Author Topic: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)  (Read 8024 times)

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Offline Bad Kid

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Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« on: January 25, 2007, 13:18:37 PM »
Here is a photo guide for freeing a stuck pressure relief valve on the Calibra Turbo C20LET engine with PAS and aircon. I hope this helps some of you who get problems.

This guide is largely the same for those Calibra's without aircon, and the C20XE variants

Attention newbies! Do not PM me asking for help, I'm sick of it! Post a question in the forums!

Disconnect the air intake hose for the turbo. Remove the air box if you have one.



Jack the car up, put on axle stands. Remove front drivers wheel.

That 24mm bolt (circled) is the bit you are after. Everything in front of it has to be moved.


Support the engine, and undo these x2 15mm bolts (circled) on the engine mount


Once that is off, undo the x3 15mm bolts that hold the mount to the PAS/aircon pumps


With the mount removed, you can slacken off the auxillary belt. Use a 15mm ring spanner on the tensioner (circled), and slip the belt off.


Next, work around the other side of the aircon pump. These x3 13mm bolts need to be removed


Pop the wiring plug out!


You should have these bolts from the aircon pump

Plus the two stubby 15mm ones for the mount

At this point I was able to remove the pump, through the O/S wheelarch. But I already had it de-gassed and the pipework union off. You may just have to move it aside

Either way, you'll be left with this

Remove the circled bolt, 15mm

The final two bolts are at the top of the whole PAS/aircon mounting shedaddle. They are also 15mm. Use a ratchet spanner if it helps


You may also have to now move the turbo oil feed. I am running a Garrett, so I simply cut the stock one out of the way as it was no longer needed.

Slide the aircon bracket forwards about an inch, and you can access the relief valve


You will want to drain your oil anyway. Do this now from the sump plug. Undo the 24mm bolt pictured, and be prepared for slight oil loss. The spring may shoot out, but it's not hardcore enough to take your eye out or anything lmao

Bolt/spring removed...


And rescued.


I couldn't get in for a proper picture, but here's a rough idea of what the bore/ stuck valve will look like


An ideal tool for removing the valve, is the spring off the slam panel. This is just right to hook inside the valve and pull it forwards. It took me all of 10 seconds to do, don't worry.


Give it all a clean, and perhaps some very fine wet and dry to remove any marks. Then reassemble, taking care to keep everything clean! I blasted it with WD40 to shift any grit.

Fingers crossed you'll now have oil pressure back :cool: :beer: :cat:
NURBURGRING CHALLENGE :-D

Calibra nut

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #1 on: January 25, 2007, 15:30:32 PM »
TOP MAN!!! A very good read and very detailed write up mate.
This will help loads of people out when they need to do it.

Good on you! +1 Karma for you.

Offline ClubCalibra

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #2 on: January 25, 2007, 21:51:03 PM »
Brilliant guide mate, moving to FAQs and rewarding credits!
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Offline carl

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #3 on: September 27, 2009, 10:29:40 AM »
damn, no bloody pictures....i wish people would keep the photos for the guides.
bodybuilding thread! the thread for winners!
http://www.clubcalibra.com/index.php?topic=34651.msg449718#msg449718
**Carl's calibra project**
http://www.clubcalibra.com/index.php?topic=34701.msg450951#msg450951
You argued with an idiot, I brought you down to my level and I beat you with experience.

Offline Bad Kid

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #4 on: September 27, 2009, 10:30:34 AM »
Sorry mate they were hosted on somebody else's photobucket. When they got moved over to mine the link has obviously broken
NURBURGRING CHALLENGE :-D

Offline carl

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #5 on: September 27, 2009, 10:40:53 AM »
also does the cambelt need to come off for this?
bodybuilding thread! the thread for winners!
http://www.clubcalibra.com/index.php?topic=34651.msg449718#msg449718
**Carl's calibra project**
http://www.clubcalibra.com/index.php?topic=34701.msg450951#msg450951
You argued with an idiot, I brought you down to my level and I beat you with experience.

Offline Bad Kid

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #6 on: September 27, 2009, 12:08:24 PM »
also does the cambelt need to come off for this?

Nope.

Literally just undo the big nut on the oil pump and use something to slide the valve free. Then just clean it up and make sure it doesn't stick again

Most of the stuff above is to do with getting round the aircon pump, you should have easy access to it if you dont have aircon! It should take u 10 mins!
NURBURGRING CHALLENGE :-D

Offline carl

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #7 on: September 27, 2009, 16:40:17 PM »
is it the bolt to the left of the oil filter? or is it on the front of the engine?

if it the one near the filter then i have f*cked the bolt, it was a 19mm so i stuck a 19mm socket on it (a fitted socket not a toothed socket) and the bolt must be made of alloy coz it just rounded off the metal was to soft, and i know it was the right 19mm socket!

never mine i am going to keep my eye out for a 8v engine...well unless i was atacking the wrong bolt.
bodybuilding thread! the thread for winners!
http://www.clubcalibra.com/index.php?topic=34651.msg449718#msg449718
**Carl's calibra project**
http://www.clubcalibra.com/index.php?topic=34701.msg450951#msg450951
You argued with an idiot, I brought you down to my level and I beat you with experience.

Offline c20t

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #8 on: April 09, 2010, 14:17:11 PM »
my valve is stuck inside, i cannot budge the thing, any ideas

Offline Bad Kid

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #9 on: April 09, 2010, 15:54:42 PM »
my valve is stuck inside, i cannot budge the thing, any ideas

Easy... go to the scrapyard and pop the bonnet on any Mk2/3/4 Astra, Cav/Calibra, Vec B, Tigra, Nova or Corsa and you'll see on the slam panel a pigtail type spring that tensions the bonnet release. Push/twist it out with a screwdriver.

This just so happens to be the perfect size to slide up inside the valve, hook onto the hole and pull it out. Sounds dodgy but trust me it's the perfect tool for the job
NURBURGRING CHALLENGE :-D

Offline c20t

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Re: Guide to Oil Pressure Relief Valve on Aircon (Cally Turbo)
« Reply #10 on: April 09, 2010, 16:49:27 PM »
ta sorted, once i got it out an cleaned it slid properly, hoping thats it fixed.