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 variantsAttention 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:
