Page 2625 of 5135

G23226Lithium soap base glycol grease
Cylinder Boot
Piston
G23225
Cylinder Boot
Piston
F45418
F45420
Front Disc Brake Cylinder Mounting
Bush Dust Boot
Lithium soap base glycol grease
32±44
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
18. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug to the disc brake cylinder assy LH.
(b) Install the bleeder plug cap to the bleeder plug.
19. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assy LH.
20. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front disc
brake piston and a new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Install the piston to the disc brake cylinder assy LH.
NOTICE:
Do not install the piston forcibly in the disc brake cylinder.
21. INSTALL CYLINDER BOOT
(a) Using SST and a hammer, install the cylinder boot to the
disc brake cylinder assy LH.
SST 09550±60010
NOTICE:
Do not damage the cylinder boot.
HINT:
Install the boot securely to the disc brake cylinder assy LH.
22. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
LH
(a) Install the front disc brake cylinder mounting LH with the
2 bolts.
Torque: 102 Nm (1,040 kgfcm, 75 ftlbf)
23. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to the sealing sur-
face of 2 new front disc brake bush dust boots.
(b) Install the 2 front disc brake bush dust boots to the front
disc brake cylinder mounting LH.
Page 2626 of 5135

F45419
Cylinder Slide Pin
Lithium soap base glycol grease
F45421
Union Bolt
±
BRAKE FRONT BRAKE
32±45
AVENSIS REPAIR MANUAL (RM1018E)
24. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Apply lithium soap base glycol grease to the a new front
disc brake cylinder slide bush.
(b) Install the front disc brake cylinder slide bush to the bot- tom side of the front disc brake cylinder slide pin (No.2).
(c) Apply lithium soap base glycol grease to the sliding part
and the sealing surface of the 2 cylinder slide pins.
(d) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting LH.
25. INSTALL FRONT DISC BRAKE PAD KIT
(a) Install the 2 front disc brake pad support plates (No.1) and 2 front disc bra\
ke pad support plates (No.2) to the front disc brake cylinder mounting LH.
(b) Install the disc brake pad kit front to the front disc brake cylinder mo\
unting LH.
NOTICE:
There should be no oil or grease on the friction surfaces of the pads an\
d the disc.
26. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder assy LH with the 2 bolts.Torque: 30 N m (306 kgf cm, 22 ft lbf)
(b) Install a new gasket and flexible hose with the union bolt.
Torque: 29 N m (296 kgf cm, 21 ft lbf)
HINT:
Install the flexible hose lock securely in the lock hole in the disc
brake cylinder assy LH.
27.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
28.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
29.BLEED BRAKE LINE (See page 32±4)
30.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
31. CHECK BRAKE FLUID LEAKAGE
32. INSTALL FRONT WHEEL
Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
Page 2627 of 5135
320GA±03
G23177
Disc Brake
Cylinder Assy LH GasketFlexible Hose
Disc Brake
Pad Kit Front
Front Disc Brake
Pad Support Plate No.1
Front Disc Brake
Cylinder Slide Pin (No.2)
Front Disc Brake
Bush Dust Boot Front Disc Brake
Cylinder Slide Pin (No.1)
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Cylinder Mounting LH
Cylinder Boot Piston Seal
Front Disc
Brake PistonFront Disc
30 (306, 22)
102 (1,040, 75)
30 (306, 22)
Bleeder Plug CapFront Disc Brake
Bleeder Plug
Non±reusable part
Nm (kgfcm, ftlbf) : Specified torque
Lithium soap base glycol grease
29 (296, 21)
10 (102, 7)
Union bolt
Front Disc Brake
Pad Support Plate No.2
102 (1,040, 75)
Front Disc Brake
Bush Dust Boot Bolt
Bolt
32±40
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BRAKE
COMPONENTS
Page 2628 of 5135

