TOYOTA AVENSIS 1999 Supplement

BR11O–01
F08965Non–reusable part N·m (kgf·cm, ft·lbf) : Specified torque
Vacuum Pump

Gasket Vacuum Hose
Casing
Rotor
BladeStraight
Pin
End Cover Check Valve
Union
O–Ring
Vacuum Hose

O–Ring

Gasket

Gasket

O–Ring
Oil Hose
Straight Pin
21 (214, 15)
74 (750, 54)
14 (140, 10)
7.8 (80, 68 in.·lbf)

Snap Ring
Coupling
BR–2
– BRAKEVACUUM PUMP (1CD–FTV)
VACUUM PUMP (1CD–FTV)
COMPONENTS

BR11P–01
F08963
Vacuum Hose
Oil Hose
– BRAKEVACUUM PUMP (1CD–FTV)
BR–3
REMOVAL
1. DISCONNECT 2 VACUUM HOSES AND OIL HOSE
FROM VACUUM PUMP
2. REMOVE VACUUM PUMP
(a) Remove the 2 bolts and vacuum pump.
(b) Remove the 2 O–rings from the vacuum pump.

BR11Q–01
F08966
F08967
F08969
F08970
F08971
BR–4
– BRAKEVACUUM PUMP (1CD–FTV)
DISASSEMBLY
1. PLACE VACUUM PUMP IN VISE
Using soft jaws on the vice, place the vacuum pump in the vice.
NOTICE:
Do not tighten the vise too tightly.
2. REMOVE VACUUM HOSE UNION
Remove the union bolt, union and 2 gaskets.
3. REMOVE CHECK VALVE
Remove the check valve and gasket.
4. REMOVE END COVER
(a) Remove the 3 bolts.
(b) Place the vacuum pump on vise, as shown in the illustra-
tion.
NOTICE:
Do not tighten the vise.
(c) Using a pin punch and hammer, drive out the 2 straight
pins.
(d) Remove the end cover and 2 O–rings.
5. REMOVE ROTOR AND 5 BLADES
NOTICE:
Be careful not to drop the blades.

F08972
– BRAKEVACUUM PUMP (1CD–FTV)
BR–5
6. REMOVE COUPLING
(a) Using a screw driver, remove the snap ring.
(b) Remove the coupling.

BR11R–01
F05382
H
LW
F05383
Vacuum Pump Side
Hose SideAir
Air
F08976
BR–6
– BRAKEVACUUM PUMP (1CD–FTV)
INSPECTION
1. INSPECT BLADE
(a) Check the blades for wear or damage.
(b) Using a micrometer, measure the height, width and length
of the blades.
Minimum height: 16.20 mm (0.6378 in.)
Minimum width: 5.95 mm (0.2343 in.)
Minimum length: 44.96 mm (1.7701 in.)
If necessary, replace the blade.
2. INSPECT CHECK VALVE OPERATION
(a) Check that air flows from the hose side to the pump side.
(b) Check that air does not flow from the pump side to the
hose side.
If necessary, replace the check valve.
3. INSPECT INSIDE SURFACE OF CASING
Inspection the inside surface on the casing for scoring.
If necessary, replace the vacuum pump assembly.

BR11S–01
F08980
F08981
F08982
New O–Ring
F08970
F08969
– BRAKEVACUUM PUMP (1CD–FTV)
BR–7
REASSEMBLY
1. INSTALL COUPLING
(a) Place the coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
2. INSTALL ROTOR INTO CASING
Coat the rotor with engine oil, and install it to the rotor shaft.
3. INSTALL 5 BLADES
(a) Coat the 5 blades with engine oil.
(b) Install the 5 blades with the round end facing outward.
HINT:
Be sure that the blades and rotor surfaces are even.
4. INSTALL END COVER
(a) Coat 2 new O–rings with engine oil, and place them to the
casing.
(b) Place the vacuum pump on the vise, as shown in the il-
lustration.
NOTICE:
Do not tighten the vise.
(c) Place the end cover, and temporarily install the 3 bolts.
(d) Using a pin punch and hammer, drive in the 2 straight
pins.
(e) Using soft jaws on the vise, place the vacuum pump in the
vise.
NOTICE:
Do not tighten the vise too tightly.
(f) Tighten the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

F08984
New Gasket
F08985
New Gasket
New Gasket BR–8
– BRAKEVACUUM PUMP (1CD–FTV)
5. INSTALL CHECK VALVE
Install the check valve with a new gasket.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
6. INSTALL VACUUM HOSE UNION
Install the vacuum hose union and 2 new gaskets with the union
bolt.
Torque: 14 N·m (140 kgf·cm, 10 ft·lbf)
HINT:
Align and insert the union pin into the matching hole of the cas-
ing.

BR11T–01


F08964
New O–RingVacuum Hose
Oil Hose
– BRAKEVACUUM PUMP (1CD–FTV)
BR–9
INSTALLATION
1. INSTALL VACUUM PUMP
(a) Coat 2 new O–rings with engine oil, and install them to the
vacuum pump.
(b) Insert the vacuum pump, align the coupling with slit of the
camshaft.
(c) Install the 2 bolts.
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
2. CONNECT 2 VACUUM HOSES AND OIL HOSE

STEERING
DRIVE BELT SR–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING FLUID SR–3. . . . . . . . . . . . . . .
POWER STEERING VANE PUMP
(2C–T, 2C–TE, 1CD–FTV) SR–6. . . . . . . . . . . . . . .
REFER TO AVENSIS/CORONA REPAIR MANUAL FOR
CHASSIS AND BODY (Pub. No. RM599E)
NOTE: The above pages contain only the points which differ
from the above listed manual.