1.9 DG Oil Pressure Switch Removal

[nathanv]

Evening all,

Our campervan sprung an oil leak before bank holiday weekend and after some investigation it was found to be the oil pressure switch under the water pump on the left-hand side of the crank case (1.9 DG).

I have removed the water pump pulley to help access, but I'm having some issues removing the duff switch because the 24mm socket is fouling on the engine mount so I can't get a grip of it. I'm unable to get the spanner in due to restrictions caused by the water pump, exhaust and other water pipes.

Wondering whether anyone has any hints or tips on extracting the switch? What tools did you use? Do I need to remove the rigid pipe from the water pump (connects to the right-hand cylinder head)? I ask this before I remove the pipe, lose the coolant and end bleeding the bleeding water system.

Thanks in advance!

[kevtherev]

because the 24mm socket is fouling on the engine mount

Is the socket to long or something?

[nathanv]

Hi Kev, it's the right length. I've even bent the contact on the switch, so I know there is enough internal clearance. There doesn't seem to be enough clearance to the engine mount.

[weimarbus]

The problem is usually between the sender and crankcase clearance ( the socket wall is too thick ) if you grind the outer diameter of the socket it should go on, the sender is unlikely to be very tight so there should not be a problem with the socket breaking. I have a spare socket for this very problem, hope that helps.

[nathanv]

The problem is usually between the sender and crankcase clearance ( the socket wall is too thick ) if you grind the outer diameter of the socket it should go on, the sender is unlikely to be very tight so there should not be a problem with the socket breaking. I have a spare socket for this very problem, hope that helps.

What diameter have you ground your socket down to? I'm think that I might buy a socket and get it turned down - if the van becomes a keeper I might need it again in the future. May be my own version of 'Love Film' with 'Love Sockets'?!

[nathanv]

Finally removed the oil pressure switch tonight!

Purchased a 16" breaker bar, due to the space constraints and the requirement to apply some direct pressure on the 24mm socket. The switch contact had been bent back so the standard socket could be used.



Used the awning mallet to gain some leverage...



Then hey presto! There was just enough contact with the switch to break the seal and extract by hand! Plan B would have been the reduced diameter socket!

So the new one is now installed, and it's back to the camper electrics again!