Engine removal, GD

So I’ve put together this list of steps involved in removing a motor from an STI, 06 specifically, but I would imagine that this would be good for anything from an 04 to an 07. I realize that there are other lists here regarding engine removal but this one deals more with the efficient order of process.

This procedure has a difficulty level of 8-10. If you don't know your way around the tool box then have a shop do this work

Please understand that this is only one of a hundred ways to remove an engine from an STI and you may not exactly agree with the order I have chosen but this is the fifth time I’m doing this on my car alone and it is the method that best suits me. Practice makes perfect. If anyone finds this useful then that is great.

All input and comments are welcome, I’m sure I missed something.

Tools…
Engine Hoist
Floor Jack
Jack Stands
Screw Driver, Flat and Phillips
10mm Socket
12mm Socket
14mm Socket
12mm Wrench
14mm Wrench
Short and Long extension
Universal Joint
Pry Bar
Breaker Bar
14mm Hex, 10mm on older models
Heavy Pliers
Hose Clamp Pliers
Magnetic Wand (because you will inevitably drop something)
Drop cloth

Procedure…
1. Unplug Fuel Pump Relay
2. Loosen Gas Cap
3. Start Engine, Allow it to stall, Crank some more. (Releases fuel pressure)
4. Remove Battery
5. Remove Strut Bar (If Installed)
6. Remove Intercooler (Provides easy access to the turbo area)
7. Remove all visible fasteners from the turbo/downpipe union
Lift Vehicle
8. Unplug Rear O2 Sensor
9. Remove remaining nut from the turbo/downpipe union
10. Remove fasteners from the downpipe/intermediate pipe union
11. Remove Down Pipe
12. Remove lower engine Bell Housing bolts
13. Remove Motor Mount Nuts
14. Drain Coolant by opening the radiator petcock. You will need a large drop cloth.
Lower Vehicle
15. For WRX models remove the throttle and cruise control cables from the throttle body. Remove electrical connections to alternator, crank sensor, AC and power steering
16. Remove Upper and Lower Radiator Hose from engine
17. Remove coolant lines leading to the filler tank (passenger side)
18. Unplug Fans
19. Remove the Radiator
20. Remove Intake and Cold Air Box (if installed)
21. Remove the alternator belt guard
22. Loosen the belt tensioner for the AC belt, Remove Belt
23. Loosen tension on the power steering/alternator belt and remove
24. Remove reservoir hose from Power Steering Pump
25. Remove Power Steering Pump from engine and set aside.
26. Remove Alternator. Remove Air Conditioning Compressor Set aside where battery was
27. Remove Coolant Filler Tank from engine
28. Remove Bracket holding power steering lines to engine. (passenger side)
29. Remove Boost Controller vacuum lines. (passenger side)
30. Unplug Front O2 Sensor (passenger side)
31. Unplug Engine Harness (Both Sides)
32. Remove the Fuel Lines and Vacuum line to the fire wall and Master Cylinder (driver side)
33. Remove Pitchstop
34. Remove Starter (driver side)
35. Remove Heater Hoses from fire wall (driver side)
36. Remove the remaining bell housing bolts
37. Expose the Clutch Fork Shaft by removing the hex plug. (14mm Hex needed, or 10mm on some models) (driver side below starter) Remove the shaft by installing a temporary 10mm bolt into threaded hole and yank. Disengage the Fork from the Throwout Bearing prior to engine removal

Now you are ready to remove the motor (Do the following)
38. Attach Hoist (I simply tie an old seat belt around both sides of the intake manifold. This method will not scratch or leave marks on any painted or prepared surfaces like a chain might)
39. Position a floor jack underneath the transmission.
40. Lift the engine a bit with the hoist, then raise the jack to the tranny. This will balance the load on the input shaft of the tranny. Never allow the full weight of the engine to rest on the jack. Let the hoist do the work. .
41. Repeat until the engine mount studs have cleared the chassis allowing free forward movement of the motor.
42. Have a friend help with this step. Pry the engine from the tranny while very slowly pulling the hoist forward. Have someone there to catch the motor when it releases.

Tada! Its out.

I imagine that installation is in reverse order. The only thing to remember here is to attach the fork and throughout bearing assembly to the tranny first prior to mating the engine to the tranny.

Updated 08-21-2011. Pics provided by 1998typesh. I just doctored them up a bit with captions. Thank you Shawn!