light MAZDA MIATA 1991 Factory Owner's Manual

Fig. 18: Test 5B. Brake Light Switch Test
Courtesy of MAZDA MOTORS CORP.
TEST 5C. PUMP TEST

1991 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System
Microsoft
Sunday, July 05, 2009 2:17:32 PMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of MAZDA MOTORS CORP.
ADJUSTMENTS
PEDAL FREE PLAY
Depress pedal several times to release vacuum. Pedal free play should be .16-.28" (4-7 mm).
PEDAL HEIGHT & STOPLIGHT SWITCH
1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.
Disconnect stoplight switch. Move switch away from pedal. Adjust brake pedal push rod until correct
released pedal height is obtained. See BRAKE PEDAL HEIGHT SPECIFICATIONS TABLE.
2. Adjust pedal free play. See PEDAL FREE PLAY under ADJUSTMENTS. Tighten push rod lock nut.
Rotate stoplight switch until it contacts pedal, then rotate an additional 1/2 turn. Tighten stoplight switch
lock nut. Reconnect stoplight switch.
3. The applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. Depress brake pedal with 132-lb. (60 kg) pressure.
4. Measure the applied pedal height. If distance is not as specified, check brake adjustment, or check for air
in system. See BRAKE PEDAL HEIGHT SPECIFICATIONS TABLE.
BRAKE PEDAL HEIGHT SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application(1) In. (mm)
Pedal Released
Miata & 9296.7-7.1 (171-181)
RX77.2-7.4 (184-189)
Pedal Applied
Miata & 9293.7 (95)
RX73.9 (100)
(1)Minimum height.
ApplicationFt. Lbs. (N.m)
Brake Caliper Mounting Bolts
Miata36-51 (49-69)
RX7
Front58-72 (79-98)
Rear33-40 (45-54)
929
Front61-69 (83-94)

1991 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System
Microsoft
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Fig. 3: Moving Quadrant on Rear Brake Adj. (Typical Protege & 323)
Courtesy of MAZDA MOTORS CORP.
2. Push adjusting lever toward backing plate. Install brake drum. Install new lock nut, and secure by
crimping. Operate parking brake a few times to reset adjuster. Adjust parking brake.
Navajo
1. Raise and support rear of vehicle. If drums are installed on vehicle, remove cover from adjusting hole at
bottom of brake backing plate. Turn adjusting screw with a brake adjusting tool until shoes drag against
brake drum and lock drum.
2. When shoes are against drum, loosen adjusting screw an additional 10-12 notches so drum rotates freely.
If drum does not rotate freely, remove wheel and drum and vacuum dust and dirt from linings. Use
sandpaper and remove rust from points where shoes touch backing plate. Apply a light coating of
molybdenum grease to brake shoe-to-backing plate contact points. Install wheel and drum and adjust
shoes.
3. To adjust brakes with rear drums removed, first clean all rust and dirt on points where shoes touch
backing plate and apply a small amount of molybdenum grease to those areas. Use a brake shoe
adjustment gauge and adjust brakes to inside diameter of drum braking surface.
4. Reverse tool and adjust brake shoes until they touch gauge. Gauge contact points on shoes must be
parallel to vehicle with center line throu
gh center of axle. Hold automatic adjusting lever out of

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:08 PMPage 5 © 2005 Mitchell Repair Information Company, LLC.

engagement while rotating adjusting screw to prevent burring screw slots. Ensure adjusting screw rotates
freely.
PARKING BRAKE
B2200 & B2600i
1. Depress brake pedal several times while vehicle is moving in Reverse. Ensure brakes are properly
adjusted. Pull parking brake lever with a force of 44 lbs. (20 kg). If stroke is 7-12 notches, parking brake
is properly adjusted.
2. If stroke is not 7-12 notches, raise and support rear of vehicle. Release parking brake lever. Loosen cable
lock nut at lever end of cable. Rotate adjusting nut until correct stroke is obtained. Operate parking brake
several times and ensure rear wheels rotate freely. Ensure parking brake warning light illuminates when
brake lever is pulled one notch.
Navajo
1. Adjust service brakes before adjusting parking brake cable. Ensure brake drums are cold. Apply parking
brake to fully depressed position. Grip threaded rod to prevent it from spinning.
2. Thread equalizer nut 6 full turns past its original position on threaded rod. See Fig. 4
. Check cable
tension at rear of equalizer assembly using Cable Tension Gauge (021-00018). If tension is not 400-600
lbs. (182-272 k
g), repeat step 2).

