Repair 7

Park the vehicle on a flat surface and set the parking brake. Open the hood and disconnect the negative battery cable.

Remove the shifter trim with a trim removal tool. A flathead screwdriver can be used, but the silver trim is easily scratched, so using the right tool can prevent damage. Remove the two screws underneath the trim with a Phillips screwdriver.

Grip the bottom of the shifter panel cover on both sides and pull out slightly to disengage the retaining tabs, then pull up on it to completely remove it.

Remove the temperature control knobs and vents by pulling them straight off by hand. Pry up the edges of the dash control panel with a flathead screwdriver to disengage the clips. Remove the dash control panel.

Remove the kick panel trim on both sides with a trim removal tool. Remove the screws holding the kick panel in place with a Phillips screwdriver. Remove the kick panels.

Remove the trim between the windshield and dash with a trim removal tool.

Open the glove compartment. Push in on the glove box and lift to remove the glove box.

Remove the screws holding the dash in place. There are two where each of the kick panels were located, four along the windshield, two inside the glove compartment cavity and three where the center control panel was removed.

If the vehicle has a standard transmission, place the shift control arm in neutral. If it has an automatic transmission, place the shift control arm in the position that is farthest from the dash. Push the button underneath the steering wheel and lower the steering wheel as far as possible.

Lift up caully on the dash, then pull it forward about one and a half feet. Unplug all of the electrical connections from the rear of the dash, including the instrument cluster and temperature controls. Depending on the vehicles features, there may be more.

Slide the dash forward, lift it over the top edge of the steering wheel, then cant it slightly sideways to fit it through the passenger side door. Removing it from the driver side is cramped and could cause damage to the interior, so avoid going that way if possible.

Disconnect the cables from the negative terminals of both batteries with a socket wrench. This prevents anyone from starting the engine while removing the cylinder head.

Put a drain pan under the radiator. Remove the drain plug with a socket wrench and allow the coolant in the radiator to drain into the pan. Store the coolant for later use.

Detach the shrouds for the radiator fan with a socket wrench. Disconnect the fan and clutch for the radiator as an assembly by using tools T83T-6312-A and T83T-6312-B. The mounting nut for the radiator fan and clutch has a left-hand thread, so you must turn it clockwise to remove the nut.

Label the electrical wiring on the alternator so you can connect it correctly later and detach the wiring from the alternator. Disconnect the bolts for the alternator and vacuum pump with a socket wrench. Remove these components from the engine block.

Disconnect the coolant hose from the cylinder head with a socket wrench. Remove the fuel injection pump from the engine block. Disconnect the intake manifold and valley cover from the engine block.

Raise the vehicle with a floor jack and support it with jack stands. Remove the exhaust pipes from the exhaust manifolds with a socket wrench. Disconnect the clamp and mounting bolt for the oil dipstick tube. Detach the oil dipstick tube from the cylinder head and lower the vehicle.

Disconnect the valve covers with a socket wrench and remove the rocker arms from the engine block. Record the position of each push rod, so you can re-install them correctly later. Remove the push rods from the engine block.

Remove the fuel injector nozzles and glow plugs from the engine block with a socket wrench. Disconnect the mounting bolts for the cylinder head with a socket wrench. Install lifting eyes on each end of the cylinder block with tool T70P-6000.

Lift the cylinder head from the engine block with the lifting eyes. Use caution to prevent the pre-chambers of the cylinder head from falling onto the engine when you remove the cylinder head.

Sit in the drivers seat and put the ignition key in, turning the key to the first position. Make sure the engine doesnt start, though.

Find the trip odometer knob and push it in, holding it down while you turn the key in the ignition to the second position. This is the position right before the engine starts.

Watch the instrument panel and look for the service engine light to flash. After it flashes three or four times, turn the key in the ignition back to the first position. Make sure you are still holding the trip odometer button down.

Let the trip button go and turn on the engine. Notice whether or not the service engine light has turned off. If it hasnt turned off, repeat the procedure.

Get into the vehicle and put the key into the ignition. Turn the vehicle on but dont start the engine.

Press on the accelerator quickly five times in five seconds and release the pedal. Make sure you press the pedal all the way down to the floor of the vehicle. Wait for about 10 seconds.

Push the pedal all the way to the floor and hold it for 10 seconds or until the engine light flashes on and off. Release the pedal.

Repeat step 3.

Turn the ignition off and wait 3 minutes. Turn on the engine. The engine light should now be off.

Disconnect the kickstand of your scooter. The kickstand is attached to your scooter by a small metal pin that is tightened by a bolt. Crack the bolt and pull the pin partially out and you will be able to remove the kickstand.

Unscrew the two or three bolts holding the plastic molded covering to which the kickstand was attached. This covering is the intake cover. Removing it will reveal the variator system.

Unscrew the six bolts. Hold the metal, flattened, cylindrical lid onto the case, revealed when you removed the intake cover. This is the variator case. Removing the six bolts will allow you to remove the lid, giving you access to the pulley system and governing washer.

Detach the front pulley wheel from the variator system. Use an impact wrench to remove the bolt holding the wheel in place. An impact wrench is an air-powered socket wrench.

Extricate the small washer from the front pulley rod. This washer acts as the governor of your scooter, limiting the variator systems ability to perform at full capacity and dropping your scooters acceleration and top speed capabilities.

Put your scooter back together, starting with the front pulley wheel, the lid of the variator case, the intake case and finally by reattaching the kickstand.

Lift the hood of your vehicle and prop it open. Remove the negative cable from the battery terminal by loosening the nut on the cable with a 10-mm end wrench. (If you have a Miata, the battery is in the trunk.)

Wait for five minutes, taking care not to allow the negative battery clamp to touch the positive clamp or the positive side of the battery.

Reattach the negative cable to the battery and tighten the nut using the end wrench.

Put the key into the ignition and turn it to "On." Look at the instrument panel to make sure the check engine light has turned off.