THE COMMON REASONS FOR PUMP FAILURE

WHY WATER PUMPS FAIL

Page 2

FOREWORD
This booklet was produced for the purpose of identifying
why water pumps fail and can be used to compare a water
pump that has been returned due to failure.
Comparisons given in this booklet will help in
determining the validity of a claim.
This publication also shows some of the other common
reasons for water pump failure such as incorrect belt
tension, cavitation, dynamic imbalance and electrolysis.

WHY WATER PUMPS FAIL

THE COMMON REASONS FOR PUMP FAILURE

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CONTENTS
PAGE 1
PAGE 4-5

FOREWORD
IDENTIFYING THE CLAIM

PAGE 6

BROKEN OR CRACKED HOUSINGS

PAGE 7

ELECTROLYSIS

PAGE 8

CAVITATION

PAGE 9

EARLY SIGNS OF SEAL FAILURE

PAGE 10-11
PAGE 12

FAILURE BY CORROSION
SEAL FAILURE FROM CORROSION

WHY WATER PUMPS FAIL

Page 4

IDENTIFYING
THE CLAIM

BROKEN / CRACKED HOUSING.

REFER BROKEN HOUSING SECTION

[Page 6]

BLACKEND SURFACE / LEAKING.

REFER ELECTROLYSIS & CAVITATION SECTION

[Page 7]

In most circumstances, the water

pump is blamed, as it is the most
obvious part that displays
evidence of failure.
The images below display all signs
that the water pump failed because
of other problems within the
cooling system.

LEAKING THROUGH WEEP HOLE.

REFER EARLY SIGN OF SEAL FAILURE SECTION

[Page 9]
4

THE COMMON REASONS FOR PUMP FAILURE

Page 5

EVIDENCE OF RUST DISPLAYED.

REFER FAILURE BY CORROSION SECTION

[Page 10-11]

The main reason given for a

claim is LEAKING. The weep hole
displays evidence that coolant
/ water has eroded through the
seal. This reason alone indicates
that some form of severe
corrosion has occurred.
If a water pump has been
returned for replacement /
warranty, compare the water
pump to the pictures below to
ascertain why the water pump
failed and then refer to the
section listed for
a detailed analysis.

EVIDENCE OF CALCIUM DISPLAYED.

REFER FAILURE BY CORROSION SECTION

[Page 10-11]

EVIDENCE OF PITTING AND CAVITATION.

REFER CAVITATION SECTION

[Page 8]

WHY WATER PUMPS FAIL

Page 6

BROKEN OR
CRACKED
HOUSINGS
These photos show a fracture around
the base of the pump housing webbing.
Failures of this type can be caused by
dynamic imbalance such as fitting an
old fan clutch to a new water pump. In
this case the fan clutch had not been
fully tensioned to the mounting boss
resulting in a major imbalance problem.

Fractures like this have

also been associated
with over tensioning of
the drive belt, although
in those cases the pump
bearing will also have
suffered

THE COMMON REASONS FOR PUMP FAILURE

Page 7

ELECTROLYSIS

All of the above photos show dark

discolouration of the inner pump
housing which is consistent with the
burning nature of current tracking
into the cooling system.
Seals removed from these pumps had
hardened and fragmented badly resulting
in serious coolant loss. Microscopic
examination of the housing surface
displayed fine pitting marks similar to
those seen in radiator core failures.

WHY WATER PUMPS FAIL

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CAVITATION

The extent of cavitation

here would indicate a
problem/s with coolant,
system bleeding and/or
air ingress.

Above and below photos show

serious damage from cavitation.
Exploding pockets of air slowly
etching away at the pump
housing caused the large
crater in the floor of the pump.
The light blue coloured hole in
the crater is sunlight shining
through from outside.

THE COMMON REASONS FOR PUMP FAILURE

Page 9

EARLY SIGNS
OF SEAL FAILURE
Apart from the rusty
coolant stains from the
bearing relief hole, look
at the build up of grease
behind the fan boss.
In this case coolant is
entering the bearing
from leaking seals and is
pushing the lubricating
grease through the
bearing and out past the
bearing seal.

Black coolant stains from the relief hole

indicate a serious electrolysis problem
with this cooling system and as a result
the seals have been badly affected.
Other causes include no coolant or
incorrect ratio of coolant allowing
contamination and erosion through the
seal assembly. Brown coloured staining
is most commonly seen in this area and
is the obvious sign that the cooling
system is contaminated with rust.

WHY WATER PUMPS FAIL

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FAILURE BY CORROSION
Both photos show extensive corrosion to the inner pump housing. The
photo on the right shows how corrosion has attacked the surface of the
pump shaft and the seal retainer collar.

Above. Shows a rusty coolant stain

from the relief hole, and corrosive
build up around both the radiator
and heater hose spigots.

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THE COMMON REASONS FOR PUMP FAILURE

Page 11

Corrosion in this case has caused breakage of the seal causing massive
coolant loss. The dark appearance of the housing would suggest this
cooling system also had a severe electrolysis problem as well.

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WHY WATER PUMPS FAIL

Page 12

SEAL FAILURE
FROM CORROSION

These seals came from pumps that had been in service for less than 4
months. Corrosion has caused severe damage to the seals resulting in
massive coolant loss and subsequent engine failure.

US Motor Works, LLC

16401 Berwyn Road

Cerritos, CA 90701 USA
www.usmotorworks.com
info@usmotorworks.com
(T) 562-404-0488
(F) 562-404-8770

The photo above shows cracking of the ceramic seal

which occurs when adding cold water to a hot engine
(thermal shock). Observe the extent of corrosion
damage to the seat under the ceramic seal.

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