1994 MAZDA MX-5 lock

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 P FRONT BRAKE (DISC) Quick Inspection, On-vehicle Disc pad 1. On level ground, jack up the front of the vehicle and sup- port it with safety stands. 2. Remove the wheels. 3. Sight through the caliper inspection hole and verify the remaining thickness of the pad. Thickness: 1 .Omm (0.04 in) min. I I 05UOPX-034 Replacement (Disc pad) 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. 1. Lock bolt 3. Outer shim Removal Note ................... below 4. Inner shim 2. Disc pad 5. Guide plate Installation Note ............. page P-26 Removal note Lock bolt 1. Remove the lower lock bolt. 2. Rotate the caliper upward and support it with a piece of rope. Gartner Banana

BRAKE SYSTEM ,$, .... "P ...% REAR BRAKE (DISC) Quick Inspection, On-vehicle Disc pad 1. On level ground, jack up the rear of the vehicle and sup- port it with safety stands. 2. Remove the wheels. 3. Sight through the caliper inspection hole and verify the remaining thickness of the pad. Thickness: 1 .Omm (0.04 in} min. I I 05UOPX-043 Replacement (Disc pad) 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. 1. Plug 4. M-spring 2. Manual adjustment gear 5. Disc pad Removal Note ................... below Inspection ................... page P-31 Installation Note ............. page P-30 6. Shim 3. Lock bolt 7. Guide plate RETRACTING BRAKE PADS Removal note Manual adjustment gear Turn the manual adjustment gear counterclockwise with an Allen wrench to pull the brake caliper piston back. Gartner Banana

BRAKE SYSTEM ADJUSTING BRAKE PADS Installation note Manual adjustment gear 1. Turn the manual adjustment gear clockwise until the brake pads just touch the disc plate. -1 2. Return the manual adjustment gear counterclockwise 113 turn. Removal 1 lnstallation (Caliper) 1. On level ground, jack up the rear of the vehicle and support it with safety stands. 2. Remove the wheels; then remove components in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to lnstallation Note. 4. Inspect all parts and repair or replace as necessary. 5. Tighten all nuts and bolts to the specified torques, referring to the figure. Parking brake cable Removal I Inspection 1 Installation ................. page P-36 Connecting bolt Brake hose Plug Manual adjustment gear Removal Note ............... page P-29 Installation Note ................. above Lock bolt 7. Caliper Disassembly I Inspection 1 Assembly .................. page P-32 8. Disc pad Replacement ................ page P-29 Inspection ................... page P-31 9. Bolt 10. Mounting support 11. Disc plate Inspection ................... page P-31 Gartner Banana

P BRAKE SYSTEM CALIPER Disassembly / Inspection / Assembly 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. REPLACE Up /REPLACE REPLACE kf'h \u b REPLACE 1. Dust seal lnspect for damage and poor sealing 2. Piston Disassembly Note ................ below Assembly Note .............. page P-33 lnspect for wear and rust 3. Manual adjustment gear 4. Snap ring 5. Adjusting bolt 6. O-ring 7. Connecting link 8. Piston seal Disassembly Note ............ page P-33 9. Spring 10. Operating lever 11. Boot 12. Cap and bleeder screw 13. Boot 14. Boot 15. Caliper body lnspect for damage and cracks Disassembly note Piston 1. Turn the manual adjustment gear clockwise with an Allen wrench. (Turn the manual adjustment gear until it turns easily.) 2. Remove the piston. Gartner Banana

BRAKE SYSTEM P Piston seal Remove the piston seal by using the SST. Assembly note Piston Insert the piston into the caliper and turn the adjustment gear counterclockwise with an Allen wrench to pull the piston in fully. (Turn the adjustment gear until it stops.) Gartner Banana

PARKING BRAKE SYSTEM P Removal 1 Inspection / lnstallation 1. Block the wheels firmly. 2. Release the parking brake. - 3. Remove in the order shown in the figure. 4. lnspect all parts and repair or replace as necessary. 5. Install in the reverse order of removal, referring to lnstallation Note. 6. After installation, adiust the arki in^ lever stroke. (Refer to page P-34.) 1. Screw 6. Release button 2. Cover 7. Spring 3. Bolt Inspect for weakness 4. Parking brake switch 8. Bolt lnstallation Note . . . . . . . . . . . . . . . . . below 9. Parking brake lever lnspect for damage and cracks 5. Adjusting nut and clip lnstallation note Parking brake switch 1. Install the parking brake switch so that it contacts the parking brake lever when the lever is fully released. 2. Turn the ignition switch ON, and verify that the parking brake warning light illuminates with the lever pulled up one notch. Gartner Banana