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I would remove the sump and have a really good look at the pickup pipe. Only a small crack can stop it sucking. Check the mounting flange connection. Take it out if possible for a good look.
I have to admire your methodical approach. Many would have given up by now. Keep at it and do not burn the car to the ground. Old cars are sent to try us.
You are almost there.
If it looks pristine, then the only possibility is the pressure relief valve.When you pulled it out it should have had a spring inside a hollow plunger with the spring nearest the cap AFAIR. Hope you refitted the same way and checked that the plunger freely travelled to the end of its travel. Maybe worth measuring the depth of the cylinder vs the depth it went in.
Regards Philip A
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Thanks Phil,
I've removed the sump and the pick up looks good. I've cleaned the face that goes to the block on a wet stone block to make sure it's very very flat.
The pressure relief valve was fully pressed as far as the spring would push it. The spring appeared strong and straight and it went back it again. There was no gum and no nicks that might cause it to stick. In fact I've been very impressed by how clean the engine is at the bottom end.
I'll carry out a few more inspections, and then remove the pump again.
I know it's character building, but in the back ground I've got the salary packaging people at work crunching numbers on a D2. Worst case scenario, I can't fix this and I replace a 22 year old V8 with a 7 year old Diesel 7 seater.
I hope I can fix it though.
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sorted
The pump and the sump came off again and were put back on again.
I expected it to run okay, but the problem persisted. I removed the oil pressure sender and nothing squirted out.
I left it for a day, to contemplate and consult.
Then I pulled the nut off the pressure release valve, removed the spring, and with a screw driver pushed the plunger in an extra millimeter. That did it! Now I have oil pressure. A quick check by backing off the filter resulted in a litre of oil on my driveway! Now to double check the oil level and hope that the rattles were not terminal, but can be soothed with some oil.
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Now everyone reading this thread will understand what "relief valve is STUCK" means. It takes a firm hand to shift it when the spring won't. Been there, done that!
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Congratulations. Tiny simple things can get you.
You should now either get a new plunger and spring and dress the cylinder lightly with a small hone or wrap some 600 /800 wet and dry around a dowel as a flapper . ie cut a slot through the dowel and insert the wet and dry and wrap it around .
If you do not replace the plunger , you should also dress it with fine wet and dry. I would concentrate on the shoulders of the plunger and round them a little . Then polish the plunger with auto cutter to get as mirror smooth a surface as possible.
I think any swarf will be caught by the filter or you could pressure it up with the filter off for a second.
Regards Philip A
