Oil Pump Drive Shaft - Is This Right?

In my quest to solve the ticking problem in my 200TDI with only 5,700 miles, I pulled the oil sump (except for the 2 bolts that decided to leave half of themselves in the block), pulled the oil pump and its drive shaft. Started to notice some metal bits in sump and other places, NOT GOOD!

So on the drive shaft, the part that meets with the cam gear, one of the splines is missing, but I don't know if it's supposed to be like that for alignment or not. Is this the source of the metal bits in the engine and am I f*ed?

I've built a couple of these but for the life of me, I can't remember that part.
I think I've a spare in the garage, I'll go have a look in a bit for you.

Looks normal and machined in to me.

Yes, it's normal.

Great, thank you all. Now to find what is broken and the source of the metal bits/chunks in the engine.

Likely find the splined shaft is the same for the older engines with the vertical cav pump as they have a master spline iIRC.

Got any pics of the metal fragments?

lynall said:

Likely find the splined shaft is the same for the older engines with the vertical cav pump as they have a master spline iIRC.

Got any pics of the metal fragments?

Click to expand...

I think you are right about the oil pump drive shaft.

I discovered last night that the metal chunks (pic below) came from a fragmented skew gear on the camshaft (video below). Looks like I'm in for a big job!

Wish I knew what caused this. Any ideas?

Maybe just oil smear but that right hand cam lobe looks kind of worn? was it a new cam?
The good news it its head off time and you will have to remove the tappets so can check them as well.
You will like it as its a great and easy engine to work on.

Stephen Lyttleton said:

I think you are right about the oil pump drive shaft.

I discovered last night that the metal chunks (pic below) came from a fragmented skew gear on the camshaft (video below). Looks like I'm in for a big job!

Wish I knew what caused this. Any ideas?

Click to expand...

tightening down the vac pump if the wrong slot is located

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looks to be but its not too easy to say from vid

Was there a conclusion on this? Has your vac pump ever been removed?
My manual says that when you replace the vac pump the oil pump driving shaft needs to go back in the same so that the mesh of the gear with that of the camshaft is "preserved". Has anyone got a handle on this?
If the drive and camshaft gears have the same number of teeth then they will always mesh with the same gear each revolution. So I guess they kind of mould to each other as they wear. So I suppose that if they go back together with a different tooth in mesh then the unmatched wear profiles could cause some sort of loading or resistance that causes something to snap.

My understanding on this is that if you take out the vacuum pump with the gear, and put the same one back in, then the teeth should be aligned to the same ones on the cam that they were with previously. This is because as they wear together over time, the wear is uneven and you want to match that when reinstalling the same parts. However, when putting in a new gear, then by definition you can’t put it back to the same teeth since the new one was never in before.

I may have bungled mine by not putting it back in right, based on the Big Bang upon restart. But that led me to find all kinds of other problems with the cam.

Just my amateur 2 cents, it’s worth what you paid.

moth said:

Was there a conclusion on this? Has your vac pump ever been removed?
My manual says that when you replace the vac pump the oil pump driving shaft needs to go back in the same so that the mesh of the gear with that of the camshaft is "preserved". Has anyone got a handle on this?
If the drive and camshaft gears have the same number of teeth then they will always mesh with the same gear each revolution. So I guess they kind of mould to each other as they wear. So I suppose that if they go back together with a different tooth in mesh then the unmatched wear profiles could cause some sort of loading or resistance that causes something to snap.

Click to expand...

gear teeth are usually matched odd and even numbers,so you dont get teeth running into each other as such, ie same teeth engaging every rotation, on a 200 tdi no alignment is necessary as oil pump and vac pump arent timed from cam only driven,the instruction comes from the time injection pumps were run from skew gear, vac pump drive shaft has 2 slots one deep one shallow aligning the wrong slot will put a great load on skew gear