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Index of /manuals/AUTOMOBILE/NISSAN/Altima/2006

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F BRAKES

SECTION

BRAKE SYSTEM C

CONTENTS

PRECAUTIONS ......................................................... 3 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................. 3 Precautions for Brake System ................................. 3
PREPARATION .......................................................... 4 Special Service Tool ................................................ 4 Commercial Service Tools ....................................... 4
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING ............................................... 5
NVH Troubleshooting Chart .................................... 5 BRAKE PEDAL ......................................................... 6
Inspection and Adjustment ...................................... 6 INSPECTION ....................................................... 6 ADJUSTMENT ..................................................... 6
Removal and Installation ......................................... 7 REMOVAL ............................................................ 7 INSPECTION AFTER REMOVAL ........................ 7 INSTALLATION .................................................... 7
BRAKE FLUID ........................................................... 9 Checking Brake Fluid Level .................................... 9 Changing Brake Fluid .............................................. 9 Bleeding Brake System ........................................... 9
BRAKE PIPING AND HOSE ................................... 10 Hydraulic Circuit .................................................... 10 Front Brake Piping and Hose ................................ 10 REMOVAL .......................................................... 10 INSTALLATION ...................................................11 Rear Brake Piping and Hose ..................................11 REMOVAL ...........................................................11 INSTALLATION .................................................. 12 Inspection .............................................................. 13
BRAKE MASTER CYLINDER ................................. 14 On-board Inspection .............................................. 14 LEAK INSPECTION ........................................... 14 Components .......................................................... 14 Removal and Installation ....................................... 14 REMOVAL .......................................................... 15

INSTALLATION .................................................. 15 BR

Disassembly and Assembly ................................... 15

DISASSEMBLY .................................................. 15

INSPECTION AFTER REMOVAL ...................... 16 G ASSEMBLY ........................................................ 16

BRAKE BOOSTER .................................................. 17

On-vehicle Service ................................................ 17 OPERATING CHECK ......................................... 17

AIRTIGHT CHECK ............................................. 17

Removal and Installation ....................................... 17 REMOVAL .......................................................... 18 I

INSPECTION AFTER REMOVAL ...................... 18

INSTALLATION .................................................. 18

VACUUM LINES ...................................................... 19 J

Removal and Installation ....................................... 19

Inspection .............................................................. 20

VISUAL INSPECTION ........................................ 20 K CHECK VALVE INSPECTION ............................ 20

CLZ25VD

FRONT DISC BRAKE .............................................. 21

Component ............................................................ 21 On-vehicle Service ................................................ 21 M
PAD WEAR INSPECTION .................................. 21 REMOVAL AND INSTALLATION OF BRAKE PAD .................................................................... 22 Removal and Installation of Caliper Assembly and Disc Rotor .............................................................. 22 REMOVAL .......................................................... 22 INSTALLATION .................................................. 23 Disassembly and Assembly of Caliper Assembly... 23

DISASSEMBLY .................................................. 23 INSPECTION AFTER DISASSEMBLY ............... 24 ASSEMBLY ........................................................ 25 Brake Burnishing Procedure .................................. 26

CLZ25VE
FRONT DISC BRAKE .............................................. 27 Component ............................................................ 27

Revision: November 2006

BR-1

2006 Altima

On-board Inspection .............................................. 28 PAD WEAR INSPECTION .................................. 28
Removal and Installation of Brake Pad .................. 28 REMOVAL .......................................................... 28 INSTALLATION ................................................... 28
Removal and Installation of Caliper Assembly and Disc Rotor .............................................................. 29
REMOVAL .......................................................... 29 INSTALLATION ................................................... 29 Disassembly and Assembly of Caliper Assembly... 30 DISASSEMBLY .................................................. 30 CALIPER INSPECTION ..................................... 30 ASSEMBLY ........................................................ 31 DISC ROTOR INSPECTION .............................. 31 Brake Burnishing ................................................... 32 REAR DISC BRAKE ................................................ 33 Component ............................................................ 33 On-Vehicle Service ................................................ 34 PAD WEAR INSPECTION .................................. 34

REMOVAL AND INSTALLATION OF BRAKE PAD .....................................................................34 Removal and Installation ........................................35 REMOVAL ...........................................................35 INSTALLATION ...................................................35 Disassembly and Assembly ...................................36 DISASSEMBLY ...................................................36 CALIPER INSPECTION ......................................37 ASSEMBLY .........................................................37 DISC ROTOR INSPECTION ..............................38 Brake Burnishing ....................................................39 DUAL PROPORTIONING VALVE ............................40 Inspection ...............................................................40 SERVICE DATA AND SPECIFICATIONS (SDS) .....41 General Specifications ...........................................41 Disc Brake ..............................................................41 Brake Pedal ...........................................................42 Control Valve ..........................................................42 Brake Booster ........................................................42

Revision: November 2006

BR-2

2006 Altima

PRECAUTIONS

PFP:00001

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT A

BELT PRE-TENSIONER"

EFS007AO

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS

system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in the SRS and SB section of this Service Man-

ual.

WARNING:

q 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.

q 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.

q 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.

Precautions for Brake System

EFS0045K

q Always use new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

q Never reuse drained brake fluid.

q Be careful not to splash brake fluid on painted areas.

q To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean I brake fluid.

q Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic

system.

q Use flare nut wrench when removing and installing brake

tube.

q Always tighten brake lines to specified torque when installing.

q 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.

WARNING: q Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.

