Left Cylinder Head

WARNING: This page is about a different variant/trim than selected.

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Clean and inspect gasket mating surfaces. Refer to CYLINDER HEAD, CLEANING .
Remove the (special tool #VM.10339, Tool, Crankshaft Timing) (1).
Set the number one piston to top dead center (TDC).

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NOTE:
Typical view of scooter block.
Using the (special tool #D-115-2A, Block, Scooter) (2) and the (special tool #C-3339A, Set, Dial Indicator) (1), position the Scooter block with dial indicator flat on the cylinder block head surface and zero the dial indicator (1).

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NOTE:
Typical view of scooter block.
Position the scooter block with dial indicator (1) onto the piston (2).

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Measure the height of the piston in the location illustrated (1) and record measurement.
Measure the height of the piston in location illustrated (2) and record measurement.
Repeat the procedure for each cylinder.

Use the highest reading of the 4 piston protrusion readings to determine the required gasket thickness.

HEAD GASKET SELECTION CHART
	Metric	Standard
PISTON CLEARANCE	0.130 - 0.220 mm	0.0051 - 0.0086 in.
CYLINDER HEAD GASKET THICKNESS	0.96 mm	0.0377 in.
GASKET IDENTIFICATION	NO HOLE

PISTON CLEARANCE	0.221 - 0.310 mm	0.0087 - 0.0122 in.
CYLINDER HEAD GASKET THICKNESS	1.06 mm	0.0417 in.
GASKET IDENTIFICATION	ONE HOLE

PISTON CLEARANCE	0.311 - 0.402 mm	0.0122 - 0.0158 in.
CYLINDER HEAD GASKET THICKNESS	1.16 mm	0.0456 in.
GASKET IDENTIFICATION	TWO HOLES

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NOTE:

The above illustration shows gasket identification marks.

Select the appropriate cylinder head gasket from the cylinder head gasket chart.

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Install the NEW head gasket (3) onto the engine block (5). Be sure the coolant passages align (part number should be facing up).
Install the cylinder head (2) onto the engine block (5) and install the NEW bolts (1) finger tight.

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Install the intake side (special tool #VM.10343A-2, Alignment Tool, Cylinder Head (Left Intake)) (1) an securely tighten bolts (2).
Install the exhaust side (special tool #VM.10343A-3, Alignment Tool, Cylinder Head (Left Exhaust)) (3) an securely tighten bolts (4).

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NOTE:
Right side shown in the illustration, left side similar.
Using the tighten sequence shown in the illustration, tighten the cylinder head bolts to:
- 30 N.m (22 ft. lbs.).
- Tighten the bolts an additional 75° turn.
- Tighten the bolts an additional 75° turn.
- Tighten the bolts an additional 75° turn.
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Remove the bolts (2) and (special tool #VM.10343A-3, Alignment Tool, Cylinder Head (Left Exhaust)) (1).
Remove the bolts (4) and (special tool #VM.10343A-2, Alignment Tool, Cylinder Head (Left Intake)) (3).

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Install the bolt securing the coolant tube (2) to the cylinder head and tighten to 25 N.m (18 ft. lbs.).
Install the water pump housing assembly. Refer to PUMP, WATER, INSTALLATION .
NOTE:
Follower and tappet assemblies must be installed in same location as when removed.
Install the followers and tappets into their original position as noted during removal.
Install the left side intake and exhaust camshafts. Refer to CAMSHAFT, ENGINE, INSTALLATION .
Install the glow plugs and tighten to 8 N.m (71 in. lbs.).
Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION .
Install the left side exhaust manifold. Refer to MANIFOLD, EXHAUST, INSTALLATION .