Club 80-90 Forums

Hi

We've just put the cylinder head on, but a bit gobsmacked. The 90 degree stages took some serious umph. Is this typical? We were left thinking that the next two 90 turns are going to be bloody hard work. Also a bit baffled by the timing as I couldn't see any reference on previous posts,,,How did you get TDC, given the T25 bell housing is set at an angle to an SB timing mark...any advice would be very welcome, as this would be a good time to find out we've screwed up. Cheers

ok,did you use the "jx" flywheel n clutch cover plate? if so the timing mark will be ok!
More info;
is the "sb" in the van?
what "jx" bits are you using?
Kr.

Hi Dave

No, we didn't use the JX flywheel. I screwed up when I gave the SB to the engineering firm. I sent it with the SB flywheel and they refaced it then refitted it. We were going to swap for the JX flywheel, but couldn't find any TDC marks on it anywhere??? I'm not sure it was a standard flywheel as there was no sign of the 'arrows'. We checked the position of the opening on Golfs, Passats etc, aligned the piston crowns with the camshaft and sort of hoped for the best, but the worries about TDC were replaced by our bafflement at the grunt required to complete the final 90 degree turn. We checked the threads and the head bolts seemed to tighten up by hand freely enough...We started to question the torque wrench, but it's a decent make and had never given any trouble before. Thanks for your reply

The "v" timing mark is on the clutch cover plate!
I use a scaffold tube to do the 90deg on the head bolts.

Doh!

Cheers Dave, we thought it was a stretch to see the rim of the flywheel!...Big relief to hear you resorted to scaffold bar as we were seriously scared we'd overcooked it. Very grateful for the help

Did you fit a spigot bearing in the end of the crank?

I've got one, just hadn't got around to fitting the clutch and didn't look closely at the cover plate, just kept on rubbing down the rim of flywheel off the JX trying to find marks that aren't there! The E D I T on my last reply appears to have deleted the use of the word 'Doh', which doesn't seem uncalled for under the circumstances...I'm using the JX diesel pump as the SB pump turned out to be shot. I'm also using the turbocharger and manifold set up. I also managed to forget to ask the engineers to fit a blank core plug as you have all recommended so I'll have to get that replaced as well, so much for attention to detail! More "cock" ups tomorrow?

Cool,i also couldn't see how you could use the "sb" flywheel!
I blocked the water outlet from the core plug!

Thanks Dave, your advice is much appreciated.

Hi

I'm unsure whether I can use the SB engine flywheel with the JX gearbox and starter. Although the diameter appears the same, the SB flywheel is deeper by some measure. Would this cause problems with the starter, input shaft etc? Cheers again for any advice from those of you who have done this swap.

Hi again

Apologies for the frequent posts...Squeaky b*m time

I'm still puzzled about using the SB engine's flywheel. Dave Friday said he couldn't see how it could be used but the posts from previous installers did not mention swapping the JX flywheel. Anyone out there use the SB flywheel? I'm just a bit worried about the difference between them...The SB flywheel is a far more substantial thing, would using the lighter JX flywheel affect the engine? I don't want to fit them and then find out it's all got to come out again! Also, Brickwerx and JK list 'special' washers for the exhaust manifold, but the local engineering firm think it will be fine with a light skim and using copper nuts with a 'waist'. They think this should be enough and I should avoid using any washers at all...Any thoughts? Finally, the turbo to exhaust studs look pretty ropey, so corroded at the base that they look like they'll shear if I try to extract them...Anyone drilled these out successfully? Cheers

I cant say any more about the "sb" flywheel as I threw it away!!! The thick washers are there so the exhaust manifold can expand n contract [ lengthways]
Keep asking questions...we've all been through it!!

Cheers Dave
Just a bit mystified about the big difference in two sort of similar engines...Due to the greater power output? i'll get the washers, no point screwing it up over eight washers eh? Thanks again

The " big difference " is due to more fuel ( on boost ) different injectors and the intercooler!