M
SBR686C

Revision: November 2006

BR-3

2006 Altima

PREPARATION

Special Service Tool

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

Description

-- (J-46532) Brake and clutch pedal height measurement tool

Measuring brake pedal height

PFP:00002
EFS004M6

Commercial Service Tools
Tool name 1 Flare nut crowfoot 2 Torque wrench

LFIA0227E

EFS0045M
Description Removing and installing each brake piping a: 10 mm (0.39 in)

Brake fluid pressure gauge

S-NT360

Measuring brake fluid pressure

Power tool

NT151
Loosening nuts, bolts, and screws

PBIC0190E

PBIC0191E

Revision: November 2006

BR-4

2006 Altima

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart

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

E
Reference page
BR

J
Possible cause and SUSPECTED PARTS
K

Symptom ×: Applicable

Revision: November 2006

Noise Shake Shimmy, Shudder

×××

Pads - damaged

BR-21, BR-33

Pads - uneven wear

BR-21, BR-34

Shims damaged

BR-21, BR-33

×××××××

Rotor imbalance

BR-24, BR-38

BR-5

Rotor damage

BR-21, BR-33

Rotor runout

BR-24, BR-38

Rotor deformation

BR-24, BR-38

Rotor deflection

BR-24, BR-38

Rotor rust

BR-26' BR-26

Rotor thickness variation

BR-21, BR-39

××××××

DRIVE SHAFT

FAX-4, "NVH Troubleshooting Chart"

×××××
M

WHEEL HUB

FAX-4, "NVH Troubleshooting Chart", RAX-4, "NVH Troubleshooting Chart"

SUSPENSION

FSU-4, "NVH Troubleshooting Chart", RSU-4, "NVH Troubleshooting Chart"

TIRES

WT-3, "NVH Troubleshooting Chart"

PFP:00003
A
EFS0045N

2006 Altima

ROAD WHEEL

WT-3, "NVH Troubleshooting Chart"

STEERING

PS-5, "NVH Troubleshooting Chart"

BRAKE PEDAL
BRAKE PEDAL Inspection and Adjustment
INSPECTION Inspect the brake pedal free height "H" from dash reinforcement panel using Tool. Adjust if necessary. Refer to BR-6, "ADJUSTMENT" .
Tool : -- (J-46532)
q Input rod (A) q Floor carpet (B) q Dash insulator (C) q Floor panel (D) q Dash reinforcement panel (E) q Dash insulator (F) q Floor carpet (G) q Gap (I1, I2) q Stop lamp switch and ASCD switch (J)

PFP:46501
EFS0045O

WFIA0423E

Free height "H"
Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch "I1, I2"
Pedal height (with engine running, brake pedal force 490 N {50 kg-f, 110 lb-f}) "H"
Pedal play

: Refer to BR-42, "Brake Pedal" . : 0.74 - 1.96 (0.0291 - 0.0772)
M/T : More than 84 (3.31) A/T : More than 90.3 (3.55) : 3 - 11 (0.12 - 0.43)

Unit: mm (in)

ADJUSTMENT

1. Loosen the stop lamp switch and ASCD switch (if equipped) by turning 45° counterclockwise.

2. Loosen lock nut on the input rod.

CAUTION: Make sure that the screw portion of the end of input rod is located inside the clevis as shown.

3. Turn input rod to adjust the pedal to specified height. Refer to BR-6, "INSPECTION" . When finished adjusting, tighten lock nut to specification. Refer to BR-17, "Removal and Installation" .

4. With the pedal pulled up and held by hand, press the stop lamp

switch and the ASCD switch (if equipped) in until threaded ends

contact rubber stops.

5. With the threaded ends of the stop lamp switch and ASCD

SBR229E

switch (if equipped) contacting the rubber stops, turn the switches 45° clockwise to lock in place.

CAUTION: Make sure that the gap (I1 , I2 ) between the rubber stops and switch ends are within specification.

6. Check the pedal play.

Revision: November 2006

BR-6

2006 Altima

BRAKE PEDAL
CAUTION: Make sure that the stop lamp goes off when the pedal is released. 7. Start the engine and check the height of the brake pedal when depressing it.
Removal and Installation

EFS0045P

1. Clevis Pin 4. Snap pin

2. Stop lamp switch 5. Brake pedal assembly

WFIA0424E

3. ASCD cancel switch

Front

REMOVAL

WARNING: Do not deform the brake tube.

1. Remove the instrument lower cover LH. Refer to IP-13, "INSTRUMENT LOWER COVER LH" .

2. Remove the stop lamp switch from the pedal assembly.

3. Remove ASCD switch (if equipped) from pedal assembly.

4. Remove snap pin and clevis pin from the clevis of brake booster.

5. Remove mounting nuts from the pedal assembly and carefully remove the brake pedal from the brake

booster.

CAUTION:

Temporarily secure brake booster to bulkhead with a hand tightened nut, to prevent damaging to

brake tubes.

INSPECTION AFTER REMOVAL

Check brake pedal for following items.

q Crack or deformation of clevis pin stopper

q Clevis pin deformation

q Crack of any welded portion

q Brake pedal bend

INSTALLATION Installation is in the reverse order of removal.

Revision: November 2006

BR-7

SBR997
2006 Altima

BRAKE PEDAL
q After installing the brake pedal assembly in the vehicle, be sure to adjust it. Refer to BR-6, "Inspection and Adjustment" .

Revision: November 2006

BR-8

2006 Altima

BRAKE FLUID

BRAKE FLUID
Checking Brake Fluid Level
q Check fluid level in reservoir tank. It should be between Max and Min lines on reservoir tank.
q Visually check around the reservoir tank for leaks. q If fluid level is extremely low, check brake system for leaks. q Release parking brake lever and see if brake warning lamp goes
off. If not, check brake system for leaks.

PFP:KN100
A
EFS0045Q
B
C
D

Changing Brake Fluid

LFIA0096E
E
EFS0045R

CAUTION:

q Refill with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

q Always keep fluid level higher than minimum line on reservoir tank.

q Never reuse drained brake fluid.

q Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is G 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.

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. 5. Loosen the air bleeder, depress the pedal slowly to the full stroke and then release it. Repeat the proce- I
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" .

Bleeding Brake System

J
EFS0045S

CAUTION:

q Carefully monitor brake fluid level at master cylinder during bleeding operation.

q Fill reservoir with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

Make sure it is full at all times while bleeding air out of system.

q Place a container under master cylinder to avoid spillage of brake fluid.

q 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.

