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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 140 (Engine Mechanical - 2.2L (LN2) (On-Vehicle)) >> Repair Instructions >> Engine Replacement (Manual Transmission) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the engine to the transmission.
  2. Install the transmission bolts. Tighten the bolts to 75 N.m (55 ft lbs).
  3. Lower the vehicle onto the engine and transmission assembly.
  4. Install the engine mount assembly.
  5. Install the transmission mount through bolts.
  6. Raise the vehicle from the support table.
  7. Install both drive axles.
  8. Install the suspension support frame.
  9. Install the starter.
  10. Connect the electrical connection to the oil pressure sensor.
  11. Connect the electrical connection to the oil level sensor.
  12. Connect the electrical connection to ground.
  13. Install the A/C compressor.
  14. Lower the vehicle.
  15. Connect the lower radiator hose to the coolant pump.
  16. Connect the heater hoses.
  17. Install the following cables to the accelerator control bracket:
    • The accelerator control (2).
    • The cruise control (1).
  18. Connect the electrical connection to the electronic ignition module.
  19. Connect the vacuum line near the master cylinder.
  20. Install the coolant surge tank.
  21. Connect the transmission shift control cables.
  22. Connect the hydraulic clutch line.
  23. Install the drive belt.
  24. Install the IAC electrical connection.
  25. Connect the generator electrical connection.
  26. Connect the electrical connection to the TPS.
  27. Connect the MAP electrical connection.
  28. Connect the EVAP emission solenoid electrical connector.
  29. Connect the injector harness.
  30. Connect the electrical connector to the ECT sensor.
  31. Reconnect the O2S sensor.
  32. Connect the engine ground wires.
  33. Connect the brake booster vacuum hose.
  34. Install the upper radiator hose at the coolant outlet.
  35. Install the air cleaner inlet duct and resonator assembly.
  36. Fill the coolant system.
  37. Refill the engine with oil.
  38. Connect the negative battery cable using the battery cable bolt. Tighten the bolt to 16 N.m (12 ft lbs).
  39. Connect the fuel lines.
  40. Start the engine and inspect for leaks.
  41. Turn the engine OFF and reinspect the fluid levels.
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