Group:  No.

:  Date: 2FW, 12
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Please ensure these pages are distributed to all relevant staff for their information; and a copy made
available for future reference, with the above repair manual.

Section Title Paragraph

COMPONENTS

1KD-FTV COOLING WATER PUMP REMOVAL

INSTALLATION

The revised pages listed above are attached.

(The corrected parts are indicated by arrows.)

This Bulletin does not cause the Flat Rate Manual to be changed.

_____________________________________________________________________________________________________
© 2012 Toyota Motor Corporation Australia Limited A.B.N. 64 009 686 097
All rights reserved. This material may not be reproduced or copied, in whole or part, without the written permission of 1/5
Toyota Motor Corporation Australia Limited, 155 Bertie Street, Port Melbourne, Victoria.
 [COMPONENTS]

1KD-FTV COOLING – WATER PUMP CO–11

CAMSHAFT TIMING PULLEY

CYLINDER BLOCK INSULATOR KEY

COMPRESSOR AND
MAGNETIC CLUTCH
98 (1000, 72)
10 (102, 7) x4
10 (102, 7)

25 (255, 18)
x4
NO. 2 TIMING BELT COVER

21 (214, 15)

x5

GENERATOR ASSEMBLY

NO. 1 COMPRESSOR
MOUNTING BRACKET
62 (632, 46)

45 (459, 33)

21 (214, 15) IDLE PULLEY ASSEMBLY

GENERATOR BRACKET

ENGINE WATER PUMP ASSEMBLY

WATER PUMP COVER

GASKET
CO

x5
13 (133, 10)
GASKET
x2
9.1 (93, 81 in.*lbf)
13 (133, 10)
x4
WATER PUMP
7.8 (80, 69 in.*lbf) SET RING PIN
STUD BOLT

WATER PUMP ASSEMBLY

WITHOUT COVER

[Corrected]

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

Non-reusable part
A299973E01

_____________________________________________________________________________________________________
© 2012 Toyota Motor Corporation Australia Limited A.B.N. 64 009 686 097
All rights reserved. This material may not be reproduced or copied, in whole or part, without the written permission of 2/5
Toyota Motor Corporation Australia Limited, 155 Bertie Street, Port Melbourne, Victoria.
 [REMOVAL]

CO–14 1KD-FTV COOLING – WATER PUMP

35. REMOVE NO. 1 TIMING BELT COVER

(a) Remove the No. 1 timing belt cover (see Pub. No.
RM990E, page 14-214).
36. REMOVE TIMING BELT
(a) Remove the timing belt (see Pub. No. RM990E,
page 14-214).
37. REMOVE CAMSHAFT TIMING PULLEY
(a) Remove the camshaft timing pulley (see Pub. No.
RM1151E, page 14-219).
38. REMOVE NO. 1 TIMING BELT IDLER SUB-
ASSEMBLY
(a) Remove the No. 1 timing belt idler sub-assembly
(see Pub. No. RM1151E, page 14-219).
39. REMOVE NO. 2 TIMING BELT COVER
(a) Remove the No. 2 timing belt cover (see Pub. No.
RM1151E, page 14-219).
[Corrected]
40. REMOVE CYLINDER BLOCK INSULATOR
41. REMOVE ENGINE WATER PUMP ASSEMBLY
(a) Remove the 2 nuts, 5 bolts, engine water pump
assembly and the gasket from the cylinder block
sub-assembly.

CO

A299976

(b) Remove the bolt, water pump assembly without

cover and the gasket from the water pump cover.
42. REPLACE STUD BOLT
HINT:
Perform this procedure only when replacement of the
stud bolts is necessary.

