28.  
  29. Remove the heater case from the vehicle.
  30.  
  31. Remove the dampers and linkages from the heater case.
  32.  
  33. Remove the heater core bracket screw and the bracket.
  34.  
  35. Remove the heater core from the heater case.

    Click image to see an enlarged view

    Fig. Disabling the air bag system-Tracker



    Click image to see an enlarged view

    Fig. Exploded view of the heater case assembly and related components-Tracker

  36.  

To install:

  1. Install the heater core to the heater case.
  2.  
  3. Install the heater core bracket and the bracket screw.
  4.  
  5. Install the dampers and linkages to the heater case.
  6.  
  7. Install the heater case to the vehicle.
  8.  
  9. In the engine compartment, install the 2 heater assembly-to-chassis nuts and the 2 bolts. Torque the nuts/bolts to 89 inch lbs. (10 Nm).
  10.  
  11. Install the relay bracket and the relay bracket screws.
  12.  
  13. If equipped with air conditioning, connect the electrical jumper harness for the air conditioning amplifier.
  14.  
  15. Install the floor duct to the heater case.
  16.  
  17. Install the speedometer cable and antenna cable (if equipped) to the heater case.
  18.  
  19. Install the SDM bracket and the 4 screws to the vehicle. Torque the screws to 49 inch lbs. (5.5 Nm).
  20.  
  21. Connect the SDM electrical connector.
  22.  
  23. Install the 2 screws securing the SIR harness clip on the Sensing and Diagnostic Module (SDM) bracket. Torque the screws to 49 inch lbs. (5.5 Nm)
  24.  
  25. If equipped with air conditioning, install the evaporator.
  26.  
  27. Install the 2 bolts and the right-side instrument panel center support.
  28.  
  29. Install the instrument panel as follows:
    1. Have an assistant help you position the instrument panel in the vehicle. When installing the instrument panel on the firewall, ensure that all of the cables, wires and hoses are routed properly.
    2.  
    3. Install and tighten the instrument panel mounting screws and bolts.
    4.  
    5. Reattach all wiring harness connectors to the instrument panel.
    6.  
    7. Install the radio, the heater control panel and the heater control cables. Be sure to adjust the heater control cables.
    8.  
    9. Install the hood latch handle.
    10.  
    11. Install the instrument cluster, then connect the cable to the speedometer.
    12.  
    13. Install the steering column in the vehicle.
    14.  
    15. If equipped, connect the cable from the ignition switch, then install the shift (key) interlock cable screw.
    16.  
    17. Install and tighten all of the steering column-to-firewall and instrument panel brace bolts to 221 inch lbs. (25 Nm).
    18.  
    19. Install and tighten the steering column shaft joint bolt to 221 inch lbs. (25 Nm).
    20.  
    21. Reattach the wiring harness connectors to the ignition switch, contact coil and combination switch.
    22.  
    23. Reattach the wiring harness connectors to the heater unit and the blower motor assembly.
    24.  
    25. Install the glove box.
    26.  
    27. Install the lower steering column cover.
    28.  
    29. Install the center console.
    30.  

  30.  
  31. Refill the cooling system.
  32.  
  33. Enable the SIR by performing the following procedure:
    1. Turn the ignition switch to LOCK and remove the key.
    2.  
    3. Connect the Connector Positive Assurance (CPA) and the yellow 4-way passenger-s inflator module connectors.
    4.  
    5. Close the instrument panel compartment.
    6.  
    7. Connect the Connector Positive Assurance (CPA) and the yellow 2-way driver Inflator module connectors and install the steering wheel side cap.
    8.  
    9. At the fuse box, located near the base of the steering column, install the AIR BAG fuse.

      Click image to see an enlarged view

      Fig. Enabling the air bag system-Tracker

    10.  

  34.  
  35. Connect the negative battery cable.
  36.  
  37. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  38.  

 
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