2. Connect a transparent vinyl tube and container to air bleeder valve.

3. Fully depress brake pedal several times.

4. With brake pedal depressed, open air bleeder valve to release air.

5. Close air bleeder valve.

6. Release brake pedal slowly.

7. Tighten air bleeder valve to specification.

Air bleeder valve : 8 N·m (0.8 kg-m, 69 in-lb)

8. Repeat steps 2. through 7. until no more air bubbles come out of air bleeder valve.
9. Bleed the brake hydraulic system air bleeder valves in the following order: Right rear brake Left front brake Left rear brake Right front brake

SBR419C

Revision: November 2006

BR-9

2006 Altima

BRAKE PIPING AND HOSE
BRAKE PIPING AND HOSE Hydraulic Circuit

PFP:46210
EFS0045T

WFIA0120E

Front Brake Piping and Hose
REMOVAL

EFS0045U

CAUTION: q 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.

q All hoses must be free from excessive bending, twisting and pulling.

q Cover the open end of lines and hoses when disconnecting to prevent entrance of dirt.

1. Connect vinyl tube and container to air bleeder valve.

2. Drain brake fluid from each air bleeder valve by depressing brake pedal.

Revision: November 2006

BR-10

SBR419C
2006 Altima

BRAKE PIPING AND HOSE

3. Remove the flare nut connecting the brake tube and hose, then

withdraw the lock spring.

4. Remove the connecting bolt and disconnect the brake hose from the cylinder body.

5. Remove lock spring from the mounting portion of the brake tube

and the mounting portion of the strut.

INSTALLATION

WFIA0087E
D

CAUTION: q Refill with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
E q Never reuse drained brake fluid.

1. Attach the brake hose to the cylinder body, then temporarily tighten the connecting bolt by hand.

CAUTION:

q Correctly attach the brake hose to the cylinder body.

q The copper washers of the connecting bolt have to be replaced with new ones every time the fit-

ting is disconnected.

2. Attach the brake hose to the strut, then secure it with a lock spring.

3. Attach the brake hose to the brake tube and temporarily tighten the flare nut as much as possible by hand,

then secure it with a lock spring.

4. Tighten all flare nuts and connecting bolts to specification, using

tool. Refer to BR-10, "Hydraulic Circuit" .

K
SBR686C

5. Refill until new brake fluid comes out of each air bleeder valve.

6. Bleed air. Refer to BR-9, "Bleeding Brake System" .

Rear Brake Piping and Hose
REMOVAL

EFS0045V
M

CAUTION: q 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.

q All hoses must be free from excessive bending, twisting and pulling.

q Cover the open end of lines and hoses when disconnecting to prevent entrance of dirt.

1. Connect vinyl tube and container to air bleeder valve.

Revision: November 2006

BR-11

2006 Altima

BRAKE PIPING AND HOSE
2. Drain brake fluid from each air bleeder valve by depressing brake pedal.

3. Remove flare nut connecting brake tube and hose, then withdraw lock spring.
4. Remove connecting bolt and disconnect brake hose from cylinder body.

SBR419C

WFIA0088E
INSTALLATION CAUTION: q Refill with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
q Never reuse drained brake fluid.
1. Attach the brake hose to the brake tube and temporarily tighten the flare nut as much as possible by hand.
CAUTION: q Correctly attach the brake hose to the cylinder body.
q The copper washers of the connecting bolt have to be replaced with new ones every time the fitting is disconnected.
2. Attach the brake hose with a lock spring, then tighten flare nut and connecting bolt to specification, using tool. Refer to BR-10, "Hydraulic Circuit" .

3. Refill until new brake fluid comes out of each air bleeder valve. 4. Bleed air from the brake system. Refer to BR-9, "Bleeding Brake System" .

SBR686C

Revision: November 2006

BR-12

2006 Altima

BRAKE PIPING AND HOSE
Inspection
CAUTION: If leakage occurs around hose and tube connections, 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 loosening connecting parts, deterioration or other damage. Replace any damaged parts. 2. Apply a stepping force of 784 N (80 kg-f, 176 lb-f) to the brake pedal with the engine running and keep it for about 5 seconds, then check each part for leaks.

EFS0045W
A B C D
SBR389C
E BR
G H I J K L M

Revision: November 2006

BR-13

2006 Altima

BRAKE MASTER CYLINDER

PFP:46010

On-board Inspection
LEAK INSPECTION

EFS0045X

Check for leaking in master cylinder installation surface, the reservoir tank installation surface, the reservoir hose connections, and the brake tube connections.

Components

EFS0045Y

1. Reservoir cap 4. Seal 7. Piston stopper 10. Stopper cap

2. O-ring 5. Cylinder body 8. Secondary piston assembly

3. Reservoir tank 6. O-ring 9. Primary piston assembly

WFIA0037E

Removal and Installation

EFS0045Z

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.

Revision: November 2006

BR-14

2006 Altima

BRAKE MASTER CYLINDER

REMOVAL 1. Remove air cleaner and inlet duct. Refer to EM-17, "Removal and Installation" (QR25DE), EM-118, A
"Removal and Installation" (VQ35DE).

2. Remove clutch fluid reservoir without disconnecting hose and position aside. Refer to CL-8, "CLUTCH

MASTER CYLINDER" .

3. Connect a vinyl tube and container to air bleeder valve.

4. 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 brake fluid master cylinder level sensor.

5. Remove brake pipe flare nuts.

6. Disconnect fluid level sensor.

7. Remove master cylinder nuts and master cylinder.

8. Remove reservoir tank and seals, if necessary.

INSTALLATION

CAUTION:

q Refill with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

q Never reuse drained brake fluid.

Installation is in the reverse order of removal.

q Plug all ports on master cylinder with fingers to prevent air suc-

tion while releasing brake pedal.

q Have driver depress brake pedal slowly several times until no air

comes out of master cylinder.

q Install the brake lines to master cylinder.

q Tighten flare nuts to specification. Refer to BR-10, "BRAKE PIPING AND HOSE" .

q Bleed air from the brake system. Refer to BR-9, "Bleeding Brake

System" .

Disassembly and Assembly
DISASSEMBLY
1. Bend claws of stopper cap outward.

WFIA0026E
J
EFS00460
K

2. Remove piston stopper while piston is pushed into cylinder.
3. Remove piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.
4. Remove the reservoir tank.

