brake fluid MAZDA MIATA 1991 Factory Service Manual

OPERATION
Under normal driving conditions, the anti-lock brake system functions as a standard brake system. When
vehicle speed reaches 3.8 MPH, the ABS system will diagnose pump motor by briefly operating motor. Pump
motor operation may be heard inside vehicle.
The Electronic Control Unit (ECU) controls ABS by detecting speed sensor signals and activating solenoid
valve in hydraulic unit. Control unit also controls pump motor and self-diagnostic function. If a problem in the
ABS system is detected, ABS system functions as a conventional brake system. The ANTI-LOCK brake
warning light will also come on.
With detection of wheel lock-up, short pedal pulsations, occurring in rapid succession, will be felt in brake
pedal and steering wheel. Vehicle body may also vibrate slightly. These conditions are normal. Pedal pulsation
will continue until there is no longer a need for anti-lock function or until vehicle is stopped.
ANTI-LOCK BRAKE SAFETY PRECAUTIONS
NEVER open a bleeder valve or loosen a hydraulic line while ABS is pressurized.
NEVER disconnect or reconnect any electrical connectors while ignition is on. Damage to ABS control
unit may result.
DO NOT attempt to bleed hydraulic system without first referring to the appropriate article.
Only use specially designed brake hoses/lines on ABS-equipped vehicles.
DO NOT tap on speed sensor components (sensor, sensor rings). Speed rings must be pressed, NOT
hammered into hubs. Striking these components can cause demagnetization or a loss of polarization,
affecting the accuracy of the speed signal returning to the ABS control unit.
DO NOT mix tire sizes. Increasing the width, as long as tires remain close to the original diameter, is
acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the
same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
DO NOT contaminate speed sensor components with grease. Only use recommended anti-corrosion
coating.
When speed sensor components have been removed, ALWAYS check sensor-to-ring air gaps when
applicable. These specifications can be found in each appropriate article.
ONLY use recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.
When installing transmitting devices (CB's, telephones, etc.) on ABS-equipped vehicles, DO NOT locate
the antenna near the ABS control unit (or any control unit).
Disconnect all on-board computers, when using electric welding equipment. CAUTION: See ANTI-LOCK BRAKE SAFETY PRECAUTIONS below.
WARNING:Refer to appropriate Anti-Lock Brakes (ABS) article for description,
operation, depressurizing, testing, system bleeding, trouble shooting and
system service. Failure to depressurize ABS could lead to physical injury.

1991 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System
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procedure.
Fig. 5: Exploded View of Front Disc Brake Assembly (Protege & 323)

Courtesy of MAZDA MOTORS CORP.
Removal (Navajo)
1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake
fluid from master cylinder. Raise vehicle, and support using safety stands.
2. Remove front wheel assembly. Place a large "C" clamp on caliper. See Fig. 9
. Tighten clamp to bottom
piston in cylinder bore. Remove clamp.
3. Remove dirt around caliper pin tabs. Tap upper caliper pin toward inboard side of vehicle until pin tabs

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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S120-645A) and Wrench (49-0603-635A).
2. Using Puller (49-S120-520A) and Adapter (49-S120-523A), remove rear axle bearings. Remove oil seal
from axle housing.
Installation
1. Install oil seal in axle housing. Install bearing inner race. Install and position oil seal flush with end of
axle casing. Apply multipurpose grease to oil seal lip. Install spacer with concave side facing backing
plate.
2. Press axle bearing onto axle shaft. Using wrench, install and tighten lock nut to 145-217 ft. lbs. (197-295
N.m). Install axle shaft assembly. Install backing plate. Reconnect brake line and parking brake cable.
Install brake drum and wheel. Bleed brake system.
MASTER CYLINDER
Removal
1. Disconnect fluid level sensor coupler (if equipped). Disconnect and plug hydraulic lines at master
cylinder to prevent entry of dirt and loss of fluid.
2. Remove nuts attaching master cylinder to firewall or power brake unit. Remove master cylinder from
vehicle. On RX7, remove proportioning valve by-pass bolt.
Installation
1. Place Adjustment Gauge (49-F043-001) onto master cylinder. Turn screw on adjuster gauge until it
contacts piston. Remove adjuster gauge. Apply 19.7 in. Hg to power brake unit.
2. Invert adjuster gauge and place it on power brake unit. Adjust push rod on power brake unit until there is
no clearance between push rod and adjuster gauge screw. Install master cylinder. Bleed hydraulic system.
POWER BRAKE UNIT
Removal & Installation
1. Remove master cylinder from power brake unit. See MASTER CYLINDER under REMOVAL &
INSTALLATION . Disconnect vacuum line at power brake unit. From inside vehicle, remove cotter pin
and clevis pin. Separate push rod from brake pedal.
2. Remove power brake unit-to-firewall nuts. Remove power brake unit. See Fig. 22
To install, reverse
removal procedure. Bleed hydraulic system. NOTE: Left wheel lock nut has left-hand threads.

