GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 S10 Pickup - 2WD 🢒 Engine 🢒 Engine Mechanical - 2.2L 🢒 Engine Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the hood. Refer to Hood Replacement in Body Front End.
  3. If the vehicle is equipped with a manual transmission, remove the shift tower. Refer to Shift Tower Replacement in Manual Transmission - NV 1500.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Disconnect the exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.

    6. Object Number: 354503 Size: SH
  6. Remove the oil filter drain deflector from the brace rod, if equipped.
  7. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  8. Remove the transmission.
    9. • Refer to Transmission Replacement in Manual Transmission - NV 1500.
    • Refer to Transmission Replacement in Automatic Transmission - 4L60-E
  9. Disconnect the oxygen sensor electrical connector. Refer to Oxygen Sensor Replacement in Engine Controls 2.2 L (L43).

    10. Object Number: 43037 Size: SH
  10. Remove the right fender wheelhouse extension. Refer to Wheelhouse Extension Replacement in Body Front End.
  11. Working through the wheelhouse opening, remove the generator rear brace using the following procedure:
    12. 11.1. Remove the bolt from the rear of the generator.
    11.2. Remove two nuts holding the brace to the engine.
    11.3. Remove the brace from the engine.

    Object Number: 567202 Size: SH
  12. Remove the bolt holding the battery negative cable (2) to the engine.
  13. Remove the bolt holding the ground wires (1) to the engine.
  14. Disconnect the following electrical connectors:
    15. • Engine oil pressure gauge sensor (6)
    • Camshaft position (CMP) sensor (5)
    • Crankshaft position (CKP) sensor (3)
    • Knock (KS) sensor (4)

    Object Number: 567198 Size: SH
  15. Disconnect both ignition control module (ICM) electrical connectors (2).
  16. Disconnect the EVAP purge canister solenoid valve electrical connector.
  17. Lower the vehicle.

    18. Object Number: 566052 Size: SH
  18. Remove the bolt holding the EVAP emission canister purge harness and if equipped the automatic transmission fluid fill tube to the intake manifold.
  19. Remove the nut holding the engine wiring harness clip to the intake manifold.
  20. Remove the nut holding the engine wiring harness clip to the intake manifold rear lower stud.
  21. Remove the air intake duct. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls 2.2 L (L43).
  22. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
  23. Remove the drive belt. Refer to Drive Belt Replacement .

    24. Important: Do not evacuate the A/C system.

  24. Remove the air conditioning compressor, if equipped, and set it aside. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.
  25. Remove the power steering pump and set it aside. Refer to Power Steering Pump Replacement in Power Steering Systems.
  26. Disconnect both heater hoses from the heater core. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating Ventilation and Air Conditioning.

    27. Object Number: 565819 Size: SH
  27. Disconnect the heating and air conditioning control vacuum source hose.
  28. Disconnect the EVAP emission purge tube from the throttle body.

    29. Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

  29. Remove the accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls 2.2 L (L43).
  30. Disconnect the cruise control cable from the throttle shaft. Refer to Cruise Control Cable Replacement in Cruise Control.

    31. Object Number: 182736 Size: SH
  31. Remove the battery positive cable cover from the underhood fuse block.

    32. Object Number: 197383 Size: SH
  32. Remove the battery positive cable bolt.
  33. Remove the battery positive cable.
  34. Disconnect the engine coolant heater, if equipped. Refer to Coolant Heater Replacement in Engine Cooling.
  35. Disconnect the electrical connections from the generator. Refer to Generator Replacement in Engine Electrical.

    36. Object Number: 565578 Size: SH
  36. Disconnect the following electrical connectors from the top of the engine:
    37. • Engine coolant temperature (ECT) sensor (3)
    • Idle air control (IAC) motor (1)
    • Manifold absolute pressure (MAP) senor (4)
    • Throttle position (TP) sensor (2)

    Object Number: 565513 Size: SH
  37. Disconnect the fuel injector harness electrical connector.
  38. Remove the fuel injector harness electrical connector from the bracket on the valve rocker arm cover.
  39. Remove the engine wiring harness from the bracket.
  40. Move and secure the engine wiring harness out of the way.
  41. Disconnect the fuel hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls 2.2 L (L43).

    42. Object Number: 395650 Size: SH
  42. Disconnect the electrical connection from the generator.
  43. Disconnect the generator output wire from the generator.
  44. Move the engine wiring harnesses aside.

    45. Object Number: 384387 Size: SH
  45. Install a suitable engine lifting device to the engine lift brackets.
  46. Raise the engine to release tension on the engine mount through bolt.

    47. Object Number: 2491 Size: SH
  47. Remove the left side engine mount through-bolt.

    48. Object Number: 3440 Size: SH
  48. Remove the right side engine mount through-bolt.
  49. Remove the engine from the vehicle.

Installation Procedure
  1. Install the engine to the vehicle.
  2. Install the right side engine mount through-bolt. Refer to Engine Mount Replacement - Right Side .
  3. Install the left side engine mount through-bolt. Refer to Engine Mount Replacement - Left Side .

