1991 MAZDA MIATA light

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
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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
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
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Fig. 7: Removing Reamer Bolt Sleeve (Miata)
Courtesy of MAZDA MOTORS CORP.
OVERHAUL
DIFFERENTIAL HOUSING & DRIVE PINION
Disassembly
1. Mount carrier in repair stand. Mark side bearing caps for reassembly purposes. Remove adjuster lock
plates. See Fig. 8
.
2. Loosen side bearing and slightly back off adjusters. Remove bearing caps and adjusters. Withdraw
differential assembly from carrier. Ensure side bearing races remain with their respective bearings.
3. Remove drive pinion lock nut. Remove companion flange using a gear puller. Remove drive pinion,
spacer, rear bearing and collapsible spacer assembly from carrier. Remove oil seal and front bearing.
NOTE: Mark position of all components before disassembly.

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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ELECTRICAL COMPONENT LOCATOR
1991 MAZDA ELECTRICAL COMPONENTS
BUZZERS, RELAYS & TIMERS
BUZZERS, RELAYS & TIMERS LOCATION
CIRCUIT PROTECTION DEVICES
CIRCUIT PROTECTION DEVICES LOCATION
CONTROL UNITS
ComponentLocation
ABS System
Check Valve RelayOn top of ABS pump motor.
Motor RelayOn top of ABS pump motor.
Buzzer & Timer UnitOn bracket, behind left side of dash.
See Fig. 1
.
Circuit Opening RelayOn bracket, behind left side of dash.
See Fig. 1
.
Cooling Fan RelayIn engine compartment fuse/relay
block. See Fig. 1
.
Dashboard Illumination Lights RelayOn bracket, near master cylinder. See
Fig. 1
.
EFI Main RelayIn engine compartment fuse/relay
block. See Fig. 1
& Fig. 2 .
Fuel Pump RelayBehind left front kick panel.
Headlight RelayOn bracket, near master cylinder. See
Fig. 1
.
Headlight Retractor RelayOn bracket, near master cylinder. See
Fig. 1
.
Horn RelayOn bracket, behind left side of dash.
See Fig. 1
.
Ignition RelayIn engine compartment fuse/relay
block.
Turn Signal/Hazard Flasher RelayOn bracket, behind left side of dash.
See Fig. 1
.
ComponentLocation
Fuse BlockBehind left side of dash.
Fuse/Relay BlockIn right rear corner of engine compartment, near firewall.
See Fig. 2
.
Heater Blower Motor Circuit BreakerIn passenger compartment fuse block.

1991 Mazda MX-5 Miata
ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS

1991 Mazda MX-5 Miata
ELECTRICAL COMPONENT LOCATOR 1991 MAZDA ELECTRICAL COMPONENTS
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