300tdi,repair to brake vacuum pump/oil leak from front cover EASY JOB

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billyloadsamud

New Member
Posts
12
Location
worthing west sussex
Had no other jobs in workshop today so did couple of jobs to own car.
FIRST set engine to TDC on No 1
Removed vacuum hose, 6 bolts which attach pump to block, and removed pump.
Fixed to bench and drilled out the factory rivets with 5mm drillbit and lifted front cover off. underneath is a shaped 'O' ring which had flattened causing the leak.
Cleaned pump face and cover well and squeezed small amount of sealant into cover indent where 'O'ring seats, and small amount to pump face, bolted back together with M5x20mm bolts, washers to both sides and nylock nuts, tightened all six evenly till the sealant squeezed out, and nipped up bolts.
Carefully removed gasket from engine block where pump fits, cleaned gasket and pump/block faces and squeezed small amount of sealant to both sides of gasket and refitted vacuum pump and hose, 1 hours work tops. SAVING £108 for a new pump(£95 Ebay)
EASY DIY JOB.
I use a special sealant, you can buy from Vauxhall, it sets in oil and is designed for fitting together gasketless joints such as sumps, timing chain covers etc(also Isuzu/Subaru etc but cheaper from Vauxhall) Suzuki call it Three Bond, brilliant stuff, never had a gasket failure with it, and can be easily parted when necessary
Billy
 
bollox. wish i knew that in December. I got a new pump fitted, then it failed on xmas day! sourced a new one and fitted it myself before new year. got a refund on the old one, but i wasted £60 in the 1st place getting it fitted. :( grrrrrrrrr.

Its not a difficult job, just fiddly. I would allow 1.5hrs for 1st time. I did mine by getting the girlfriend to turn the camshaft (using a ratchet on the alt pulley to turn everything) whilst i looked into the bellhousing underneath. when the mark came around and lined up thats it, stop, job done. think there is a narrow mark and a ider mark, seem to recall needing the wide mark. you dont need to lock it, just set it.

Billy - if the pump goes again, expect a PM re fitting that O ring :)

cheers

G
 
billyloadsamud said:
Had no other jobs in workshop today so did couple of jobs to own car.
FIRST set engine to TDC on No 1
Removed vacuum hose, 6 bolts which attach pump to block, and removed pump.
Fixed to bench and drilled out the factory rivets with 5mm drillbit and lifted front cover off. underneath is a shaped 'O' ring which had flattened causing the leak.
Cleaned pump face and cover well and squeezed small amount of sealant into cover indent where 'O'ring seats, and small amount to pump face, bolted back together with M5x20mm bolts, washers to both sides and nylock nuts, tightened all six evenly till the sealant squeezed out, and nipped up bolts.
Carefully removed gasket from engine block where pump fits, cleaned gasket and pump/block faces and squeezed small amount of sealant to both sides of gasket and refitted vacuum pump and hose, 1 hours work tops. SAVING £108 for a new pump(£95 Ebay)
EASY DIY JOB.
I use a special sealant, you can buy from Vauxhall, it sets in oil and is designed for fitting together gasketless joints such as sumps, timing chain covers etc(also Isuzu/Subaru etc but cheaper from Vauxhall) Suzuki call it Three Bond, brilliant stuff, never had a gasket failure with it, and can be easily parted when necessary
Billy
Click to expand...

Hi Billy,
Just joined the forum and glad I did. Just looked at what you wrote about break vacume pump oil leak, I think that I have one. Not much oil is being lost but it looks like it coming from there, I found a drip hanging from the sreering damper. I dont feel any loss in breaking, looks like a pump stip out:doh:.
Cheers
Baz
 
Pump on my disco is leaking lots of oil too and there is no vacuum when driving short distances, so the pedal is solid and need to ensure I leave enough gap to stop!

Question is, does the oil leak make the pump loose vacuum, or is there something else wrong here as well?

Any feedback would be greatly excepted, I am trying to avoiding spending money buying another due to hard times.
 
discofan said:
Pump on my disco is leaking lots of oil too and there is no vacuum when driving short distances, so the pedal is solid and need to ensure I leave enough gap to stop!

Question is, does the oil leak make the pump loose vacuum, or is there something else wrong here as well?

Any feedback would be greatly excepted, I am trying to avoiding spending money buying another due to hard times.
Click to expand...

Yeah - we can simpathise with the hard times....... But its yo BRAKES ffs!
 
I didn't mean I don't want to fix the brakes or the pump, I just want to figure out whether the pump needs to be replaced or I can fix it as suggested in the thread and if the other guys had the same loss of vacuum. Right now the car is parked up and not being used, I am on two wheeled pedal powered vehicle:)
 
Sean said:
Vacuum Pump Oil Leak - LR4x4 - The Land Rover Forum
Click to expand...

Sean, thanks for the link.

I ended up getting a pump off the Ebay for 99pence!! postage cost me £5.90!

I didn't worry setting the engine to tdc, I just unbolted the faulty one after taking off the engine breather pipe which was in the way.
Fortunately the highest point of the cam lob was facing away, so caught the bolts on with the good pump in place and tightened it all up.
Took approx 40mins because it was it was bit difficult to work due to lack of clearance and also making sure I was putting back everything correctly.

I might fix the old pump and either ebay it or keep it incase I need it again.

My next task is to fix the door locks, the passenger door won't open from outside, feels like the latch is slipping.

Many thanks for all the advice from everyone.
 
Just did this job... 1 hour to take off repair and put back ... All is good so cheers for the info... Do not be afraid to tackle this it's easy and cheap
 
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