M
SBR938A

Revision: November 2006

BR-15

SBR231C
2006 Altima

BRAKE MASTER CYLINDER
INSPECTION AFTER REMOVAL Master Cylinder Inner Wall q Check the inner wall of the cylinder for damage, abrasion, corrosion and pin holes. If defective, replace
the master cylinder.
Piston q Check for deformation of or scratches on piston cups.
ASSEMBLY 1. Insert secondary piston assembly. Then insert primary piston
assembly. q Pay attention to alignment of secondary piston slit with piston
stopper mounting hole of cylinder body.

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

SBR354C

3. Push reservoir tank seals into cylinder body. 4. Push reservoir tank into cylinder body. 5. Install piston stopper while piston is pushed into cylinder.

SBR940A

SBR435B

Revision: November 2006

BR-16

2006 Altima

BRAKE BOOSTER
BRAKE BOOSTER On-vehicle Service
OPERATING CHECK 1. Stop engine and depress brake pedal several times. Check that
pedal stroke does not change. 2. Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal. CAUTION: Depress brake pedal in 5 second intervals.
AIRTIGHT CHECK q Start engine, and stop it after one or two minutes. Depress brake
pedal several times slowly. The pedal should go further down the first time, and then it should gradually rise thereafter. q Depress brake pedal while engine is running, and stop engine with pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds. CAUTION: Depress brake pedal in 5 second intervals.
Removal and Installation

PFP:47200
A
EFS00461
B

BRA0037D

H
SBR365AA
I
EFS00462
J

Revision: November 2006

BR-17

WFIA0248E
2006 Altima

BRAKE BOOSTER

1. Master cylinder 4. Gasket

2. Reservoir tank 5. Nut

3. Brake booster 6. Lock nut

REMOVAL CAUTION: q 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. q Be careful not to deform or bend brake pipes during removal of booster. q Replace clevis pin if damaged. q Refill with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" . q Never reuse drained brake fluid. q Take care not to damage brake booster mounting bolt thread when installing. Due to the acute
angle of installation, the threads can be damaged with the dash panel. 1. Remove air cleaner and inlet duct. Refer to EM-17, "Removal and Installation" (QR25DE), EM-17, "AIR
CLEANER AND AIR DUCT" (VQ35DE). 2. Remove clutch fluid reservoir without disconnecting hose and position aside. Refer to CL-9, "CLUTCH
RESERVOIR TANK" . 3. Remove the brake master cylinder. Refer to BR-14, "Removal and Installation" . 4. Remove vacuum hose from the brake booster. Refer to BR-19, "Removal and Installation" . 5. Remove instrument lower cover LH. Refer to IP-13, "INSTRUMENT LOWER COVER LH" . 6. Remove the brake pedal attachment snap pin and clevis pin from inside the vehicle. 7. Remove the nuts on the brake booster and brake pedal assembly. 8. Remove brake booster assembly from the engine compartment side.
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)

INSTALLATION Installation is in the reverse order of removal. q 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)
q Tighten the lock nut temporarily and when installing the booster assembly in the vehicle.
q Adjust the height and play of the brake pedal. Refer to BR-6, "Inspection and Adjustment" .
q Bleed air from brake system. Refer to BR-9, "Bleeding Brake System" .

SBR208E SBR237EA

Revision: November 2006

BR-18

2006 Altima

VACUUM LINES Removal and Installation

VACUUM LINES

PFP:41920
A
EFS00463
B

1. Clamp 4. Vacuum piping

2. Check valve inclusion position stamp 3. Vacuum hose Brake booster

WFIA0421E
J

CAUTION: q Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer K

to the stamp or label to confirm correct installation. The brake booster will not operate normally if

the hose is installed in the wrong direction.

q Insert the vacuum hose at least 24 mm (0.94 in).

q Never use lubricating oil during assembly.

SBR225B

Revision: November 2006

BR-19

2006 Altima

VACUUM LINES
Inspection
VISUAL INSPECTION Check for improper assembly, damage and deteriorate.
CHECK VALVE INSPECTION Airtightness Inspection Use a hand-held vacuum pump to check.
When connected to booster side: Vacuum decrease should be within 1.3 kPa (10 mmHg, 0.39 inHg) for 15 seconds under a vacuum of (66.7 kPa) [(500 mmHg), (19.69 inHg)]
When connected to engine side: No vacuum will be applied

EFS00464 SBR844B

Revision: November 2006

BR-20

2006 Altima

FRONT DISC BRAKE Component

FRONT DISC BRAKE

[CLZ25VD]
PFP:41000
A
EFS00465
B

G
WFIA0566E

1. Main pin (apply grease only to sliding portion) 2. Pin boot

3. Torque member bolt

4. Torque member 7. Inner pad

5. Shim cover

6. Inner shim

8. Pad retainer

9. Outer pad

10. Outer shim

11. Connecting bolt

12. Copper washer

13. Main pin bolt 16. Piston seal

14. Bleed valve

15. Cylinder body

17. Piston

18. Piston boot

Front

WARNING:

Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other

materials.

CAUTION:

q When cylinder body is open, do not depress the brake pedal because the piston will pop out.

q It is not necessary to remove connecting bolt except for disassembly or replacement of cylinder

body. In this case, suspend cylinder body with wire so as not to stretch brake hose.

q Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads.

q Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if M a soft pedal occurs at very low mileage. Refer to BR-26, "Brake Burnishing Procedure" .

On-vehicle Service
PAD WEAR INSPECTION
q 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.

EFS00466

Standard pad thickness : 11 mm (0.43 in)

Pad wear limit

: 2.0 mm (0.079 in)

Revision: November 2006

BR-21

BRA0010D
2006 Altima

FRONT DISC BRAKE

[CLZ25VD]

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

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

SBR976B

SBR932C

Installation

1. Apply Molykote M-77 grease between pad plate and shim, shim and shim cover, and shim cover and piston. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

2. Attach the inner shim and shim cover to the inner pad and attach the outer shim to the outer pad.

3. Apply grease to the contact surface of pad retainer with the pads, then attach the pad retainer and pads to the torque member. Make sure the upper pad retainer end is inserted through the loop on the audible wear indicator as shown.

