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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 95 (Engine Mechanical - 2.2L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement (Manual Transmission) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 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 TRANSMISSION MOUNT REPLACEMENT - SIDE .
  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)) .
  18. Connect the generator electrical connectors.
  19. Connect the starter electrical connectors.
  20. Install the AC compressor to the engine. Refer to COMPRESSOR REPLACEMENT .
  21. Install the engine drive belt. Refer to Drive Belt Replacement .
  22. Install the drive axles. Refer to AXLE SHAFT .
  23. Install the front suspension cross member. Refer to FRONT SUSPENSION CROSSMEMBER REPLACEMENT .
  24. Lower the vehicle.
  25. Connect the following electrical connectors:
    • IAC motor
    • TPS
    • 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) .
  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) .
    Fig 1: Installing Radiator Outlet Hose
    G01580576Courtesy of GENERAL MOTORS CORP.
  31. Install the inlet (1) and outlet (2) heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET (L61) and HEATER HOSE REPLACEMENT - OUTLET (L61) .
    Fig 2: Identifying Inlet & Outlet Heater Hoses
    G01580577Courtesy 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 .
  34. Install the power steering pump and bolts. Refer to POWER STEERING PUMP REPLACEMENT (2.2L (L61)) .
    Fig 3: Installing Power Steering Pump
    G01580578Courtesy of GENERAL MOTORS CORP.
  35. Connect the accelerator and cruise control cable.
    Fig 4: Connecting Accelerator & Cruise Control Cables
    G01580579Courtesy of GENERAL MOTORS CORP.
  36. Connect the brake booster hose at the brake booster.
  37. Connect fuel lines.
  38. Install the air inlet duct and resonator.
    Fig 5: Installing Air Inlet Duct & Resonator
    G01580580Courtesy of GENERAL MOTORS CORP.
  39. Fill the engine with oil.
  40. Connect the negative battery cable.
  41. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (L61) .
  42. Install the hood. Refer to HOOD REPLACEMENT .
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