check engine MAZDA MIATA 1991 Factory Service Manual

Fig. 7: Locating JC-02 Connector
Courtesy of MAZDA MOTORS CORP.
ANTI-LOCK WARNING LIGHT
Operational Test (Miata)
1. Start engine, and observe ANTI-LOCK light. Light should illuminate for a few seconds. If light does not
illuminate as described, remove instrument cluster. Connect 12 volts to terminal 2k of instrument cluster.
See Fig. 8
. Using a jumper wire, connect terminal 1K of instrument cluster to ground. ANTI-LOCK light
should illuminate. If light does not illuminate, check bulb. If bulb is okay, check meter fuse and wiring
harness.
2. Install instrument cluster, and recheck warning light operation. If light still does not illuminate for a few
seconds, check wiring harness between ANTI-LOCK light and control unit and between ANTI-LOCK
light and hydraulic unit. Check operation of hydraulic unit valve relay.
Operational Test (RX7)

1991 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System
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1. Start engine, and observe ANTI-LOCK light. Light should illuminate for a few seconds. If light does not
illuminate as described, remove clock and bezel assembly from dashboard. Slide warning and clock unit
from instrument panel. Connect terminal "E" to ground. See Fig. 9
. ANTI-LOCK light should illuminate.
If light does not illuminate, check bulb. If bulb is okay, check meter fuse and wiring harness.
2. Install instrument cluster, and recheck warning light operation. If light still does not illuminate for a few
seconds, check wiring harness between ANTI-LOCK light and control unit, and ANTI-LOCK light and
hydraulic unit. Check operation of hydraulic unit valve relay.
Operational Test (929)
1. Start engine, and observe ANTI-LOCK light. Light should illuminate for a few seconds. If light does not
illuminate as described, remove instrument cluster. Connect 12 volts to terminal "J" of instrument cluster
connector I-06. See Fig. 10
. Using a jumper wire, connect terminal "E" of instrument cluster connector I-
08 to negative ground. ANTI-LOCK light should illuminate. If light does not illuminate, check bulb. If
bulb is okay, check meter fuse and wiring harness.
2. Install instrument cluster, and recheck warning light operation. If light still does not illuminate for a few
seconds, check wiring harness between ANTI-LOCK light and control unit and between ANTI-LOCK
light and hydraulic unit. Check operation of hydraulic unit valve relay.
Fig. 8: Testing ANTI
-LOCK Warning Light (Miata)
Courtesy of MAZDA MOTORS CORP.

1991 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System
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TEST 1. CONNECTION POWER UP
CONNECTION/POWER-UP
1. Locate ABS Control Unit.
2. Disconnect Control Unit Harness from Control Unit.
3. Connect ABS Tester Harness to Control Unit Harness Connector.
4. Turn Ignition Key to "ON" position.
TEST 2 ALTERNATOR TEST
ALTERNATOR TEST START ENGINE (ALTERNATOR TESTED BY RUNNING ENGINE)
Tester will rapidly display several messages during an Initial Segment Check.
Fig. 14: Test 2 Alternator Test

Courtesy of MAZDA MOTORS CORP.
TEST 3 ABS SYSTEM TEST

1991 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System
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ABS SYSTEM TEST TURN IGNITION KEY ON (DO NOT RUN ENGINE
Tester will rapidly display several messages during an Initial Segment Check.
Fig. 15: Test 3 ABS System Test

Courtesy of MAZDA MOTORS CORP.
TEST 4 SYSTEM VOLTAGE TEST

1991 Mazda MX-5 Miata
ANTI-LOCK BRAKE SYSTEM 1988-91 BRAKES Mazda Anti-Lock Brake System
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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
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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
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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
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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
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Fig. 5: Identifying Drive Belt Routing & Deflection Check Point (1 Of 3)
Courtesy of MAZDA MOTORS CORP.

1991 Mazda MX-5 Miata
1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata
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Fig. 6: Identifying Drive Belt Routing & Deflection Check Point (2 Of 3)
Courtesy of MAZDA MOTORS CORP.

1991 Mazda MX-5 Miata
1990-93 ENGINE COOLING Drive Belt Routing & Adjustment - MX-5 Miata
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