Complete powertrain swap: 2.2L stick in place of 2.4L AT

[comanche]

This is an idea I have going, not a definite, but has potential.
I am considering purchasing a 99' Alero with bad engine, and swapping in from a 02+ Alero a 5spd and Ecotec. (from a salvage yard)

I know I will need the following:
Engine
Transmission
Driveaxles
Computer
Wiring Harness
Alternator, AC Compressor, etc.
Shifter box and cables
Radiator and hoses
Clutch pedal
Master cylinder (and everything else that goes with it).
Brake pedal


Is there anything else I will need?

Has anyone done this before? I looked at the j-body website, but obviously the j-body is a completely different car...

[Alero_1986]

why not just buy an alero already equipped with a 5 speed and save yourself the trouble. You can find them pretty cheap if you look.

[comanche]

1. 5spd aleros are common only in Canada (I have looked) and 90 % of the time they are 2-doors. I want an alero with 4 doors (safer, fewer rust problems, lighter doors, etc)
2. I can pick up a bad engine alero for under $1000 and I can buy all the parts necessary for the conversion for about $1000, which equals about 2000. It is hard to find a stick 4-door alero for that price.

[Spilner521]

4 door cars have lighter doors, but there's also 2 more of them. It all evens out.

You'll also need the radiator and hoses from the Ecotec car, and the clutch pedal, master cylinder, and everything else that goes with it. It would also be a good idea to get the brake pedal so you don't have to cut yours.

As far as I know nobody has done it in an Alero. I'm swapping my 2.4 for the Ecotec but going with the automatic.

[comanche]

Thanks, I forgot about that. I will add that stuff to the list. Anybody think of anything else?

[slvralero420]

also the subframe is needed since all the mounts are going to be different.

[Spilner521]

You don't need the entire subframe, but you will need the engine and transmission mounts. Since this is an automatic car, I think for the manual transmission to be mounted, the mount needs to be welded to the frame. I forget the details exactly.

[slvralero420]

I thought it was the whole thing since he's swapping from an auto to a manual it would have different mounting locations and whatnot. I'm not 100% sure tho.

[Spilner521]

Different mounting location, yes, but the entire front subframe of the car doesn't need to be swapped. Maybe Cliff will jump in here, he knows a lot of little details about this kind of stuff.

[slvralero420]

I know the entire subframe wouldn't NEED to be swapped but its easier and some of us don't have access to a welder. Thats what I was thinking at least.

[Alero_1986]

Originally Posted by Alero_1986

why not just buy an alero already equipped with a 5 speed and save yourself the trouble. You can find them pretty cheap if you look.

I was not aware of that. I guess that's why I am seeing so many of them local.

[Spilner521]

Originally Posted by slvralero420

I know the entire subframe wouldn't NEED to be swapped but its easier and some of us don't have access to a welder. Thats what I was thinking at least.

Swapping the entire subframe of a car to another car is easier than having a shop weld in a mount?

[Cliff8928]

Originally Posted by Spilner521

Swapping the entire subframe of a car to another car is easier than having a shop weld in a mount?

Yes... I would think so.

For a reference pic, I used one from Alero_1986.

That mount on the right side of the pic (drivers side of the car) is not there in an autotragic Alero.




Also, don't forget the console trim. The good thing about this swap is that the powertrain harness is separate from the rest. It interfaces with the 2 PCM plugs and I think 2 others?

I'm not sure if the A/C line off the back of the compressor is different between the two, that's something to check. Unless you're going to have one fabricated at a local shop, get the exhaust downpipe too.

If you want to get nit picky about it you would also get the clutch safety switch and the bezel around the ignition cylinder.

I would also snag the BCM from the donor car if it's cheap just to avoid having the existing one reprogrammed. You will need the PCM bracket from the Ecotec car too.. The Ecotec PCM is less than half the size of the 2.4/3400 one.

[Alero_1986]

Those are my shoes!

[Alero_1986]

btw. I may have some better pics if you need any assistance.

[comanche]

Thanks everyone... now I just need to find a cheap alero to do this to...

[comanche]

Ok, here's another idea for the experts?

What if I bought an older alero (cheaper) with the 2.4L and a 5 spd?
How much work would it take then? (to swap in an Ecotec)
Is the trans the same, or workable? I know I would still need coolers, wiring harness, and PCM, etc.

Is it worth it?

[comanche]

Hey, I just bought what I wanted: Here


I didn't post this earlier in fear that someone else would buy it. Now my project will have to be postponed until necessary.

[comanche]

So yes, Alero1986, I did have to go to Canada to buy what I wanted!

I will be in Norwich, ON over New Years (2x per year traditional trip to visit relatives). I hope to pick the alero up monday or tuesday and drive it back on saturday.

I wouldn't mind living in Canada, except that I would have to give up my Sig P226 (learned that recently at a CPL class) and miss all of my American benefits (lower taxes), a great President (bush) and all of the great stuff that makes the us America.

I was looking on Kijiji, and if anyone wants to buy aleros, go to Ontario. They are cheap and easy to find. VERY CHEAP. Manual trans. are easy to find too.

[Cliff8928]

Hah, that's funny... I was near Richmond Hill earlier this year.

Good buy... Too bad it wasn't a GL2.