Lude Generation

Will do mate... cheers for the help

Torque on that bolt is something like 185lb/ft. It needs brute strength.

Yes, the manual has a very specific piece of advice about which parts must be meticulously clean, and which parts must be lubricated with regard to the crank nose, the pulley, the bolt and the washer.

I suspect that if you do not lock the crank (via the flywheel to the block), it would be hard to apply that torque without slipping the clutch or similar. I've certainly seen the problem in reverse, trying to loosen a crank pulley on a honda engine - so much torque needed, that even with the car in gear and brake discs locked, the clutch slipped before the bolt undid...

follow up from Ranj - he sent me some pics of the crank nose and old pulley.

The woodruf key is present but mangled (still driving timing sprocket and balance belt ok im assuming based on above) , and all the splines are worn off the crank nose and pulley.

I recon the only easy fix is to:

1) bolt the new pulley to the crank, try and get it centered (im guessing there will be a little slack). Maybe jam in something to take up the slack caused by splines disappearing (some old feeler gauges perhaps?)
2) take out bolt
3) Weld the pulley directly onto the crank nose.
4) bolt back on the the correct torque/procedure (make sure the welds dont protrude to interfere with the bolt/washer mating surface, not sure how easy that will be!).

not a fancy job by any means, but anything else is new crank / rebuild territory?

Without a new key - the pulley wont take the torque since the splines are gone (and also be hard to tighten without the correct tool)
to replace the key means all the cambelt off etc
Putting a new key is a waste of time in this situ i think, since the crank is already damaged
welding it on centered solves both the issue of having to replace the key and allowing the pulley to take the torque (both in operation and tightening).

Worth a go you recon?

There are no splines on the crank nose.

I have no idea why Honda put slots on the pulleys.......

Some photos in here for reference.....

viewtopic.php?t=790&start=410

Ah yes - i see what you mean now, there are no splines on the crank nose - i realise its the reflection of the serated notches in the cambelt guard that give the appearance of notches having worn away. Seems strange the H22 pulley (at least the replacement ranj bought) has a splined receiver - perhaps it fits multiple honda/cranks.

eitherway, even with a new key, the nose is damaged and the pulley is unlikely to sit centrally any more, last thing you need at high revs

@Free Ranj Egg get some pics on here, you'll get a fix.