THE DIRECTIONS I HAVE FOR REMOVAL OF THE CRANK SHAFT PULLEY SAY THAT THERE ARE FOUR ALLAN HEADED BOLTS. AND ONE 17,MM BOLT IN THE CENTER. I HAVE NO ALLEN HEADED BOLTS JUST A 17MM CENTER BOLT. THE PULLEY ABOVE THE CRANKSHAFT PULLEY HAS FOUR ALLEN HEADS AND A LARGER CENTER HEAD. THAT SAID I IN TRYING TO REMOVE THE PULLEY BROKE THE TOOTHED " GEAR BEHIND IT. DOES THIS MATTER? WILL I NEED TO GET A NEW ONE?
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Special Tools Needed:
Honda Crankshaft Pulley Removal Tool
3/4" breaker bar
-Remove tire and place the Pilot on a jack stand.
-Remove the clips holding the fender liner and lower splash shield in place (x7) and fold them out of the way.
-Make sure the #1 piston is on top dead center using the marks on the crank pulley and lower timing belt cover (19mm in the crank pulley).
-Remove the Alternator-Compressor belt (14mm boxend) & Power Steering belt. (2-12mm and 1-12mm tensioner bolt)
-Loosen the crank pulley. If you have an impact wrench or a long breaker bar it makes it easier to remove the bolt. You will also need a special tool crankshaft pulley holder (50mm) (19mm and special tool).
-Remove the side engine mount bracket (5-14mm bolts).
-Remove the crankshaft pulley.
-Remove the oil dipstick & tube (10mm).
-Remove the front & rear 'upper covers' of the timing belt housing, moving the wire harness out of the way first (5-10mm bolts for each cover).
-Remove the lower cover (7-10mm bolts).
-Remove the engine mount bracket that is bolted to the block (3-14mm bolts).
-Remove the hydraulic tensioner (2-10mm bolts).
-Remove the tensioner pulley (you will reuse the inner sleave) (14mm bolt).
-Remove the idler pulley bolt (14mm bolt with thread locker on it) (I used Loctite 242 during the reinstall because I had it on the shelf).
-Remove the timing belt.
-Before installing a new timing belt, make sure the pulleys, belt guide plate, upper & lower covers are clean and check to see if the crank and cams have rotated (mine did not move).
-The install is the reverse order of removal (make sure you torque everything correctly!)
-The removal of the lock pin in the hydraulic tensioner gave me a little trouble so I used pliers.
-Once the crank pulley is back on, check the lower timing mark (and the cam marks) before the top covers are installed.
Hi there:I dont have this diagram for 2S-ELC, 3S-FE and 5S-FE Engines, but pay attention at this... To install:
Align the cutouts of the oil pump pulley and shaft, and slide the pulley on. Retain the pulley while tightening the nut to 21 ft. lbs. (28 Nm).
Align the crankshaft timing pulley set key with the key groove of the crankshaft pulley, then slide the pulley on.
Install the No. 2 idler pulley with the bolt and tighten to 31 ft. lbs. (42 Nm). Be sure the pulley moves smoothly.
Remove any oil or water on the idler pulley and keep it clean.
Temporarily install the No. 1 idler pulley with the retaining bolt. Hint: use a 1.65 inch (42mm) bolt in length. Do not tighten the bolt yet. Install the tension spring. Pry the pulley toward the left as far as it will go, then tighten the bolt.
Turn the crankshaft until the key groove in the crankshaft timing pulley is facing upward. Install the timing belt on the crankshaft timing, oil pump, No. 2 idler and water pump pulleys.
If the old timing belt is being reinstalled, make sure the directional arrow is facing in the original direction and that the belt and crankshaft gear matchmarks are properly aligned.
Install the lower (No. 1) timing belt cover and new gasket with the four bolts.
Align the crankshaft pulley set key with the pulley key groove. Install the pulley. Tighten the pulley bolt to 80 ft. lbs. (108 Nm).
On 2S-ELC engines, turn the crankshaft pulley and align the 0 mark on the lower (No. 1) timing belt cover.
Align the camshaft knock pin with the matchmarks on the oil seal retainer.
