Engine bolt torque settings

[S2central.net]

Quick & Dirty from manual in no particular order - for Graham & others...

TIMING BELT

Crankshaft harmonic damper = 450Nm or 200Nm plus 180 degrees
Do NOT use transmission to lock engine - proper tool required

Coolant pump and idle bolts = 20Nm

Camshaft sprocket bolt = 65Nm

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TURBO & Exhaust Manifold
Oil return pipe bolts = 10Nm

Coolant return pipe bolt = 25Nm
Adapter for above = 30Nm

Coolant feed pipe =30Nm
Adapter for above = 35Nm

Oil feed pipe bolts = 10Nm

Turbo to downpipe = 40Nm

Wastegate to downpipe = 25Nm

Banjo bolt to WG = 25Nm

Wastegate to manifold = 25Nm

Turbo to manifold = 60Nm

Manifold to head = 25Nm

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CYLINDER HEAD

Camshaft bearing cap nuts = 15Nm
After installing camshafts or hydraulic tappets you MUST wait 30 mins before starting engine. Turn crankshaft by hand thru two full rotations to ensure there is no piston contact with valves.

Inlet manifold to head = 20Nm

Camshaft cover bolts = 10Nm, tightened diagonally

Exhaust manifold to head = 25Nm

Coil pack to cam cover = 10Nm

Cam cover bolts = 10Nm

Water rail bolts = 10Nm

Cylinder head bolts MUST be of same spec (eg 10.9). Tightening sequence is a diagonal spiral sequence starting from the center of the head in three stages.

Stage 1 = 40Nm
Stage 2 = 60Nm
Stage 3 = 180 degrees

All done cold.

[Doug_RS2]

WRONG - edit your post paul - Do NOT use 20Nm on the tensioner bolts - these are only M6 and should be 10Nm - if you use 20Nm you WILL strip the threads. There is a disclaimer at the beginning of the engine manual saying what all the torques should be and stating the only exceptions.

Also - Do NOT use the camshaft pulley to lock the shaft when tightening the camshaft pulley bolt to 65Nm - you will break the woodruff key. Lock a lob of the cams with a huge adjustable wrench.

[S2central.net]

I just double checked the manual and it clearly states 20Nm for the coolant pump and idle pulley bolts.

Also, ones I didn't list - the little bolts holding the vibration damper to pulley are 20Nm plus 90 degrees in the latest manual.

[S2central.net]

Oh actually there is a proper camshaft locking tool listed - 3036.

Good point Doug

[Doug_RS2]

Maybe I am getting confused - the 3 M6 bolts that hold the tensioner to the block are only 10Nm - are these what you are saying are 20Nm plus 90degrees?

[S2central.net]

I'm not talking about them... i'm on about the four allen headed chaps that hold the damper to the crank pulley.

Paul

[Doug_RS2]

Ok what does your manual say the 3 M6 bolts that hold the belt tensioner onto the block? Mine says 20Nm which is wrong for M6.

[Doug_RS2]

While I'm pointing out all my BTDTs with these - take the Cam Pulley off before trying to remove the camshaft - or you will end up breaking the Cam position sensor - not cheap

I think there are 2 holes in the EM that are smaller than the others - these are to align it properly - make sure the studs have not been previously driven in too much - even with new studs the fatter centre section might go too far into the head, so the manifold doesn't align properly(small hoels around fat section of stud). I loctited the studs and didn't tighten them into the head too much - not sure what the proper procedure was for them?