Removing
Engines 1.7 l SOHC
1. Remove the rear timing belt cover (see Removing and installing timing cover).
2. Remove the casting section of the oil pan (see Removal and installation of the oil pan).
3. Remove tensioner assembly and intermediate roller (see Removal and installation of timing chain tensioners (engines 2.0 l).
4. On models with a manual transmission, ask an assistant to block the crankshaft from turning, turn on the highest gear and depress the foot brake pedal all the way. On models with AT, unscrew one of the torque converter mounting bolts and tighten the latter to the transmission case using a steel bar and suitable bolts with washers (see chapter automatic transmission). If the engine is removed from the vehicle, the flywheel/drive plate must be blocked (see Removal, condition check and installation of a flywheel / drive disk). Turn out a fixing bolt and remove a cogwheel.
5. Disconnect the oil pipe from the oil filter housing and move the pipes along with the bracket to the side.
6. Disconnect the electrical wiring from the oil pressure sensor.
7. Turn out six fixing bolts and remove the oil pump from directing plugs.
8. Using a screwdriver, remove the stuffing box from the pump housing and discard it - during assembly, the stuffing box must be replaced without fail.
Engines 1.7 L DOHC
The oil pressure reducing valve is screwed into the cylinder block and cannot be removed without first dismantling the injection pump.
1. Remove the timing belt (see Removing and installing timing belt).
2. Remove the oil pump and crankshaft gears (see Removal and installation of the belt tensioner and timing gears (engines 1.7 l).
3. Remove the cast section of the oil pan (see Removal and installation of the oil pan). Remove the mounting bolts, slide the oil pump cover to the crankshaft trunnion, taking precautions not to drop the guide bushings. Remove the o-ring fitted around the oil pump housing and discard it - the ring must be replaced during assembly without fail.
4. Mark the position of the outer rotor of the pump with a marker - when assembling, the components must be installed strictly in the same way.
5. Remove the inner and outer rotors from the cylinder block.
6. If necessary, remove the injection pump (see chapter Power and exhaust systems) and unscrew the pressure reducing valve from the rear of the cylinder block. The valve is located to the right of the lower injection pump mounting bracket. Remove the sealing ring.
Engines 2.0 l
The oil pump is built into the timing cover, refer to the manual for removal and installation procedures. Removing and installing timing cover.
The oil pump pressure relief valve can be removed without removing the timing cover. To dismantle the valve, it is enough to remove the oil pan.
Examination
Engines 1.7 l SOHC
1. With the pump removed from the motor, remove the Phillips screws and remove the pump inner cover.
2. Check the gaps between the teeth of the outer and inner rotors, as well as between the outer rotor and the pump casing (outer rotor radial clearance).
3. Using a steel ruler and a blade-type feeler gauge, measure the axial clearance (backlash) rotors.
4. If the measurement results are outside the allowable ranges (see Specifications), replace the relevant components. Note that the outer rotor has a landing mark on the surface.
5. The relief valve can be removed from the pump body to clean and check the condition of the components.
And — the Piston of the reducing valve
B - Pressure reducing valve assembly spring
C - Thermostatic valve
D - plug
6. The emergency oil pressure switch is screwed into the back of the pump. Defective sensor must be replaced (see chapter Engine electrical equipment).
7. The oil cooler thermostatic valve/filter bypass valve is screwed into the oil filter housing.
Engines 1.7 L DOHC
1. Thoroughly clean all components and carefully examine the condition of the rotors, pump housing and cover. Replace defective components if damage or excessive wear is found. If the pump housing in the cylinder block is marked, contact an Opel authorized workshop for advice.
2. If the condition of the components is found satisfactory, install the rotors in the pump assembly housing. Using a blade-type feeler gauge, measure the gap between the outer rotor and the pump casing and the gap between the teeth of the inner and outer rotor. Measure the axial play of the rotors and check the flatness of the cover. If the measurement results are out of range (see Specifications), replace worn components.
3. If the pressure reducing valve was removed, check the freedom of movement of the piston and the smoothness of its return under the influence of the force developed by the spring. Replace the valve assembly if necessary.
