1994 MAZDA MX-5 SECTION T

P BRAKE SYSTEM Removal / Installation 1. When disconnecting the flexible hose and brake line, remove the clip after loosening the flare nut by using the SST. > 2. When connecting the flexible hose, do not over tighten or twist it. 3. Verify that the hose does not contact other parts when the vehicle bounces or when the steering wheel is turned all the way to the left or right. 4. Modify the brake pipe tightening torque to allow for a torque wrench-SST combination. (Refer to section GI) "Torque Formulas". 5. Tighten the flare nut by using the SST. Tightening torque: 13-22 N.m (1 3-2.2 kgf-m, %&-I 6 ft-lbf} 6. Bleed the air from the brake system. BRAKE FLUID Inspection Check the fluid level in the reservoir. It should be between MAX and MIN. If the fluid level is extremely low, check the brake system for leaks. J Fluid specification: FMVSS 11 6: DOT-3 Replacement 1. Follow the procedure outlined in Air Bleeding. (Refer to page P-7.) 2. Continuity air bleeding and replacing the brake fluid until only clean fluid is seen. 3. Fill the reservoir to MAX. 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 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 Removal I Installation note Brake pipe Caution ,..- 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 pipes 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, 9.4-1 6 ftslbf) Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P ABS CONTROL UNIT 35-PIN CONNECTOR OHMMETER 15UOPX-OI Check rotor Check the rotor for missing or damaged teeth and replace as necessary. Check alternator Refer to section G. Check wheel-speed sensor Caution To prevent damage to the terminals, create a probe by wrapping a thin wire around the tester lead before inserting. 1. Using an ohmmeter, check for continuity at the control unit connector terminals. 0----0: Indicates continuity Right front Left rear Right rear 2. If the continuity is not as specified, check the wiring har- ness (Wheel-speed sensor - Control unit). 3. If the continuity is OK, check voltage between 1K and 1 G, 10 and 1 Q, 1 U and 1 F, and 1 L and 1 P while rotating the wheel one rotation per second by hand. 4. If voltage is not approximately 50 mV--60 mV, the wheel-speed sensor is faulty. 5. If voltage is approximately 50 mV-60 mV, the control unit is faulty. 1L Check hydraulics Verify that all brake fluid connections are tight and that no fluid is leaking. IP 1Q Left front 0--0 Check hydraulic unit wiring 1. Verify that the hydraulic unit connectors are properly secured. 2. Verify that the valve relay and motor relay are properly secured. IG 1K 0-4 1U 10 S-0 IF 0-4 Gartner Banana

P ANTILOCK BRAKE SYSTEM (ABS) Disassembly 1 Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. 2.2-2.6 Nm [22-27 kgfcm, 2&29 [2--3,14--22) 6.9-9.8 Nm (70-1 00 kgfcm, 81-47 Inlbf) 1 15--25 11 S-2.5,11-18) 19-25 [1.92.6,14--19) t4.m [kgfm, Wlbf) 25uopx-o: 1. Nut, washer . 2. ABS bracket 3. Connector bolt 4. Gasket 5. Pipe joint 6. Bolt 7. Clip Installation Note 8. Cover 9. Motor relay ................... Inspection page P-56 10. Valve relay ................... Inspection page P-57 11. Casing 12. Mount 13. Stud ................. below 14. Nut, washer 15. Ground wire 16. Hydraulic unit Assembly note A SECTION A-A Clip Secure only the larger part of the wiring harness in the clips. The 2-pin connector part of the harness should re- main outside the clips. Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P ABS SENSOR ROTOR (FRONT) Removal l Inspection / lnstallation 1. Inspect the ABS sensor rotor for missing and damaged teeth. Note The sensor rotor does not need to be removed unless you are replacing it. 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 25UOPX-03 1. Wheel hub 2. ABS sensor rotor .......... Removal / Installation section M Removal Note ................... below Installation Note ................. below Removal note ABS sensor rotor Remove the sensor rotor from the wheel hub with the SST. lnstallation note ABS sensor rotor Press a new sensor rotor onto the wheel hub with the SST. Gartner Banana

ANTILOCK BRAKE SYSTEM (ABS) P ABS SENSOR ROTOR (REAR) Removal / Inspection 1. Inspect the ABS sensor rotor for missing and damaged teeth. Note The sensor rotor does not need to be removed unless you are replacing it. 2. Remove in the order shown in the figure, referring to Removal Note. 25uopx-o: 1. Drive shaft 2. Sensor rotor Removal . :. . . . . . . . . . . . . . . . . . . section M Removal Note . . . . . . . . . . . . . . . . . . . below 3. Boot band and boot Removal note Sensor rotor Tap the sensor rotor off the drive shaft with a chisel. Gartner Banana