Removal, maintenance and installation of the oil pump (Opel Corsa B)

Removal

The pressure reducing valve can be removed without prior dismantling of the pump assembly.

1. Remove the timing belt (see section Removal and installation the timing belt).

2. Remove the crankshaft and camshaft gears and the timing belt tensioner (see section Removal and installation timing gear wheels).

3. Unscrew the bolts securing the rear timing drive cover from the cylinder head and oil pump housing, remove the cover from the engine.

4. Remove the oil pan and oil pickup (see section Removal and installation the oil pan).

5. Disconnect the electrical wiring from the oil pressure sensor.

6. Unscrew the crankshaft position sensor mounting bolt and move the sensor away from the pan.

7. Unscrew the oil pump housing fastening bolts. Remove the pump housing from the crankshaft journal with extreme care - try not to let the guide bushings fall out. Remove the housing sealing gasket. The gasket can be thrown away - it must be replaced during assembly.

Service

1. Loosen the mounting screws and remove the rear cover of the pump.

Unscrewing the oil pump cover mounting screws



2. With a marker (under no circumstances use a center punch or a chisel!) mark the installation position of the internal and external gears of the pump - during assembly, the components must be installed in exactly the same way.



3. Remove the inner and outer gears from the pump assembly housing.

Removal the pump gears



4. Unscrew the plug of the pressure reducing valve from the assembly body, remove the spring and plunger from the seat - try to remember the installation position of the components. Remove the sealing washer from the plug.

Pressure Reducing Valve Components

The valve can be disassembled without prior removal of the pump.

5. Thoroughly clean all components and carefully inspect them for signs of excessive wear, chips, scoring and other mechanical damage. Replace any failed components. If defects are found in the gears or housing, the entire pump assembly must be replaced.



6. Assemble the pump in reverse order. Please note the following:

• Make sure both gears are installed correctly (see markings applied during dismantling);
• Don't forget to replace the copper sealing washer of the pressure reducing valve plug - tighten the plug itself to the required force;
• Before screwing in, clean the threaded portion of the fastening bolts and apply a layer of fresh sealant to it, make sure that all fasteners are tightened with the required force;
• Once assembly is complete, fill the pump with fresh engine oil by manually rotating its internal gear.

Installation

1. Before installing the pump, remove the crankshaft oil seal from its housing by carefully prying it off with a suitable slotted screwdriver. Insert the new oil seal with its sealing lips into the engine.

(Material provided by this website: Opelbook.ru)

2. Press the seal using a cylindrical mandrel flush with the pump body. Make sure that the mandrel rests only on the rigid outer edge of the seal.

Fitting the crankshaft oil seal into the oil pump housing

A suitable size socket head or a section of pipe of the appropriate diameter can be used as a mandrel. After installing the seal, lubricate its sealing lips with clean engine oil.

3. Make sure that the mating surfaces of the pump body and the block are absolutely clean and dry. Make sure that the guide bushings are in their proper places.

4. Install a new sealing gasket on the cylinder block.

5. Carefully install the pump in place - make sure that the internal gear is correctly engaged with the crankshaft chamfers. Extremely carefully seat the pump assembly on the guide bushings - try not to damage the seal lips.

When installing the pump assembly, ensure that the seal is not damaged by the protrusions (1) and chamfers (2) of the crankshaft journal



6. Screw in the pump body mounting bolts and tighten them to the required torque.

7. Connect the electrical wiring to the oil pressure sensor sensor. Install the crankshaft position sensor (CKP) in its place in the pump housing, screw in and tighten the mounting bolt to the required torque.

8. Install the oil pickup and oil pan (see section Removal and installation the oil pan).

9. Install the rear timing cover onto the engine, making sure that the mounting bolts are tightened to the required torque.

10. Install the timing belt sprockets and tensioner (see section Removal and installation timing gear wheels). Install the timing belt (see section Removal and installation the timing belt).

11. Finally, replace the oil filter (see Chapter Vehicle settings and routine maintenance).