F BRAKES

B
SECTION
BRAKE SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 3 On-vehicle Service ................................................. 17 BR
Precautions for Supplemental Restraint System OPERATING CHECK .......................................... 17
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- AIRTIGHT CHECK .............................................. 17
SIONER” .................................................................. 3 Removal and Installation ........................................ 17 G
Precautions for Brake System .................................. 3 REMOVAL ........................................................... 17
Wiring Diagrams and Trouble Diagnosis .................. 3 INSPECTION AFTER REMOVAL ....................... 18
PREPARATION ........................................................... 4 INSTALLATION ................................................... 18
H
Commercial Service Tools ........................................ 4 VACUUM LINES ....................................................... 19
NOISE, VIBRATION, AND HARSHNESS (NVH) Removal and Installation ........................................ 19
TROUBLESHOOTING ................................................ 5 Inspection ............................................................... 19
NVH Troubleshooting Chart ..................................... 5 HOSES AND CONNECTORS ............................. 19 I
BRAKE PEDAL .......................................................... 6 CHECK VALVE .................................................... 19
Inspection and Adjustment ....................................... 6 FRONT DISC BRAKE ............................................... 20
Removal and Installation .......................................... 7 Component ............................................................. 20 J
REMOVAL ............................................................. 7 On-vehicle Service ................................................. 20
INSPECTION AFTER REMOVAL ......................... 7 INSPECTION ...................................................... 20
INSTALLATION ..................................................... 8 PAD REPLACEMENT ......................................... 21
K
BRAKE FLUID ............................................................ 9 Removal and Installation ........................................ 21
Changing Brake Fluid ............................................... 9 REMOVAL ........................................................... 21
Bleeding Brake System ............................................ 9 INSTALLATION ................................................... 22
Checking Brake Fluid Level ..................................... 9 Disassembly and Assembly .................................... 22 L
BRAKE PIPING AND HOSE .................................... 10 DISASSEMBLY ................................................... 22
Hydraulic Circuit ..................................................... 10 INSPECTION AFTER DISASSEMBLY ................ 23
Front Brake Piping and Hose ................................. 10 ASSEMBLY ......................................................... 24 M
REMOVAL ........................................................... 10 Brake Burnishing Procedure ................................... 25
INSTALLATION ................................................... 10 REAR DISC BRAKE ................................................. 26
Rear Brake Piping and Hose ...................................11 Component ............................................................. 26
REMOVAL ............................................................11 On-vehicle Service ................................................. 26
INSTALLATION ....................................................11 INSPECTION ...................................................... 26
Inspection ............................................................... 12 PAD REPLACEMENT ......................................... 27
BRAKE MASTER CYLINDER .................................. 13 Removal and Installation ........................................ 28
Removal and Installation ........................................ 13 REMOVAL ........................................................... 28
REMOVAL ........................................................... 13 INSTALLATION ................................................... 28
INSTALLATION ................................................... 13 Disassembly and Assembly .................................... 29
Disassembly and Assembly ................................... 14 DISASSEMBLY ................................................... 29
COMPONENTS .................................................. 14 INSPECTION AFTER DISASSEMBLY ................ 29
DISASSEMBLY ................................................... 14 ASSEMBLY ......................................................... 30
INSPECTION AFTER REMOVAL ....................... 15 Brake Burnishing Procedure ................................... 30
ASSEMBLY ......................................................... 15 DUAL PROPORTIONING VALVE ............................. 31
BRAKE BOOSTER ................................................... 17 Inspection ............................................................... 31

Revision: May 2004 BR-1 2002 Altima

SERVICE DATA AND SPECIFICATIONS (SDS) ...... 32 Brake Pedal ............................................................32
General Specifications ............................................ 32 Dual Proportioning Valve ........................................32
Disc Brake .............................................................. 32 Brake Booster .........................................................32

Revision: May 2004 BR-2 2002 Altima

 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EFS001FF

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual. C
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer. D
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section. E
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors. BR
Precautions for Brake System EFS001FG

● Recommended fluid is brake fluid “DOT 3”. G

● Never reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.
● To clean or wash all parts of master cylinder, disc brake cal- H
iper and wheel cylinder, use clean brake fluid.
● Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system. I
● Use flare nut wrench when removing and installing brake
tube.
● Always tighten brake lines to specified torque when install- SBR686C J
ing.
● Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing
pads or linings, or if a soft pedal occurs at very low mileage. K
Refer to BR-30 (Front disc brake) and BR-25 (Rear disc brake) for brake burnishing procedure.
WARNING:
● Clean brake pads and shoes with a waste cloth, then wipe with a dust collector. L
Wiring Diagrams and Trouble Diagnosis EFS001FH