1991 Mazda MX-5 Miata
BRAKE SYSTEM 1991 BRAKES Mazda Brake System
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DIFFERENTIAL CAPACITY SPECIFICATIONS (1)
FLUID TYPE
DIFFERENTIAL LUBRICATION SPECIFICATIONS
(1)
TROUBLE SHOOTING
See TROUBLE SHOOTING - BASIC PROCEDURES article in the TROUBLE SHOOTING Section.
REMOVAL & INSTALLATION
REAR AXLE SHAFTS & BEARINGS
Removal (B2200 & B2600i)
1. Raise and support vehicle. Remove rear wheels. Remove brake drum and shoes. Using a dial indicator,
measure axle flange lateral movement. If bearing play is not within specification, bearing shim must be
adjusted during installation. See END PLAY SPECIFICATIONS
.
2. Disconnect brake line from wheel cylinder. Plug line openings. Disconnect parking brake cable. Remove
backing plate retaining nuts. Remove axle shaft and backing plate as an assembly.
ApplicationQts. (L)
B2200 (Front & Rear)1.3 (1.2)
B2600i
Front1.6 (1.5)
Rear1.8 (1.7)
Miata.69 (.65)
MPV 2WD1.6 (1.5)
MPV 4WD
Front1.8 (1.7)
Rear1.6 (1.5)
Protege 4WD.69 (.65)
RX7
Non-Turbo1.4 (1.3)
Turbo1.5 (1.4)
9291.4 (1.3)
(1)Fill to lower edge of filler plug hole.
ApplicationSpecification
Above 0°F (-18°C)GL-5/SAE 90W
Below 0°F (-18°C)GL-5/SAE 80W
(1)Fill to lower edge of filler plug hole.

1991 Mazda MX-5 Miata
1990-91 DRIVE AXLES Differentials & Drive Axles - 929, B2200, B2600i, MX-5 Miata, MPV, Protege & RX-7
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CONTROL UNITS LOCATION
SENDING UNITS & SENSORS
SENDING UNITS & SENSORS LOCATION
MOTORS
MOTORS LOCATION
SOLENOIDS & SOLENOID VALVES
SOLENOIDS & SOLENOID VALVES LOCATION
ComponentLocation
ABS Control UnitBehind center of dash, near ECU.
Cruise Control UnitBehind left side of dash, above fuse block.
Engine Control Unit (ECU)Behind center of dash. See Fig. 2 .
Supplemental Safety Restraint (SRS)
ModuleBehind left side of dash. See Fig. 3 .
ComponentLocation
ABS Wheel SensorsOn each front & rear wheel hub
assembly.
Airflow MeterConnected to air filter housing. See Fig.
2 .
Atmospheric Pressure SensorBuilt-in ECU.
Brake Fluid Level SensorInside brake master cylinder.
Coolant Temperature SensorOn water outlet, at left rear of engine. See
Fig. 2
.
Cooling Fan ThermoswitchOn thermostat housing.
Crank Angle SensorOn right rear side of cylinder head. See
Fig. 2
.
Intake Air ThermosensorIn airflow sensor unit.
Oil Pressure SensorOn left side of engine near oil filter.
SRS Crash/Impact Sensors
FrontOn center, left and right front of
vehicle. See Fig. 3
.
CenterBehind center of dash. See Fig. 3 .
Throttle Position Sensor (TPS)Mounted on side of throttle body. See
Fig. 2
.
ComponentLocation
A/C-Heater Blower MotorBehind left side of dash.
Wiper MotorOn right side of firewall.

1991 Mazda MX-5 Miata
ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS
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ANTI-LOCK BRAKE SYSTEM
The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by
improperly installed or high output radio transmitting equipment. Since this interference could cause the
possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.
On models equipped with anti-lock brake systems, ALWAYS observe the following cautions:
DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK
BRAKE SYSTEM article in the BRAKES Section.
DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is
acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the
same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.
BATTERY WARNING
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the
electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect
amperage rating fuse may result in a dangerous electrical system overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.
CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in
possible damage to converter and vehicle. service.
WARNING:R-134a service equipment or vehicle A/C systems SHOULD NOT be
pressure tested or leak tested with compressed air. Some mixtures of
air/R134a have shown to be combustible at elevated pressures. These
mixtures are dangerous and may cause fire and/or explosions. See AIR
CONDITIONING SERVICE article in GENERAL INFORMATION section.
WARNING:When battery is disconnected, vehicles equipped with computers may
lose memory data. When battery power is restored, driveability problems
may exist on some vehicles. These vehicles may require a relearn
procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION section.

1991 Mazda MX-5 Miata
FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1990-95 Mazda
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