2.2E engine won't turn on assembly

[RobFrost]

I'm pretty sure this was a working engine before it originally seized.

Detective work pointed to its original car being in a smash, resulting in the engine running dry of oil. A couple of piston rings were smeared up the sides of their pistons. It needed a new pil pump but all else seems good. None of the con rods are bent.

I am now reassembling the engine with new bearings, 964 oil pump, new pistons and cylinders.

The crank measures all standard and I believe I saw the letters "std." on the bearings. The intermediate shaft turns in situ with the oil pump attached, and the crank beds in and turns in situ., with the case in halves.

On closing the engine halves, it seems pretty tight as the flanges come within 5mm of each other, and once they're pulled fully together there seems to be no way to turn the engine. I put the pulley bolt on the end and tried to turn it with a wrench, but it's stuck.

The con rods aren't butting up against anything and the chains aren't caught.

I tested the crank turns in the old bearings some time ago and I found it tight, but provided i gave it a bit of a turn before bolting the halves together, to get everything to bed in perfectly straight, it turned fine.

How much torque is normally required to turn the engine?

I haven't pulled everything apart again yet, but I'm wondering if maybe the bearings are for an undersize crank. The only other theory I have is insufficient backlash on the ims drive gear. But I don't think either of those is likely, so I'm all out of ideas. Any suggestions?



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[john walker's workshop]

With a mag case, that usually means that the mainline is not true. Probably needs a line hone or an over bore, worst case with oversize OD bearings.