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I don't have a manual yet, and have an engine to install in my car on Monday so would appreciate if someone could let me know what torque settings / methodology are to be used for the following:

Big end bearing caps
Main bearing caps
Clutch cover plate bolts
Flywheel bolts

Many thanks

There isn't any GTI specific stuff in the manual but the DOHC stuff is useful.

I'm not taking any responsibility for engine failure
Quote from Haynes
Big end caps: stage 1 - 30NM
stage 2 - angle tighten a further 90 degrees

Flywheel: stage 1 - 60NM
Stage 2 - angle tighten a further 90 degrees

Clutch cover to flywheel: 20NM

Haynes says 'all engines have an alloy block and the crankshafts must not be removed, or the block main bearings will distort. Even loosening the main bearing caps will have this effect. If crankshaft or main bearing wear is suspected, the crank and block must be renewed complete and there are no specification dimensions provided by the manufacturers.'

That's fantastic Stan, very much appreciated. The torque figures look sensible against the amount of effort I needed to remove them during the week.

I don't know what Haynes are on about with their warnings sometimes these days, almost all the engines I have worked on have an alloy block so it doesn't seem particularly special construction from my perpective, but then again I don't have experience with these engines. Given the warning then,I must have had my sensible head on because I removed and replaced them one at at time. Maybe this is also the reason why the usual sources don't have main bearings in stock.

I'll have another look around and see what values I can come up with for the main bearing caps, otherwise it looks like I'll be using my own skill & judgement

The best info I have found suggests the main bearing bolts should be set as follows:

Stage 1 32nm
Stage 2 65nm

That's what I am going to use in the morning, unless anyone knows better

http://workshop-manuals.com/volkswagen/ ... ng_engine/

This may help - albeit I seem to have linked to the diesel page, that's an online copy of the vw workshop manual. Have a flick through. All the torque specs are in there

937carrera wrote:
I don't know what Haynes are on about with their warnings sometimes these days, almost all the engines I have worked on have an alloy block so it doesn't seem particularly special construction from my perpective, but then again I don't have experience with these engines

Yeah, I've completely stripped and rebuilt a few K series engines which use the soft sand cast alloy extensively throughout with no problems. Glad to hear you're getting somewhere