torque MAZDA MX-5 1994 Workshop Manual

BRAKE SYSTEM P MIRROR AIR BLEEDING The brakes should be bleed whenever a brake line is dis- connected. If a hydraulic line is disconnected at the mas- ter cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the next closest slave cylinder until all four cylinders have been bled. If the disconnection point is anywhere except the master cylinder, start at the point closest to the disconnection, and move to the next farthest slave cylinder until all four cylinders have been bled. 1. On level ground jack up the vehicle and support it evenly on safety stands. 2. Remove the bleeder cap and attach a vinyl tube to the bleeder screw. 3. Place the other end of the vinyl tube in a clear container. 4. One person should depress the brake pedal a few times, and then hold it in the depressed position. 5. A second person should loosen the bleeder screw, drain out the fluid, and close the screw by using the SST. 6. Repeat steps 4 and 5 until only clean fluid is seen. The reservoir should be kept about 3/4 full during bleeding to prevent air from reentering the lines. 7. Modify the brake pipe tightening torque to allow for a torque wrench-SST combination. (Refer to section GI) "Torque Formulas". 8. Tighten the brake pipe by using SST. 9. Check for correct brake operation. 10. Verify that there is no fluid leakage. Clean away any spilled fluid with rags. 11. After bleeding the air, add brake fluid to the reservoir up to the specified level. BRAKE HYDRAULIC LINE On-vehicle Inspection Check the following and replace parts as necessary. 1. Cracks, damage, and corrosion of the brake hose 2. Damage to the brake hose threads 3. Scars, cracks, and swelling of the flexible hose 4. All lines for fluid leakage Gartner Banana

P BRAKE SYSTEM Removal / Installation 1. When disconnecting the flexible hose and brake line, remove the clip after loosening the flare nut by using the SST. > 2. When connecting the flexible hose, do not over tighten or twist it. 3. Verify that the hose does not contact other parts when the vehicle bounces or when the steering wheel is turned all the way to the left or right. 4. Modify the brake pipe tightening torque to allow for a torque wrench-SST combination. (Refer to section GI) "Torque Formulas". 5. Tighten the flare nut by using the SST. Tightening torque: 13-22 N.m (1 3-2.2 kgf-m, %&-I 6 ft-lbf} 6. Bleed the air from the brake system. BRAKE FLUID Inspection Check the fluid level in the reservoir. It should be between MAX and MIN. If the fluid level is extremely low, check the brake system for leaks. J Fluid specification: FMVSS 11 6: DOT-3 Replacement 1. Follow the procedure outlined in Air Bleeding. (Refer to page P-7.) 2. Continuity air bleeding and replacing the brake fluid until only clean fluid is seen. 3. Fill the reservoir to MAX. Gartner Banana

BRAKE SYSTEM P CLEARANCE BRAKE PEDAL On-vehicle Inspection Pedal height Verify that the distance from the center of the upper surface of the pedal pad to the carpet is as specified. Pedal height: l7l-l8l mm (6.93-7.13 in} (With carpet) Adjustment 1. Disconnect the stoplight switch connector. 2. Loosen locknut@ and turn switch @ until it does not con- tact the pedal. 3. Loosen locknuts @I and turn rod 0 to adjust the height. 4. Adjust the pedal free play and tighten operating rod lock- nuts @I. 5. Turn the stoplight switch until it contacts the pedal; then turn an additional 1 /2 turn. Tighten the locknuts. Tightening torque: 14--18 N.m (1.4--1.8 kgf-m, 10-13 ft-lbf) 6. Connect the stoplight switch connector. 7. Verify that the stoplight operates correctly. Pedal play 1. Depress the pedal a few times to eliminate the vacuum in the system. 2. Lightly depress the pedal by hand until resistance is felt, and check the free play. Free play: 4--7mm (0.16-4.28 in) Adjustment 1. Loosen locknuts @I and turn rod to adjust the free play. 2. Check the pedal height and verify that the stoplight switch operates correctly. Tightening torque: 24--34 N.m (2.4--3.5 kgf-m, 17-25 ft-lbf} Pedal-to-floor clearance 1. Verify that the distance from the floor panel to the center of the upper surface of the pedal pad is as specified when the pedal is depressed with a force of 589 N (60 kgf, 132 Ibf}. Pedal-to-floor clearance: 95mm (3.74 in} (Without carpet) 2. If the distance is less than specified, inspect for air in the brake system. Gartner Banana

P BRAKE SYSTEM ADJUSTING BOLT I ADJUSTING BOLT ' CKNUT Removal note Brake pipe Caution . Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off lm- mediately. 1. Modify the brake pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI) "Torque Formulas'' 2. Disconnect/connect the brake pipe fromlto the master . . cylinder by using the SST. 3. Tighten the brake pipe by using the SST. Tightening torque: 13-22 N-m (1.3-2.2 kgfem, 9.4--16 ft-lbf) Installation note Master cylinder 1. Measure the clearance between the push rod of the power brake unit and the piston of the master cylinder. (1) Place the SST atop the master cylinder. Turn the adjusting bolt until it bottoms in the piston. i (2) Apply 66.7 kPa (500 mmHg, 19.7 inHg} vacuum to the power brake unit with a vacuum pump. (3) Invert the SST used in step 1, and place it on the power brake unit. (4) Measure the clearance between the end of the adjusting bolt and the push rod of the power brake unit. If it is not Omm (0 in}, loosen the push rod locknut and turn the push rod to make the adjustment. Gartner Banana

