Campaign - Water Pump Pulley Flange Cracks: Overview
08-038October 25, 2008
Applies To:
See VEHICLES AFFECTED
Product Update: Water Pump Pulley Flange Cracks
(Supersedes 08-038, dated August 1, 2008, to update the information marked by the black bars and shown with asterisks.)
BACKGROUND
Due to a manufacturing problem, the water pump pulley flange may crack. A cracked pulley flange may create a pulley noise, cause the water pump to fail, and cause the drive belt to break.
VEHICLES AFFECTED
Some of the vehicles affected by this product update may be in your used vehicle inventory. These vehicles should be updated before they are sold or leased.
To verify vehicle eligibility, check for at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition, check for a punch mark below the ninth character of the engine compartment VIN. A punch mark in that location means this product update has already been completed.
CUSTOMER NOTIFICATION
Owners of affected vehicles were sent a notification of this product update. An example of the customer notification is shown in this service bulletin.
CORRECTIVE ACTION
Install a water pump kit.
PARTS INFORMATION
REQUIRED MATERIALS
REQUIRED SPECIAL TOOLS
WARRANTY CLAIM INFORMATION
REPAIR PROCEDURE
1. * Drain the engine coolant from the radiator into a clean container, and save it for reuse:
^ Refer to steps 1 thru 3 on page 10-7 of the 2006-2008 Civic Service Manual, or
^ Online, enter keywords COOLANT REPLACE, select Coolant Replacement (R18A1 and R18A4 Engine) from the list, and do steps 1 thru 3.
2. Drain the engine coolant from the engine block. Do not reuse the coolant that drains from the block:
^ Refer to steps 4 thru 6 on page 10-7 of the service manual, or
^ Online, enter keywords COOLANT REPLACE, select Coolant Replacement (R18A1 and R18A4 Engine) from the list, and do steps 4 thru 6.*
3. From above the engine, set a long-handled, boxed-end wrench on the drive belt auto-tensioner. Slowly turn the wrench counterclockwise, then remove the drive belt.
*NOTE:
On vehicles without A/C, the drive belt will be reused.*
4. Remove the alternator:
^ Refer to page 4-45 of the service manual, or
^ Online, enter keyword ALT REM, and select Alternator Removal and Installation (R18A1 and R18A4 Engine) from the list.
5. Insert a pulley holder (see REQUIRED SPECIAL TOOLS) into one of the holes in the water pump pulley at the 12 o'clock position. The tool holds the pulley so you can loosen or tighten the pulley bolts.
6. Remove the water pump pulley (three bolts).
7. Remove the drive belt auto-tensioner (one pivot bolt and one hex bolt).
8. Remove the water pump (five bolts).
*NOTE:
Do not reuse the coolant that drains out when the pump comes off.*
9. Clean the mating surface of the water pump O-ring on the engine block.
10. Install a new water pump and O-ring. Tighten the water pump bolts to 12 N.m (8.7 lb-ft).
11. Reinstall the drive belt auto-tensioner with the original hex bolt and a new pivot bolt. Torque the hex bolt to 24 N.m (17 lb-ft). Torque the pivot bolt to 54 N.m (40 lb-ft).
NOTE:
For important tips on installing the pivot bolt correctly, refer to ServiceNews article A07030I, Replacing the Drive Belt Auto-tensioner Pivot Bolt? Read This First.
12. Install a new water pump pulley with three new bolts. Insert the pulley holder in the 12 o'clock position to keep the pulley from moving while you torque the bolts to 14 N.m (10 lb-ft).
NOTE:
^ The exact torque is critical for a successful repair. To guarantee the correct torque, you must use an accurately calibrated torque wrench. It's OK to use a crowfoot socket wrench with the torque wrench.
^ Do not install the drive belt before you torque the pulley bolts. If you do, you won't get accurate torque readings.
^ Remove the pulley holder after you torque the pulley bolts,
13. Reinstall the alternator:
^ Refer to page 4-46 of the service manual, or
^ Online, enter keyword ALT INST, and select Alternator Removal and Installation (R18A1 and R18A4 Engine) from the list.
14. * On vehicles with A/C, route a new drive belt around the engine pulleys as shown above. On vehicles without A/C, route the original drive belt as shown in step 3.*
15. From above the engine, set a long-handled boxed end wrench on the drive belt auto-tensioner. Slowly turn the wrench counterclockwise, and slip the belt over the auto-tensioner pulley. Release the auto-tensioner, and remove the wrench.
16. * Refill the radiator with the coolant you removed in step 1, then add about 2 quarts of new coolant, and loosely install the radiator cap.*
17. Start the engine, let it run until the radiator fan cycles twice, then stop the engine.
18. Top off the coolant in the radiator, then install the radiator cap, and clean up any coolant spills.
19. Center-punch a completion mark below the ninth character of the engine compartment VIN:
^ Slide open the FRAME NUMBER door on the center cowl cover.
^ Use a long punch to reach the VIN.
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