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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2. Release parking brake lever. Using a screwdriver, reach through parking brake handle hole in console and
rotate adjusting screw until stroke is 6-8 notches. Ensure rear wheels rotate freely. Ensure parking brake
warning light illuminates when brake lever is pulled one notch.
Miata, MX-6, MPV, Protege, RX7, 323, 626
1. On models with rear disc brakes, depress brake pedal several times. On models with rear drum brakes,
start engine and depress brake pedal several times while vehicle is moving in Reverse. Stop engine.
2. On all models, pull parking brake lever with a force of 22 lbs. (10 kg). If stroke is 5-7 notches, parking
brake is properly adjusted. If stroke is not 5-7 notches, raise and support rear of vehicle. Release parking
brake lever.
3. Rotate cable adjusting nut at lever end of cable (under console cover) until stroke is within specification.
On models equipped with rear disc brakes, ensure clearance between stopper and lever (at each caliper) is
not less than .08" (2 mm) on RX7, or zero on all other models. On all models, ensure parking brake
warning light illuminates when brake lever is pulled one notch.
PARKING BRAKE SHOES
929
Raise and support vehicle. Remove rear wheels. Remove service plug from rotor. Using a screwdriver, rotate
star wheel adjuster toward axle until rotor locks. Rotate adjuster in opposite direction 3-5 notches. Ensure rotors
turn freely and parking brake functions properly. Install service plug and rear wheels.
PEDAL FREE PLAY
Depress pedal a few times to eliminate vacuum. Pedal free play should be .16-.28" (4-7 mm). Adjust play by
loosening push rod lock nut. Turn push rod until correct free play is obtained. Tighten push rod lock nut.
PEDAL HEIGHT & STOPLIGHT SWITCH
1. Released pedal height is measured from carpet surface on vertical portion of firewall to pedal pad center.
Disconnect stoplight switch electrical connector. Loosen lock nut on stoplight switch. Move switch away
from pedal. Loosen push rod lock nut. Turn rod until correct pedal height is obtained. See BRAKE
PEDAL HEIGHT SPECIFICATIONS .
2. Adjust pedal free play. See PEDAL FREE PLAY
under ADJUSTMENTS. Tighten push rod lock nut.
Rotate stoplight switch until it contacts pedal and then rotate an additional 1/2 turn. Tighten stoplight
switch lock nut. Reconnect stoplight switch electrical connector.
3. Applied pedal height is measured from angled portion of firewall (without carpet) to pedal pad center.
Start engine. On B2200, B2600i and MPV, depress brake pedal with 33 lbs. (15 kg) pressure. On all other
models, depress brake pedal with 132 lbs. (60 k
g) pressure. tension should be checked and adjusted.
NOTE: Pedal height and stoplight switch information is not available for Navajo.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:08 PMPage 8 © 2005 Mitchell Repair Information Company, LLC.

4. On all models, measure applied pedal height. If distance is not as specified, check brake adjustment or
system for air. See BRAKE PEDAL HEIGHT SPECIFICATIONS TABLE.
BRAKE PEDAL HEIGHT SPECIFICATIONS
TESTING
POWER BRAKE UNIT
1. With engine off, depress brake pedal several times. Press and hold brake pedal and start engine. If brake
pedal moves down slightly immediately after engine starts, power brake unit is operating. If brake pedal
does not move as specified, go to next step.
2. Run engine for 1-2 minutes. Stop engine. Press brake pedal several times and note if first pedal stroke is
longer than subsequent strokes. If first pedal stroke is longer than subsequent strokes, power brake unit is
operating. If length of strokes is equal, test check valve and vacuum hose between vacuum source and
power brake unit. Repair as necessary, and go to next step.
3. Start engine. Press and hold brake pedal. Stop engine. Hold pedal down for about 30 seconds. If pedal
height remains at same height, power brake unit is operating. If pedal height recedes, test check valve and
vacuum hose between vacuum source and power brake unit. Repair as necessary.
REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
Removal & Installation (Protege & 323)
Raise and support front of vehicle. Remove wheels. Remove spring "A". See Fig. 5 . Remove spring "B".
Remove pad pins. Remove pads, shims and anti-squeak shim. Replace pad if lining thickness is less than
specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) TABLE. To install, reverse removal
ApplicationIn. (mm)
Pedal Released
B2200 & B2600i7.1-7.3 (180-185)
Miata, MX-6, 626 & 9296.7-7.1 (171-181)
MPV7.5-7.9 (191-201)
Protege & 3237.6-7.7 (193-196)
RX77.2-7.4 (184-189)
Pedal Applied (1)
B2200 & B2600i4.1 (105)
Miata, MX-6, 626 & 9293.7 (95)
MPV5.2 (133)
Protege & 3232.8 (70)
RX73.9 (100)
(1)Minimum height.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
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Fig. 13: Removing Front Rotor (Navajo with Automatic Locking Hubs)
Courtesy of FORD MOTOR CO.
3. If necessar
y, rotate adjusting nut slightly to relieve pressure on locking key. Using Hex Lock Nut Wrench