When you read wiring diagrams, refer to the following:

M
● Refer to GI-12, "How to Read Wiring Diagrams" .
● Refer to PG-3, "POWER SUPPLY ROUTING CIRCUIT" for power distribution circuit.
When you perform trouble diagnosis, refer to the following:
● Refer to GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES" .
● Refer to GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" .
● For trouble diagnoses of models with ABS, refer to BRC-7, "TROUBLE DIAGNOSIS" .
● For trouble diagnoses of models with TCS even if the diagnostic items are related to the ABS system,
refer to BRC-50, "TROUBLE DIAGNOSIS" .

Revision: May 2004 BR-3 2002 Altima

 PREPARATION

PREPARATION PFP:00002

Commercial Service Tools EFS001FI

Tool name Description

1 Flare nut crowfoot Removing and installing each brake piping
2 Torque wrench a: 10 mm (0.39 in)

S-NT360

Brake fluid pressure gauge Measuring brake fluid pressure

NT151

Power tool Loosening bolts and nuts

PBIC0190E

Revision: May 2004 BR-4 2002 Altima

 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

A
NVH Troubleshooting Chart EFS001FJ

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
B

FSU-4, RSU-4
BR-20, BR-26

BR-20, BR-26

BR-20, BR-26

BR-23, BR-29

BR-20, BR-26

BR-23, BR-29

BR-23, BR-29

BR-23, BR-29

BR-20, BR-26
BR-25

FAX-4

FAX-4

WT-2

WT-2

PS-5
Reference page
C

Rotor thickness variation

D

Pads - uneven wear

Rotor deformation
Pads - damaged

Rotor imbalance
Shims damaged

Rotor deflection

ROAD WHEEL
DRIVE SHAFT

SUSPENSION
Possible cause and

Rotor damage

Rotor runout
SUSPECTED PARTS

STEERING
E

Rotor rust

TIRES
AXLE
BR
Noise X X X X X X X X X
Symptom BRAKE Shake X X X X X X X
Shimmy, Judder X X X X X X X X X X X X G
X: Applicable

Revision: May 2004 BR-5 2002 Altima

 BRAKE PEDAL

BRAKE PEDAL PFP:46501

Inspection and Adjustment EFS002O0

Inspect the brake pedal free height "H" from dash reinforcement panel. Adjust if necessary.
Free height "H" Refer to BR-32, "Brake Pedal" .
Clearance between pedal
stopper and threaded end of
0.74 - 1.96 mm (0.0291 - 0.0772 in)
stop lamp switch and ASCD
switch "C1, C2"
Pedal height (with engine M/T vehicle : More than 84 mm (3.31 in)
running, brake pedal force
490 N {50 kgf, 110 lbf}) "H2" A/T vehicle : More than 90.3 mm (3.55 in)

Pedal play "A" 3 - 11 mm (0.12 - 0.43 in)

WFIA0022E

1. Loosen the stop lamp switch and ASCD switch (if equipped) by
turning 45° counterclockwise.
2. Loosen lock nut on the input rod, then turn input rod to adjust the
pedal to specified height. When finished adjusting, tighten lock
nut.
CAUTION:
Make sure that the screw portion of the end of input rod is
located inside the clevis.
Lock nut : 16 - 21 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
3. With the pedal pulled up and held by hand, press the stop lamp SBR229E

switch and the ASCD switch (if equipped) in until threaded ends
contact rubber stops.
4. With the threaded ends of the stop lamp switch and ASCD switch (if equipped) contacting the rubber
stops, turn the switches 45° clockwise to lock in place.
CAUTION:
Make sure that the gap (C1 , C2 ) between the rubber stops and switch ends are within specifica-
tion.
5. Check the pedal play.
CAUTION:
Make sure that the stop lamp goes off when the pedal is released.
6. Start the engine and check the height of the brake pedal when depressing it.