Engines 2.0 l
1. Remove the mounting bolts and remove the pump cover from the inside of the chain cover.
2. Mark the mounting positions of both rotors with a marker.
3. Remove the rotors from the pump housing.
4. Remove the oil pressure control valve plug at the base of the pump housing.
5. Remove the spring, bushing and plunger - try to remember the installation position of the components. Remove the o-ring from the valve plug.
6. Unscrew the pressure relief valve plug from the back of the chain cover, the valve is mounted over the three bolts at the back of the cover.
7. Remove the spring and plunger from the cover - try to remember the installation position of the components. Remove the sealing ring from the plug.
8. Clean all components. Assess the wear on the rotors, pump housing and valve plugs. Replace defective components. If the pump rotors are already marked, replace the entire pump assembly.
9. If the condition of all components is not in doubt, reassemble them in reverse order, paying attention to the following points:
10. Follow the correct orientation of the rotors and plungers when installing them in the pump assembly;
11. Do not forget to replace the sealing rings of the plugs, make sure that the plugs are tightened with the required force;
12. Make sure that the pump cover bolts are also tightened to the required torque;
13. Finally, fill the oil pump with clean engine oil by turning the inner rotor by hand.
Installation
Engines 1.7 l SOHC
1. If removed, install a new pressure reducing valve O-ring and install the valve assembly into the cylinder block, tightening to specification.
2. With a cylindrical mandrel (interchangeable end head of the appropriate size, or a piece of pipe of a suitable diameter) or heads, put a new oil seal in the oil pump housing (sealing lips inside), - make sure that the mandrel rests only on the hard outer edge of the stuffing box. Make sure the seal is pressed flush with the body surface.
Lubricate the oil seal seals with clean engine oil before installation.
3. Lubricate the pump rotors with clean engine oil and seat them in the pump housing. Follow the correct alignment of the installation marks applied during the dismantling process. The marking must face the inside of the engine.
4. Apply a bead of suitable sealant to the inside mating surface of the pump housing inner cover and install it on the housing.
5. Screw in the cover fixing screws and tighten them to the required torque.
6. Thoroughly wipe the mating surfaces of the pump housing and block. Check that the pump guide bushings are in place. Remove all traces of sealant from the threaded portion of the pump mounting bolts.
7. Replace the gasket and install the pump on the cylinder block, being careful not to damage the seal lips on the crankshaft. Ensure that the cutouts in the inner rotor mesh properly with the corresponding lugs on the crankshaft stub. Tighten the fixing bolts to the required torque.
8. Further installation is carried out in the reverse order to the dismantling of the components. Pay attention to the following points:
9. Tighten all fasteners to the required torque;
10. When installing the oil cooler oil pipe, be sure to replace the sealing elements;
11. Check engine oil level, correct if necessary (see chapter Current service);
12. Do not forget to replace the crankshaft gear bolt.
Engines 1.7 L DOHC
1. If the pressure reducing valve was removed, replace the sealing ring and install the valve assembly in the cylinder block, tightening it to the required torque.
2. Lubricate the pump rotors with clean engine oil and install them into the pump housing using the pre-marked marks.
3. Before installation, carefully prying with a screwdriver, remove the oil pump and crankshaft oil seals. Install the new oil seals with the jaws inside the engine and press them flush with the body using a suitable cylindrical mandrel (see above Engines 1.7 l SOHC, item 2).
4. Make sure that the mating surfaces of the oil pump and cylinder block are absolutely clean and dry. Check that the guide bushings are in place. Remove all traces of sealant from the threaded parts of the pump mounting bolts.
5. Install a new seal in the groove around the pump body in the bonnet and apply a coat of suitable sealant to the mating surface of the pump bonnet.
6. Carefully reinstall the pump cover - try not to damage the lips of the crankshaft and rotor shaft seals. Align the cover with the guide bushings and press it against the block, controlling the position of the glands.
7. Lubricate the threaded parts of the mounting bolts with a special sealant for fixing threaded connections. Screw in the bolts and tighten them to the required torque. Please note that the longest bolt must be screwed into the lower left hole in the cover.
8. Install the gears and timing belt (see Removal and installation of the belt tensioner and timing gears (engines 1.7 l).
9. Install the oil pan (see Removal and installation of the oil pan).
10. Finally, fill the engine with clean oil (see chapter Current service).
Engines 2.0 l
See Removal, service and installation of the oil pump.
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