brakes MAZDA MX-5 1994 User Guide

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

BRAKE SYSTEM P MASTER CYLINDER (STANDARD) Removal / Installation 1 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 the brakes, and check for fluid leakaae. 1. Fluid level sensor connector 5. Proportioning bypass valve and bracket Inspection ................... page P-13 6. Master cylinder 2. Brake pipe Installation Note ............. page P-12 Removal Note ............... page P-12 Disassembly 1 Assembly I 3. Connector bolt Inspection ................. page P-18 4. Nut and washer Gartner Banana

BRAKE SYSTEM P MASTER CUUNDER PRESSURE kPa #gflcm2, psi) 15UOPX-025 Replacement PROPORTIONING BYPASS VALVE Inspection When disconnecting and connecting the brake pipes, do so by using the flare nut wrench SST. 1. Connect the SST and the adapters to the brake pipes as shown in the figure. 2. Bleed the air from the brake system. (Refer to page P-7.) 3. Measure the fluid pressure from the master cylinder and to the rear brakes. If not as specified, replace the valve assembly. Specification 4. Add brake fluid and bleed the air. (Refer to page P-7.) 5. Check the brake lines for fluid leakage. Fluid pressure kPa (kgf/cm2, psi) Caution Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off immediately. A A' I B 1. Remove in the order shown in the figure, referring to Removal Note. 2. Install in the reverse order of removal, referring to lnstallation Note. 3. After installation: (1) Add brake fluid and bleed the air. (Refer to page P-7.) (2) Check the brake lines for fluid leakage. 6' 1. Brake pipe 2. Bolt Removal Note ............... page P-24 3. Proportioning bypass valve Installation Note ............. page P-24 Gartner Banana

P PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM TROUBLESHOOTING GUIDE I Problem I Possible cause I Brake fluid or oil on pads -- Brakes do not release Parking brake does not hold well I Hardening of pad surfaces or poor contact Improper return of parking brake cable or improper adjustment Excessive lever stroke Brake cable stuck or damaged Action 1 page 1 d Repair or adjust Adjust Repair or replace Clean or replace Grind or replace 25UOPX-026 PARKING BRAKE LEVER Inspection 1. Depress the brake pedal several times. 2. Verify that the stroke is within specification when the parking brake lever is pulled with a force of 196 N (20 kgf, 44 Ibf). Stroke: 7-9 notches Adjustment 1. On level ground, jack up the rear of the vehicle until the wheels are free to turn, and support it with stands. 2. Depress the brake pedal several times. 3. Remove the cover. 4. Turn the adjusting nut to adjust the lever stroke. --/, 5. Depress the parking brake pedal one notch, and verify that the parking brake warning light comes on. Release the parking brake. 6. Turn the wheels by hand, and verify that the brakes do not drag. 7. Lower the vehicle. Gartner Banana

PARKING BRAKE SYSTEM PARKING BRAKE CABLE Removal / Inspection 1 Installation 1. Block the wheels firmly. 2. Release the parking brake. 3. Remove the parking brake lever. 4. On level ground, jack up the vehicle and support it evenly on safety stands. 5. Remove the parking brake cable in the order shown in the figure. 6. Install in the reverse order of removal. 7. After installation: (1) Adjust the parking brake lever stroke. (Refer to page P-34.) (21 Deoress the brake oedal a few times. (3j ve;ify that the rear brakes do not drag while the wheels are rotated by hand. 1. Adjusting nut and clip 2. Clip 3. Spring lnspect for weakness 4. Front cable lnspect for damage 5. Rear cable lnspect for damage 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

u GENERAL SERVICE INFORMATION TIEDOWN HOOK - FRONT /'-- TIEDOWN HOOK - REAR -?-A TOWING Proper towing equipments are necessary to prevent damage to the vehicle during any towing operation. Laws and regulations applicable to vehicles in tow must always be observed. Release the parking brake, place the shift lever in neutral, and set the ignition switch in the ACC posi- tion. As a rule, towed vehicles should be pulled with the driving wheels off the ground. WITH MANUAL TRANSMISSION If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels. If any of these components are damaged, use a towing dolly. CAUTION The power assist for the brakes and steering are inoperable while the engine is off. Do not use the tiedown hooks under the front or rear of the vehicle for towing. These hooks are designed ONLY for transport tiedown. If the tiedown hooks are used for towing, the front or rear skirt and bumper will be damaged. IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER (VIN) ENGINE MODEL AND NUMBER L i Gartner Banana