On 2S-ELC/USA engines, align the knock pin with the pin hole on the timing pulley E mark side. On 2S-ELC/Canadian engines, align the knock pin with the pin hole on the timing pulley. On 3S-FE and 5S-FE engines, align the knock pin with the groove of the pulley, and slide the pulley onto the camshaft with the plate washer and set bolt.
On 2S-ELC engines, make sure that the Matchmark on the oil seal retainer and center hole of the small hole on the camshaft timing pulley are aligned.
Using the removal tool to hold the pulley stationary, install and tighten the pulley set bolt to 40 ft. lbs. (54 Nm) on the 2S-ELC and the 3S-FE. On the 5S-FE, tighten the set bolt to 27 ft. lbs. (37 Nm).
On 3S-FE and 5S-FE engines, turn the crankshaft pulley and align the 0 mark on the lower (No. 1) timing belt cover.
Install the timing belt and check the valve timing as follows:
Align the matchmarks that you made previously, and install the timing belt onto the camshaft pulley.
Loosen the No. 1 idler pulley set bolt 1 / 2 turn.
Turn the crankshaft pulley two complete revolutions TDC to TDC. ALWAYS turn the crankshaft CLOCKWISE. Check that the pulleys are still in alignment with the timing marks.
Tighten the No. 1 idler pulley set bolt to 31 ft. lbs. (42 Nm).
Make sure there is belt tension between the crankshaft and camshaft timing pulleys.
Install the upper (No. 2) timing cover with a new gasket(s). On the 5S-FE, align the two clamps for the engine wiring harness with the cover mounting bolts.
Install the spark plugs.
Install the right mounting insulator with bracket. Tighten the bracket bolts to 38 ft. lbs. (52 Nm), insulator nuts to 38 ft. lbs. (52 Nm) and thru-bolt to 52 ft. lbs. (71 Nm). On the 5S-FE, install the No. 2 engine mount bracket and tighten to 38 ft. lbs. (52 Nm); install the control rod and tighten the bolts to 47 ft. lbs. (64 Nm).
Lower the engine.
On 3S-FE and 5S-FE engines, install the alternator and alternator bracket. On 2S-ELC engines, install the power steering reservoir tank.
Install the drive belt and adjust the tension.
Install the cruise control actuator with bracket.
Install the fender apron seal and right engine under cover.
CHECK SEE IF CRANK SHAFT PULLEY BOLTS LOOSE.IF CRANKSHAFT PULLEY LONG BOLT TORQUE IS FOR 130 FT LBS FOR 1.8L ENGINE. IF YOU HAVE THESE ENGINES CRANKSHAFT BOLT TORQUE IS 174 - 181 FT LBS ENGINES ARE 3.0L 3.2L 3.5L 2.3L 2.5L IF CRANKSHAFT PULLEY BOLT IS TIGHT.THE CRANKSHAFT PULLEY ITSELF BROKEN NEED REPLACING.
look at bottom of motor, crankshaft pulley , put some glasses on and go under truck and look up its mounted on the block near the top of the pulley it will have a switch and a plug. , one or two bolts hold them on to motor. it points to the pulley.
go here too
Section 03-01: Engine 1996 Villager Workshop Manual
Water Pump Removal
Drain the cooling system. Refer to Section 03-03 for the procedure.
Disconnect the battery ground cable (14301).
Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedures.
Raise and support the vehicle.
Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
Remove the water pump pulley from the water pump (8501).
Remove the crankshaft pulley (6312). Refer to the procedure in this section.
Remove the five lower engine front cover bolts and the lower engine front cover (6019).
NOTE: Make a note of the location of the one water pump stud/bolt for ease of installation.
Remove the six water pump bolts.
Remove the water pump.
NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material.
Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block.
NOTE: Refer to the note made during removal for the location of the stud/bolt.
Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft).
Position the water pump pulley on the water pump and install the four water pump pulley bolts.
Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley, and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft).
Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in).
Install the crankshaft pulley. Refer to the procedure in this section.
Lower the vehicle.
Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the installation and adjustment procedures.
Connect the battery ground cable.
Fill the cooling system. Refer to Section 03-03 for the procedure.
Start the engine (6007) and check for leaks.