Here is some info.
Ecotec swap guide 5 speed.
Ok guys I told you I was going to write I nice guide for a Eco swap, and yes this is SunCavi.
1st of all this is only available to My friends from the ORG and good luck.
I am not even going to bother writing how to pull the 2.4L or the OHV motor or the tranny out because if you don't know how to do it you are not going to be able to do the swap, and please have someone else do it if you really want it.
The parts that are needed for this swap are:
*Engine with full accesiories.
*Alternator
*Starter*
*TB
*power steering pump
*Power steering hoses
*Extend the gas lines
*Cooling hoses both
*Radiator, if you want or just rig the crap out of the old hose
*Complete engine wiring harness
*Headlight wiring harness, unless you wanna splice and stuff.
*Body wiring harness because the pin outs are NOT the same and IT WILL NOT WORK.!!!
*Gauge cluster
*BCM
*ECU
*Center console if you want it or just cut the old one
*Brake master cylinder
*Bend your old brake lines.
*Upper motor mount BTW too.
Ok another thing I wanna add is Trottle body bracket to hold the Throtlle cable.Ok now what I did with the fuel lines since mine were cut it I went and bought like a couple of feet of just regural hard brake line that fits in my stock fuel line and then bought more fuel line and extended it that way with some hose clamps. GHETTO. lol
This tranny crap is for the guys that are doing a 5 speed swap Getrag.
*Tranny
*Tranny mounts
*Axles
*Shifter
*Shifter cables
*Flywheel
*disk
*pressure plate
*throw out bearing
*Rear tranny mount bracket
*bracket on the tranny that holds the shifter cables
*MAKE SURE THEY GIVE YOU ALL THE BOLTS FROM THE BELL HOUSING AND THE PRESSURE PLATE TO FLYWHEEL, AND GIVE YOU THE CLIPS THAT HOLD THE SHIFTER CABLES DOWN, AND THE CLUTCH MASTER CYLINDER TOGETHER WITH THE THROW OUT BEARING.
If you don't have these clips when you push the clutch pedal it WILL pop out of the bearing and you won't have pedal.
Now I found the problem to this damn thing because I just got Nitrous put on my Eco and what I did is, I bent the little clip, kinda of like folded it and doubled up on it with some plyers and stuck it in there so that is doesn't flex and it doesn't give me crap anymore, hence NO problems there anymore I have been spraying on the motor like there is no tomorrow.
If your car had Isuzu 5 speed in it that you WILL be able to re-use the front tranny mount bracket it just needs to be shaved a little to clear the Getrag and drill a different hole in it. What I mean with this is that if you are looking straight at the bracket once you pull the wheel off you will see it as a little rectangle, well just shave the bottom right edge of it and RE-DRILL a hole about 2-3 inches to the left and you will be able to work with that.
The rear one, cut it off, go to GM dealer and buy a new one and weld it on.
PART NUMBER IS 22629361!!!!!!!!!!!.
The way you are going to do this is, bolt the tranny on the motor, and the tranny mounts on the tranny. Then put the bracket on the mounts and adjust the motor and the tranny with the cherry picker or a Jack where it need to be positioned and stuff, so that way the motor sits correct in the engine bay and not crooked.
I can also tell you about Evap canister, and the gas tank and the module.
Ok lets start and see what I did 1st.
I don't have any pics or anything, I am sorry because these swaps are pain in the a$$ and I am NOT usually happy when I do them because my car IS my daily driver and I need it on the road. I am going to referre to engine harness as EH, body harness as BH and head light harness as HH.
I pulled the Quad 4 out with the tranny so 1st of all I put the Eco motor with full accessories in it and mounted it on the upper and lower motor mount, I was looking at it and I said why not try to start it without the tranny with just the flywheel on and my old BH in it. I hooked everything up, all the new EH and left the old BH in it, and it did not crank whatsoever, the car was not ALIVE and that is when I figured out that I need the BH and the BCM and more crap.So I said I am going to junk yard and I am going to pull the BCM and the BH and go from there, I am also going to pull the cooling hosss out because they were different.
Next day I went to hook up the cooling hoses when I realized that the radiators were different and I had to find a way to hook it up, so I used the Ecotec hose that goes to the tranny side of the radiator and the other one, well lets just say I made that damn thing fit by, zip tying it to the oil dip stick away from the damn belt.Ok now I have to figure out the heater hoses, so I went to Auto Store find a hose with a 180 degree bend in it and just BYPASSED the heater core since I don't have a heater in the car. Gas lines were already done, Power steering was done, so now we are off to brake master cylinder. I had the 00+ master cylinder and let me tell you, you have to put the bracket 1st on the booster and the the master cylinder on the bracket and tighten down, and make sure you don't mix up the break lines, but you can just bend them to fit. Ok so now you have the cooling to the motor and you got gas, you have power steering and brakes. The motor is mounted, but the tranny is not.
