Challenges:
* Engine Mounts: The engine mounts will almost certainly be different. You'll need to fabricate custom mounts or adapt existing ones.
* Transmission: The Ecotec likely uses a different transmission than the 1996 Sunfire's. This means you might need a new transmission, transmission mounts, driveshaft, and potentially even a rear differential (depending on the transmission choice). Compatibility needs careful checking.
* Wiring Harness: The engine wiring harness is completely different. You'll need to either heavily modify the existing harness, or source a harness from a donor car (a 2002 Cavalier) and wire it into the Sunfire's system. This is probably the most complex part of the swap.
* Computer (ECU): The Ecotec engine requires its own ECU. You'll need to source this as well, and it will likely need tuning or adjustments to work correctly in the Sunfire.
* Exhaust System: The exhaust system will need modification or replacement to fit the Ecotec.
* Cooling System: The cooling system components might not be directly compatible.
* Accessories: Power steering, alternator, and AC components might require modification or replacement for proper fitment.
Feasibility:
While challenging, it's *feasible* with sufficient mechanical skills, fabrication abilities, and electrical knowledge. This isn't a project for a beginner. You'll need access to wiring diagrams, a donor car for parts, and likely specialized tools.
Recommendations:
* Research: Thoroughly research the specific engine codes and transmission codes for both the donor Cavalier and the Sunfire. This will help determine compatibility issues.
* Donor Car: Ideally, find a complete donor car (2002 Cavalier) to harvest parts from.
* Professional Help: Consider seeking assistance from an experienced mechanic or swap shop. This project is very time-consuming and could easily go wrong without proper expertise.
In short, while technically possible, it's a very involved project requiring extensive mechanical knowledge, fabrication skills, and a significant time investment. The cost could potentially outweigh the benefits unless you have access to parts at a very low cost. Weigh the complexity and cost against the potential gains before starting.
