Torque Settings
The days of guesstimating tightening torques are well gone.
These torques are set by the manufacture for a very good reason. They have measured the tolerances and clearances of many components and these should be strictly adhered to.
Example of failures we have encountered.
The over tightening of the camshaft tensioner nut resulted in the tensioner position stud being stretched and eventually breaking. The result was very similar to a cambelt failure and many bent valves in the cylinder head. A very expensive and labour intensive job to rectify.
Another example was the over tightening of the camshaft caps. The engine was making a squeaking sound and was very difficult to determine where it was coming from. After a full strip down, we noticed one of the caps was heavily scored due to over tightening. This could only be resolved by fitting a new cylinder head which by luck for the customer we had to hand.
A customer came to us complaining of a vibration from the steering wheel. After a very quick investigation we found that both front wheels were loose. The car had tyres fitted by one of the very well known quick fit centres. Luckily enough after a quick tightening to the correct torque the vibration was gone and happy customer on her way with no charge.
Last but not least we had an engine that was making a woeful racket and giving a big vibration when revved. We were sure this was coming from the gearbox end so duly investigated. After removing the gearbox there was about 1 to 2 mm free play in the flywheel. A new clutch and flywheel had been fitted 2 weeks previously. We can only assume the flywheel have not been tightened to the correct torque causing this to happen. The result was a new crankshaft had to be fitted to the car as the vibration totally destroyed the threads for the flywheel bolts. So much for a cheap job.
As you can clearly see many catastrophic failures can occur by simply not adhering to the manufactures torque settings.
We have 4 digital torque wrenches in our garage and these are used on and every day basis. A 1/4” very low torques, a 3/8” for medium, a 1/2” for heavy and a 3/4” for heavy duty. These are properly maintained and calibrated on an annual basis.
Engine Torque Settings
1.6 Engine BFS and AYD Stage 1 Stage 2 Stage 3
Cylinder head bolts (new)
40Nm
90°
90°
Camhaft bearing cap nuts
20Nm
N/A
N/A
Camshaft sprocket bolt
100Nm
N/A
N/A
Rocker cover nuts
10Nm
N/A
N/A
Exhaust manifold nuts(new)
25Nm
N/A
N/A
Inlet manifold nuts
25Nm
N/A
N/A
Camshaft tensioner nut
20Nm
N/A
N/A
Big end bearing nuts (new bolts)
30Nm
90°
N/A
Main bearings
45Nm
N/A
N/A
Crankshaft sprocket bolt (new)
90Nm
90°
N/A
Pulley to crankshaft
20Nm
N/A
N/A
Flywheel bolts (new)
60Nm
90°
N/A
Spark plugs
25Nm
N/A
N/A
Water pump
15Nm
N/A
N/A
Drain plug (new washer)
30Nm
N/A
N/A
2.0 Engine AQY, AZJ,BER,BHP and BEV Stage 1 Stage 2 Stage 3
Cylinder head bolts (new)
40Nm
90°
90°
Camhaft bearing cap nuts
20Nm
N/A
N/A
Camshaft sprocket bolt
100Nm
N/A
N/A
Rocker cover nuts
10Nm
N/A
N/A
Exhaust manifold nuts(new)
25Nm
N/A
N/A
Inlet manifold nuts
25Nm
N/A
N/A
Camshaft tensioner nut
20Nm
N/A
N/A
Big end bearing nuts (new bolts)
30Nm
90°
N/A
Main bearings
45Nm
N/A
N/A
Crankshaft sprocket bolt (new)
90Nm
90°
N/A
Pulley to crankshaft
20Nm
N/A
N/A
Flywheel bolts (new)
60Nm
90°
N/A
Spark plugs
25Nm
N/A
N/A
Water pump
15Nm
N/A
N/A
Drain plug (new washer)
30Nm
N/A
N/A
1.4 Engine BCA Stage 1 Stage 2 Stage 3
Cylinder head bolts (new)
40Nm
90°
90°
Camhaft bearing cap nuts
20Nm
N/A
N/A
Camshaft sprocket bolt
100Nm
N/A
N/A
Rocker cover nuts
10Nm
N/A
N/A
Exhaust manifold nuts(new)
25Nm
N/A
N/A
Inlet manifold nuts
25Nm
N/A
N/A
Camshaft tensioner nut
20Nm
N/A
N/A
Big end bearing nuts (new bolts)
30Nm
90°
N/A
Main bearings
45Nm
N/A
N/A
Crankshaft sprocket bolt (new)
90Nm
90°
N/A
Pulley to crankshaft
20Nm
N/A
N/A
Flywheel bolts (new)
60Nm
90°
N/A
Spark plugs
25Nm
N/A
N/A
Water pump
15Nm
N/A
N/A
Drain plug (new washer)
30Nm
N/A
N/A
1.8 Turbo Engine AWU Stage 1 Stage 2 Stage 3
Cylinder head bolts (new)
40Nm
90°
90°
Camhaft bearing cap nuts
20Nm
N/A
N/A
Camshaft sprocket bolt
100Nm
N/A
N/A
Rocker cover nuts
10Nm
N/A
N/A
Exhaust manifold nuts(new)
25Nm
N/A
N/A
Inlet manifold nuts
25Nm
N/A
N/A
Camshaft tensioner nut
20Nm
N/A
N/A
Big end bearing nuts (new bolts)
30Nm
90°
N/A
Main bearings
45Nm
N/A
N/A
Crankshaft sprocket bolt (new)
90Nm
90°
N/A
Pulley to crankshaft
20Nm
N/A
N/A
Flywheel bolts (new)
60Nm
90°
N/A
Spark plugs
25Nm
N/A
N/A
Water pump
15Nm
N/A
N/A
Drain plug (new washer)
30Nm
N/A
N/A
1.9 Turbo Diesel Engine BEW Stage 1 Stage 2 Stage 3
Cylinder head bolts (new)
40Nm
90°
90°
Camhaft bearing cap nuts
20Nm
N/A
N/A
Camshaft sprocket bolt
100Nm
N/A
N/A
Rocker cover nuts
10Nm
N/A
N/A
Exhaust manifold nuts(new)
25Nm
N/A
N/A
Inlet manifold nuts
25Nm
N/A
N/A
Camshaft tensioner nut
20Nm
N/A
N/A
Big end bearing nuts (new bolts)
30Nm
90°
N/A
Main bearings
45Nm
N/A
N/A
Crankshaft sprocket bolt (new)
90Nm
90°
N/A
Pulley to crankshaft
20Nm
N/A
N/A
Flywheel bolts (new)
60Nm
90°
N/A
Spark plugs
25Nm
N/A
N/A
Water pump
15Nm
N/A
N/A
Drain plug (new washer)
30Nm
N/A
N/A
Wheels