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The lumpy idle, could be down to it having the correct timing now. They always have a slightly lumpy idle, and in last experience tend to idle better when the timing is out.
I know some dynos have atmospheric correction on them. I.e they will allow for heat producing a lower output and give a higher readout. Same for it being cold, they'll read lower than it has done. So theory then means that it'll have read 180.1 on a cold day.
Provided you've put the bearing back in the boot and replaced the clip, you should be ok. I assume you checked the driveshaft and it wasn't missing any rollers on the end?
Full gearbox takes 3.1-3.4 litres depending on what box it is.
Timing can't be 180 degrees out. It simply wouldn't run. Chances are he out the tools in 180 degrees out. Did you see the tools he used to lock them? Were they silver or black? Did he use a tool to lock the actual pulleys? Looks like this...
yeh, but don't just start it and run it for a few minutes as that will do more damage than good. Make sure its run up for a good 30-45 minutes, get it up to temperature properly.