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]

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]

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]

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.


http://www.aleromod.com/forums/attachment.php?attachmentid=5655&stc=1&d=1229897412

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 (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=280295571858&ssPageName=STRK:MEWA:IT&ih=018#ht_827wt_182)


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.

[comanche]

Yeah, I know, too bad it wasn't a GL2.

I wanted a 4-door stick ecotec for a good price, and that's what I got.

I will add fog-lights, remote start probably, and also somehow make the front passenger's window power - the drivers and the rest I will leave manual. And of course I will have a to-do list - add rear calipers, upgrade to corvette brakes, etc.

[Cliff8928]

The rear should be disc on a '02. I have the front lighting harness for mine to add in the fog lights, just haven't gotten any yet.

[Alero_1986]

Nice buy! That should save you some trouble with the swap :p

Hope it works out!

[comanche]

Car is now in hand, at home.

NOT as described, but good enough.

I dislike the stiffness of the shifting of the manual trans, but I know they are all that way. Needs a LH upper strut mount. Does have a block heater though - I love that. I will probably put a grand am gt stock muffler on (dual out) for starters, this muffler doesn't sound too great.

And somehow get the smoking smell out of this (as described) non-smoking car....

Runs and drives good - I hope to get it looking very good. Border crossing was relatively easy, just make sure you have your paperwork ready.

I also want to switch out the steering wheel - this is the first alero I have had without the leather wrapped steering wheel, and I miss it.

[Vinalero]

Car is now in hand, at home.

NOT as described, but good enough.

I dislike the stiffness of the shifting of the manual trans, but I know they are all that way. Needs a LH upper strut mount. Does have a block heater though - I love that. I will probably put a grand am gt stock muffler on (dual out) for starters, this muffler doesn't sound too great.

And somehow get the smoking smell out of this (as described) non-smoking car....

Runs and drives good - I hope to get it looking very good. Border crossing was relatively easy, just make sure you have your paperwork ready.

I also want to switch out the steering wheel - this is the first alero I have had without the leather wrapped steering wheel, and I miss it.

Stiffness of the shifting? I always thought mine was sloppy and unprecise before the short shifter, and even now lol. Also the friction point seems to not be at the same place from shifts to shifts :lol: But hey, I take a stick over an auto anytime.

try the newspaper trick for the cigarette smell.

[Cliff8928]

I guess the trans could be better described as notchy versus stiff.

That's strange that it doesn't have the leather wheel! Even my GX has one.

[Spilner521]

I will probably put a grand am gt stock muffler on (dual out) for starters, this muffler doesn't sound too great.

That's not going to change a thing besides having an extra tip. It's the exact same muffler that comes stock on every Alero and Grand Am, except it has an extra tip to fit the GAGT rear bumper. Just wait 'til you can do the whole exhaust.

[comanche]

That's all I wanted - the extra tip.

I don't have the money for a full exhaust right now, or in the near future, so I figured this was the cheapest way for dual exhaust.