Description

 "Dear Mazda Owner:

This notice is sent to you in accordance with the requirements of
the National Traffic and Motor Vehicle Safety Act.

Mazda Motor corporation has determined that a defect which
relates to motor vehicle safety exists on some 1991 MX-5 Miata
models equipped with the optional ABS (Anti-lock Brake System).

Mazda was informed by its supplier that during a certain period
of production a return passage for the front brake fluid may have
been incorrectly drilled. When the brake is applied under the
specific condition which operates the anti-lock system, such as
icy road conditions, the brake fluid in the secondary chamber of
the master cylinder could return to the primary chamber of the
master cylinder. This may result in poor braking performance.
Normal brake application (ABS not activated) does not affect
brake performance in any way.

We have made arrangements for you to have the ABS hydraulic unit
on your vehicle inspected and replaced, if necessary, free of
charge at any authorized Mazda dealer on or after June 14, 1991.

In order to minimize your inconvenience, we recommend that you
make an appointment with your dealer for the inspection and/or
replacement of the ABS hydraulic unit on your vehicle. We
estimate the actual repair will take approximately one hour.
Scheduling time will vary from dealer to dealer. Please allow
time for the dealer to order the necessary part for your vehicle.

If you no longer own your 1991 Miata, please complete and mail
the enclosed "Change of Ownership" prepaid postcard as soon as
possible.

Should you have any questions regarding this program, please
contact your nearest authorized Mazda dealer or Mazda
Regional/Distributor office listed in your owner's Manual. If
your dealer or distributor does not remedy the defect without
charge within a reasonable amount of time, you may wish to notify
the Administrator, National Highway Traffic Safety
Administration, Washington D.C. 20590, or you may call the
toll-free Auto Safety Hotline, telephone number (800)424-9393.
For residents of Washington D.C., call 366-0123.

Please accept our apologies for any inconvenience this may cause
you. We hope you understand that this program is being conducted
to ensure your full satisfaction.

Sincerely,

Robert T. Evan
Vice president, Customer Support
Mazda Motor of America, Inc."

VIN of Affected Vehicles

MX-5 Miata with ABS
VIN JMlNA351 * NO225241 - JMlNA351 * NO233341 (* can be replaced with any letter)

If the driver's side door has a green label, this vehicle is not a subject vehicle for recall. This vehicle was inspected or repaired by MMA.

Parts Information

NOTE:
Recall Labels will be shipped to you without charge for your initial use. Additional labels can be ordered free of charge from Helm (800)782-4356.

Repair Procedure

Step 1 - Inspection

1. Verify subject vehicle VIN number to check if the vehicle falls within the recall VIN range.
2. If the ABS Hydraulic unit has an alphanumeric stamp, such as "1CLL" in the casting at the indicated area, that ABS Hydraulic unit is OK. Please proceed to step 5.

Step 2 - Hydraulic Unit Replacement

Caution: Brake fluid damages painted surfaces. If you get brake fluid on your hands and clothing, remove it before you transfer it to a painted surface. Perform all repairs with the ignition key in the "OFF" position.

A. Removal

1. Place a protective cover on the right front .
2. Place a shop towel on the bottom and side of the Hydraulic Unit Assembly. A drain pan placed under the hydraulic unit will prevent floor .
3. Disconnect the 2 electrical connectors in portion .
4. Loosen 3 flare nuts in portion B with suitable l0mm flare nut wrench. Loosen 2 flare nuts in portion C with suitable l0mm flare nut wrench.
   Note: You can use the SST(P/N: 490259 770B) as a suitable 10 mm flare nut wrench.
5. Remove I nut and washer in portion .
6. Remove 2 bolts in portion .
7. Remove the Hydraulic Unit Assembly.

B.Installation

Note: Replacement unit is filled with brake fluid to aid air bleeding procedure. Remove plastic plugs by unscrewing them. Use caution not to spill the fluid.

1. Place the ABS unit into position, fasten the ground cable to the outer mounting point, install the outer rear mounting bolt and front nut and washer. See portion D .
2. Tighten 1 nut and washer in portion E and 2 bolts in portion D..
3. Tighten 2 flare nuts in portion C to the Hydraulic Unit Assembly.
4. Tighten 3 flare nuts in portion B to the Hydraulic Unit Assembly.
5. Reconnect the connector A completely (until a click sound is heard.) .
6. Flush the area around the ABS unit to prevent drips occurring after the customer receives the vehicle.
   Note: To facilitate installation of the 2 lower brake lines, removal of 2 attaching clamps for wiring harness is recommended.

Flare Nut Tightening Torque. ("B" and "C")

13-22Nm 1.3-2.2 m-kg. 10-16 ft.-lb.

Bolt and Nut Tightening Torque. ("D" and "E")

l9~25 Nm 1.9-2.6 m-kg. 14-19 ft.-lb.

Step 3 - Air Bleeding (Manual process shown)

Brake Fluid Type - DOT 3 FMVSSll6 or SAEJ1703

Caution : The fluid in the reservoir must be maintained at the 3/4 level or higher during air bleeding.
Do not spill brake fluid onto painted surfaces.

Notes:

1. If utilizing a power bleeder, follow manufacturers instructions supplied with the unit.
2. This procedure must be performed by a qualified brake service technician.
3. Wheel bleeding sequence left rear, right rear, left front, right-front.

1. Raise the vehicle on a hoist.
2. Remove the rubber cap on the bleeder valve and attach a rubber tube to the bleeder valve with the SST. (P/N: 490259 770B)
3. Place the other end of the rubber tube in a clear container and keep the tube end immersed in brake fluid during air bleeding.
4. Pump the brake pedal several times.
5. While maintaining the depressed brake pedal, loosen the bleeder screw to let fluid and air escape.

   Tightening torque

   Front:5.9-8.8 Nm (60-90 cm-kg, 56-78 in-1b)

   Rear: 6.9-9.8 Nm (70-100 cm-kg, 61-87 in-lb)

6. Repeat Steps 4 and 5 at each wheel location until there are no air bubbles in the fluid.
7. Check for correct brake operation.
8. Check that there is no fluid leakage. Be sure to clean away any spilled fluid with rags.
9. After bleeding the air, add brake fluid to the specified level in the reservoir.

Step 4 - Inspection after installation

Note: Be sure that the brake pipe lines are correctly installed to the hydraulic unit as shown in the illustration.

1. The brake pipe for the front left wheel has a yellow marking. This pipe should be connected to the right connector of the ABS unit as shown in portion A.
2. The brake pipe for the front right wheel should be connected to the center connector of the ABS unit as shown in portion B.
3. The brake pipe for the rear wheels should be connected to The left connector of the ABS unit as shown in portion C.
   Caution: Be sure that there are no obstructions with the routing of the brake pipe lines, and that the brake pipe lines have not been removed from the pipe holders.
   
4. Check the ABS warning light when the ignition switch is turned on, the ABS warning light should come on and 3 seconds after the engine starts, the ABS warning light should be off.
5. Road Test. Be sure the pedal is firm and not spongy.

Step 5 - Affixing the Recall Label

1. Affix the Recall label onto the driver's side door for future confirmation that the Recall Campaign has been carried out for that vehicle.

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