I have a 2000 accord with 2.3 engine. Somehow the camshaft seems to have separated from the pulley. Looks like a broken Woodridge key, but I'm not sure. Camshaft is not broken, just not really connected to the cam pulley in any way. Looking for advise on how to repair this.

 

Pretty sure the "key" is integral to the cam sprocket on all variants of the F23 (your engine code). it's not a separate piece, so the sprocket itself would need to be replaced. you could check part numbers, but I'm pretty sure the older 2.2l VTEC engines used the same sprocket (F22B1).

anyway, assuming this happened while the engine was running there's a good chance of valve-vs-piston damage. also, this is not a typical fail point on these engines which suggests another cause that you would want to pinpoint before attempting a repair (same failure may happen again if you just replace the sprocket)

 

I'm wondering if I should even try to replace the pulley or just get a good low mileage head or refurb head. What are the chances it could have serious issues with the lower end?

 

if you pull the head, you'll be able to see the extent of the damage. check the valves for leaks (from bending) or other damage. check the tops of the pistons for signs of valve contact. you can decide what to do from there.

 

Isn't the cam gear also bolted to the shaft?

 

yes, but it's only intended to keep the sprocket from sliding axially so the key can do it's job. there isn't enough clamp force or surface area to keep the sprocket from spinning. And, the direction of rotation of the engine will loosen the bolt if the key breaks.

 

What could have caused the key to break in the first place?

 

the only thing that comes to mind is oil starvation to the cam journals and the cam seizing in the head. I've seen this happen before, but each time it broke the timing belt not the key. though they were all older models with a different sprocket design.

...or at some point someone had the sprocket off, damaged the key then slapped it back together. pretty unlikely, but possible.