4. Install the cylinder body to the torque member.

5. Insert a main pin bolt (on the lower side) and tighten it to specification. Refer to BR-21, "Component" .

6. Inspect fluid level, then install master cylinder reservoir cap.

7. Check the brakes for drag.

CAUTION: Burnish the brake contact surfaces after refinishing or replac-

LFIA0226E

ing brake rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-26,

"Brake Burnishing Procedure" .

Removal and Installation of Caliper Assembly and Disc Rotor
REMOVAL 1. Remove master cylinder reservoir cap.
2. Connect the vinyl tube and container to the air bleeder.
3. Depress the brake pedal and drain the brake fluid gradually from the air bleeder.

EFS00467

Revision: November 2006

BR-22

2006 Altima

FRONT DISC BRAKE
4. Remove connecting bolt and torque member fixing bolts, using power tool.
5. Remove the brake caliper. 6. Remove disc rotor. 7. Separate brake caliper from torque member as required.

[CLZ25VD]
A B

INSTALLATION

WFIA0243E
D

CAUTION: q Refill with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
E q Never reuse drained brake fluid.

1. Install disc rotor.

2. Install the brake caliper to torque member and tighten main pin bolt to specification, if required. Refer to BR BR-21, "Component" .

CAUTION:

When installing the cylinder body in the vehicle, wipe oil from the seating surface of the knuckle spindle washer and the mounting surface of the cylinder body.

3. Install brake cylinder body to steering knuckle and tighten torque member bolts.

4. Install brake hose to caliper and tighten connecting bolt.

CAUTION:

q The copper washer of the connecting bolt has to be

replaced every time the fitting is disconnected. I
q Correctly attach the brake hose to the projecting portion

of the cylinder body.

5. Inspect brake fluid level, then install master cylinder reservoir cap.

6. Bleed air from brake system. Refer to BR-9, "Bleeding Brake

System" . CAUTION:

WFIA0244E

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-26, "Brake Burnishing Procedure" .

Disassembly and Assembly of Caliper Assembly

L
EFS00468

DISASSEMBLY

1. Push out piston with piston boot using compressed air.

WARNING:

Do not place your fingers in front of piston.

SBR772

Revision: November 2006

BR-23

2006 Altima

FRONT DISC BRAKE
2. Remove piston seal with a suitable tool. CAUTION: Do not scratch or score cylinder wall.

[CLZ25VD]

INSPECTION AFTER DISASSEMBLY Caliper

WFIA0029E

CYLINDER BODY
CAUTION: Use brake fluid to clean. Never use mineral oil.
q 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.
q Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

TORQUE MEMBER Check for wear, cracks or other damage. Replace if necessary.

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 conditions 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.

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 specifications before measuring runout. Refer to FAX-5, "FRONT WHEEL BEARING" . 3. Change relative positions of rotor and wheel hub so that runout is minimized.
Maximum runout : 0.07 mm (0.0028 in)
4. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).

SBR219C

Revision: November 2006

BR-24

2006 Altima

FRONT DISC BRAKE
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 ASSEMBLY 1. Apply rubber grease to new piston seal and insert 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. Make sure piston boot is properly installed.

[CLZ25VD]
A

SBR574

J
WFIA0030E
K

WFIA0031E

Revision: November 2006

BR-25

WFIA0032E
2006 Altima

FRONT DISC BRAKE

[CLZ25VD]

Brake Burnishing Procedure

EFS00469

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 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.

Revision: November 2006

BR-26

2006 Altima

FRONT DISC BRAKE Component

FRONT DISC BRAKE

[CLZ25VE]
PFP:41000
A
EFS004M9
B

1. Union bolt 4. Sliding pin bolt 7. Air bleeder 10. Piston seal 13. Torque member 16. Inner pad 19. Outer pad 22. Torque member bolts

2. Copper washer 5. Sliding pin 8. Cylinder body 11. Piston 14. Inner shim cover 17. Pad retainer 20. Outer shim Front

3. Brake hose 6. Cap 9. Sliding pin boot 12. Piston boot 15. Inner shim 18. Pad retainer 21. Outer shim cover

WFIA0494E

CAUTION: q Clean dust on caliper and brake pad with a vacuum dust collector. Do not blow with compressed
air.
q While the brake pad and cylinder body are separated, the piston may suddenly jump out, so do not depress the brake pedal.
q It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of the caliper assembly. In this case, hang cylinder body with a wire so that brake hose is not under tension.
q Do not damage piston boot.
q If any shim is subject to serious corrosion, replace it with a new one.
q Always replace shims and shim covers as a set when replacing brake pads.
q Keep the rotor clean of brake fluid.

Revision: November 2006

BR-27

2006 Altima

FRONT DISC BRAKE

[CLZ25VE]

q Burnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-32, "Brake Burnishing" .

On-board Inspection
PAD WEAR INSPECTION
q Inspect the thickness of the pad through the cylinder body inspection hole. Use a scale for inspection if necessary.

EFS004MA

Standard pad thickness Pad wear limit

: 9.5 mm (0.374 in) : 2.0 mm (0.079 in)

Removal and Installation of Brake Pad
REMOVAL 1. Remove tires from vehicle using power tool.
2. Remove lower sliding pin bolt.
3. Hang the cylinder body with a wire then remove the pads, pad retainers, and shims from the torque member.
CAUTION: When removing the pad retainer from the torque member, lift the pad retainer in the direction shown by the arrow (shown in the figure) so as not to deform it.

BRA0010D EFS004MB

SBR556E

INSTALLATION
1. Apply Molykote M-77 grease between pad plate and shim, shim and shim cover, and shim cover and piston. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

2. Attach the pad retainer and pad to the torque member.

CAUTION: q When attaching the pad retainer, attach it firmly so that it
does not float up higher than the torque member, as shown in the figure.

3. Push the piston in so that the pad is firmly attached and attach the cylinder body to the torque member.

NOTE: Using a disc brake piston tool (commercial service tool), makes it easier to push in the piston.

CAUTION: q By pushing in the piston, the brake fluid returns to the
master cylinder reservoir tank. Watch the level of the surface of the reservoir tank.

PFIA0273E

4. Install the sliding pin bolt and tighten to specification. Refer to BR-27, "Component" .

5. Check brake for drag.

6. Attach the tires to the vehicle. Refer to WT-7, "Rotation" .

CAUTION: Burnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-32, "Brake Burnishing" .

