There have been a lot of engine failure posts as of late and threads of people pulling their motors. We all know the labor costs of having work done on your S4 at an indy or dealership. For those that can turn wrenches, I have complied a comprehensive DIY for a motor pull. Along with actually getting your motor out it is a good reference for a vast amount pertaining to the S4. I hope you all find it useful.
Since this DIY is so big with over 150 pictures it makes it hard to post here because of the limitation of pictures allowed per post. I have it hosted on ea where i could post it easily since the settings are more laxed. If you don't want to venture over there, that is fine i just simply wanted to make you all aware that there is an article out there that could save a lot of time and money.
Here is the beginning parts...
Here is the DIY that you all have been waiting for. I have taken a lot of time to put together this DIY while i removed the engine on my avant. You can use this entire DIY to pull the motor or use sections of it to remove certain parts that are also involved with the engine pull.
Please note this DIY is NOT for the faint of heart. It is a very very detailed, tiring, and time consuming process. I highly recommend that you have a few capable hands working with you. If this is the case you should be able to have it pulled in a day if you work hard. If this is your first time do not be surprised if you cannot fit the engine removal and re-install in a weekend.
This is also a very good time to do maintenance items while you are pulling the motor for whatever reason. We all know the engine bay is cramped and hard to work in sometimes. With the motor out you really have no restrictions or limitations to working. Take advantage and do as much maintenance items as possible. It is also a good time for other modifications.
While the motor is out, you should consider the following:
Maintenance
Timing Chain Service ( Tensioners, Tensioner Guides, Timing Chains, Adjusters)
Valve Cover Gaskets
Serpentine Belt / Idler Pulley / Belt Tensioner
Spark Plugs
Coil Packs
Air Filter
Oil Change
Modifications
JHM Headers (Recommend Ceramic Coating or Header Wrap) / Aftermarket Downpipes
JHM Intake Manifold
JHM LW Pulley
Snub Mount
Upgraded Motor Mounts
LW Flywheel / Upgraded Clutch
JHM Shifter Trio
JHM Tune
JHM Intake Spacers
What you will need for re-install
2 Jugs of G12 Coolant (1.5 liter)- $25
1 Can of Powder Steering Fluid (1 liter)- Recommend CHF- $20
AC Recharge- $100
Various Hose Clamps (Buy an assorted pack)- $10
Estimate Total Cost of Necessary Parts: $155
Equipment / Tools Required
Critical Equipment
Engine Hoist- Must be rated at least 1/2 ton(Harbor Freight)
Lift Chains / Securing Hooks
4 Jack Stands
Jack
Tools Necessary
*Not all of these tools are absolutely necessary. For example you will not use every single socket in the 1/4 set, or you might prefer to use a 3/8 set instead of a 1/4. However, all are good to have and with many options it can make certain tasks easier with the right assortment of tools
1/4, 3/8, 1/2 Ratchets
1/4, 3/8, 1/2 Socket Sets (Shallow and Deep)
1/4, 3/8, 1/2 Breaker Bars (Assorted Lengths for Leverage)
Assortment of Flat Head Screw Drivers
Assortment of Philips Screw Drivers
Angled Pick Set
TORX Socket Set (T25, T30, T45 mostly used)
HEX Socket Set (6mm mostly used)
Ratcheting Wrench Set
Assorted Wrench Set (Metric)
Triple Square Set (110 mostly used)
Hose Clamp Removal Tool (Make things a lot easier)
Assortment of Pliers (Needle Nose, Channel Locks, Pliers)
Hammer
Rubber Mallet
Pry Bars
Can of PB Blaster / Spray Lubricant
Phases / Difficulty / Time Estimates
This DIY will be broken out into phases. Below is an outline of the phases involved for the motor pull process. I have also rated each phase based on difficulty with a scale of 1-10 (ten begin extremely difficult). Each section also has an estimated time to complete (note that this estimation is taking into account someone who is familiar with working on this section of the car).
Phase 1: Bumper Removal- Difficulty: 4 / Time: 45 Minutes
Phase 2: Radiator Removal- Difficulty: 5 / Time: 1 Hour
Phase 3: Stock Cat-back Removal- Difficulty: 2 / Time: 20 Minutes
Phase 4: Engine Bay Plumbing and Component Removal- Difficulty: 6 / Time: 1.5 Hours
Phase 5: Engine Electrical Harness Removal- Difficulty: 6 / Time: 2 Hours
Phase 6: Dropping the Shifter Box- Difficulty: 3 / Time: 45 Minutes
Phase 7: Final Components and Engine Pull- Difficulty: 8 / Time: 2-3 Hours
Total Time Estimate: 8-9 Hours
This gives us a realistic time frame of how long it will take to pull the motor first time around, working at a decent pace and taking short breaks. I have done this motor twice now and i can say i would feel comfortable getting it done in about 5-6 hours with capable assistance.
Air Conditioning Discharge / Recharge
The Air Condition lines must be disconnected during this engine pull DIY. It is up to you whether or not you want to have the system discharged professionally. Having it done properly will be better for the environment. However, this is totally up to you. An AC discharge should only run about $20. You can also buy a kit to do the discharge yourself. If wish to do it the lazy way, locate this AC line in the upper passenger side of the engine bay. Remove this black cap. Stick a pick or a small screw driver down in to vent the freon as shown below.
You will also need a Re-Charge upon completion. Prices vary, but expect to pay around $100 for it.
Helpful Recommendations
- Be Patient, Don't rush! It is a long process. If you become frustrated take a break. Going to quickly or getting upset will only lead to stuff breaking
- Ask Questions! If you become stuck or if something is not clear, take the time to ask. It is a long DIY and some things may not be crystal clear. Get in touch with me as i am more than happy to help
- Have Fun! Enjoy your passion and really learn about your car. Working on it is half the love for these cars
Again, the remainder can be found on euro addiction.
Enjoy all
Reply With Quote
Originally Posted by littleredwagen
Bookmarks