I have not seen a VFAQ about the disassembly of the 4G63 engine. I will post some pictures of my JDM 6-bolt disassembly and comment about them:
Reason for tearing this engine down was due to a skipped timing belt.
Start off by putting your engine on a stand. I bought mine from cummins tools but you can find them pretty much at any auto parts stores.
I always like to get the Intake manifold off first so let's start there:
Remove the bolts holding the throttle body elbow and throttle body down: 2 x 12mm bolts 2 x 12mm nuts. Don't forget the bracket that connects from the CAS to the Throttle Body. There is a 12mm nut on the CAS that you need to take off for that.
Remove the Throttle Body Elbow and coolant lines from throttle body.
Remove the throttle body
I removed the fuel rail prior to removing the engine from the car 3 x 12mm bolts 2 x 10mm bolts for the feed line and pop off the return line with some pliers. If you did not do this, remove the fuel rail and injectors now. Then, start removing all the top intake manifold bolts.
The studs on the end of the intake manifold are a larger size than the others. 2 x 14mm nuts and 3 X 12mm bolts on top.
Now, remove the bolts from the underside of the intake manifold 4 x 12mm bolts.
Now that all the bolts are out you can remove the intake manifold and gasket.
Now we can focus on the Exhaust Manifold and the Turbo:
Remove the four bolts holding the turbo to the manifold 4 x 14mm. Make sure you have disconnected the coolant hoses to the turbo (use pliers on the clamps) and the oil feed line 17mm Banjo bolt and return line 2 x 10mm bolts on oil pan and 2 x 10mm bolts on underside of turbo. After that is done you can remove the turbo and set it aside.
Turbo Removed:
Reason for tearing this engine down was due to a skipped timing belt.
Start off by putting your engine on a stand. I bought mine from cummins tools but you can find them pretty much at any auto parts stores.
You must be logged in to view this image or video.
I always like to get the Intake manifold off first so let's start there:
Remove the bolts holding the throttle body elbow and throttle body down: 2 x 12mm bolts 2 x 12mm nuts. Don't forget the bracket that connects from the CAS to the Throttle Body. There is a 12mm nut on the CAS that you need to take off for that.
You must be logged in to view this image or video.
Remove the Throttle Body Elbow and coolant lines from throttle body.
You must be logged in to view this image or video.
Remove the throttle body
You must be logged in to view this image or video.
I removed the fuel rail prior to removing the engine from the car 3 x 12mm bolts 2 x 10mm bolts for the feed line and pop off the return line with some pliers. If you did not do this, remove the fuel rail and injectors now. Then, start removing all the top intake manifold bolts.
You must be logged in to view this image or video.
The studs on the end of the intake manifold are a larger size than the others. 2 x 14mm nuts and 3 X 12mm bolts on top.
You must be logged in to view this image or video.
Now, remove the bolts from the underside of the intake manifold 4 x 12mm bolts.
You must be logged in to view this image or video.
Now that all the bolts are out you can remove the intake manifold and gasket.
You must be logged in to view this image or video.
Now we can focus on the Exhaust Manifold and the Turbo:
Remove the four bolts holding the turbo to the manifold 4 x 14mm. Make sure you have disconnected the coolant hoses to the turbo (use pliers on the clamps) and the oil feed line 17mm Banjo bolt and return line 2 x 10mm bolts on oil pan and 2 x 10mm bolts on underside of turbo. After that is done you can remove the turbo and set it aside.
You must be logged in to view this image or video.
Turbo Removed:
You must be logged in to view this image or video.
Last edited by a moderator: