ABS MAZDA MX-5 1994 Owner's Manual

INDEX INDEX LEVER STROKE 7-9 NOTCHES AT 196 N (20 kgf, 44 IbfJ 9 MAX NOTCHES 19 NOTCHES FLUID SPECIFICATION FMVSS116, DOT-3 1. Brake hydraulic line 7. Front brake (Disc) On-vehicle inspection ......... page P- 7 Quick Inspection, On-vehicle . . page P-25 ...... Removal / Installation ......... page P- 8 Replacement (Disc pad) page P-25 2. Brake fluid Removal / Installation (Caliper) page P-26 ................... Inspection ................... page P- 8 Inspection page P-27 Replacement ................ page P- 8 8. Caliper 3. Brake pedal Disassembly / Inspection l On-vehicle inspection ......... page P- 9 Assembly .................. page P-28 Removal / Inspection / 9. Rear brake (Disk) Installation ................ page P-10 Quick Inspection, On-vehicle . . page P-29 ...... 4. Master cylinder Replacement (Disc pad) page P-29 (Standard) Removal / Installation (Caliper) page P-30 ................... Removal / Installation / Inspection page P-31 Inspection ................. page P-1 1 10. Caliper (ABS) Disassembly 1 Inspection / Removal / Installation / Assembly .................. page P-32 Inspection ................. page P-14 11. Parking brake lever ................... Disassembly / Inspection / Inspection page P-34 Assembly .................. page P-18 Adjustment .................. page P-34 5. Power brake unit Removal / Inspection / Quick Inspection, On-vehicle . . page P-20 Installation ................. page P-35 Removal / Installation ......... page P-22 12. Parking brake cable J 6. Proportioning bypass valve Removal / Inspection 1 Inspection ................... page P-23 Installation ................. page P-36 ................ Replacement page P-23 Gartner Banana

INDEX P ANTILOCK BRAKE SYSTEM (ABS) 1. Hydraulic unit 5. ABS sensor rotor (front) Removal / Installation ......... page P-53 Removal / Ins~ection / ................. Disassembly / Assembly ...... page P-54 Installation page P-59 2. ABS control unit 6. ABS wheel-speed sensor (rear) Removal I Installation ......... page P-55 Removal 1 Inspection I ................. 3. Relays Installation page P-60 Removal / Inspection / 7. ABS sensor rotor (rear) ......... ................. w Installation page P-56 Removal / Inspection page P-61 .................. 4. ABS wheel-speed sensor (front) Installation page P-62 Removal / Inspection / ................. Installation page P-58 Gartner Banana

BRAKE SYSTEM MASTER CYLINDER (ABS) Removal / Installation / lnspection 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to Installation Note. 3. After installation, add brake fluid, bleed air, and check for fluid leakage. Caution Brake fluid will damage painted surfaces. If it does get on a painted surface, wipe it off immedi- Fluid level sensor connector 5. Proportioning bypass valve and bracket Inspection ................... page P-17 6. Master cylinder Brake pipe Installation Note ............. page P-15 Removal Note ............... page P-15 Disassembly 1 Assembly 1 Connector bolt Inspection ................. page P-18 Nut and washer Gartner Banana

BRAKE SYSTEM Disassembly / Assembly / lnspection 1. After removing the brake fluid, disassemble in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of removal, referring to Assembly Note. Caution The brake master cylinder Is made of aluminum, and can be easily damaged by tightening in a vise. When securing the master cylinder in a vise, tighten only the master cylinder flange. 1. Fluid level sensor connector 7. Snap ring Inspection ................... page P-17 8. Snap ring and spacer (ABS) 2. Screw 9. Primarv ist ton assemblv 3. Reservoir assembly inspect for abnormal wear, rust, and damage Inspect for damage and deformation 10. Secondary piston assembly 4. Bushings Inspect for abnormal wear, rust, and damage 5. Stop screw and O-ring 11. Master cylinder body e Assembly Note .............. page P-19 Inspect for abnormal wear, rust, and damage 6. Stop pin and O-ring (ABS) Replace unit as an assembly if damaged Assembly Note .............. page P-19 Gartner Banana

BRAKE SYSTEM P Assembly note Stop screw and O-ring 1. Push the primary piston assembly in fully. 2. Install and tighten a new O-ring and the stop screw. 3. Push and release the piston to verify that it is held by the stop screw. Stop pin and O-ring (ABS) 1. Install the secondary piston isembly with the piston hole facing the stop pin. 2. Install and tighten a new O-ring and the stop pin. 3. Push and release the piston to verify that it is held by the stop pin. Gartner Banana

P BRAKE SYSTEM Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 3. Take the following steps after installation: (1) Check and adust the push rod and piston clearance. (Standard: refer to page P-12 1 ABS: refer to page P-15.) (2) Add fluid and bleed the air. (Refer to page P-7.) (3) Check all parts for fluid leakage. (4) Check and adjust the brake pedal height and free play. (Refer to page P-9.) (5) Make an on-vehicle check of the unit. (Refer to page P-20.) (6) Check that the vacuum hose does not contact other parts. ABS 1~22 (1.3--2.2,~.&16} STANDARD 35UOPX-01 1. Fluid level sensor connector 5. Clevis tin 2. Brake pipe and proportioning bypass valve 6. Power 'brake unit 3. Master cylinder 7. Gasket 4. Vacuum hose with check valve Apply sealant to the gasket contact surface Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P ANTILOCK BRAKE SYSTEM (ABS) DESCRIPTION - 1. There is the following distinctive characteristics in the ABS vehicles compared with the non-ABS vehicles. Note that it does not indicate malfunction. When the brakes are applied rapidly or on a slippery road surface, the ABS will activate; the brake pedal will pulsate slightly and the vehicle and the steering wheel will vibrate slightly. When the vehicle speed reaches approximately 6 kmh (3.8 mph}, the pump motor sound is heard momentarily. This sound is due to ABS self-diagnosis. 2. By retaining or reducing the hydraulic fluid pressure in the hydraulic unit, the ABS tester is used to locate the cause of a problem within the antilock brake system. Because there is no way to check the ABS control unit itself, replace the control unit assembly only after first confirming that the other electrical parts operate normally. PREPARATION SST Wrench, flare nut 49 H026 101 A Installer, sensor rotor 49 F027 007 Attachment 072 For removal and installation of brake pipe For installation of sensor rotor (rear) For removal of sensor rotor (front) 49 0839 425C Puller set, bearing Installer, oil seal Harness, adapter For removal of sensor rotor (front) For installation of sensor rotor (front) For connection of ABS tester Gartner Banana

P ANTILOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING GUIDE Troubleshooting Guide with ABS Tester ABS tester ADAPTER PART No.0000-42-0010 HYDRAULIC UNIT CONNECTOR POSSlTlVE BATTERY 97UOPX469 Connecting ABS tester 1. Turn the ignition switch OFF. 2. Connect the SST harness to an extension harness, and wrap the connection with electrical tape to prevent short- ing. 3. Connect the SST between the hydraulic unit wiring har- ness connectors and to the positive battery terminal. 4. Roll back the carpet and remove the protecter. 5. Connect the ABS tester to the control unit connector at harness side .using the adaptor. Warning Driving the vehicle while the tester is connected to the ABS control unit is extremely dangerous. The brakes could fail, resulting in death or seri- / -1 ous injury. Disconnect the tester from the ABS control unit before driving the vehicle. Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P LISTED BELOW IS AN EXPLANATION OF THE 5B. BRAKE LIGHT SWITCH TEST PROCEDURE - INDICATES TESTER DISPLAY I u U ,INDlCAlES ( TESTER SWITCHES I PRESS BRAKE PEDAL FIRMLY AND HOLD PRESSURE.. . I IF NO FAULTS A'RE DETECTED. IF A FAULT I; DETECTED. TESTER WILL DISPLAY: TESTER WILL DISPLAY. TESTER WlLL GlVE INST RUCTIONSIINFORMATION. "THEN* INDICATES THE TESTER WlLL ALTERNATE THE TWO DISPLAYS. TESTER "ASKS A OUESTION" WHICH MUST BE ANSWERED BY PRESSING THE SWITCH UNDER THE DESIRED ANSWER. NOTE: IN THIS CASE. PRESS YES - TEST CONTINUES. PRESS NO - T ESTER DISPLAYS: PRESS BRK - - - - HOLD TESTER WlLL PROCESS INFORMATION. 1 IYES CONTINUE? NO[ TESTER WlLL GlVE NEW INStRUCTIONSllNFORMATI~ AND CONTINUE. Gartner Banana

P ANTILOCK BRAKE SYSTEM (ABS) Troubleshooting procedure 2. ALTEnuAtOR TEST START mtmE (ALTWJATOR TESTED BY RWNa ENQlNE) 3. A88 SYSTEM TEST TURN IGNITION K€Y ON (00 NOT ROES EWWE) - - 1. LOCATE ABS CONTROL UNIT. 2. DISCONNECT CONTROL UNlT HARNESS CONNECTOR FROM CONTROL UNIT. 3. CONNECT ABS TESTER HARNESS TO CONTROL UNlT HARNESS CON- NECTOR. 4. TURN IGNITION KEY TO ON POSITION. TESTER WlLL RAPIDLY DISPLAY SEVERAL MESSAGES DURING AN INITIAL SEGMENT CHECK I THEN 1 I MAZDA ABS 2 TEST 1 4 I YES ENG RUN? NO 1 I MAZDA ALT TEST I CHK ALTERNATOR NO FAULT DETECTED t I TURN OFF ENGINE I TESTER WlLL RAPIDLY DISPLAY SEVERAL MESSAGES DURING AN INITIAL SEGMENT CHECK. I THEN t 1 YES ENG RUN? NO t 1 MAZDA ABS 2 TEST I Gartner Banana