320W2±01
G24251
Vacuum Hose
Oil Hose
F45364
F08966
F08967
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±35
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
1. REMOVE AIR CLEANER CAP SUB±ASSY
2. REMOVE VACUUM PUMP ASSY
(a) Disconnect the 2 vacuum hoses and oil hose from the
vacuum pump assy.
(b) Remove the 2 bolts and vacuum pump assy.
(c) Remove the 2 O±rings from the vacuum pump assy.
3. INSPECT VACUUM PUMP ASSY
(a) Turn the coupling counterclockwise direction by hand
when seeing from the coupling direction and check for
any abnormality such as dragging or torque fluctuation.
NOTICE:
Pay coupling attention, because the engine oil remained in
the pump escapes while coupling is turning.
4. REMOVE VACUUM PUMP UNION
(a) Using soft jaws on a vise, hold the vacuum pump assy in
a vise.
NOTICE:
Do not tighten the vise excessively and perform the work
while holding the vacuum pump assy by hand.
(b) Remove the union bolt, vacuum pump union and 2 gas-
kets.
5. REMOVE CHECK VALVE SUB±ASSY
(a) Remove the check valve sub±assy and gasket.
Page 2629 of 5135

F08969
F08970
F08971
F08972
Snap Ring
F45365
Vacuum Pump Housing
Vacuum Pump End Cover
32±36
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE VACUUM PUMP ROTOR SUB±ASSY
(a) Remove the 3 bolts.
(b) Using soft jaws on the vise, place the vacuum pump assy
on the vise, as shown in the illustration.
NOTICE:
Only place the vacuum pump assy, never hold the in±low
of the housing with a vise.
(c) Using a pin punch and hammer, drive out the 2 straight
pins.
(d) Remove the end cover and 2 O±rings.
(e) Remove the vacuum pump rotor and 5 blades.
NOTICE:
Do not damage the housing with the rotor.
7. REMOVE VACUUM PUMP COUPLING
(a) Using a screwdriver, remove the snap ring.
(b) Remove the coupling.
8. INSPECT VACUUM PUMP HOUSING
(a) Inspect the inside surface on the housing for scoring.
If necessary, replace the vacuum pump assy.
9. INSPECT VACUUM PUMP END COVER
(a) Inspect the inside surface on the vacuum pump end cover
for scoring.
If necessary, replace the vacuum pump assy.
Page 2630 of 5135

F05383
Air
Hose Side Vacuum Pump Side
Air
F08981
F08982
New O±Ring
F08970
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±37
AVENSIS REPAIR MANUAL (RM1018E)
10. INSPECT CHECK VALVE SUB±ASSY
(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.
NOTICE:
Block off the 4 holes on the side surface of the check valve
when checking.
If necessary, replace the check valve.
11. INSTALL VACUUM PUMP COUPLING
(a) Place the vacuum pump coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
12. INSTALL VACUUM PUMP ROTOR SUB±ASSY
(a) Coat the rotor with engine oil, and install it to the rotor shaft.
13. INSTALL VACUUM PUMP BLADE A
(a) Apply the engine oil to the rotor, and install the rotor in the
housing.
(b) Apply the engine oil to the 5 new blades.
(c) Install the 5 blades with the round end facing outward.
NOTICE:
Install so that the blade attaches on the housing.
(d) Coat 2 new O±rings with engine oil, and install them on
the housing.
(e) Using soft jaws on the vise, place the vacuum pump on
the vise, as shown in the illustration.
NOTICE:
Only place the vacuum pump assy, never hold the in±low
of the housing with a vise.
(f) Place the end cover, and temporarily install the 3 bolts.
(g) Using a pin punch and hammer, drive in the 2 straight
pins.
NOTICE:
Install so that the blade and end cover of the eccentric ring
does not interfere with each other.
Page 2631 of 5135
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 Nm (80 kgfcm, 69 in.lbf)
14. INSTALL CHECK VALVE SUB±ASSY
(a) Install the check valve sub±assy and a new gasket.
Torque: 74 Nm (750 kgfcm, 54 ftlbf)
15. INSTALL VACUUM PUMP UNION
(a) Install the vacuum pump union and 2 new gaskets with
the union bolt.
Torque: 14 Nm (140 kgfcm, 10 ftlbf)
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.
Page 2632 of 5135

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 Nm (214 kgfcm, 15 ftlbf)
(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