2005 TOYOTA AVENSIS brake

F08969
F08984
New Gasket
F08985
New Gasket
New Gasket
F45364
32±38
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(h) Using soft jaws on the vise, hold the vacuum pump in the
vise.
NOTICE:
Do not tighten the vise to tightly.
(i) Tighten the 3 bolts.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
14. INSTALL CHECK VALVE SUB±ASSY
(a) Install the check valve sub±assy and a new gasket.
Torque: 74 N
m (750 kgf
cm, 54 ft
lbf)
15. INSTALL VACUUM PUMP UNION
(a) Install the vacuum pump union and 2 new gaskets with
the union bolt.
Torque: 14 N
m (140 kgf
cm, 10 ft
lbf)
HINT:
Align and insert the pin of the union into the matching hole of
the casing.
16. INSPECT VACUUM PUMP ASSY
(a) Turn the gear counterclockwise direction by hand when
seeing from the vacuum pump gear direction and check
for any abnormality such as dragging or torque fluctua-
tion.

G24250
Vacuum HoseNew O±Ring
Oil Hose
F45366
Vacuum Gauge
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±39
AVENSIS REPAIR MANUAL (RM1018E)
17. INSTALL VACUUM PUMP ASSY
(a) Coat 2 new O±rings with engine oil, and install them to the
vacuum pump assy.
(b) Install the vacuum pump assy aligning the coupling with
the slit of the camshaft.
(c) Install the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(d) Connect 2 vacuum hoses and oil hose.
18. INSPECT CHECK VACUUM PUMP OPERATION
(a) Slide the clip, then disconnect the vacuum hose from vac-
uum pump assy.
(b) Connect the hose of the vacuum gauge to the vacuum
pump assy.
(c) Block off another hose of the vacuum gauge with the hose
clamp No.2.
(d) Start the engine and warm it up for more than 2 minutes.
(e) With the engine idle, check the negative pressure of the
vacuum pump assy.
Standard: More than 650 mmHg (86.7 kPa).
(f) Remove the vacuum gauge from the vacuum pump assy.
(g) Connect the vacuum hose with the clip to the vacuum
pump assy.
19. INSTALL AIR CLEANER CAP SUB±ASSY

32092±05
G24249
Oil Hose
Vacuum HoseO±Ring
Vacuum Pump Assy
Vacuum Hose
Check Valve Sub±assy
Vacuum Pump Union Gasket
Straight Pin
Vacuum Pump End Cover Snap Ring
CouplingVaccup Pump Housing
Vacuum pump Blade A
Straight Pin
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part

O±Ring



Gasket

Gasket


O±Ring

Union bolt
7.8 (80, 69 in.
lbf)
7.8 (80, 69 in.
lbf)
7.8 (80, 69 in.
lbf)
14 (140, 10)
21 (214, 15)
21 (214, 15)
Air Cleaner Cap Sub±assy
74 (750, 54)
Connector
Vacuum pump Rotor
32±34
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

32091±05
F45366
Vacuum Gauge
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±33
AVENSIS REPAIR MANUAL (RM1018E)
VACUUM PUMP ASSY (1CD±FTV)
ON±VEHICLE INSPECTION
1. OPERATIONING CHECK
(a) Slide the clip, then disconnect the vacuum hose from vac-
uum pump assy.
(b) Connect the hose of the vacuum gauge to the vacuum
pump assy.
(c) Block off another hose of the vacuum gauge with the hose
clamp No.2.
(d) Start the engine and warm it up for more than 2 minutes.
(e) With the engine idle, check the negative pressure of the
vacuum pump assy.
Standard: More than 650 mmHg (86.7 kPa).
(f) Remove the vacuum gauge from the vacuum pump assy.
(g) Connect the vacuum hose with the clip to the vacuum
pump assy.

320W4±01
G24211
F42291
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±25
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2.REMOVE BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
3.REMOVE CLUTCH MASTER CYLINDER ASSY (M/T TRANSAXLE) (See page 42±13) SST 09023±00100
4. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (1AZ±FSE ENGINE TYPE) (See page 14±204)
5. REMOVE ENGINE COVER NO.1
6.REMOVE IGNITION COIL ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
7.REMOVE CYLINDER HEAD COVER SUB±ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
8.REMOVE TIMING BELT NO.2 COVER (DIESEL ENGINE TYPE) (See page 14±307)
9.REMOVE CYLINDER HEAD COVER SUB±ASSY (DIESEL ENGINE TYPE) (See page 14±318)
10.REMOVE INJECTOR ASSY (DIESEL ENGINE TYPE) (See page 14±318)
11. REMOVE FRONT WHEEL RH
12. REMOVE BRAKE TUBE
(a) w/o VSC:Using SST, disconnect the 6 brake tubes from the brake
actuator.
SST 09023±00100
(b) w/ VSC: Using SST, disconnect the 6 brake tubes from the brake
actuator.
SST 09023±00100, 09023±38400

F45057
w/o VSC:
w/ VSC:
To Master
Cylinder Rear
To
Master
Cylinder
Front
To Rear Wheel
RH
To Front Wheel LH
To Front Wheel RH
To Rear Wheel
LH
A
To
Master
Cylinder
FrontTo Master
Cylinder
Rear
To Rear
Wheel RH
To Front Wheel LHTo Front Wheel RH
To Rear
Wheel LH
AA
AA
BB
C80802
C80806
32±26
± BRAKEBRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Use tags or make a memo to identify the place to recon-
nect.
(d) Using SST and a spanner, disconnect the brake tube from
the flexible hose of the front brake RH.
SST 09023±00100
(e) Remove the 2 bolts and disconnect the 2 brake tube
clamps.

F45361
F45362
F45367
F45363Vacuum tank
C81275
± BRAKEBRAKE BOOSTER ASSY (RHD)
32±27
AVENSIS REPAIR MANUAL (RM1018E)
(f) Using SST, disconnect the 3 brake tubes from the ways.
SST 09023±00100
(g) Disconnect the brake tube from the clamp and remove
the brake tubes.
(h) Disconnect the 3 brake tubes from the clamp and remove
the brake tubes.
13. REMOVE BRAKE BOOSTER ASSY
(a) Gasoline engine type:
Remove the 2 bolts and separate the vacuum pipe from
the body.
(b) Diesel engine type:
Remove the 2 bolts and remove the vacuum tank from the
body.
(c) Disconnect the vacuum hose from the brake booster
assy.
(d) Remove the engine under cover.
(e) Remove the 2 nuts from the engine mounting bracket RH.
(f) Remove the bolt from the rear engine mounting bracket.
(g) Remove the bolt and nut from the front engine mounting
bracket.

F40021
Wooden Block
C82119
C80809
C80805
32±28
± BRAKEBRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
(h) Hold the engine with a jack, putting a wooden block be-
tween them.
(i) Remove the 3 bolts and separate the engine mounting
bracket RH from the body.
(j) Gradually tilt the engine by lowering the jack to remove
the brake booster assy.
(k) Remove the 4 nuts and clevis.
(l) Pull out the brake booster assy.
14. REMOVE BRAKE BOOSTER GASKET
(a) Pull out the brake booster gasket.
15. REMOVE CHECK VALVE
(a) Remove the check valve from the brake booster assy.
16. INSTALL CHECK VALVE
(a) Install the check valve and grommet to the brake booster assy.
17. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assy.