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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 236 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement (Manual Transmission) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 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. Refer to Engine Oil and Oil Filter Replacement .
    • 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. Refer to Transmission Mount Replacement - Rear and to Transmission Mount Replacement - Side in Manual Transmission.
  15. Install the engine mount. Refer to Engine Mount Replacement .
  16. Raise the vehicle.
  17. Connect the front exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold Replacement (2.2L (L61)) in Engine Exhaust.
  18. Connect the generator electrical connectors.
  19. Connect the starter electrical connectors.
  20. Install the AC compressor to the engine. Refer to Compressor Replacement in Heating, Ventilation, and Air Conditioning.
  21. Install the engine drive belt. Refer to Drive Belt Replacement .
  22. Install the drive axles. Refer to Wheel Drive Shaft Replacement in Front Wheel Drive Shafts.
  23. Install the front suspension cross member. Refer to Crossmember Replacement in Frame and Underbody.
  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). Refer to Radiator Hose Replacement - Inlet (2.2L - L61) in Engine Cooling.
    Fig 1: Radiator Outer & Inlet Hose View
    GM772800Courtesy of GENERAL MOTORS CORP.
  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). Refer to Radiator Hose Replacement - Outlet (2.2L - L61) in Engine Cooling.
    Fig 2: View Of Radiator Outlet Hose
    GM780869Courtesy of GENERAL MOTORS CORP.
  31. Install the inlet (1) and outlet (2) heater hoses. Refer to Heater Hose Replacement - Inlet (L61) and to Heater Hose Replacement - Outlet (L61) in Heating, Ventilation, and Air Conditioning.
    Fig 3: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  32. Connect the transmission shift control cables.
  33. Connect the clutch actuator cylinder to the transmission. Refer to Clutch Actuator Cylinder Replacement in Manual Transmission.
  34. Install the power steering pump and bolts. Refer to Power Steering Pump Replacement in Power Steering System.
    Fig 4: View Of Power Steering Pump
    GM631999Courtesy of GENERAL MOTORS CORP.
  35. Connect the accelerator and cruise control cable. Refer to Accelerator Controls Cable Replacement in Engine Controls - 2.2L (L61).
    Fig 5: View Of Cruise Control Cable At Throttle Body Cam Lever
    GM792955Courtesy of GENERAL MOTORS CORP.
  36. Connect the brake booster hose at the brake booster.
  37. Connect fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.2L (L61).
  38. Install the air inlet duct and resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).
    Fig 6: Exploded View Of Air Inlet Duct & Resonator
    GM785334Courtesy of GENERAL MOTORS CORP.
  39. Fill the engine with oil. Refer to Capacities - Approximate Fluid in Maintenance and Lubrication.
  40. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  41. Fill the cooling system. Refer to Draining and Filling Cooling System (L61) in Engine Cooling.
  42. Install the hood. Refer to Hood Replacement in Body Front End.
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