Revision: May 2004 BR-6 2002 Altima

 BRAKE PEDAL

Removal and Installation EFS001FL

BR

WFIA0023E

1. ASCD cancel switch 2. Stop lamp switch 3. Clevis pin G

REMOVAL
WARNING: H
Do not deform the brake tube.
1. Remove the instrument panel lower cover on driver side. Refer to IP-13, "Driver Lower Instrument Panel" .
2. Remove the stop lamp switch from the pedal assembly. I
3. Remove snap pins and clevis pins from the clevis of brake booster.
4. Remove mounting nuts from the pedal assembly, then carefully remove the brake booster from the bulk-
J
head so as not to deform the brake tube.
5. Remove the clevis of brake booster from the input rod.
6. Remove the steering column assembly from the steering member.
K
7. Pushing down the pedal assembly to the right, remove it from the vehicle while keeping the steering post
bracket stay out.
INSPECTION AFTER REMOVAL L
Check brake pedal for following items.
● Brake pedal bend
● Clevis pin deformation M
● Crack of any welded portion
● Crack or deformation of clevis pin stopper

SBR997

Revision: May 2004 BR-7 2002 Altima

 BRAKE PEDAL

INSTALLATION
● Install all parts in the reverse order of removal.
● After installing the brake pedal assembly in the vehicle, be sure to adjust it.

Revision: May 2004 BR-8 2002 Altima

 BRAKE FLUID

BRAKE FLUID PFP:KN100

A
Changing Brake Fluid EFS002O1

CAUTION:
● Refill with new brake fluid “DOT 3”. B
● Always keep fluid level higher than minimum line on reservoir tank.
● Never reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is C
splashed on painted areas, wash it away with water immediately.
1. Connect a vinyl tube and container to the air bleeder.
2. Depressing the brake pedal, drain the brake fluid gradually from the air bleeder of each wheel. D
3. Turn the ignition switch to OFF and disconnect the ABS actuator and control unit connector.
4. Clean inside of reservoir tank, and refill with new brake fluid.
E
5. Loosen the air bleeder, depress the pedal slowly to the full stroke and then release it. Repeat the proce-
dure every 2 or 3 seconds until the new brake fluid comes out, then close the air bleeder while depressing
the pedal. Refer to BR-9, "Bleeding Brake System" .
BR
Bleeding Brake System EFS001FN

CAUTION:
● Carefully monitor brake fluid level at master cylinder during bleeding operation. G
● Fill reservoir with new brake fluid “DOT 3”. Make sure it is full at all times while bleeding air out of
system.
● Place a container under master cylinder to avoid spillage of brake fluid. H
● Do not loosen the connecting portion of the actuator during air bleeding.
1. For models with ABS, turn ignition switch OFF and disconnect ABS actuator and control unit connectors
or battery ground cable. I
2. Connect a transparent vinyl tube to air bleeder valve.
3. Fully depress brake pedal several times.
4. With brake pedal depressed, open air bleeder valve to release J
air.
5. Close air bleeder valve.
6. Release brake pedal slowly. K
7. Tighten air bleeder valve.
Tightening torque : 7 - 9 N·m (0.7 - 0.9 kg-m, L
61 - 78 in-lb)
8. Repeat steps 2. through 7. until clear brake fluid comes out of air SBR419C

bleeder valve. M
9. Bleed air in the following order.
Right rear brake → Left front brake → Left rear brake → Right front brake
Checking Brake Fluid Level EFS001FO

● Check fluid level in reservoir tank. It should be between Max and

Min lines on reservoir tank.
● Visually check around the reservoir tank for leaks.
● If fluid level is extremely low, check brake system for leaks.
● Release parking brake lever and see if brake warning lamp goes
off. If not, check brake system for leaks.

LFIA0096E

Revision: May 2004 BR-9 2002 Altima

 BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSE PFP:46210

Hydraulic Circuit EFS001FP

WFIA0075E

Front Brake Piping and Hose EFS001FQ

REMOVAL
CAUTION:
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
● All hoses must be free from excessive bending, twisting and pulling.
● Cover openings to prevent entrance of dirt whenever disconnecting brake line.
1. Connect vinyl tube and container to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing brake pedal.
3. Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
4. Remove the connecting bolt and disconnect the caliper assem-
bly from the brake hose.
5. Remove lock plates from the mounting portion of the brake tube
and the mounting portion of the strut.

WFIA0087E

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
1. Attach the brake hose to the caliper assembly, then tighten the connecting bolts to the specified torque.
CAUTION:
● Correctly attach the brake hose to the cylinder body.

● The copper washer of the connecting bolt has to be replaced with a new one every time the fit-
ting is disconnected.
2. Attach the brake hose to the strut, then install a lock plate.
3. Attach the brake hose to the brake tube and temporarily tighten the flare nut as much as possible by hand,
then install a lock plate.

