I want to know how to put engine?transmission back ...

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1991-94 1.6L and 1991-96 2.0L Engines

See Figures 19 - 22

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Fig. 19: Exploded view of outer components on the intake side-GA16DE engine

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Fig. 20: Exploded view of outer components on the exhaust side-GA16DE engine

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Fig. 21: Exploded view of outer components-SR20DE engine

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Fig. 22: Exploded view of outer components exhaust side-SR20DE engine

It is recommended that the engine and transaxle be removed as a unit. If necessary, they may be separated after removal.

The 1.6L (GA16DE) engine cannot be removed separately from the transaxle. Remove the engine and the transaxle as a unit. If equipped with 4WD, remove the engine, transaxle and transfer case together.

1. Mark the hood hinge relationship and remove the hood.

2. Release the fuel system pressure, disconnect the negative (-) battery cable and raise and support the vehicle safely.

3. Drain the cooling system and the engine oil.

<Remove the air cleaner and disconnect the throttle cable.

4. Disconnect or remove the following:

   1. Drive belts.

   2. Ignition wire from the coil to the distributor

   3. Ignition coil ground wire and the engine ground cable

   4. Block connector from the distributor

   5. Fusible links

   6. Engine harness connectors

   7. Fuel and fuel return hoses

   8. Upper and lower radiator hoses

   9. Heater inlet and outlet hoses

   10. Engine vacuum hoses

   11. Carbon canister hoses and the air pump air cleaner hose

   12. Any interfering engine accessories: power steering pump, air conditioning compressor or alternator

   13. Driveshaft from transfer unit for 4WD vehicles.

Make sure to matchmark the driveshaft flanges.

6. Remove the air pump air cleaner.

7. Remove the carbon canister.

8. Remove the auxiliary fan, washer tank, grille and radiator (with fan assembly).

9. Remove the clutch cylinder from the clutch housing for manual transaxles.

10. Remove both buffer rods without altering the length of the rods. Disconnect the speedometer cable.

11. Remove the spring pins from the transaxle gear selector rods.

12. Install engine slingers to the block and connect a suitable lifting device to the slingers. Do not tension the lifting device at this point.

13. Disconnect the exhaust pipe at both the manifold connection and the clamp holding the pipe to the engine.

14. Remove the lower ball joints.

15. Drain the transaxle gear oil.

16. Disconnect the right and left side halfshafts from their side flanges and remove the bolt holding the radius link support.

When drawing out the halfshafts, it is necessary to loosen the strut head bolts.

17. Lower the shifter and selector rods, and remove the bolts from the engine mount brackets. Remove the nuts holding the front and rear engine mounts to the frame.

18. Disconnect the clutch and accelerator wires and remove the speedometer cable with its pinion from the transaxle.

19. Lift the engine/transaxle assembly up and away from the vehicle.

To install:

20. Lower the engine/transaxle assembly into the vehicle. When lowering the engine onto the frame, make sure to keep it as level as possible.

21. Check the clearance between the frame and clutch housing and make sure the engine mount bolts are seated in the groove of the mounting bracket.

22. After installing the engine mounts, adjust and install the buffer rods. The front should be 3.50-3.58 in. (89-91mm), and the rear 3.90-3.98 in. (99-101mm).

23. Tighten the engine mount bolts first, then apply a load to the mounting insulators before tightening the buffer rod and sub-mounting bolts.

24. Connect the clutch and accelerator wires and install the speedometer cable with its pinion to the transaxle.

25. Raise the shifter and selector rods to their normal operating positions.

26. Connect the halfshafts.

27. Connect the lower ball joints and install new cotter pins.

28. Connect the exhaust pipe to the manifold connection and the clamp holding the pipe to the engine.

29. Disconnect the lifting device and remove the engine slingers.

30. Insert the spring pins into the transaxle gear selector rods.

31. Connect the speedometer cable.

32. Mount the clutch cylinder onto the clutch housing.

33. Install the auxiliary fan, washer tank, grille and radiator (with fan assembly).

34. Install the carbon canister.

35. Install the air pump air cleaner.

36. Install or connect all hoses, belts, harnesses, connectors and components that were necessary to remove the engine.

37. Connect the throttle cable and install the air cleaner.

38. Fill the transaxle and cooling system to the proper levels.

39. Install the hood and connect the negative (-) battery cable.

40. Make all the necessary engine adjustments. Charge the air conditioning system. Road test the vehicle for proper operation.

Hope this helps, an accept would be appreciated.

Edited by FirstHogman on April 17 2006 at 3:45pm

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If more information is needed, please ask me.

Hope this helps, an accept would be appreciated.
Firsthogman
Love them Harley's

THE DIAGRAM ARE TO SMALL,CAN NOT SEE WERE THE MOTOR MOUNTS ARE.PLEASE HRLP!

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