Hi Everyone,

I'm a new member and this is my first post on here so apologies if I have missed anything and this has been an issue answered in a previous thread! I did a search and couldn't find anything and I have always found posts on here and everyones advice to be so useful so decided it was about time I signed up!

Today was a nice day and first time I've had some time off in a while so thought I'd do some much needed bits on my 200tdi Disco.

I thought I'd ease it into it with some basic servicing bits so not to startle him (oil drain, valve clearances, rocker gasket etc) and was off to an easy and good start...I knew however that this was likely not to continue!!

The Sump Gasket (sealant) had started to give out so removed the sump and whilst I had the sump off I decided to give the oil pump a once over to check everything and replace the gaskets...this is where my FIRST issue started!

No matter what I did the Oil Pump just won't release from the block; and yes I have undone the necessary 2 bolts ! I have tried twisting it, wiggling it, hanging off it (virtually doing reverse press ups off it), as well copious amounts of swearing at it but nada...not even a mm (the sump sealant was very strange and a bugger to get off and I am not sure if it looks like someone has used a bit of the same sealant as well as the gasket I can see on the Oil Pump which may be causing this).

After more time than I care to remember I decided to see if I could release it from the top by removing the Vacuum Pump and driving the shaft down. This is where issue TWO reared its head as the Vacuum Pump wouldn't release from the block either. This time, unlike with the Oil Pump, I at least got some movement as it will twist about 30degrees in both directions and lift a few mm but that's it.

Has anyone on here had this issue or heard of this issue before... am I missing something incredibly simple and being stupid!!?

My main fear is that the drive shaft linking the Oil Pump and the Vacuum Pump has somehow worn it's gears in such a way that it won't release. Whilst it is not hugely vital right now that I get of the Oil Pump or Vacuum Pump right now, it is just asking for trouble if I can't check it, particularly the Oil Pump, as it only a matter of time without maintenance that it will fail and I am left with a 2.5l lump of uselessness!

Any help or suggestions from you wonderful people would be greatly appreciated as I will be back at it tomorrow and have no clue where I am going to start!

P.s. Whilst my mood is currently all for using the well known "hammer of gentle persuasion" I am not too sure I am comfortable hitting my Oil Pump (quite vital and containing several gears still connected to the linking drive shaft) with said device!!

 

You need to have #1 at TDC before pulling off. Refit the bolts loosely and rotate the motor then try again.

 

Thanks for the reply ihscouts.

Unfortunately still no luck on getting off either the Oil Pump or Vacuum Pump even with #1 set at TDC.

Any other ideas as this is really starting to get to me now lol!

 

"During normal operation of the engine the camshaftand skew gear teeth develop a mated a wear pattern. It is therefore important that if the skew gear
is to be re-used it should be fitted so that the teeth on the gear and camshaft engage in the original running position."

I think your right about the bits being worn together. I don't think what your trying to do to remove either component has ever been done to this engine since new..... I know the vacuum servo mounting bolts go through the skew gear flange which is why you can swivel the vacuum servo - they are basically welded together..... I'd try tapping with a rubber or plastic mallet to see which end comes off first, the oil pump or the vacuum servo. Try holding the vacuum servo right where it's mounting bolts go through the skew gear flange, in other words in it's normal location. Try separating with side taps of the mallet, not so hard as to break the servo but hard enough to break the seal between them. The oil pump might be locked in it's bore because of the ladder frame, try installing a few sump pan bolts back into it.

 

Thanks again ihscouts.

Unfortunately I had to reinstall the sump and get it back up and running for some light use this week before seeing your post.

Over the next few weeks / months whilst the weather is better here there are some bits of wheel arch and front wing welding on both sides that needs to be done before the MOT is due (it is a disco after all!) so for ease with all of it I may just pull the engine and give it a proper going over at the same time. It will make the welding easier and give me much better access to the Vacuum and Oil Pumps being able to rotate the engine etc.

As we seem to both agree that is worn gears most likely causing this issue do you know if it would be recommended to replace the skew gear etc once I have got the Vac Pump off...or if this is renewed does it mean replacing multiple other parts such as the oil pump drive gears, camshaft etc (I know if you replace the camshaft you should replace the skew so presume it works the other way around too), so not worth the expense or bother and just reinstall them in the same position!?

When I get the time to get back out and do the rest of the work I will update this thread with what worked to get both the pumps off.