Revision: May 2004 BR-10 2002 Altima

 BRAKE PIPING AND HOSE

4. Tighten all flare nuts and connecting bolts.

A
Specification
Flare nut : 5 - 18 N·m (1.5 - 1.8 kg-m,
11 - 13 ft-lb) B
Connecting bolt : 17 - 20 N·m (1.7 - 2.0 kg-m,
12 - 14 ft-lb)
5. Refill until new brake fluid comes out of each air bleeder valve. C
6. Bleed air. Refer to BR-9, "Bleeding Brake System" .
SBR686C

D
Rear Brake Piping and Hose EFS001FR

REMOVAL
CAUTION:
E
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
● All hoses must be free from excessive bending, twisting and pulling.
BR
● Cover openings to prevent entrance of dirt whenever disconnecting brake line.
1. Connect vinyl tube and container to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing brake pedal. G
3. Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
4. Remove the lock plate and the connecting bolt, and then remove H
it from the vehicle.

J
WFIA0088E

INSTALLATION
CAUTION: K
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
L
1. Attach the brake hose to the brake tube and temporarily tighten the flare nut as much as possible by hand.
2. Install the brake hose with a lock plate, then tighten the connecting bolt to the specified torque. Tighten the
flare nut with a torque wrench to specification.
M
Specification
Flare nut : 5 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting
: 17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
bolt
3. Refill until new brake fluid comes out of each air bleeder valve.
4. Bleed air. Refer to BR-9, "Bleeding Brake System" .

SBR686C

Revision: May 2004 BR-11 2002 Altima

 BRAKE PIPING AND HOSE

Inspection EFS001FS

CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for leaks, cracks, distor-
tion, deformation, without interfering with other parts or loosen-
ing connecting parts, deterioration or other damage. Replace
any damaged parts.
2. Apply the stepping force of 784 N (80 kgf, 176 lbf) to the brake
pedal with the engine running and keep it for about 5 seconds,
then check each part for leaks.

SBR389C

Revision: May 2004 BR-12 2002 Altima

 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

A
Removal and Installation EFS001FT

CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is B
splashed on painted areas, wash it away with water immediately.
REMOVAL
1. Connect a vinyl tube and container to air bleeder valve. C
2. Drain brake fluid from each air bleeder valve by depressing brake pedal to empty fluid from the master cyl-
inder. Remove the harness connector of the liquid level sensor.
3. Remove brake pipe flare nuts. D
4. Remove master cylinder mounting nuts.
INSTALLATION E
CAUTION:
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid. BR
1. Place master cylinder onto brake booster and secure mounting nuts lightly.
2. Tighten the mounting nuts.
Tightening torque : 12 - 15 N·m (1.2 - 1.5 kg-m, G
9 - 11 ft-lb)
3. Fill the reservoir tank with new brake fluid. H
4. Plug all ports on master cylinder with fingers to prevent air suc-
tion while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no air I
comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts. J
Tightening torque : 15 - 18 N·m (1.5 - 1.8 kg-m,
11 - 13 ft-lb)
K
8. Bleed air from brake system. Refer to BR-9, "Bleeding Brake WFIA0026E
System" .

Revision: May 2004 BR-13 2002 Altima

 BRAKE MASTER CYLINDER

Disassembly and Assembly EFS001FU

COMPONENTS

WFIA0037E

1. Reservoir cap 2. O-ring 3. Reservoir tank

4. Seal 5. Cylinder body 6. O-ring
7. Piston stopper 8. Secondary piston assembly 9. Primary piston assembly
10. Stopper cap

DISASSEMBLY
1. Bend claws of stopper cap outward.

SBR938A

Revision: May 2004 BR-14 2002 Altima

 BRAKE MASTER CYLINDER

2. Remove piston stopper while piston is pushed into cylinder.

A

SBR231C

D
3. Remove piston assemblies.
If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.
4. Draw out reservoir tank. E

INSPECTION AFTER REMOVAL

Master Cylinder Inner Wall BR
● Check the inner wall of the cylinder for damage, abrasion, corrosion and pin holes. If NG, replace the cyl-
inder.
Piston G
● Check for deformation of or scratches on piston cups.
ASSEMBLY
H
1. Insert secondary piston assembly. Then insert primary piston
assembly.
● Pay attention to alignment of secondary piston slit with valve
stopper mounting hole of cylinder body. I

K
SBR354C

2. Install stopper cap. L

Before installing stopper cap, ensure that claws are bent inward.

SBR940A

3. Push reservoir tank seals into cylinder body.

4. Push reservoir tank into cylinder body.

Revision: May 2004 BR-15 2002 Altima

 BRAKE MASTER CYLINDER

5. Install piston stopper while piston is pushed into cylinder.

SBR435B

Revision: May 2004 BR-16 2002 Altima

 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

A
On-vehicle Service EFS001FV

OPERATING CHECK
1. Stop engine and depress brake pedal several times. Check that
B
pedal stroke does not change.
2. Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
C

SBR002A
E
AIRTIGHT CHECK
● Start engine, and stop it after one or two minutes. Depress brake
pedal several times slowly. The pedal should go further down BR
the first time, and then it should gradually rise thereafter.
● Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change after G
holding pedal down for 30 seconds.

SBR365AA

I
Removal and Installation EFS001FW

REMOVAL
CAUTION: J
● Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
● Be careful not to deform or bend brake pipes during K
removal of booster.
● Replace clevis pin if damaged.
L
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
● Take care not to damage brake booster mounting bolt
M
thread when installing. Due to the acute angle of installa- SBR232CB
tion, the threads can be damaged with the dash panel.
1. Remove the vacuum piping from the brake booster.
2. Remove the master cylinder.
3. Remove snap pin and clevis pin from clevis, then remove the input rod from the brake pedal.
4. Remove the mounting nuts from the brake booster and the brake pedal assembly.
5. Remove the booster assembly from the engine compartment.

Revision: May 2004 BR-17 2002 Altima

 BRAKE BOOSTER

INSPECTION AFTER REMOVAL

Output Rod Length Check
1. Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to brake
booster with a hand vacuum pump.
2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.
3. Check output rod length.
Specified length : 10.275 - 10.525 mm
(0.4045 - 0.4144 in)

SBR208E

INSTALLATION
1. Adjust the length of the input rod by loosening the lock nut so
that the dimensions shown match the standard value.
Standard value : 125 mm (4.92 in)
2. Tighten the lock nut temporarily and install the booster assembly
in the vehicle.
3. Connect the brake pedal part to the clevis part of the input rod.
4. Tighten the mounting nut for the pedal assembly to the specified
torque.
: 13 - 16 N·m (1.3 - 1.6 kg-m, SBR237EA

9 - 12 ft-lb)
5. Install the master cylinder in the booster assembly.
6. Adjust the height and play of the brake pedal.
7. Tighten the lock nut of the input rod to the specified torque.
: 16 - 21 N·m (1.6 - 2.2 kg-m,
12 - 15 ft-lb)
8. Bleed air. Refer to BR-9, "Bleeding Brake System" .

Revision: May 2004 BR-18 2002 Altima

 VACUUM LINES

VACUUM LINES PFP:41920

A
Removal and Installation EFS001FX

CAUTION:
When installing vacuum hoses, pay attention to the following points. B
● Do not apply any oil or lubricants to vacuum hose with
check valve.
● Insert vacuum tube into vacuum hose as shown. C
● Install vacuum hose with internal check valve, paying atten-
tion to its direction.
D

E
SBR225B

Inspection EFS001FY

HOSES AND CONNECTORS BR

Check vacuum lines and connections for airtightness, improper attachment, chafing and deterioration.
CHECK VALVE G
Check vacuum with a vacuum pump.
Connect to booster side Vacuum should exist
H
Connect to engine side Vacuum should not exist

J
SBR844B

Revision: May 2004 BR-19 2002 Altima

 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

Component EFS001FZ

WFIA0086E

1. Main pin 2. Pin boot 3. Torque member fixing bolt

4. Torque member 5. Shim cover 6. Inner shim
7. Inner pad 8. Pad retainer 9. Outer pad
10. Outer shim 11. Connecting bolt 12. Copper washer
13. Main pin bolt 14. Bleed valve 15. Cylinder body
16. Piston seal 17. Piston 18. Piston boot
19. Pad return spring

WARNING:
Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other
materials.
CAUTION:
● When cylinder body is open, do not depress the brake pedal because the piston will pop out.
● It is not necessary to remove connecting bolt except for disassembly or replacement of caliper
assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.
● Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing
pads.
● Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing
pads or linings or if a soft pedal occurs at very low mileage.
Refer to BR-25, "Brake Burnishing Procedure" .
On-vehicle Service EFS002O8

INSPECTION
Pad Thickness
● Remove a wheel with the vehicle lifted up, and then check the
thickness of the pad from the inspection hole of the cylinder
body. If necessary, check it with a micrometer.
Standard pad thickness : 11 mm (0.43 in)
Pad wear limit : 2.0 mm (0.079 in)

BRA0010D

Revision: May 2004 BR-20 2002 Altima

 FRONT DISC BRAKE

PAD REPLACEMENT
Removal A
● If shims are rusted or show peeling of the rubber coat, replace them with new shims.
● Whenever the brake pads are replaced, the inner shim, the outer shim and the shim cover have to be
replaced as a set. B
1. Remove master cylinder reservoir cap.
2. Remove pin bolt, using power tool.
C