[Added]

A224975

_____________________________________________________________________________________________________
© 2012 Toyota Motor Corporation Australia Limited A.B.N. 64 009 686 097
All rights reserved. This material may not be reproduced or copied, in whole or part, without the written permission of 3/5
Toyota Motor Corporation Australia Limited, 155 Bertie Street, Port Melbourne, Victoria.
 [REMOVAL]

1KD-FTV COOLING – WATER PUMP CO–15

(a) Remove the 4 stud bolts from the water pump

assembly without cover.
(b) Install the 4 stud bolts to the water pump assembly
without cover.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
43. REPLACE WATER PUMP SET RING PIN
HINT:
Perform this procedure only when replacement of the
water pump set ring pin is necessary.
A267255

(a) Remove the water pump set ring pin from the water
pump cover.
(b) Using a plastic-faced hammer, tap in the water
pump set ring pin to the water pump cover.

[Added]

A267256

INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the water hole and air hole for
coolant leakage.
If leakage is found, replace the water pump
assembly.
(b) Turn the pulley, and check that the pump bearing
moves smoothly and quietly.
A099952E01
If it moves roughly or noisily, replace the water
pump assembly.
CO
INSTALLATION
1. INSTALL ENGINE WATER PUMP ASSEMBLY
(a) Temporarily install a new gasket and the water
pump assembly without cover to the water pump
[Corrected] cover with the bolt.
(b) Temporarily install a new gasket and the engine
water pump assembly to the cylinder block sub-
assembly with the 2 nuts and 5 bolts.

_____________________________________________________________________________________________________
© 2012 Toyota Motor Corporation Australia Limited A.B.N. 64 009 686 097
All rights reserved. This material may not be reproduced or copied, in whole or part, without the written permission of 4/5
Toyota Motor Corporation Australia Limited, 155 Bertie Street, Port Melbourne, Victoria.
 [INSTALLATION]

CO–16 1KD-FTV COOLING – WATER PUMP

(c) Fully tighten the 5 bolts A and the 2 nuts.

Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(d) Fully tighten the bolt B.
Bolt A Torque: 9.1 N*m (93 kgf*cm, 81 in.*lbf)
Bolt A
2. INSTALL CYLINDER BLOCK INSULATOR
Bolt A
3. INSTALL NO. 2 TIMING BELT COVER
Nut
(a) Install the No. 2 timing belt cover (see Pub. No.
Bolt A RM1151E, page 14-222).
4. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
Bolt B Bolt A (a) Install the No. 1 timing belt idler sub-assembly (see
Pub. No. RM1151E, page 14-222).
Nut 5. INSTALL CAMSHAFT TIMING PULLEY
(a) Install the camshaft timing pulley (see Pub. No.
A112074E04
RM1151E, page 14-222).

[Corrected]
6. INSTALL TIMING BELT
(a) Install the timing belt (see Pub. No. RM990E, page
14-216).
7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page )
8. INSTALL VENTILATION PIPE (See page )
9. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY
(See page )
10. INSTALL MANIFOLD STAY WITH VACUUM
SWITCHING VALVE (See page )
11. TEMPORARILY INSTALL ELECTRIC EGR CONTROL
VALVE WITH NO. 2 EGR VALVE AND EGR COOLER
CO (See page )
12. INSTALL NO. 2 INTAKE AIR CONNECTOR (See page
)
13. TEMPORARILY INSTALL INTAKE AIR CONNECTOR
(See page )
14. TIGHTEN NO. 2 INTAKE AIR CONNECTOR AND
INTAKE AIR CONNECTOR (See page )
15. TIGHTEN INTAKE AIR CONNECTOR AND INTAKE
MANIFOLD (See page )
16. TIGHTEN EGR COOLER (See page )
17. INSTALL ELECTRIC VACUUM REGULATING VALVE
ASSEMBLY (See page )
18. INSTALL WIRE HARNESS BRACKET (See page )
19. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY
(See page )
20. INSTALL WATER HOSE SUB-ASSEMBLY (for Cold
Area Specification Vehicles) (See page )
21. INSTALL VENTURI BRACKET (See page )

_____________________________________________________________________________________________________
© 2012 Toyota Motor Corporation Australia Limited A.B.N. 64 009 686 097
All rights reserved. This material may not be reproduced or copied, in whole or part, without the written permission of 5/5
Toyota Motor Corporation Australia Limited, 155 Bertie Street, Port Melbourne, Victoria.