Revision: November 2006

BR-28

2006 Altima

FRONT DISC BRAKE

[CLZ25VE]

Removal and Installation of Caliper Assembly and Disc Rotor
REMOVAL

EFS004MC
A

1. Remove tires from vehicle with power tool.

2. Drain brake fluid. Refer to BR-9, "Changing Brake Fluid" .

3. Remove union bolt and torque member bolts using power tool, then remove caliper assembly.

4. Remove disc rotor.

q Prior to removing disc rotor, make alignment mark using a marker between the hub and disc rotor. C
INSTALLATION

CAUTION:

q Refill with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

q Never reuse drained brake fluid.

1. Install disc rotor.

q Align marks made during removal on the hub and disc rotor.

2. Install caliper assembly to the vehicle, and tighten torque mem-

ber bolts to the specification. Refer to BR-27, "Component" .

CAUTION:

When attaching the caliper assembly to the vehicle, wipe

any oil off the knuckle spindle washers and caliper assem-

bly attachment surfaces.

3. Install brake hose to the caliper assembly, and tighten union bolt to the specification. Refer to BR-27, "Component" .
CAUTION: q Do not reuse the copper washer for union bolts.
q Attach the brake hose to the protrusion on the caliper assembly attachment part.

H
PFIA0411E
I
J
K

L
PFIA0404E
4. Refill new brake fluid and bleed air. Refer to BR-9, "Bleeding Brake System" . M
5. Attach the tires to the vehicle. Refer to WT-7, "Rotation" . CAUTION: Burnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-32, "Brake Burnishing" .

Revision: November 2006

BR-29

2006 Altima

FRONT DISC BRAKE
Disassembly and Assembly of Caliper Assembly
DISASSEMBLY 1. Remove the sliding pin bolt, and then remove the pad, shim,
shim cover, and pad retainer from the torque member. CAUTION: When removing the pad retainer from the torque member, lift it in the direction indicated by the arrow in the figure so that it does not deform.
2. Remove sliding pins and sliding pin boots from torque member. 3. Place a wooden block as shown, and blow air from union bolt
mounting hole to remove pistons and piston boots. CAUTION: Do not get your fingers caught in the piston.

[CLZ25VE]
EFS004MD
SBR556E

4. Remove the piston seal from the cylinder body using a srewdriver or suitable tool.
CAUTION: Be careful not to damage cylinder inner wall.

MAA0272D

PFIA0269E
CALIPER INSPECTION Cylinder Body CAUTION: q Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene. q Check for corrosion, wear, or damage to the cylinder inner wall, and replace the caliper if there are
any non-standard conditions. q Minor flaws caused by corrosion or a foreign material can be removed by polishing the surface
with a fine sandpaper. Replace the cylinder body, if necessary.
Torque Member Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston CAUTION: q Since the piston surface is plated, do not repair using sandpaper. q Check piston surface for corrosion, wear, and damage. If any non-standard condition is detected,
replace applicable part.

Revision: November 2006

BR-30

2006 Altima

FRONT DISC BRAKE

[CLZ25VE]

Sliding Pins, Sliding Pin Bolts, and Sliding Pin Boots Check sliding pins, sliding pin bolts, and sliding pin boot for wear, damage, and cracks. If damage or deforma- A tion is present, replace the affected part.

ASSEMBLY
B CAUTION: Do not use Nissan Rubber Grease (KRE00 00010 or KRE00 00010 01) when assembling.

1. Apply rubber grease to the piston seal and attach to cylinder

body.

CAUTION: Do not reuse the piston seals.
D

2. Apply brake fluid or rubber grease to the piston boot, place it on the piston, and firmly insert the piston boot cylinder-side lip into the cylinder body groove.
CAUTION: Do not reuse the piston boot.

SFIA0156E

3. Apply brake fluid or rubber grease to the piston, insert into the cylinder body by hand and firmly attach the piston boot pistonside lip into the piston groove.
CAUTION: Press the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
4. Install sliding pins and sliding pin boots to torque member.

I
SFIA0157E
J
K
L

M
PFIA0272E
5. Attach the inner shim and shim cover to the inner pad and the outer shim to the outer pad. 6. Install cylinder body. Tighten sliding pin bolt to the specified torque.
DISC ROTOR INSPECTION Visual Inspection Check surface of the disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is detected, replace applicable part.
Runout Inspection 1. Using wheel nuts, fix disc rotor to the wheel hub in 2 or more positions.

Revision: November 2006

BR-31

2006 Altima

FRONT DISC BRAKE

2. Inspect runout using a dial gauge.

Standard value (measured at 10 mm (0.39 in) inside the disc edge)

Runout limit

: 0.07 mm (0.0028 in)

(with it attached to the vehicle) or less

CAUTION: Before measuring, make sure the axle endplay is 0 mm (0 in). Refer to FAX-5, "FRONT WHEEL BEARING" .
3. If runout is outside the limit, find the minimum runout point by shifting mounting positions of the disc rotor and wheel hub by one hole.

Thickness Inspection
Using a micrometer, check thickness of the disc rotor. If thickness does not meet specification, replace disc rotor.

Standard thickness

: 28 mm (1.10 in)

Minimum thickness

: 26 mm (1.02 in)

Maximum uneven wear : 0.015 mm (0.0006 in) or (measured at 8 positions) less

[CLZ25VE]
BRA0013D

SBR020B

Brake Burnishing

EFS004ME

Burnish the brake contact surface according to the following procedure after refinishing or replacing rotors, after replacing pads, 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: November 2006

BR-32

2006 Altima

REAR DISC BRAKE Component

REAR DISC BRAKE

PFP:44000
A
EFS0046A
B

1. Connecting bolt 4. Cap 7. Cylinder body 10. Piston boot 13. Inner shim 16. Outer pad 19. Sliding pin boot Front

2. Brake hose 5. Air bleeder 8. Piston seal 11. Retaining ring 14. Inner pad 17. Outer shim 20. Torque member bolts

3. Copper washer 6. Sliding pin 9. Piston 12. Inner shim cover 15. Pad retainer 18. Outer shim cover 21. Torque member

WFIA0495E

WARNING: Clean dust on caliper and brake pad with a vacuum dust collector. Do not blow with compressed air.
CAUTION: q While removing cylinder body, never depress the brake pedal because the piston will pop out.
q It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of the cylinder body. In this case, hang cylinder body with a wire so that brake hose is not under tension.
q Do not damage piston boot.
q Always replace shims and shim covers as a set when replacing brake pads.
q Keep the rotor clean of brake fluid.
q Burnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-39, "Brake Burnishing" .

