Here's a general overview. Specific steps may vary slightly depending on the year and model of your Tracker (1.6L or 2.0L engine will have differences). Always consult a repair manual specific to your vehicle's year and engine for precise instructions and torque specifications.
I. Preparation:
1. Safety First: Disconnect the negative battery terminal. Work in a well-ventilated area away from any ignition sources. Use proper eye protection and gloves. Have a fire extinguisher readily available.
2. Gather Tools: You'll need jack stands, a jack, wrenches (various sizes), sockets, ratchets, screwdrivers (Phillips and flathead), fuel line disconnect tools, a fuel pump removal tool (often a specialized socket), safety glasses, gloves, rags, and possibly a fuel pressure gauge. A repair manual is crucial.
3. Drain Fuel: This is highly recommended. If you have a way to safely siphon fuel out of the tank, do so to minimize the amount of fuel you need to work around.
4. Locate the Fuel Pump: On most Trackers, the fuel pump is located inside the fuel tank. This means you'll need to drop the fuel tank.
II. Dropping the Fuel Tank:
1. Disconnect Fuel Lines: Carefully disconnect the fuel lines from the fuel pump. Use the appropriate disconnect tools to avoid damaging the lines. Be prepared for some fuel spillage, even if you drained the tank. Have rags ready. Once disconnected, plug the lines to prevent fuel leakage.
2. Disconnect Electrical Connections: Disconnect the electrical connector from the fuel pump.
3. Release Fuel Tank Straps: Most Trackers have straps securing the fuel tank. Loosen and remove these straps. You may need to remove some underbody panels or exhaust components to access the straps.
4. Lower the Fuel Tank: Carefully lower the fuel tank. It's usually heavy, so use jack stands for support. Have a helper if possible.
III. Fuel Pump Replacement:
1. Access the Fuel Pump: Once the tank is lowered, you'll typically find the fuel pump assembly at the top of the tank. It might be held in place by a retaining ring.
2. Remove the Fuel Pump Assembly: Use the specialized fuel pump removal tool to remove the assembly. This often involves unscrewing or unclipping the pump from the tank.
3. Install the New Fuel Pump Assembly: Carefully install the new fuel pump assembly, ensuring all seals and gaskets are properly seated.
4. Reassemble: Reinstall the fuel pump assembly, securing it with the retaining ring.
IV. Reinstallation:
1. Raise the Fuel Tank: Carefully raise the fuel tank back into its position.
2. Reconnect Everything: Reconnect the fuel lines, electrical connectors, and tank straps. Double and triple check everything is securely connected before proceeding.
3. Fill the Tank (Partially): Add some fuel to the tank to ensure the pump is submerged.
4. Reconnect the Battery: Reconnect the negative battery terminal.
5. Test the System: Start the engine and check for leaks and proper fuel pressure. If you have a fuel pressure gauge, this is essential.
V. Important Considerations:
* Repair Manual: This is absolutely essential. A Haynes or Chilton manual specific to your vehicle's year and model will provide detailed, illustrated instructions and torque specifications.
* Fuel Safety: Always prioritize fuel safety. Work in a well-ventilated area and take precautions to avoid sparks or flames.
* Professional Help: If you're uncomfortable performing this repair yourself, take your vehicle to a qualified mechanic. The cost of a wrong repair could far outweigh the labor costs.
This is a simplified guide. The actual process can be more complex depending on your specific vehicle. Always consult a repair manual specific to your Chevy Tracker before attempting this repair. Improperly installing a fuel pump can lead to serious problems, including fire.