    4. Object Number: 384387 Size: SH
  4. Remove the engine lifting device from the engine lift brackets.
  5. Connect the fuel hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls 2.2 L (L43).

    6. Object Number: 565513 Size: SH
  6. Position the engine wiring harness.
  7. Install the engine wiring harness to the bracket.
  8. Install the fuel injector harness electrical connector to the bracket on the valve rocker arm cover.
  9. Connect the fuel injector harness electrical connector.

    10. Object Number: 565578 Size: SH
  10. Connect the following electrical connectors to the top of the engine:
    11. • Engine coolant temperature (ECT) sensor (3)
    • Idle air control (IAC) motor (1)
    • Manifold absolute pressure (MAP) senor (4)
    • Throttle position (TP) sensor (2)
  11. Connect the engine coolant heater, if equipped. Refer to Coolant Heater Replacement in Engine Electrical.
  12. Connect the generator electrical connectors. Refer to Generator Replacement in Engine Electrical.

    13. Object Number: 197383 Size: SH
  13. Attach the battery positive cable with bolt to the underhood fuse block.

    14. Tighten
    Tighten the battery positive cable to the underhood fuse block bolt to 10 N·m (89 lb in).


    Object Number: 182736 Size: SH
  14. Install the battery positive cable cover.

    15. Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

  15. Install a NEW accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls 2.2 L (L43).
  16. Connect the cruise control cable to the throttle body, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
  17. Install both heater hoses to the heater core. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating Ventilation and Air Conditioning.
  18. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering Systems.
  19. Install the air conditioning compressor, if equipped. Refer to Air Conditioning Compressor Replacement in Heating Ventilation and Air Conditioning.
  20. Install the drive belt. Refer to Drive Belt Replacement .
  21. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
  22. Install the air intake duct. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls 2.2 L (L43).

    23. Object Number: 565819 Size: SH
  23. Connect the heating and air conditioning control vacuum source hose.
  24. Connect the EVAP emission purge tube from the throttle body.

    25. Object Number: 566052 Size: SH
  25. Install he bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.

    26. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  26. Install the nut holding the engine wiring harness clip and the battery negative cable clip to the intake manifold.

    27. Tighten
    Tighten the engine wiring harness clip nut to 10 N·m (89 lb ft).

  27. Install the nut holding the engine wiring harness clip to the intake manifold rear lower stud.

    28. Tighten
    Tighten the engine wiring harness clip nut to 30 N·m (22 lb ft).

  28. Raise the vehicle to a height in order to work through the wheelhouse opening.

    29. Object Number: 567202 Size: SH
  29. Connect the following electrical connectors to the right side of the engine:
    30. • Engine oil pressure sensor (6)
    • Camshaft position (CMP) sensor (5)
    • Crankshaft position (CKP) sensor (3)
    • Knock (KS) sensor (4)
  30. Install the bolt and the ground wires (1) to the engine.

    31. Tighten
    Tighten the ground wire bolt to 35 N·m (26 lb ft).

  31. Install the bolt and the battery negative cable (2) to the engine.

    32. Tighten
    Tighten the battery negative cable bolt to 35 N·m (26 lb ft).


    Object Number: 567198 Size: SH
  32. Connect both ignition control module (ICM) electrical connectors (2).
  33. Connect the EVAP purge canister solenoid valve electrical connector (1).

    34. Object Number: 43037 Size: SH
  34. Install the generator brace using the following procedure.
    35. 34.1. Install the brace to the engine.
    34.2. Install the two nuts holding the brace to the engine.
    34.3. Install the bolt to the rear of the generator.

    Tighten
    Tighten the generator rear brace nuts and bolt to 25 N·m (18 lb ft).

  35. Install the right fender wheelhouse extension. Refer to Wheelhouse Extension Replacement in Body Front End.
  36. Connect the oxygen sensor electrical connector. Refer to Oxygen Sensor Replacement in Engine Controls 2.2 L (L43).
  37. Install the transmission.
    38. • Refer to Transmission Replacement in Manual Transmission - NV 1500.
    • Refer to Transmission Replacement in Automatic Transmission - 4L60-E.
  38. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.

    39. Object Number: 354503 Size: SH
  39. Install the oil filter drain deflector on the transmission brace rod, if equipped.
  40. Connect the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.
  41. Lower the vehicle.
  42. Install the manual transmission shift tower, if removed. Refer to Shift Tower Replacement in Manual Transmission - NV 1500.
  43. Install the hood. Refer to Hood Replacement in Body Front End.
  44. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  45. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  46. Fill the cooling system with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  47. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
  48. Start the engine and listen for unusual noises.
  49. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.

    50. If necessary, install an oil pressure gauge and measure the engine oil pressure.

  50. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature.
  51. Listen for improperly adjusted or sticking valves, sticking valve lifters, or other unusual noises.
  52. Inspect for oil and/or coolant leaks while the engine is operating.
  53. Verify that the distributor is properly positioned.
  54. Perform a final inspection for the proper engine oil and coolant levels.