2. Remove the air filter cover with air duct.
3. Disconnect the accelerator cable.
4. Remove the four clamps and disconnect the wiring harness.
5. Disconnect the crankcase ventilation hose.
6. Disconnect the vacuum hoses at the locations shown in the figure.
7. Disconnect the connectors of the exhaust gas recirculation solenoid valve (EVRV) and the EGR solenoid valve.
Removal and installation of the cylinder head assembly (ZS-T)
1 - accelerator cable,
2 - vacuum hose,
3 - cylinder head cover assembly with vacuum pump,
4 - wiring harness,
5 - vacuum hoses,
6 - electromagnetic valve for vacuum regulation (EVRV) of the exhaust gas recirculation system,
7 - EGR electro-pneumatic valve,
8 - heater hoses,
9 - fuel supply hose,
10 - fuel return hose,
11 - Cooling system hose (radiator supply hose),
12 - air filter cover with air duct,
13 - fuel hoses,
14 - temperature sensor connector,
15 - timing belt cover No.3,
16 - high pressure fuel pipes,
17 - clamp No.2 of the high-pressure fuel pipe,
18 - fuel pump connector bracket,
19 - fuel return hose,
20 - gasket,
21 - drainage tube,
22 - coolant bypass hose,
23 - oil dipstick guide,
24 -, 25-, 27-, 28-, 31 - gasket,
26 - exhaust system receiving pipe,
29 - cylinder head assembly,
30 - turbocharger cooling hose No.1.
Unscrew the three bolts and remove the indicated valves.
Note: Do not disconnect the vacuum hoses from the valves.
8. Remove the three bolts and move the vacuum tube to the side.
Note: Do not disconnect the vacuum hose.
9 Remove the cylinder head cover with the vacuum pump.
a) Remove the plug of timing belt cover No.2.
b) Turn the crankshaft clockwise until the mark on the camshaft pulley is positioned at the bottom.
In this position, the vacuum pump piston is at BDC and the spring compression becomes minimal.
c) Unscrew the two bolts of timing belt cover No.2.
d) Unscrew the wiring harness mounting bolt.
d) Unscrew 10 bolts and remove the cover with the pump.
10. Remove the timing belt (see the relevant section).
11. Disconnect the two coolant bypass hoses. Loosen the bolt, slide the clamp and disconnect the coolant supply hose.
12. Disconnect the radiator supply hose.
13. Disconnect the wiring harness from the glow plug connector.
14. Remove timing belt protective cover No.3.
15. Disconnect the coolant level indicator sensor connector.
16. Remove the clamp, then remove the dipstick guide.
17. Disconnect the fuel hose.
18. Remove the high pressure fuel pipes.
a) Unscrew 3 nuts, remove the fuel injection pump connector mounting bracket and clamp No.2 of the high-pressure fuel pipe.
b) Unscrew the four fastening nuts shown in the figure and disconnect the fuel pipes from the injectors.
c) As shown in the figure, unscrew the four nuts and disconnect the fuel pipes from the high-pressure fuel pump.
19. Remove the drainage tube.
20. Disconnect the fuel and heater hoses.
21. Remove turbocharger cooling hose No.1.
22. Unscrew 3 nuts and remove the exhaust pipe.
23. Loosen the bolt and disconnect the exhaust manifold and strut.
Remove the two nuts and disconnect the oil pipe from the turbocharger.
24. Removing the cylinder head.
a) Loosen the 18 cylinder head mounting bolts in the sequence shown in the figure, then unscrew them completely and remove them together with the washers.
b) Remove the cylinder head.
c) Remove the cylinder head gasket.