Day Off... and a little progress

Spent the morning buying beer for Christmas. That left me with the afternoon to put my AFN together.
Easing into it, I was tired of oil dripping from the Sharan turbo oil return point in the sump, so fitted a Block Bung. As the oil will return to standard T3 oil return point in the sump, this is no longer needed.

Next I have the issue of the clutch and flywheel to sort. I'm going for a Dual Mass Flywheel rather than going for the standard JX flywheel and clutch setup. Simply because I dont believe the JX setup will handle the power and torque of the AFN.
This means changing the input shaft in the gearbox to one specifically made for the TDI but it also introduces another complication... that of the TDC (Top Dead Centre) marking...

Because the DMF is designed to go in a different vehicle the TDC marks necessary to set the timing are in a diffent place to the T3 location. To get around this Ive fitted the standard JX flywheel, fitted the timing belt using the original timing marks. Used a tool which bolts to the engine to bell housing bolt holes to take a reference point from the original marks on the JX flywheel... then fitted the DMF and transferred the mark.
A bit of a faff, and whilst I could have not worried about the mark this means that the next time I do the timing belt I wont have the hassle of finding TDC. I can just line the marks up...

Original timing mark on the JX Clutch

New marking in the DMF

Before torquing the flywheel bolts down, ive fitted a Spigot Shaft Bearing.
This supports the end of the input shaft on the T3. The Sharan doesnt have one, so theres nothing to remove. It goes in the end of the crank before fitting the Flywheel.

I also fitted the Flywheel Cover Plates or "Shit Plates" as theyre known. These are necessary because the Diesel bell housing isnt the same shape as the Diesel engine... so it covers the gaps.
You can see this in the next photo... once the Sump is fitted there is another piece that covers the bottom of the bell housing to stop any crud or small mammals getting in.

Next up, the fit of the TDI Input Shaft is checked. Here its located into the splines on the Friction Plate and supported by the spigot shaft bearing... The shaft will be fitted to my existing gearbox once Ive removed the AAZ engine thats in there. I'll also need to clearance the bell housing very slightly for the slightly larger DMF:

Ive also modified the power steering bracket to clear the connection of the hose to the water pump.
Ive used the original Alternator bracket from the Sharan, new waterpump obviously as it would be crazy to refit the engine with the original Sharan pump for the sake of a few quid! Also new thermostat and a thermostat cover that will line the connection up with the T3 hoses.
This meant removing the rear support on the power steering pump bracket and refitting the threaded boss into the end of the alternator bracket. You can see where Ive cut it off below:

Lastly for today, ive fitted the inlet manifold. This is an original JX inlet manifold which has been welded and match ported to the AFN cylinder head. Tidier and more "standard" looking that using the AFN manifold and means my exsisting Charge Cooler setup will connect up to it and make fitting the AFN simpler. It also means I can use the standard Air Box and add provision for the MAF (Mass Air Flow meter)

Oh... refitted the rocker cover and timing belt covers and measured up for the auxilliary belt.
Then went home and drank some Bradfields Belgian Blue Beer... purchased this morning...
No, I dont know why its red???