I5 Engine Removal/Refit Advice Please

[Derek]

Iain,

When I removed / reinstalled the motor on my 4kq I lowered it and the
transmission from the bottom.  I pretty much followed the proceedure that
Bently outlines for the UrQ.

Here's a brief outline of what I did.  (the undocumented proceedure for
changing the air filter)

*Disconnect everything from the motor, pull the injectors out, hoses,
coolant, drain oil, power steering pump, throttle cable, cruise, mark wires
and disconnect.
*AC... I removed it long ago.  It may be possible to tie the compressor out
of the way and not discharge the system.  YMMV.
*Once everything I could reach on top of the motor was done, I jacked the
car up a few feet and set it on the biggest stands I could find..
*Undo everything underneath, gearshift linkage, exhaust, consider removing
the radiator, diff lock vac lines, rear driveshaft, ground straps, starter
wiring, etc.
*You can undo the inner CV's and tie the halfshafts out of the way, or undo
the outer CV and the axles will come out with the transmission.
*Remove the front subframe bolts, loosen the rear...but don't remove.
They're holding the transmission up.
*Figure out how you're going to support the motor and gearbox.  I used a
floor jack, with an assistant to help steady the motor.  The balance point
is the rear of the oil pan, where the flywheel cover bolts to the block.  I
left the subframe attached to help spread the load.
*With the motor supported, _carefully_ undo the motor mounts and rear
subframe bolts..  I did this from beside rather than under the car.
*Hopefully there isn't some sender still plugged in, and the motor and
gearbox can be lowered to the ground.  Unless you remove the inlet manifold,
you'll need to move the motor to the (UK) passengers side so as to clear the
frame rail under the airbox.
*Breathe a huge sigh of relief when it's on the ground.
*Don't forget to stand in the empty engine bay just for kicks. :)

http://www.users.qwest.net/~daleep/audi/outsmall.jpg

As for getting it back in... I went and bought an engine crane.  This
allowed me to slide the motor and gearbox under the car, attach the crane,
and lift it back in.  The crane makes it a one person job.

Hope this helps.
-Derek L.