SBR976B
BR

3. Suspend the cylinder body with wire. Then remove pads with
retainers, inner and outer shims and pad return springs.
G

SBR932C

Installation J
1. Attach the inner shim and shim cover to the inner pad and attach the outer shim to the outer pad.
2. Apply grease to the contact surface of pad retainer with the pads, then attach the pad retainer, pads and
pad return spring to the torque member. K
3. Install the cylinder body to the torque member.
4. Insert a main pin bolt (on the lower side) and tighten it to specification. Refer to BR-20, "Component" .
5. Check the brakes for drag. L
CAUTION:
Burnish the brake contact surfaces after refinishing or replacing brake rotors, after replacing pads, or
if a soft pedal occurs at very low mileage. Refer to BR-25, "Brake Burnishing Procedure" . M

Removal and Installation EFS002O9

REMOVAL
1. Connect the vinyl tube and container to the air bleeder.
2. Depress the brake pedal and drain the brake fluid gradually from the air bleeder.
3. Remove torque member fixing bolts using power tool and brake
hose connecting bolt.
4. Remove the brake caliper, using power tool.
5. Remove brake rotor.

SBR979B

Revision: May 2004 BR-21 2002 Altima

 FRONT DISC BRAKE

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
1. Install brake rotor.
2. Install the brake caliper and tighten main pin bolt to specification. Refer to BR-20, "Component" .
CAUTION:
When installing the caliper assembly in the vehicle, wipe oil from the seating surface of the
knuckle spindle washer and the mounting surface of the caliper assembly.
3. Install brake hose to caliper and tighten connecting bolt to spec-
ification. Refer to BR-20, "Component" .
CAUTION:
● The copper washer of the connecting bolt has to be
replaced every time the fitting is disconnected.
● Correctly attach the brake hose to the projecting portion
of the cylinder body.
4. Bleed air from brake system. Refer to BR-9, "Bleeding Brake
System" .
CAUTION: SBR980B
Burnish the brake contact surfaces after refinishing or replac-
ing brake rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-25,
"Brake Burnishing Procedure" .
Disassembly and Assembly EFS002OA

DISASSEMBLY
1. Push out piston with piston boot using compressed air.
WARNING:
Do not place your fingers in front of piston.

SBR772

2. Remove piston seal with a suitable tool.

CAUTION:
Do not scratch or score cylinder wall.

WFIA0029E

Revision: May 2004 BR-22 2002 Altima

 FRONT DISC BRAKE

INSPECTION AFTER DISASSEMBLY

Caliper A

CYLINDER BODY
CAUTION: B
Use brake fluid to clean. Never use mineral oil.
● Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If
any of the above conditions are observed, replace cylinder body. C
● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
D
TORQUE MEMBER
Check for wear, cracks or other damage. Replace if necessary.
E
PISTON
CAUTION:
Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are BR
stuck to sliding surface.
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-
ditions are observed. G

SLIDE PIN, PIN BOLT AND PIN BOOT

Check for wear, cracks or other damage. Replace if any of the conditions are observed. H

Rotor
I
VISUAL INSPECTION
Check rotor for roughness, cracks or chips.
J
RUNOUT
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator. K
Make sure that wheel bearing axial end play is within the specifi-
cations before measuring runout. Refer to FAX-5, "Front Wheel
Bearing" . L
3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout : 0.07 mm (0.0028 in) M
4. If the runout is still out of specification, turn rotor with on-car
brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equiva- SBR019B

lent).

THICKNESS
● Check thickness using a micrometer.
Thickness variation : Maximum 0.015 mm
(At least 8 positions) (0.0006 in)
● If thickness variation exceeds the specification, turn rotor with
on-car brake lathe.
Rotor thickness : 22.0 mm (0.866 in)
repair limit

SBR020B

Revision: May 2004 BR-23 2002 Altima

 FRONT DISC BRAKE

ASSEMBLY
1. Apply rubber grease to new piston seal and insert seal into
groove on cylinder body.

