BRAKE

BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . BR–1

VACUUM PUMP (1CD–FTV) . . . . . . . . . . . . . . BR–2

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.
 BR–1
BRAKE – BRAKE PEDAL

BRAKE PEDAL
BR11N–01

COMPONENTS
RHD M/T
Clevis Pin
Stop Light Switch Connector
Stop Light Switch

Clip

Brake Pedal Bracket A/T

z Bushing
Return Spring

36.8 (375, 27)

Collar Cushion Plate
z Bushing Pedal Pad

Pedal Pad

Brake Pedal

LHD M/T Brake Pedal

Clip
Stop Light Switch Connector
Stop Light Switch
Clevis Pin

Brake Pedal Bracket A/T

z Bushing

Return Spring

36.8 (375, 27)

Pedal Pad
Collar
Cushion Plate
z Bushing
Pedal Pad

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part Brake Pedal
Brake Pedal
Lithium soap base glycol grease
F08962
BR–2
BRAKE – VACUUM PUMP (1CD–FTV)

VACUUM PUMP (1CD–FTV)

BR11O–01

COMPONENTS
Oil Hose

z O–Ring

Vacuum Hose

Vacuum Pump
Vacuum Hose
z O–Ring
21 (214, 15)

Check Valve
74 (750, 54)

Union

z Snap Ring
z Gasket
Coupling 14 (140, 10)
z Gasket

z Gasket
Casing

Rotor
Straight
Blade
Pin
End Cover
z O–Ring

7.8 (80, 68 in.·lbf)

N·m (kgf·cm, ft·lbf) : Specified torque Straight Pin
z Non–reusable part F08965
 BR–3
BRAKE – VACUUM PUMP (1CD–FTV)
BR11P–01

Vacuum Hose
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.

Oil Hose
F08963
BR–4
BRAKE – VACUUM PUMP (1CD–FTV)
BR11Q–01

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.

F08966

3. REMOVE CHECK VALVE

Remove the check valve and gasket.

F08967

4. REMOVE END COVER

(a) Remove the 3 bolts.

F08969

(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.

F08970

5. REMOVE ROTOR AND 5 BLADES

NOTICE:
Be careful not to drop the blades.

F08971
 BR–5
BRAKE – VACUUM PUMP (1CD–FTV)

6. REMOVE COUPLING
(a) Using a screw driver, remove the snap ring.
(b) Remove the coupling.

F08972
BR–6
BRAKE – VACUUM PUMP (1CD–FTV)
BR11R–01

H
INSPECTION
1. INSPECT BLADE
L W (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.)
F05382
If necessary, replace the blade.

2. INSPECT CHECK VALVE OPERATION

(a) Check that air flows from the hose side to the pump side.
Air (b) Check that air does not flow from the pump side to the
hose side.
Hose Side Vacuum Pump Side If necessary, replace the check valve.

Air

F05383

3. INSPECT INSIDE SURFACE OF CASING

Inspection the inside surface on the casing for scoring.
If necessary, replace the vacuum pump assembly.

F08976
 BR–7
BRAKE – VACUUM PUMP (1CD–FTV)
BR11S–01

REASSEMBLY
1. INSTALL COUPLING
(a) Place the coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.

F08980

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.

F08981

4. INSTALL END COVER

New O–Ring
(a) Coat 2 new O–rings with engine oil, and place them to the
casing.

F08982

(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.

F08970

(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)

F08969
BR–8
BRAKE – VACUUM PUMP (1CD–FTV)

5. INSTALL CHECK VALVE

Install the check valve with a new gasket.
New Gasket Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)

F08984

6. INSTALL VACUUM HOSE UNION

New Gasket Install the vacuum hose union and 2 new gaskets with the union
bolt.
New Gasket
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.

F08985
 BR–9
BRAKE – VACUUM PUMP (1CD–FTV)
BR11T–01

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.
New O–Ring
Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)
A09669 Vacuum Hose 2. CONNECT 2 VACUUM HOSES AND OIL HOSE

F08963
Oil Hose F08964