Fitting flywheel and clutch

I decided to replace the whole clutch assembly  because the old clutch disc and pressure plate were totally gone.

The old and new clutch disc. See the words "gearbox side" on the new one

Old and new Sachs pressure plate, see the worn out "fingers" on the old one

New Sachs clutch assembly, incl. new thrust bearing and spline lube

First I had to take the engine off the engine stand. I used the engine crane, strapped the engine and stand with 3 ratchet tie downs to it and then removed the stand.

After balancing the engine I took the flywheel and bolted it on the crankshaft. The easiest way to do this is to keep a couple of mm distance between the crankshaft and the flywheel. This will make it easier to put in the bolts. Then I tightened the bolts to a torque of 54 Nm.To stop the flywheel from turning I used a bolt and and a big screwdriver as a wedge.

Tightening the flywheel bolts

Now it was time for the pressure plate and clutch disc. First I took the spline lube that came with the clutch kit and applied some of it to the centre hole of the clutch disc. When you fit the clutch disc make sure you do it right, the Sachs set I had made it easy because it was written on both sides of the disc. Before fitting the clutch assembly don't forget to degrease the flywheel, clutch disc and pressure plate.
When the pressure plate and clutch disc were lightly bolted to the flywheel you have to line up the clutch disc with the pilot bearing in the crankshaft. The easiest way to do this is using a spare gearbox shaft but because I didn't have one I used the whole gearbox to line up.

Lining up the clutch disc and pilot bearing with the gearbox

Lining up the clutch disc and pilot bearing - Close up

When the shaft is in the pilotbearing and clutch disc they are automatically lined up. According to the Haynes manual you have to tighten the bolts securely..... What's securely ? I found a nice table with standard torque settings which you can use when no torque setting is given in the manual. 

table with standard torque settings
1Ft lb = 1.356 Nm = 0.1883 kg fm = 12 lb in

I used a torque of 24 Nm to secure the pressure plate -flywheel bolts. When the bolts were secured I took off the gearbox. 

Hard to catch on a pic but the clutch disc and pilot bearing are lined up nicely

Fitting new freeze plugs and pilot bearing crankshaft

When the engine took a chemical bath all the old freeze plugs were damaged. Fitting new freeze plugs is a simple matter when the engine is out of the car. That's what I thought...

Here is how I did it:
- clean the plugs and plug holes with alcohol or some solvent
- apply some liquid gasket on the edge of the plugs
- put the plug in the hole, flush with the engine
- take a socket just a bit smaller then the plug and put it with the solid side on top of the plug
- hit it one or two times with a heavy hammer to put the plug in the correct position
- take a ball-pein hammer and put it with the ball on the plug
- hit it one or two times with a heavy hammer
- apply liquid gasket on the edge of the plugs

Freeze plugs Volvo 122S B20B

Liquid gasket - Permatex Gasket Sealant 2 - on the freeze plugs

Left plug ready to hit, right plug already in

Freeze plugs fitted in the Volvo B20B engine block

Grinding the el cheapo ball-pein hammer

When I hit the plugs with the ball-pein hammer it seemed that the ball was too pointy, which resulted in not so nice dents in the plugs. I took the el cheapo ball hammer put it on the bench and made it nice round with the grinder. Then the plugs were hit again. Next time I'll use a bigger and better quality ball-pein hammer...

Freeze plugs hammered in the Volvo B20B engine block 

Freeze plugs fitted in the Volvo B20B engine block

I also put in the plug at the rear end of the camshaft. It's a good idea to do this after you place the camshaft so you don't push it out accidently.

Camshaft plug at rear of engine Volvo 122S B20B

Fingers crossed I hit them hard enough and they won't leak or fall out. Especially the camshaft plug which is unreachable when the engine is back in the bay.

While the engine was still off the engine stand I also fitted the new pilot bearing in the crankshaft. With a 1 inch socket it was tapped in place.

New crankshaft pilot bearing, cover plate and spring Volvo 122S B20B

Volvo B20B crankshaft ready for the new pilot bearing

Pilot bearing in place

Done