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Old 13-02-2012   #1
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JTD Lightened Flywheel and clutch kit (350NM)

I found this gem on german ebay.

A single mass, lightened, straight swap flywheel and clutch kit. Rated at 350NM (the maximum limit of the gearbox on a JTD) 795 euro incl shipping.
And it arrived today.

This should be the solution to all your judder problems, and then some.
My punto has currently done 302.000 Km, and the 108 bhp remap makes my flywheel judder like crazy. Anyone with a remapped punto will tell you this.

I'm hoping to take it up to 135-140 BHP, I will update you once I get it fitted, just thought I would let all you other smokers know

ps, to anyone who have done a 140 bhp remap, is the gsr induction kit really needed?
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Current Car: 2000 Mark 2 Punto 80bhp 1.9JTD, 190k Miles
Modifications: 107 bhp rolling road remap at 140k miles, single mass lightened flywheel & 350Nm clutch kit, lowered 35mm, blanked EGR return at the exhaust manifold, diy 125 psi compressor horn.
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Old 14-02-2012   #2
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Re: JTD Lightened Flywheel and clutch kit (350NM)

The 110/115 engines can chip/remap to 130 and more if the turbo is tweaked and a custom map done. The 90 will go to 110 with a generic remap.
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Old 15-02-2012   #3
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Re: JTD Lightened Flywheel and clutch kit (350NM)

Oh, i totally forgot the sellers name:

cufaro-racing
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Current Car: 2000 Mark 2 Punto 80bhp 1.9JTD, 190k Miles
Modifications: 107 bhp rolling road remap at 140k miles, single mass lightened flywheel & 350Nm clutch kit, lowered 35mm, blanked EGR return at the exhaust manifold, diy 125 psi compressor horn.

Last edited by DanielR; 15-02-2012 at 17:11.
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Old 15-02-2012   #4
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Re: JTD Lightened Flywheel and clutch kit (350NM)

I'd suspect that this (at least, pre-lightening) may be a stock part off an Alfa parts shelf. Might be worth a bit of research on ePer.
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Old 01-02-2013   #5
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Hard to find time eh?

And so it begins. a year later. (shameless bumb)

The guide on this recommends dropping the engine, I say you can do without. ^^ (that's a no money back guarantee)

Heating the exhaust bolts.


Zip ties holding caliper and axle, less things to disconnect. (proper tools ahem), lost the "top" for unbolting the axle, worked around that.


Stuffing the turbo, this is for added speed.


Boop


Accidentally found the oil leak source, found out later the packing behind the flywheel is leaking. About to remove the clutch.


aaaand stuck.

Since the new flywheel is 20mm thinner, the original bolts are that much too long. Can't cut the bolts since they aren't threaded all they way, can't re-thread them since, A, they're hardened, B, where its not threaded, the shaft is 1mm thinner. It's Friday, and the lift has to be cleared Monday -_-

BTW, fiat spend allot of time and effort putting things in the way of every bolt.

Reading the above, I guess it won't be a great idea to remap the 80bhp to more than 110.
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Current Car: 2000 Mark 2 Punto 80bhp 1.9JTD, 190k Miles
Modifications: 107 bhp rolling road remap at 140k miles, single mass lightened flywheel & 350Nm clutch kit, lowered 35mm, blanked EGR return at the exhaust manifold, diy 125 psi compressor horn.
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Old 01-02-2013   #6
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Re: Hard to find time eh?

If you can find a FIAT/Alfa dealer open on Saturday morning (or a fastener dealer) you might get the right bolts. Just out of interest, any identification marks on the front face of the box?
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Old 01-02-2013   #7
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Re: Hard to find time eh?

I will promise to take a look tomorrow.
Unfortunately none of the dealers are open, but I can get a new gasket for the leak from generic outlets.

Also discovered this old picture, might suggest I threw away the bolts. (smaller box to the right)
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Current Car: 2000 Mark 2 Punto 80bhp 1.9JTD, 190k Miles
Modifications: 107 bhp rolling road remap at 140k miles, single mass lightened flywheel & 350Nm clutch kit, lowered 35mm, blanked EGR return at the exhaust manifold, diy 125 psi compressor horn.
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Old 02-02-2013   #8
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Re: JTD Lightened Flywheel and clutch kit (350NM)

Btw, which box? forgot to take a look today.

Found
this on ePer

Product code:
46415038

Does anyone know the specifications for this bolt? from what I (obviously mean my dear father) can gather its class 8 hardened steel, 12mm diameter with a fine grain thread of either 1.20 or 1.25mm.

No sure about the thread though.
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Current Car: 2000 Mark 2 Punto 80bhp 1.9JTD, 190k Miles
Modifications: 107 bhp rolling road remap at 140k miles, single mass lightened flywheel & 350Nm clutch kit, lowered 35mm, blanked EGR return at the exhaust manifold, diy 125 psi compressor horn.
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Old 02-02-2013   #9
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Re: JTD Lightened Flywheel and clutch kit (350NM)

Assuming that the other bolts fit in the hole (that is, that without the flywheel, they'll screw up (don't force them), it's most likely that what you want will just be an 8.8 high tensile bolt of the same thread. Can't help with the length, but 8.8 or better should be fine. Any old fastener stockist (but not a DIY store!) will have them for a few cents.
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Old 04-02-2013   #10
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Re: JTD Lightened Flywheel and clutch kit (350NM)

Thanks, found them at WŁerth, box of 10.
Class 12 high tensile, should do the trick aswell.
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Current Car: 2000 Mark 2 Punto 80bhp 1.9JTD, 190k Miles
Modifications: 107 bhp rolling road remap at 140k miles, single mass lightened flywheel & 350Nm clutch kit, lowered 35mm, blanked EGR return at the exhaust manifold, diy 125 psi compressor horn.

Last edited by DanielR; 04-02-2013 at 15:32.
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Old 06-02-2013   #11
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Re: JTD Lightened Flywheel and clutch kit (350NM)

The part number on the clutch casing was scratched off, but I think it says:

Luk 123 0192 10


Some more pictures



Running:


So it definately does not slip, theres more noise though. Lower rpm sounds rough on the engine in high gear. Revving is phenomenal! Idle sounds the same, which is good for a flywheel half the weight.

After replacing all this, it took us a further hour just to get the headlights working, since i had blown a bulb. After replacing that, the other one blew while testing -_-. Lots of contact cleaner and light fixture mingling later they worked. Btw, this would've been even harder with the standard light fixtures
The ground wire running from the chassis to the engine was almost completely "oxidated" or what you say, at the top, it snapped off while remounting it. The insulation had formed a little trough around the chassis connection to just sit and collect water. Fixed that, starting was a problem before, now it just springs to life, almost like a petrol version :P

*edit, oh yeah, also the turbo vacume hose had snapped at that electric valve thingie, so it's been going full beans all through the winther, from what I'm guessing. Also fixed that, but I suspect it's hurt the turbo a bit.

All in all, I think I'm going to be happy with this.
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Current Car: 2000 Mark 2 Punto 80bhp 1.9JTD, 190k Miles
Modifications: 107 bhp rolling road remap at 140k miles, single mass lightened flywheel & 350Nm clutch kit, lowered 35mm, blanked EGR return at the exhaust manifold, diy 125 psi compressor horn.

Last edited by DanielR; 06-02-2013 at 00:22. Reason: turbo vacume hose
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Old 06-02-2013   #12
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Re: JTD Lightened Flywheel and clutch kit (350NM)

Number doesn't throw anything up in a search -- but it does look like one of the bigger Alfa/FIAT boxes.
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