LEMON Manuals: Even more car manuals for everyone
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 (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 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. Refer to Engine Flywheel Replacement .
  7. Install the clutch pressure plate and disk.
  8. Install the engine to the transmission.
  9. Install the engine and transmission assembly to an engine support table. Use a block of wood under the front of the engine to support the engine.
  10. Remove the engine hoist.
  11. Remove J 42451  .
  12. Position the engine support table under the vehicle.
  13. Lower the vehicle while aligning the engine and transmission mounts to the vehicle.
  14. Install the bolts which secure the transmission mount to the frame.
  15. Install the engine mount.
  16. Raise the vehicle.
  17. Connect the front exhaust pipe to the exhaust manifold.
  18. Connect the generator electrical connectors.
  19. Connect the starter electrical connectors.
  20. Install the AC compressor to the engine.
  21. Install the engine drive belt.
  22. Install the drive axles.
  23. Install the front suspension cross member.
  24. Lower the vehicle.
  25. 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
  26. Install the radiator inlet hose (3).
  27. Install the hose from the surge tank to the cylinder head (2).
  28. Connect the outlet hose from the surge tank to the radiator (1).
  29. Install the bolt retaining the cooling system fill hose to the intake manifold.
  30. Install the radiator outlet hose (1).
  31. Install the inlet (1) and outlet (2) heater hoses.
  32. Connect the transmission shift control cables.
  33. Connect the clutch actuator cylinder to the transmission.
  34. Install the power steering pump and bolts.
  35. Connect the accelerator and cruise control cable.
  36. Connect the brake booster hose at the brake booster.
  37. Connect fuel lines.
  38. Install the air inlet duct and resonator.
  39. Fill the engine with oil.
  40. Connect the negative battery cable.
  41. Fill the cooling system.
  42. Install the hood.
scientia non olet · About LEMON Manuals