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J23 engine swap from '04 Aerio (A/T) into a '98 Tracker (5spd) Questions

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Bracket? I thought the Tracker throttle cable would bolt in as TT guys did not mention anything about this. Could you take a picture and let me know what it looks like?
Own: 1998 Chevy Tracker, 1.6L, 16v, 5spd, 4x4, 2dr, soft top
Previously owned: 1990 Geo Tracker, 1.6L, 8v, 5spd, 4x4, 2dr, soft top
Location: Southern Colorado

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Offline Drone637

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Looks sharp!

Something I didn't think about before hand, it's pretty easy to make a bracket so you can use your stock throttle cable.  Just one of those little things you find out when connecting everything together.
x-SJ-410, 96 Geo Tracker, White Rabbit, Project Trouble

Crawlers NorthWest
Trouble Racing

The engine is finally here. I'll ship the wiring harnesses to TT ASAP and start working on the engine next week.
Own: 1998 Chevy Tracker, 1.6L, 16v, 5spd, 4x4, 2dr, soft top
Previously owned: 1990 Geo Tracker, 1.6L, 8v, 5spd, 4x4, 2dr, soft top
Location: Southern Colorado

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Offline BRD HNTR

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We originally used the A/C fan but that couldn't quite keep up so instead picked up a generic fan off Amazon.  It seems to do the job but doesn't really compare to real Flex-a-lite fan.  As for the size just get one that matches your radiator and will fit in front of the motor.

If you still find it getting hot you can put some hood louvers to improve the airflow when your going slow.

Thanks. I'll go to the junk yard and find a dual fan system I could use. If not, I'll get two 10" electric fans and mount them. However, I've read the fans won't have maximum efficiency unless I install them with shroud and the ones that come with shroud cost big $$$. I'm also thinking of getting a single 16" fan and use it with the Tracker shroud. I'd have to enlarge the fan opening.
I am running the single 16" as a pusher because there is no room between the radiator and motor.  Using the stock shroud would increase the efficiency of the fan as a puller.
93 Tracker,XL7 springs & 1" raised spring pads in front with YJ springs in back, home built bumpers rear & front (w/winch), 2" x 4" rock tubes,  ARB front & rear, converted Sami rear to IFS, 33x12.5x15  aluminum rims, roll cage, 2.7L w/5 speed auto.

We originally used the A/C fan but that couldn't quite keep up so instead picked up a generic fan off Amazon.  It seems to do the job but doesn't really compare to real Flex-a-lite fan.  As for the size just get one that matches your radiator and will fit in front of the motor.

If you still find it getting hot you can put some hood louvers to improve the airflow when your going slow.

Thanks. I'll go to the junk yard and find a dual fan system I could use. If not, I'll get two 10" electric fans and mount them. However, I've read the fans won't have maximum efficiency unless I install them with shroud and the ones that come with shroud cost big $$$. I'm also thinking of getting a single 16" fan and use it with the Tracker shroud. I'd have to enlarge the fan opening.
Own: 1998 Chevy Tracker, 1.6L, 16v, 5spd, 4x4, 2dr, soft top
Previously owned: 1990 Geo Tracker, 1.6L, 8v, 5spd, 4x4, 2dr, soft top
Location: Southern Colorado

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Offline BRD HNTR

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I believe I did the same thing.  Exhaust pipe works good.  No photos of the bottom.
93 Tracker,XL7 springs & 1" raised spring pads in front with YJ springs in back, home built bumpers rear & front (w/winch), 2" x 4" rock tubes,  ARB front & rear, converted Sami rear to IFS, 33x12.5x15  aluminum rims, roll cage, 2.7L w/5 speed auto.

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Offline Drone637

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We originally used the A/C fan but that couldn't quite keep up so instead picked up a generic fan off Amazon.  It seems to do the job but doesn't really compare to real Flex-a-lite fan.  As for the size just get one that matches your radiator and will fit in front of the motor.

If you still find it getting hot you can put some hood louvers to improve the airflow when your going slow.
x-SJ-410, 96 Geo Tracker, White Rabbit, Project Trouble

Crawlers NorthWest
Trouble Racing

Now I see how you could use the Tracker radiator. I do have the pipe from the 2.0, so I don't need to use a long pipe like you did. May be I can use a flexpipe to go from the pipe to the radiator top inlet. What about the bottom. Do you have any pictures?

Also, what kind of fan did you use? Brand name and/or part number would be very useful. Did you use the Tracker shroud? No shroud? A custom one?
Own: 1998 Chevy Tracker, 1.6L, 16v, 5spd, 4x4, 2dr, soft top
Previously owned: 1990 Geo Tracker, 1.6L, 8v, 5spd, 4x4, 2dr, soft top
Location: Southern Colorado

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Offline BRD HNTR

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I will that without proper airflow a bigger radiator takes longer to heat up.  That is why I stressed a good fan.  I ran my 2.7L on the stock Tracker radiator, and it did fine at home and backroads, but I had overheating at Moab and long slow stretches.  My bigger radiator overheated until I got a 3000 cfm fan.

