I had to replace my A/C tensioner pulley about 40,000 miles ago because it was noisy. Just had the dealer replace it while doing the timing belt. Now it's noisy again. Is this a common problem on b16's?

Could there be something causing this pulley to be wearing out? Tension in the belt is fine.

 

I had the same problem on my 99 civic vp and I suppose I still have the problem but what fixed it for me is a belt conditioner spray. Just spray it on the idler/tensioner pulley and belt, and drive the car for a while and the noise will be gone. Remember to drive it, because the noise will get quiet after you spray it but once the spray dries it might get a little noisier but that will get fixed after you drive it on a few occasions. Now my A/C belt pulley is pretty quiet.

Check out the thread I made about the same problem: https://honda-tech.com/forums/honda-civic-del-sol-1992-2000-1/sqeaking-noise-hmm-2580475/ and read the whole thing.

 

Are you sure the noise is coming from the idler pulley?

 

I'm absolutely sure the noise is coming from the A/C tensioner pulley. It's not the belt slipping on the pulley, it's the pulley bearing making the noise.

 

Maybe the dealer is over tightening the A/C belt? It's not too hard to replace it yourself.

 

its 2 bolts to change it out, 5 minute job. spray some lubricant in the bearing

 

I didn't realize it was so easy to change out. Do you remove it bracket and all? Looks like it'd be pretty difficult to get a socket on there....

 

Nope, you loosen the bolt that connects the alternator with the bracket on the top. Loosen the bolt that the Alternator pivots on the bottom. Pull alternator towards you, take belt off. Put on new belt, reverse everything. I had my A/C belt off at the time though, not sure if that makes it any harder.
But if you do need to take off the A/C belt, loosen the bolt in the middle of tensioner, then loosen the long bolt. Again, really easy

Oh and I had to use wrenches to get the bolts loose, I couldn't fit a socket in there

 

I got it done. It was nothing like you described, but maybe because I have a b series. I unbolted the power steering pump and bracket and moved them to the side to access the a/c tensioner from the top. My alternator never came into play in this job. Job took about an hour in a parking lot. You need a deep socket, a few extensions, and an articulating ratchet.

I actually just took the entire a/c tensioner arm off to remove the pulley with my electric impact wrench.

Here is a photo of the old pulley next to the new. You can see where the bearing puked out something...