1994 MAZDA MX-5 brake

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

P BRAKE SYSTEM ADJUSTING BOLT I ADJUSTING BOLT ' CKNUT Removal note Brake pipe Caution . Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off lm- mediately. 1. Modify the brake pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI) "Torque Formulas'' 2. Disconnect/connect the brake pipe fromlto the master . . cylinder by using the SST. 3. Tighten the brake pipe by using the SST. Tightening torque: 13-22 N-m (1.3-2.2 kgfem, 9.4--16 ft-lbf) Installation note Master cylinder 1. Measure the clearance between the push rod of the power brake unit and the piston of the master cylinder. (1) Place the SST atop the master cylinder. Turn the adjusting bolt until it bottoms in the piston. i (2) Apply 66.7 kPa (500 mmHg, 19.7 inHg} vacuum to the power brake unit with a vacuum pump. (3) Invert the SST used in step 1, and place it on the power brake unit. (4) Measure the clearance between the end of the adjusting bolt and the push rod of the power brake unit. If it is not Omm (0 in}, loosen the push rod locknut and turn the push rod to make the adjustment. Gartner Banana

BRAKE SYSTEM CLEARANCE JSH ROD 2. By making'the above adjustment, the clearance between . the push rod and piston (after installation of the brake mas- ter cylinder and the power brake unit) will be as shown in the table below. - Clearance When vacuum applied to unit is approx. 0.1 -4.4mm 66.7 kPa (500 mmHg, 19.7 inHg) (0.004--0.016 in) Inspection Fluid level sensor connec 1. Disconnect the sensor connector. 2. Connect an ohmmeter to the connector. 3. Starting with the fluid level above the MIN mark on the reservoir, verify that there is no continuity. 4. Remove the brake fluid and verify continuity when the level is below the MIN mark. 5. Replace the sensor if necessary. Gartner Banana

BRAKE SYSTEM MASTER CYLINDER (ABS) Removal / Installation / 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 air, and check for fluid leakage. Caution Brake fluid will damage painted surfaces. If it does get on a painted surface, wipe it off immedi- Fluid level sensor connector 5. Proportioning bypass valve and bracket Inspection ................... page P-17 6. Master cylinder Brake pipe Installation Note ............. page P-15 Removal Note ............... page P-15 Disassembly 1 Assembly 1 Connector bolt Inspection ................. page P-18 Nut and washer Gartner Banana

BRAKE SYSTEM P I I TOUCHING 1 T~~H,IN~ I ADJUSTING NUT 97GOPX-O Removal note Brake pipe Cautlon Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off im- mediately. 1. Modify the brake pipe tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI) "Torque Formulas" 2. Disconnect~connect the brake pipe fromlto the master cylinder by using the SST. 3. Tighten the brake pipe by using the SST. Tightening torque: 13--22 N-m (1 3-2.2 kgf-m, 9.4--16 ft-lbf) Installation note Master cylinder Inspect the push rod clearance as follows. 1. Turn the nut of the SST clockwise to fully retract the SST gauge rod. Attach the SST to the power brake unit. Tightening torque: 9.8-15.7 N.m (1 .&I .6 kgf.m, 7.2-11.6 ft4bf) 2. Apply 66.7 kPa (500 mmHg, 19.7 inHg) vacuum using a vacuum pump. 3. Turn the adjusting nut of the SST counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and SST body. Gartner Banana

BRAKE SYSTEM CLEARANCE (0) CLEARANCE (C) CLEARANCE (B) 4. Remove the SST from the power brake unit without dis- turbing the adjusting nut. Set the SST onto the master cylinder as shown in the figure. -J Caution When pushing only use enough pressure to bot- tom the rod in the piston. If too much pressure is applied a false reading will occur. 5. Push lightly on the end of the SST gauge rod to be sure it is bottomed in the master cylinder piston, but do not push so hard that the piston mores. Note Any clearance between the SST body and the adjusting nut (clearance B) or between the body and the master cylinder (clear- ance C). Adjust the push rod as necessary as outlined in "Adjustment" below. I Measurement 1 Push rod I I Clearance at (B) I Too short I Adjustment The threads of the push rod are specially designed so that the bolt becomes harder to turn past a certain point. This is to prevent the bolt from coming loose. Turn the bolt only within this range when adjusting. Clearance at (C) No clearance at (B) or (C) '.A Clearance at B 1. Push lightly on the end of the SST gauge rod, and mea- sure the clearance between the adjusting nut and the SST body. Too long OK 2. Using the SST, turn the nut to lengthen the power booster push rod an amount equal to the clearance mea- sured at B. Clearance at C 1. Measure and record height Dl of the gauge rod. Gartner Banana

BRAKE SYSTEM ADJUSTING NUT 1 2. Turn the adjusting nut until the SST body sets squarely on the master cylinder. (Turn only enough for the body to touch.) I 3. Measure and record height 02 of the gauge rod. I 4. Subtract Dl from 02 and, by using the SST, turn the nut to shorten the power booster push rod an amount equal to the sum. Inspection Fluid level sensor connector 1. Disconnect the sensor connector. 2. Connect an ohmmeter to the connector. 3. Starting with the fluid level above the MIN mark on the reservoir, verify that there is no continuity. 4. Remove the brake fluid and verify continuity when the level is below the MIN mark. 5. Replace the sensor if necessary. Gartner Banana

BRAKE SYSTEM Disassembly / Assembly / lnspection 1. After removing the brake fluid, disassemble in the order shown in the figure. 2. lnspect all parts and repair or replace as necessary. 3. Assemble in the reverse order of removal, referring to Assembly Note. Caution The brake master cylinder Is made of aluminum, and can be easily damaged by tightening in a vise. When securing the master cylinder in a vise, tighten only the master cylinder flange. 1. Fluid level sensor connector 7. Snap ring Inspection ................... page P-17 8. Snap ring and spacer (ABS) 2. Screw 9. Primarv ist ton assemblv 3. Reservoir assembly inspect for abnormal wear, rust, and damage Inspect for damage and deformation 10. Secondary piston assembly 4. Bushings Inspect for abnormal wear, rust, and damage 5. Stop screw and O-ring 11. Master cylinder body e Assembly Note .............. page P-19 Inspect for abnormal wear, rust, and damage 6. Stop pin and O-ring (ABS) Replace unit as an assembly if damaged Assembly Note .............. page P-19 Gartner Banana