Good news: went out to the rover and pushed the FUEL door button and it worked just like it was suspossed to. I dont know how i f@cked that one up the other night; I blame the beer.

Tomorrow I will go to the local pick-a-part and see if they have fan assembly or whatnot...

 

If you are going to sacrifice something to appease the Rover gods then it's a crap shoot as too which part is the cheapest, but the only way I can see is if you cut a chunk out of the pulley big enough to get a 36mm wrench in there to undo that fan nut. You will need a new pulley and you will need to be very careful not to cut up the fan or any other parts you want to keep.

 

Pilsner, where are you located. There has to be a wrecking yard somewhere in your area. find a wrecked Discovery and snag the water pump and pulley. Your agony is killing me. phil

 

I am in Olympia, WA. I am gonna try to get to the local pick-a-part and see what they have. In the mean time I am gonna bust out the dremel and a poopton of metal blades and see if I can cut the pulley in half to get a wrench in there. wish me luck. btw the old waterpump I pulled off of there is still in great shape so if I can get the fan and clutch off in one piece I will only need a pulley. i think...

 

There's a DII at the yard in SE Olympia off of Fir Rd. I think the engine bay was picked clean tho...they have a DI also with a mostly complete engine if I remember correctly.

 

If you are going to trash it you should try both these things first:
1. Mount the assembly on the engine or in a vice.
Then get a drill with a rubber sanding pad on it (no sanding disc).
Run the drill with the edge of the pad on the pulley ? I think you need the pulley running clockwise viewed from the front.
Let the assembly spin up and then apply some resistance to the front of the fan ? use a brush or broom.
This might offer enough resistance to unscrew the fan clutch. If the resistance is not enough apply heat to the coil while it is spinning. Then apply resistance again.
Unless you are an octopus you are going to need a couple of friends to help you with this.


2. If the first thing doesn?t work and there is a millimetre or so gap between the pulley and the fan clutch you may be able to make a tool to grip it. make it out out a couple of strips of thin metal - it should flex enough to find the nut! place the tool around the assembly and force the edges into the gap (like scissors). once you have it in just grip it closed and try and unscrew the pulley.

if neither of these work I'm all out of ideas!

Good luck!

________
Roll Blunts

 

I am certain that I will hafta trash the pulley - its the cheapest part among them. I plan to put the pulley into my vise and drill 2 holes at 3 and 9 o'clock in the edge (i.e. the part that the belt rides on) and then use my dremel to cut the pulley to connect the two holes. Then cut fromo the 3 o'clock and 9 o'clock holes to the inside edge of the pulley (i.e. toward the fan) making a large section of the pulley cut-a-way. The idea is to get the fan unscrewed. I am willing to sacrafice the pulley to get it apart. I assume that welding the pulley back together is a bad idea? or just buy a new one, hopefully from the junk yard.

I dont see anyway to fab a piece to fit that little slot. not nearly enough room to work inside there.

 

Yes bad idea, a used one can be had for nearly nothing. Use a sawzall with a hacksaw blade. Harbor Freight has a $24 copy, just add a Milwaukee blade.

 

I figured that would be the case. It looks like I am making a trip to the local junk yard. Now just to find one that has a D2...

 

Just call will tillery, paul grant or Justin at lucky 8 if you have no luck.