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This is a follow-on project done one year after the original 2.2L
stroker motor was built. I had wanted an aluminum flywheel for the
original build but ran out of money. I was given a used, lightened
steel flywheel from a friend and ran that for a year. In January
of 2010 I ordered my aluminum flywheel.
Parts Used
- JBR 228mm
aluminum flywheel (JBR part# 520-100-228)
- 2002tii clutch disk (21 21 1 223 174)
- E30 M3 pressure plate (21 21 2 226 505)
- 323i throw out bearing (21 51 1 204 525)
Was that a 215mm or 228mm I wanted?
| I started the project planning on simply installing a 215mm
aluminum flywheel with my still new (less than 6K miles) clutch
that I originally installed on the 2.2L motor. I ordered
the flywheel and I was very excited when it arrived. I
placed my shiny new flywheel on the kitchen table (my wife was
out of the house), and dropped my clutch on it to see how it
looked. Something was wrong, the pressure plate was too
small! After about 30 seconds of thought I realized that I
had been given a 228mm M10 flywheel and not the 215mm that I
ordered. Upon closer inspection, I realized that JB Racing
had miss-labeled the box. The box says 215mm but the
contents was a 228mm. |
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The box says 215mm but the flywheel was a 228mm. |
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So, instead of getting upset I decided to interpret this as a sign than
I was always supposed to upgrade to the 228mm and proceeded to research
the best combination of clutch components to use with my unexpectedly
large flywheel. I found a few sources on the 2002 forums that had
very good luck with a combination of the stock 2002tii clutch disk, the
pressure plate from an E30 M3 for more holding force, and the 323i throw
out bearing to match it up to the 5-speed transmission. This
appears to be the combination of parts that Ireland Engineering sells in
their high performance 228mm clutch kit. The claim is that this
combination of parts is good up to about 250 HP. I never expect my
engine to go over 170HP so I have no worries.
Clutch Components
There has been a lot of discussion on if the 323i throw out bearing
which is about 5mm longer than the 320i bearing is really necessary.
The height of the stock E21 pressure plate and the E30 M3 plate is the
same when measured from the bottom of the pressure plate to the top-most
point on the clutch fingers. The one thing I noticed is that the
228mm pressure plate's fingers are longer from their pivot point to the
tip. This makes sense since the pressure plate is larger in
diameter. I suspect that the ends of the fingers, that contact the
bearing, might be pushed closer to the flywheel when the clutch is
bolted up.
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323i throw out bearing. Bearing is about 5mm longer than a 320i bearing. |
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215mm E21 and 228mm E30 M3 pressure plates. |
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Bottom sides of the two pressure plates. |
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2002Tii OEM clutch disk |
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Flywheel
| A couple pictures of the aluminum flywheel. I added
timing marks to the edge of the flywheel since I prefer to check
timing this way instead of with the crank pulley. The JBR
flywheel does not have a TDC mark so measured the location of
the TDC mark on my OEM flywheel and attempted to transfer the
measurements over to the new flywheel. I'll see how well I
did with this in a few weeks. For the timing marks I first
painted the edge white and then used a black sharpie marker.
The dots represent 5 degrees of advance each and are visible
through the hole in the top of the bell housing with a timing
light. |
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Installation
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Installation was no different that the stock flywheel and
clutch. The JBR flywheel comes with new, reusable flywheel
bolts and pressure plate mounting bolts. There is also a
steel ring that is placed on the face of the flywheel under the
mounting bolts to keep the bolts from deforming the aluminum. |
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