SBR574

WFIA0030E

2. With piston boot fitted to piston, insert piston boot into groove on
cylinder body and install piston.

WFIA0031E

3. Make sure piston boot is properly installed.

WFIA0032E

Revision: May 2004 BR-24 2002 Altima

 FRONT DISC BRAKE

Brake Burnishing Procedure EFS001G4

A
Burnish the brake contact surfaces according to the following procedure after refinishing or replacing brake
rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution. B
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH).
C
Adjust brake pedal/foot pressure so that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
D

BR

Revision: May 2004 BR-25 2002 Altima

 REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

Component EFS001G5

WFIA0089E

1. Main pin bolt 2. Pin boot 3. Torque member fixing bolt

4. Torque member 5. Shim cover 6. Inner shim
7. Inner pad 8. Pad retainer 9. Outer pad
10. Outer pad 11. Connecting bolt 12. Copper washer
13. Bleed valve 14. Cylinder body 15. Piston seal
16. Piston 17. Piston boot 18. Retainer

WARNING:
Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other
materials.
CAUTION:
● When cylinder body is open, do not depress brake pedal because piston will pop out.
● Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing
pads.
● It is not necessary to remove connecting bolt except for disassembly or replacement of caliper
assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.
● Burnish the brake contact surfaces after refinishing or replacing brake rotors, after replacing pads
or linings, or if a soft pedal occurs at very low mileage.
Refer to BR-30, "Brake Burnishing Procedure" .
On-vehicle Service EFS002O5

INSPECTION
Pad Thickness
● Remove a wheel with the vehicle lifted up, and then check the
thickness of the pad from the inspection hole of the cylinder
body. If necessary, check it with a scale.
Standard pad thickness : 8 mm (0.31 in)
Pad wear limit : 1.5 mm (0.059 in)

BRA0010D

Revision: May 2004 BR-26 2002 Altima

 REAR DISC BRAKE

PAD REPLACEMENT
Removal A
● If shims are rusted or show peeling of the rubber coat, replace them with new shims.
● Whenever the brake pads are replaced, the inner shim, the outer shim and the shim cover have to be
replaced as a set. B
1. Remove master cylinder reservoir cap.
2. Remove lower pin bolt, using power tool.
C

SBR090C
BR

3. Open cylinder body upward and secure with wire. Then remove
pad retainers, and inner and outer shims.
G

SBR042C
M

Installation
1. Apply grease to the inner and outer shim, and then attach them to the pads.
2. Attach the pad retainer to the torque member, and then attach it to the pad.
3. When installing new pads, push piston back into cylinder body.
● Carefully monitor brake fluid level because brake fluid will return to the reservoir when pushing back
piston.
4. Close cylinder body down into the torque member.
5. Insert a main pin bolt and tighten it to specified torque. Refer to BR-26, "Component" .
6. Check the brake for drag.
CAUTION:
Burnish the brake contact surfaces refinishing or replacing brake rotors, after replacing pads, or if a
soft pedal occurs at very low mileage. Refer to BR-30, "Brake Burnishing Procedure" .

Revision: May 2004 BR-27 2002 Altima

 REAR DISC BRAKE

Removal and Installation EFS002O6

REMOVAL
WARNING:
Clean brakes with a vacuum dust collector to minimize the hazard of airborne particles or other mate-
rials.
1. Connect the vinyl tube and container to the air bleeder.
2. Depress the brake pedal and drain the brake fluid gradually from the air bleeder.
3. Remove torque member fixing bolts using power tool and brake
hose connecting bolt.

WFIA0078E

4. Remove caliper and brake rotor. If the brake rotor cannot be removed, remove as follows:
● Make sure parking brake lever is completely disengaged.

● Hold down the brake rotor with the wheel nut and remove the brake rotor plug.

● Insert a flat-bladed screwdriver through the plug opening and

rotate the star wheel on the adjuster assembly in the direction
shown to loosen and retract the brake shoes.
● Remove wheel nuts and rotor.

WFIA0018E

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
1. Install brake rotor.
2. Install caliper assembly and tighten main pin bolt to specification. Refer to BR-26, "Component" .
3. Install brake hose to caliper and tighten connecting bolt to spec-
ification. Refer to BR-26, "Component" .
CAUTION:
● The copper washers for the connecting bolt have to be
replaced every time the fitting is disconnected.
4. Bleed air from brake system. Refer to BR-9, "Bleeding Brake
System" .
5. Adjust the parking brake. Refer to PB-3, "Adjustment" .
CAUTION:
Burnish the brake contact surfaces refinishing or replacing SBR093C
brake rotors, after replacing pads, or if a soft pedal occurs at
very low mileage. Refer to BR-30, "Brake Burnishing Procedure" .

Revision: May 2004 BR-28 2002 Altima

 REAR DISC BRAKE

Disassembly and Assembly EFS002O7

DISASSEMBLY A
1. Remove piston boot retainer with a flat-bladed screwdriver.

D
SBR028A

2. Push out piston and piston boot with compressed air. E

WARNING:
Do not place your finger in front of piston.
3. Remove piston seal with a suitable tool. BR
CAUTION:
Do not scratch or score cylinder wall.
G

H
SBR772

INSPECTION AFTER DISASSEMBLY

I
Caliper
CYLINDER BODY
CAUTION: J
Use brake fluid to clean. Never use mineral oil.
● Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If
any of the above conditions are observed, replace cylinder body. K
● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
L
TORQUE MEMBER
Check for wear, cracks or other damage. Replace if necessary.
M
PISTON
CAUTION:
Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface.
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-
ditions are observed.