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
Microsoft
Sunday, July 05, 2009 2:18:08 PMPage 20 © 2005 Mitchell Repair Information Company, LLC.

shoe-to-anchor spring. Unhook cable anchor, and remove anchor pin plate.
4. Remove cable guide, shoe hold-down springs, brake shoes, adjusting screw, pivot nut and socket.
Remove parking brake link spring and link. Note color and position of springs for reassembly.
5. Disconnect parking brake cable from lever. Remove secondary shoe. Disassemble parking brake lever
from shoe by removing retaining clip and spring washer. See Fig. 20
.
Fig. 20: Exploded View of Rear Drum Brake Assembly (Navajo)

Courtesy of MAZDA MOTORS CORP.
Installation
Clean and sand brake shoe contact points on backing plate. Apply a light coating of lithium base grease to
contact points. Lubricate adjusting cable eye and anchor pin area. Lubricate adjusting screw, pivot and socket.
To install, reverse removal procedure.
PARKING BRAKE SHOES
Removal (929)

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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CHARGING SYSTEM TROUBLE SHOOTING
TROUBLE SHOOTING PRECAUTIONS
Miata
Obtain code number and deactivate audio anti-theft system before disconnecting battery.
All Models
DO NOT reverse battery cable connections. Rectifier will be damaged.
DO NOT use high voltage type testers.
PROBLEM Possible CauseAction
NO START CONDITION
Dead BatteryCheck/Replace Battery
Bad Cable ConnectionsClean/Replace Cables
Ignition Switch/Circuit FaultCheck Switch/Circuit
CHARGING SYSTEM WARNING LIGHT STAYS ON
Loose/Worn Alternator BeltTighten/Replace Belt
Loose Alternator ConnectionsCheck/Repair
Connections
Warning Light WiringCheck/Repair Wiring
Faulty Stator/DiodesTest/Repair Alternator
Faulty Voltage RegulatorTest/Repair Regulator
WARNING LIGHT OFF WITH IGNITION SWITCH ON
Blown FuseCheck/Replace Fuse
Faulty AlternatorTest Alternator
Bad Warning Light BulbTest/Replace Bulb
WARNING LIGHT ON WITH IGNITION SWITCH OFF
Alternator Wiring ShortCheck/Repair Wiring
Faulty Rectifier BridgeTest/Repair Alternator
AMMETER INDICATES DISCHARGE
Loose/Worn Alternator BeltTighten/Replace Belt
Loose Alternator ConnectionsCheck/Repair
Connections
Faulty AmmeterTest/Replace Ammeter
NOISY Defective BatteryReplace Battery
Defective AlternatorTest/Repair Alternator
Defective RegulatorTest/Repair Regulator
NOTE: Observe the following precautions when trouble shooting or testing charging
system:

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
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Battery voltage is always applied to terminal "B".
DO NOT ground terminal "L" while engine is running.
DO NOT start engine with connector disconnected from terminals "L" and "S".
DO NOT apply battery voltage to terminal "L".
ON-VEHICLE TESTING
ALTERNATOR OUTPUT
1. Connect an ammeter (80-amp minimum) in-line between terminal "B" connector and wire. See Fig. 2
,
Fig. 3
and Fig. 4 . Turn all headlights and accessories on and depress brake pedal. With engine operating
at 2500-3000 RPM, measure output amperage. NOTE: Check alternator wiring harness connections and drive belt tension. Battery
must be fully charged before testing. Wait at least 30 seconds after starting
engine before measuring system voltage.
CAUTION: Ensure alternator terminal "B" does not contact ground.

1991 Mazda MX-5 Miata
ALTERNATOR & REGULATOR 1990-92 ELECTRICAL Alternators & Regulators - Mitsubishi
Microsoft
Sunday, July 05, 2009 2:14:54 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.