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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 148 (Engine Mechanical - 2.2L (L61) (On-Vehicle)) >> Repair Instructions >> Engine Replacement (Automatic 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 J 42451  to the right rear of the cylinder head.
  2. Mount the engine to a stand.
  3. Install the following components:
    • Oil filter cap and filter.
    • Exhaust manifold studs.
    • Exhaust manifold.
    • Intake manifold studs.
    • Intake manifold.
    • Engine mount bracket.
    • Engine lift bracket.
    • Camshaft cover and seal.
    • Fuel rail.
    • Engine block heater.
    • Water pump.
    • Drive belt tensioner.
    • Thermostat housing and feed pipe.
    • Generator.
    • Oil level indicator and tube.
    • Crankshaft sensor.
    • Camshaft sensor.
    • Oil pressure sensor.
    • Ignition coil and module assembly.
    • Crankshaft balancer.
  4. Install an engine hoist to the engine.
  5. Remove the engine from the engine stand.
  6. Install the flywheel.
  7. Install the engine to the vehicle.
  8. Align the engine to the transmission.
  9. Install the upper bell housing bolts. Tighten the bolts to 90 N.m (66 lb ft).
  10. Install the engine mount.
  11. Remove the engine hoist.
  12. Remove J 42451  .
  13. Raise the vehicle.
  14. Install the lower bell housing bolts. Tighten the bolts to 90 N.m (66 lb ft).
  15. Install the torque convertor bolts. Tighten the torque convertor bolts to 62 N.m (46 lb ft).
  16. Install the starter.
  17. Install the brace from the transmission to the engine. Tighten the brace bolts to 72 N.m (53 lb ft).
  18. Connect the front exhaust pipe to the exhaust manifold.
  19. Connect the generator electrical connectors.
  20. Connect the starter electrical connectors.
  21. Install the AC compressor to the engine.
  22. Install the engine drive belt.
  23. Lower the vehicle.
  24. Connect the following electrical connectors:
    • IAC motor
    • TPS
    • Map sensor
    • Crankshaft sensor
    • Camshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil and module assembly
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
  25. Install the radiator inlet hose (3).
  26. Install the hose from the surge tank to the cylinder head (2).
  27. Connect the outlet hose from the surge tank to the radiator (1).
  28. Install the bolt securing the surge tank outlet hose to the intake manifold.
  29. Install the radiator outlet hose (1).
  30. Install the inlet (1) and outlet (2) heater hoses.
  31. Install the power steering pump. Tighten the power steering pump bolts to 25 N.m (19 lb ft).
  32. Connect the accelerator and cruise control cables.
  33. Connect the brake booster hose.
  34. Connect the fuel lines.
  35. Install the air inlet duct and resonator.
  36. Fill the engine with oil.
  37. Connect negative battery cable.
  38. Fill the cooling system.
  39. Install the hood.
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