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Hello all my son has a 145 1.6 t.spark and just recently big ends went bought new set and fitted but still knocking so bought new crank shaft bearings but each time we torque 96nm
crank wont turn any ideas please:
 

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Did you oil the shells?
 

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Slacken big end bolts one at a time and check for rotation. If all big ends are tight, crank needs measurement to see if its already been reground. Was crank reground anyway or did you just replace the shells? If one big end only is tight and the pistons and small ends are free then examine very carefully the crank journals for any damage or white metal picked up on them. If there are any marks on the big end journals then the crank MUST be reground and oversize shells fitted. Otherwise failure will quickly occur.
 

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BY THE WAY!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Correct torque for the big end bolts is 25 nm + 50 degrees of angular rotation. If you have tightened the bolts to over 90 newton metres then replace the bolts as they will have been hugely over tightened! 96 nm is for the main bearing caps only.
 
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