1994 MAZDA MX-5 Workshop Manual

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

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 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

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

ANTILOCK BRAKE SYSTEM (ABS) P LISTED BELOW IS AN EXPLANATION OF THE 5B. BRAKE LIGHT SWITCH TEST PROCEDURE - INDICATES TESTER DISPLAY I u U ,INDlCAlES ( TESTER SWITCHES I PRESS BRAKE PEDAL FIRMLY AND HOLD PRESSURE.. . I IF NO FAULTS A'RE DETECTED. IF A FAULT I; DETECTED. TESTER WILL DISPLAY: TESTER WILL DISPLAY. TESTER WlLL GlVE INST RUCTIONSIINFORMATION. "THEN* INDICATES THE TESTER WlLL ALTERNATE THE TWO DISPLAYS. TESTER "ASKS A OUESTION" WHICH MUST BE ANSWERED BY PRESSING THE SWITCH UNDER THE DESIRED ANSWER. NOTE: IN THIS CASE. PRESS YES - TEST CONTINUES. PRESS NO - T ESTER DISPLAYS: PRESS BRK - - - - HOLD TESTER WlLL PROCESS INFORMATION. 1 IYES CONTINUE? NO[ TESTER WlLL GlVE NEW INStRUCTIONSllNFORMATI~ AND CONTINUE. Gartner Banana