Revision: November 2006

BR-33

2006 Altima

REAR DISC BRAKE

On-Vehicle Service
PAD WEAR INSPECTION
q Inspect the thickness of the pad through the cylinder body inspection hole. Use a scale for inspection if necessary.

Standard pad thickness : 8.0 mm (0.315 in)

Pad wear limit

: 1.5 mm (0.059 in)

REMOVAL AND INSTALLATION OF BRAKE PAD Removal 1. Remove master cylinder reservoir cap. 2. Remove tires from vehicle with power tool. 3. Remove bottom sliding pin bolt. 4. Hang cylinder body with a wire, and remove pads, pad retainers,
shims from torque member.

EFS0046B BRA0010D

SBR042C
Installation 1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease between pad plate and shim, shim and
shim cover, and shim cover and piston. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
2. Attach the inner shim and shim cover to the inner pad, and the outer shim and outer shim cover to the outer pad.
3. Attach the pad retainer and pad to the torque member.
4. Push the piston in so that the pad is firmly attached and attach the cylinder body to the torque member.
NOTE: Using a disc brake piston tool (commercial service tool), makes it easier to push in the piston.
CAUTION: By pushing in the piston, the brake fluid returns to the master cylinder reservoir tank. Watch the level of the surface of the reservoir tank.
5. Install the sliding pin bolt and tighten to the specified torque.

Revision: November 2006

BR-34

2006 Altima

REAR DISC BRAKE

Sliding pin bolt : 38 48 N·m (3.9 4.8 kg-m, 25 35 ft-lb)

6. Inspect brake fluid level, then install master cylinder reservoir cap.

7. Check brake for drag.

8. Attach the tires to the vehicle. Refer to WT-7, "Rotation" .

Removal and Installation
REMOVAL 1. Remove master cylinder reservoir cap.
2. Remove tires from vehicle using power tool.
3. Drain brake fluid. Refer to BR-9, "Bleeding Brake System" .
4. Remove connecting bolt and torque member bolts using power tool, and remove cylinder body.

EFS0046C
D
E

5. Remove caliper and disc rotor. If the disc rotor cannot be removed, remove as follows:
q Make sure parking brake lever is completely disengaged.
q Hold down the disc rotor with the wheel nut and remove the adjuster hole plug.
q 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.
q Prior to removing disc rotor, make alignment mark using a marker between the hub and disc rotor.
q Remove wheel nut and rotor.

H
WFIA0246E
I
J
K
L

WFIA0018E

INSTALLATION

CAUTION: q Refill with new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

q Never reuse drained brake fluid.

1. Install disc rotor.

q Align marks made during removal on the hub and disc rotor.

2. Install cylinder body to the vehicle, and tighten torque member bolts to the specified torque.

Torque member bolts : 157 196 N·m (16 19 kg-m, 116 144 ft-lb)

CAUTION: Before installing cylinder body to the vehicle, wipe off oil and grease on washer seats on axle assembly and mounting surface of cylinder body.
3. Install brake hose to cylinder body and tighten connecting bolt to the specified torque.

Connecting bolt : 16.7 19.6 N·m (1.7 1.9 kg-m, 13 14 ft-lb)

CAUTION: q Do not reuse the copper washer for connecting bolts.

Revision: November 2006

BR-35

2006 Altima

REAR DISC BRAKE

q Securely attach brake hose to protrusion on cylinder body. 4. Add new brake fluid and bleed air. Refer to BR-9, "Bleeding Brake System" . 5. Install master cylinder reservoir cap. 6. Adjust the parking brake. Refer to PB-5, "Adjustment" . 7. Attach the tires to the vehicle. Refer to WT-7, "Rotation" . CAUTION: Burnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-39, "Brake Burnishing" .

Disassembly and Assembly
DISASSEMBLY

EFS0046D

1. Remove the sliding pin bolt, and then remove the pad, shim, shim cover, and pad retainer from the torque member and cylinder.

2. Remove sliding pin boot from torque member.

3. Remove the retaining ring from the cylinder body using a screwdriver or suitable tool, as shown.

4. Place a wooden block as shown, and blow air from connecting bolt mounting hole to remove pistons and piston boots. WARNING: Do not place your finger in front of piston.
5. Remove piston seals from cylinder body using a screwdriver or suitable tool, as shown. CAUTION: Be careful not to damage cylinder inner wall.

SBR028A BRD0041D PFIA0269E

Revision: November 2006

BR-36

2006 Altima

REAR DISC BRAKE

CALIPER INSPECTION

Cylinder Body

CAUTION: q Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene. q Check inner wall of cylinder for corrosion, wear, and damage. If any non-standard condition is B
detected, replace cylinder body.

q Minor flaws caused by corrosion or a foreign material can be removed by polishing the surface

with a fine sandpaper. Replace the cylinder body, if necessary.

Torque Member

Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.

Piston

CAUTION:

Since the piston surface is plated, do not repair using sandpaper.

Check piston surface for corrosion, wear, and damage. If any non-standard condition is detected, replace

applicable part.

Sliding Pin Bolts and Sliding Pin Boots

Check that there is no wear, damage, or cracks in the sliding pin bolts and sliding pin boots, and if there are, replace them.

ASSEMBLY

CAUTION:

Do not use Nissan Rubber Grease (KRE00 00010 or KRE00 00010 01) when assembling.

1. Apply a rubber grease to the piston seal and attach to cylinder

body.

CAUTION:

Do not reuse the piston seals.

