Recall - Power Steering Pump Pulley Defect

Section : Engine

TSB No. TS 09 11095

Division: Automotive

Category: Technical

SUBJECT: RECALL CAMPAIGN "KJ" POWER STEERING (PS) PUMP PULLEY
REPLACEMENT

MODEL(S): VERONA

YEAR: 2005~2006

AFFECTED VIN(S):SEE VIN LIST, PAGES 6 THRU 10

CONDITION:
During engine operation the Power Steering(PS) Pump Pulley flange may
separate from its hub.

CAUSE:
Improper manufacturing.

CORRECTION:
Please inspect the PS Pulley according to the attached instructions on vehicles with VIN numbers from the attached VIN list. If the PS Pulley is found to be defective please replace it with the updated part. Use the attached instructions for inspection and replacement.

WARRANTY:
Please refer to the Campaign Bulletin SC-30 for claim submission instructions and labor times.




PARTS INFORMATION:

INSPECTION INSTRUCTIONS:



1. Open the engine compartment hood. With the engine off inspect the PS Pump Pulley at the indicated location.




2. If the outer face of the pulley (away from the engine) has a flat surface on the circumference (pulley at the left) the pulley must be replaced. Follow the

REPLACEMENT INSTRUCTIONS:



1. Remove the coolant reservoir and set it on top of the intake manifold cover. Do
not open the reservoir cap or disconnect the hoses.




2. Before removing the serpentine belt loosen the PS Pulley mounting nut by
wedging 1/4 inch drive extension thru the pulley opening between the pump housing and high pressure line mounting nut.This will stop the pulley from moving. Then turn the nut counterclockwise to loosen but do not remove.




3. Locate the self adjusting belt tensioner and attach a wrench to the 14mm bolt head.




4. Move wrench handle toward the front of the vehicle to release the tension on the serpentine belt. Carefully remove the belt from the PS Pump Pulley.




5. Keep the tensioner released and slip the defective pulley off of the PS Pump shaft. Then install the new Pulley onto the PS Pump shaft. Hand tighten the nut. Allow the tensioner to re-tension the belt and torque the PS Pulley nut to 60 Nm (44 lb-ft).




6. Visually check to be sure the belt is aligned properly on all of the pulleys. Re-install the coolant reservoir. Torque the coolant reservoir bolts to 6 Nm (53 lb-in). Start the engine to make sure the belt seats into all pulley




7. Fill out the "KJ" label with the dealer number and affix it to the core support.

















AFFECTED VINS