BRAKE SYSTEM P I I TOUCHING 1 T~~H,IN~ I ADJUSTING NUT 97GOPX-O Removal note Brake pipe Cautlon Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off im- mediately. 1. Modify the brake pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI) "Torque Formulas" 2. Disconnect~connect the brake pipe fromlto the master cylinder by using the SST. 3. Tighten the brake pipe by using the SST. Tightening torque: 13--22 N-m (1 3-2.2 kgf-m, 9.4--16 ft-lbf) Installation note Master cylinder Inspect the push rod clearance as follows. 1. Turn the nut of the SST clockwise to fully retract the SST gauge rod. Attach the SST to the power brake unit. Tightening torque: 9.8-15.7 N.m (1 .&I .6 kgf.m, 7.2-11.6 ft4bf) 2. Apply 66.7 kPa (500 mmHg, 19.7 inHg) vacuum using a vacuum pump. 3. Turn the adjusting nut of the SST counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and SST body. Gartner Banana

BRAKE SYSTEM Removal I Installation note Brake pipe Caution ,..- Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off im- mediately. 1. Modify the brake pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI) "Torque Formulas" 2. Disconnect/connect the brake pipes by using the SST. 3. Tighten the brake pipe by using the SST. Tightening torque: 13-22 N-m (1 3-2.2 kgf-m, 9.4-1 6 ftslbf) Gartner Banana

P BRAKE SYSTEM Installation note Disc pad 1. Push the piston inward by using the 2. Install the new pads in the mounting SST. support. 1 I 15UOPX-030 Removal I lnstallation (Caliper) 1. On level ground, jack up the front of the vehicle and support it with safety stands. 2. Remove the wheels; then remove components in the order shown in the figure. 3. Install in the reverse order of removal. 4. Tighten all nuts and bolts to the specified torques, referring to the figure. 1. Brake hose 5. Shim 2. Connecting bolt 6. Bolt 3. Caliper 7. Mounting support Disassembly / Inspection / 8. Disc plate Assembly .................. page P-28 Inspection ................... page P-27 4. Disc pad ................... Inspection page P-27 Gartner Banana

BRAKE SYSTEM ADJUSTING BRAKE PADS Installation note Manual adjustment gear 1. Turn the manual adjustment gear clockwise until the brake pads just touch the disc plate. -1 2. Return the manual adjustment gear counterclockwise 113 turn. Removal 1 lnstallation (Caliper) 1. On level ground, jack up the rear of the vehicle and support it with safety stands. 2. Remove the wheels; then remove components in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Inspect all parts and repair or replace as necessary. 5. Tighten all nuts and bolts to the specified torques, referring to the figure. Parking brake cable Removal I Inspection 1 Installation ................. page P-36 Connecting bolt Brake hose Plug Manual adjustment gear Removal Note ............... page P-29 Installation Note ................. above Lock bolt 7. Caliper Disassembly I Inspection 1 Assembly .................. page P-32 8. Disc pad Replacement ................ page P-29 Inspection ................... page P-31 9. Bolt 10. Mounting support 11. Disc plate Inspection ................... page P-31 Gartner Banana

WHEELS AND TIRES SHOULDER WEAR CENTER WEAR (c) (4 FEATHERED EDGE TOE-IN OR TOE- UNEVEN WEAR OUT WEAR Troubleshooting guide Abnormal tire wear patterns, such as those shown in the illustration can occur. Refer to the chart for the possible causes and actions. d' Possible cause I Action I I Underinflation (both sides worn) I Measure and adjust pressure Overinflation Measure and adjust pressure Lack of rotation Rotate tires I Incorrect camber (one side worn) Hard cornering Lack of rotation Incorrect toe-in I Adjust toe-in I Repair or replace suspension parts Reduce speed Rotate tires 1. Cracks, damage, and foreign matter (such as metal pieces, nails, and stones) in the tire and cracks, deformation, and damage to the wheel. 2. Loose wheel lug nut(s). 3. Air leaking from valve stem. Incorrect camber or caster Malfunctioning suspension Unbalanced wheel Out-of-round brake drum or disc Other mechanical conditions Lack of rotation REMOVAL / INSTALLATION When reinstalling a wheel, retighten the lug nuts to the specified torque after about 1,000 km (620 miles} driv- ing. Repair or replace suspension parts Repair or replace Balance or replace Correct or replace Correct or replace Rotate tires Caution Applying oil to the lug nuts, bolts, or wheels will cause the lug nuts to become loosened. Tighten the lug nuts to the specified torque in a criss- cross fashion. Verify that the wheel-to-hub contact surfaces are clean. Tightening torque: 88-11 8 N.m (9-1 2 kgf.m, 65--87 ft-lbf) Gartner Banana

WHEEL ALIGNMENT LEFT WHEEL INCREASE CAM BOLT RIGHT WHEEL 0) '. jr INCREASE Adjustment Maximum steering angle 1. Remove the steering gear boot clamp. 2. Loosen the tie rod locknut. 3. Turn the tie rod to provide the correct maximum steering angle. 4. After adjustment, tighten the locknut to the specified torque. Tightening torque: 3539 N-m (3.W.0 kgf-m, 26-28 ftdbf) 5. Adjust the toe-in. (Refer to page R-8.) 6. Verify that the boot is not twisted, and install the boot clamp. Caster Caster is adjusted by turning the front and/or rear adjust- ing cam bolts at the lower arm. Caution Adjust the caster before adjusting the camber. 1. Loosen the front and/or rear cam nuts. 2. Turn the front and/or rear adjusting cam bolts to provide the correct caster angle. Left wheel Right wheel Caster I Front cam I Rear cam I Front cam I Rear cam Counter- 1 Clockwise I Clockwise 1 I Increase I ( clockwise Note Turning the front cam one graduation on the scale changes the caster angle about 22' and the camber about 25'. Turning the rear cam one graduation changes the caster angle about 22' and the camber about 2'. Decrease 3. Adjust the camber and the toe-in. Clockwise Clockwise Counter- clockwise Counter- clockwise Gartner Banana