K
SFIA0156E
L
M

SFIA0157E

Revision: November 2006

BR-37

2006 Altima

REAR DISC BRAKE
3. Apply a brake fluid to the piston, insert into the cylinder body by hand and firmly attach the piston boot piston-side lip into the piston boot. CAUTION: Press the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
4. Fix piston boot with retaining ring. CAUTION: q Make sure the boot is firmly in the cylinder body groove. q Do not reuse the retaining ring.

PFIA0272E

SFIA0158E

5. Attach the sliding pin bolt and sliding pin boot to the torque member.
6. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to the rear of the pad and to both sides of the shim, and attach the inner shim and shim cover to the inner pad, and the outer shim and outer shim cover to the outer pad.
7. Attach the pad retainer and pad to the torque member.
CAUTION: When attaching the pad retainer, attach it firmly so that it does not float up higher than the torque member, as shown in the figure.
8. After assembling shims and shim covers to pad, install it to the torque member.
9. Install cylinder body. Tighten sliding pin bolts to the specified torque.

PFIA0273E

DISC ROTOR INSPECTION Visual Inspection
Check surface of the disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is detected, replace applicable part.

Runout Inspection 1. Using wheel nuts, fix disc rotor to the wheel hub in two or more positions. 2. Inspect runout using a dial gauge.

Measurement position
Runout limit (with it attached to the vehicle)

: At a point 10 mm (0.39 in) from outer edge of the disc.
: 0.07 mm (0.0028 in) or less

CAUTION: Before measuring, make sure the axle endplay is 0 mm (0 in).

BRA0013D

Revision: November 2006

BR-38

2006 Altima

REAR DISC BRAKE

3. If runout is outside the limit, find the minimum runout point by shifting mounting positions of the disc rotor

and wheel hub by one hole.

Thickness Inspection

Using a micrometer, check thickness of the disc rotor. If thickness is

not within specification, replace disc rotor.

Standard thickness

: 9.0 mm (0.350 in)

Minimum thickness

: 8.0 mm (0.310 in)

Maximum uneven wear

: 0.015 mm (0.0006 in) or

(measured at 8 positions) less

Brake Burnishing

SBR020B

EFS0046E

Burnish the brake contact surface according to the following procedure after refinishing or replacing rotors,

after replacing pads, 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: November 2006

BR-39

2006 Altima

DUAL PROPORTIONING VALVE

PFP:46400

Inspection

EFS0046F

CAUTION: q Carefully monitor brake fluid level at master cylinder.
q Use new brake fluid. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .

q 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.
1. Connect Tool to air bleeders of front and rear brakes on either LH and RH side.

2. Bleed air from the Tool. 3. Check fluid pressure by depressing brake pedal.

Applied pressure : 7,355 kPa (75 kg/cm2, 1,067 psi) (Front brake)

Output pressure : 5,100 - 5,492 kPa (52 - 56 kg/cm2,

(Rear brake)

739 - 796 psi)

If output pressure is out of specification, replace dual proportioning valve.
4. Bleed air after disconnecting the Tool. Refer to BR-9, "Bleeding Brake System" .

SBR822BA SBR823BA

Revision: November 2006

BR-40

2006 Altima

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

PFP:00030
A
EFS0046G

Unit: mm (in)

Brake model Cylinder bore diameter

CLZ25VD disc brake 57.2 (2.25)

CLZ25VE disc brake

57.2 (2.25)

Front brake

Pad Length × width × thickness

125.6 × 46 × 11 (4.94 × 1.81 × 111.0 × 62.5 × 9.5 (4.37 × 2.46

0.43)

× 0.37)

Rotor outer diameter × thickness

297 × 24 (11.7 × 0.94)

320 × 28 (12.6 × 1.10)

Rear brake

Brake model
Cylinder bore diameter
Pad Length × width × thickness Rotor outer diameter × thickness

AD9A disc brake

34.9 (1.3740)

89.1 × 39.5 × 10 (3.508 × 1.555 × 0.31)
E
292 × 9 (11.5 × 0.35)

Master cylinder

Cylinder bore diameter

23.81 (15/16)

Control valve

Screw in type Booster model

30 × 0.4 (1.18 × 0.02)

M215T

Brake booster

Diaphragm diameter

Primary Secondary

230 (9.06)

205 (8.07)

Recommended brake fluid
Disc Brake

Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
H
EFS004M7
Unit: mm (in)

Brake model

CLZ25VD

CLZ25VE

AD9A

Pad wear limit

Minimum thickness

2.0 (0.079)

1.5 (0.059)

Rotor repair limit

Maximum runout
Minimum thickness
Maximum thickness variation (At least 8 positions)

0.07 (0.0028) 22.0 (0.866)

0.07 (0.0028) 26.0 (1.02)
0.015 (0.0006)

0.07 (0.0028)
J
8.0 (0.31)
K

Revision: November 2006

BR-41

2006 Altima

Brake Pedal

SERVICE DATA AND SPECIFICATIONS (SDS)

EFS0046I
Unit: mm (in)

WFIA0423E

M/T Free height "H"*
A/T

Pedal height (with engine running, brake pedal force 490 N M/T

{50 kg-f, 110 lb-f) "H"

A/T

Clearance "I1 or I2" between pedal stopper and threaded end of stop lamp switch or ASCD switch

Pedal play

164.1 - 174.1 (6.46 - 6.85) 173.1 - 183.1 (6.81 - 7.21)
More than 84 (3.31) More than 90.3 (3.55)
0.74 - 1.96 (0.0291 - 0.0772)
3 - 11 (0.12 - 0.43)

*: Measured from surface of dash reinforcement panel to surface of pedal pad A: Input rod B: Floor carpet C: Dash Insulator D: Floor Panel E: Dash reinforcement panel F: Dash insulator G: Floor carpet I1, I2: Gap J: Stop lamp switch and ASCD switch

Control Valve
Applied pressure (front) Output pressure (rear)

EFS0046J
Unit: kPa (kg/cm2 , psi) 7,355 (75, 1,067) 5,100 - 5,492 (52 - 56, 739 - 796)

Brake Booster
Output rod length Clevis length

10.275 - 10.525 (0.4045 - 0.4144) 130 (5.12)

EFS0046K
Unit: mm (in)

Revision: November 2006

BR-42

2006 Altima

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