I'm assuming your husband is the principal applicant and you are the sponsor (and not immigrating/accompanying him from Brazil). The wording in the CIC email is a little confusing. My wife's email said they were expecting the passport and photo of "yourself, your spouse or common-law partner and dependent children (if applicable)". That basically means the principal applicant, plus whomever else might also be immigrating. In your case (and mine), it's just the principal applicant.
That's also called a CoPR. When he sends in his passport, they will insert a one-time entry visa, and also include the CoPR. That's his official identity document confirming he's a permanent resident, until his PR card arrives in the mail. When he lands in Canada, they will staple the CoPR into the passport. They'll include instructions about all this when they send back the passport.
In my wife's email, they said she had until her medical exam expires (normally 12 months from the date of the exam), or until her passport expires, whichever is soonest. It's best to be quick about it. From what I understand, if you miss their entry window, it's all over and you have to start your applications from scratch. Seriously.
Again, if you are the Canadian sponsor and your husband is the principal applicant and there are no other accompanying applicants, they just want his photos and passport. One photo is for the CoPR, one is for the PR card. The wording in their emails is confusing.
Yup. Include this information in a note that you send CIC along with your passport. That information is important because it's included in the CoPR, and used to verify the identity of the principal applicant.
I believe so. I know someone else that did this. They accepted the documents and told him it would take about 5 business days to get them back to him. It turned out to be about 8 or 9 business days, or something. I don't think there's any harm in preparing everything and paying a visit to the fine folks at the Canadian consulate.
Yeah, it was a big day for us when we got the CIC email and saw the "Decision Made" on the website. Parabens, and enjoy the moment - you only immigrate once.