93 Tracker,XL7 springs & 1" raised spring pads in front with YJ springs in back, home built bumpers rear & front (w/winch), 2" x 4" rock tubes,  ARB front & rear, converted Sami rear to IFS, 33x12.5x15  aluminum rims, roll cage, 2.7L w/5 speed auto.

Has anyone ever tried using the aerio fans/rad? It has 2 full sized electric fans.


I've read most (if not all) 2.3 swap threads out there but never seen one with Aerio fans. In fact, I haven't pictures of the radiator set up at all. In any case, my engine will not come with fans but I was thinking of mounting a pair of these diagonally on my Tracker radiator: http://www.ebay.com/itm/172433216567?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

or may be one of these: http://www.ebay.com/itm/16-INCH-ELECTRIC-COOLING-FAN-12-VOLT-PUSH-IN-RADIATOR-FIN-PROBE-THERMOSTAT-KIT-/231727573294?hash=item35f40a292e:g:P28AAOSwstxVgMSM&vxp=mtr

Because I hear it's more about the air flow than it is about the radiator itself. What do you guys think?
Own: 1998 Chevy Tracker, 1.6L, 16v, 5spd, 4x4, 2dr, soft top
Previously owned: 1990 Geo Tracker, 1.6L, 8v, 5spd, 4x4, 2dr, soft top
Location: Southern Colorado

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Offline Perryd

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Has anyone ever tried using the aerio fans/rad? It has 2 full sized electric fans.
1998 Tracker 2 door soft top, 3spd auto, 4x4, 215/57R15 BFG A/T, bone stock.

The spec's on that one is the same as what you are running now.  Save you $55 and use it towards a better fan.  We had overheating issues with both stock AC booster fan and stock radiator.

If they have the same cooling capacity I'd like to use mine and save $55. However, I think the inlet and outlet of Tracker radiator are on the wrong side, aren't they? They are on the passenger side on Tracker and on the passenger side on 2.3. If that is the case, How do I fix it? Flexible coolant hoses, may be?
« Last Edit: March 06, 2017, 01:33:26 PM by trackerER »
Own: 1998 Chevy Tracker, 1.6L, 16v, 5spd, 4x4, 2dr, soft top
Previously owned: 1990 Geo Tracker, 1.6L, 8v, 5spd, 4x4, 2dr, soft top
Location: Southern Colorado

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Offline BRD HNTR

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  • Gender: Male
The spec's on that one is the same as what you are running now.  Save you $55 and use it towards a better fan.  We had overheating issues with both stock AC booster fan and stock radiator.
93 Tracker,XL7 springs & 1" raised spring pads in front with YJ springs in back, home built bumpers rear & front (w/winch), 2" x 4" rock tubes,  ARB front & rear, converted Sami rear to IFS, 33x12.5x15  aluminum rims, roll cage, 2.7L w/5 speed auto.

So, it seemd like the only loose end left is the radiator. Dillon at TT says that the alternator from a 2.0 should work fine. So, I found this: http://www.rockauto.com/en/catalog/suzuki,2000,vitara,2.0l+l4,1364598,cooling+system,radiator,2172

$55 isn't too bad for a brand new radiator. What do you think? Would this work?
« Last Edit: March 06, 2017, 11:21:08 AM by trackerER »
Own: 1998 Chevy Tracker, 1.6L, 16v, 5spd, 4x4, 2dr, soft top
Previously owned: 1990 Geo Tracker, 1.6L, 8v, 5spd, 4x4, 2dr, soft top
Location: Southern Colorado

I think you'll be safe with that list. I've had 2 aerios and they are very reliable. A big bonus with having it in the tracker will be the ease of service. I was going to say have the alternator tested and possibility rebuilt, because I've had it fail on both of them. But when in the tracker that would be a very easy job to complete as it's right out in front and not squat down under everything. I'd test and clean the EGR too as they have given me some issues in the past too.

I'll definitely have the alternator tested. Also, good call on the EGR cleaning. In fact, I wanted to add the EGR valve in my list but decided that cleaning the old one is a better idea after seeing the price tag, $230!  :o

Also, decided to remove the oil pump from the list too as rockauto does not have one I didn't want to buy a cheap one on ebay. I'll install an oil pressure gauge and monitor. If it's too low, I'll have to bite the bullet and buy one for $100+.
Own: 1998 Chevy Tracker, 1.6L, 16v, 5spd, 4x4, 2dr, soft top
Previously owned: 1990 Geo Tracker, 1.6L, 8v, 5spd, 4x4, 2dr, soft top
Location: Southern Colorado