Third time out we are attacking the tranny: So I did have Ishizu tranny in the car and I had the bottom bracket on there and the rear one, not that rear one mattered I had to cut it off and orded the GM one, I left you all a part number.Ok I mounted the tranny without the flywheel and the clutch on the motor with a couple of bellhousing bolts on there and positioned it how it is suppose to be in the engine bay and just left it there. Smoked a cigarette, brought out the welder, cutting wheel, and a drill. I put the tranny mounts on the tranny and tighten them down and then put the rear bracket on the mount and the bolt trough the middle, come on you guys know the drill, positioned the rear bracket and welded it. I cut the bottom one and RE-DRILLED the hole. Took the tranny off and installed the flyweel with the bolts, pressure plate and clutch disk with the aligment tool and the bolts, and broke one (THEY ARE BRITTLE), and went to put the tranny on the motor.It took me about 4 hours and it wouldn't clear. My friend came over and said you are tired aren't you, I was like why?? He said you didn't even undo the lower motor mount so HOW DO YOU EXPECT THE TRANNY TO GO IN THERE?? After I chased him away with the 23 mm WRENCH I did that and the tranny was on, with no PROBLEM, So from now on that is how we are doing it. Tighten the mounts and everything on and I went to sleep
Next time out, I am almost ready I got my BH and the BCM and HH and EH that was already in there. I changed the shifter and the shifter cables, changed the BH and the BCM put the HH on there I was like what the hell, threw some axles on the car (Getrag ones) Here in a Big one( 1st TIME I PUT THE ISUZU AXLES IN IT AND THEY WORKED!!!!!)but my dad made take them off because he MICKED THE AXLES ON THE GETRAG and told me they were thicker, he was sick of me braking the axles, so I did that. Now that everything is hooked up I am tired and went to sleep.
Next time out Everything is hooked up but the car will crank and it won't turn, MAN WAS I MAD!!!!!!!!!!!!! So I saw that my speedo won't hook up to the new BH so I thought that was the problem and I went and got one. Hooked it up and the Theft light came ON!!! Damn it!!! So I also realized the the RADIO plug is different and the cigarette lighter!! Damn it. Before you guys do this make sure all the FUSES ARE IN THE FUSE BOX AND THE ARE GOOD!! Please. So I call my friend at local GM dealership and he said the PASS LOCK IS ACTIVATED BECAUSE YOU ARE USING BCM, BH from one car, and the KEY with the magnetic pick up from your old car with the ignition. He said this is how you TEACH THE BCM to take it up the A$$.
You disconnect the battery and connect it while the ignition is off, get in the car and sit and DON'T TOUCH ANYTHING ASSOCIATED WITH POWER EVEN DOOR CHIME!!! Just sit there. When you get in the car, put the ignition ON and the Theft light SHOULD BLINK, leave it because it WILL blink for 10 minutes and stop, you have to catch it because as soon as it stops, you have a 5 second WINDOW, turn the ignition OFF and back ON, and it should start blinking for another 10 minutes. After the second 10 minutes it will stop and again you have a 5 SECOND frame to turn it OFF and back ON, now wait for the 3rd time and when the Theft light goes OFF, you can go ahead and START THE ECOTEC.
Ok now, it takes about 4-5 quarts of ENGINE OIL, 4.1 Quarts of Dextron Mercon Auto tranny fluid in the Getrag. You need to fill up the power steering, Coolant, and the brake master cylinder and the clutch(same fluid like the brakes). I am not going any further into the details about putting the master cylinder on and the throttle cable, you all should know how to do this, and I TOOK THE CAR FOR A SPIN!!!!!
Ok I am going to tell you all I had the motor in the car for almost 2 weeks, and I have:
*3 inch turbo exhaust on it, * Just regural air filter* No AC (but the compressor is still there)* RK lower mount* 55 shot Zex dry* strut tower bar* lower A-arm bar with poly bushings* Azenis at 20 PSI.
I ran a 9.53 in the 1/8th at like 73 mph with my gilrfriend in the car with me, and 2.2 60" time so I am guessing about 9.30's for me and the motor is bone stock. So about 14.3's in the 1/4.
Well that is about it and I am going to find the belt to run with NO AC, and I am going to post the DAMN belt size since everyone"""""" who has this done""""""", won't say the belt size number a$$holes, except you Craig.
SunCaviEco member since ealry 2000 contributing to you all like always.
From 2.2 OHV 3 speed to 55 shot to 65 shot, to 2.4L 4 speed to 55 shot to 65 shot, to 2.4L 5 speed to 2.4L all forged Turbo 10 PSI, to 2.2 DOHC 5 speed Getrag to 55 shot to TURBO VERY SOON.!!!
I hope this helps
SunCavi
<br>
Best time:"""11.946""" @ 114.73 mph @17psi 1.83--60"
11 second daily driver!!!!
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