I was replacing the camshaft seal on my 1989 Accord LXi coupe and discovered a couple issues.
When I removed the cam pulley bolt there was some kind of plastic filler behind it.
Almost like someone tried to glue the pulley onto the camshaft.
After wrestling with the pulley for a while I got it off and discovered why.
Apparently the previous owner lost the cam key and a piece of random metal had been cut and filed to roughly fit the slot and from the looks of it hammered in and filed down flush with the pulley face.
The key slot in the camshaft is chewed up from the way the key was forced in.
Additionally the pulley fits quite loosely on the camshaft now that the filler is gone.
With the bolt loose I can wobble the pulley back and forth at least 3 to 4 degrees out of alignment.
The internal diameter of the pulley appears to be stepped with the diameter of the section that goes over the camshaft being a larger dimension than the small part that doesn't.
Did it come from the factory this way?
Did someone bore it out for some dumb reason?
Is this is the wrong pulley for the engine?
Was the camshaft ground down making it loose now for the pulley?
What is the correct OD of the camshaft supposed to be? The ID of the pulley?

I wasn't planning on replacing these parts, just the seal but if I have to replace the cam and pulley I will.
The problem is there's none of these cars in my local junk yards and hasn't been since I started checking in March.
As far as searching online I can only find replacement cams (and only a few) but no pulleys at all.
If it's just the cam that's been ground down than I can buy a new one of those and be good but if the pulley needs replaced as well then I'm stumped as to where to get one.
Anyone have answers?

 

sure sounds like someone did a number on the vehicle. hope this info helps a bit. https://www.engine-specs.net/honda/a...%20cylinder%29. parts you can google what you are looking for and many salvage yards respond and with cost.

 

Thanks for the link. There's some good information there, unfortunately for me nothing that I don't already have in the factory shop manual.

 

I just checked the dimensions on my messed up cam and pulley.
Margin of error could be 0.01mm either way but clearly there's an issue here.
Camshaft OD where pulley fits: 19.91mm
Pulley ID where camshaft fits: 20.08mm
Pulley ID where it's stepped down: 19.85mm

The question remaining is what are the correct dimensions?