SLIDE PIN, PIN BOLT AND PIN BOOT

Check for wear, cracks or other damage. Replace if any of the conditions are observed.

Rotor
VISUAL INSPECTION
Check rotor for roughness, cracks or chips.

Revision: May 2004 BR-29 2002 Altima

 REAR DISC BRAKE

RUNOUT
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the specifi-
cations before measuring runout. Refer to RAX-5, "Rear Wheel
Bearing" .
3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout : 0.07 mm (0.0028 in)

SBR019B

THICKNESS
Check thickness using a micrometer.
Rotor repair limit
Standard thickness : 9 mm (0.35 in)
Minimum thickness : 8 mm (0.31 in)
Thickness variation (At : Maximum 0.015 mm
least 8 positions) (0.0006 in)

SBR020B

ASSEMBLY
1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove on
cylinder body and install piston.
3. Secure piston boot with retainer.

SBR044C

Brake Burnishing Procedure EFS001GA

Burnish the brake contact surfaces according to the following procedure after refinishing or replacing brake
rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH).
Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

Revision: May 2004 BR-30 2002 Altima

 DUAL PROPORTIONING VALVE

DUAL PROPORTIONING VALVE PFP:46400

A
Inspection EFS001GB

CAUTION:
● Carefully monitor brake fluid level at master cylinder. B
● Use new brake fluid “DOT 3”.
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on paint areas, wash it away with water immediately. C
1. Connect Tool to air bleeders of front and rear brakes on either
LH and RH side.
D

BR
SBR822BA

2. Bleed air from the Tool. G

3. Check fluid pressure by depressing brake pedal.
Applied pressure : 7,355 kPa (75 kg/cm2, 1,067 psi)
H
(Front brake)
Output pressure : 5,100 - 5,492 kPa (52 - 56 kg/cm2,
(Rear brake) 739 - 796 psi)
I
If output pressure is out of specification, replace dual proportion-
ing valve.
4. Bleed air after disconnecting the Tool. Refer to BR-9, "Bleeding J
SBR823BA
Brake System" .

Revision: May 2004 BR-31 2002 Altima

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications EFS001GC

Unit: mm (in)
Brake model CLZ25VD disc brake
Cylinder bore diameter 57.2 (2.252)
Front brake Pad
125.6 × 46 × 11 (4.94 × 1.81 × 0.43)
Length × width × thickness
Rotor outer diameter × thickness 296 × 26 (11.65 × 1.02)
Brake model AD9V disc brake
Cylinder bore diameter 34.9 (1.3740)
Rear brake Pad
89.1 × 39.5 × 10 (3.508 × 1.555 × 0.31)
Length × width × thickness
Rotor outer diameter × thickness 292 × 9 (11.50 × 0.35)
Master cylinder Cylinder bore diameter 23.81 (15/16)
Control valve Screw in type 30 × 0.4 (1.18 × 0.02)
Booster model M215T
Brake booster Primary 230 (9.06)
Diaphragm diameter
Secondary 205 (8.07)
Recommended brake fluid DOT 3

Disc Brake EFS001GD

Unit: mm (in)
Brake model CLZ25VD AD9V
Pad wear limit Minimum thickness 2.0 (0.079) 1.5 (0.059)
Maximum runout 0.07 (0.0028) 0.07 (0.0028)
Rotor repair limit
Minimum thickness 22.0 (0.866) 8 (0.31)

Brake Pedal EFS001GE

Unit: mm (in)
M/T 164.1 - 174.1 (6.46 - 6.85)
Free height “H”*
A/T 173.1 - 183.1 (6.81 - 7.21)
Clearance “C” between pedal stopper and threaded end of stop lamp switch or ASCD switch 0.74 - 1.96 (0.0291 - 0.0772)
*: Measured from surface of dash reinforcement panel to surface of pedal pad

Dual Proportioning Valve EFS001GF

2
Unit: kPa (kg/cm , psi)
Applied pressure (front) 7,355 (75, 1,067)
Output pressure (rear) 5,100 - 5,492 (52 - 56, 739 - 796)

Brake Booster EFS001GG

Unit: mm (in)
Output rod length 10.275 - 10.525 (0.4045 - 0.4144)
Clevis length 130 (5.12)

Revision: May 2004 BR-32 2002 Altima