[MikeVT]

Where are the TDC alignment marks on the flywheel on the manual? I have a repair manual with a sketch but I must be missing it. I don’t see them.

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[jlm968]

<!--quoteo(post=78420:date=Aug 22 2009, 10:14 AM:name=MikeVT)-->QUOTE (MikeVT @ Aug 22 2009, 10:14 AM) <{POST_SNAPBACK}><!--quotec-->Where are the TDC alignment marks on the flywheel on the manual? I have a repair manual with a sketch but I must be missing it. I don’t see them.<!--QuoteEnd--><!--QuoteEEnd-->

It's been a while, but I seem to recall there's a dime-sized rubber dust plug in place over the hole. Remove that plug and you can see the TDC alignment marks on the flywheel.

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[PorscheDude]

Top rear drivers side of the engine block.

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[Cloud9...68]

Amazing how Porsche turned such a simple thing into such a mysterious freakin' treasure hunt, one which seems to have thirty-five different paths. Giving up on finding the mark on the flywheel you guys are referring to, I resorted to rotating the engine until the rotor was pointing to the #1 connector in the distributor cap (no simple task, given the odball shape of the cap), and confirming that the mark on the cam sprocket then lined up with the corresponding mark on the belt cover thingy. Turned out to be very straightforward, and, since I was replacing the belts anyway, I had the belt dust cover off. But I kept thinking there has to be an easier way to find something so simple. Since then, I've heard you really have to lean over the fender to see the window to the flywheel mark, so next time, I'll try looking harder, with a very bright flashlight in tow.

But beware that there is a lot of variation in these cars. For example, some have marks on the flywheel that are visible through the opening when you remove the starter, but mine definitely doesn't have these. And don't even get me started on the fact that some (I suspect very few) engines have a coolant drain plug in the block (again, definitely a no-go for me here), while the rest of us have to live with only being able to drain about 80% of the coolant. Good luck!

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[MikeVT]

I'm looking for this marking. I cant really tell by the sketch where it would be.

I lined up the rotor and mark on the camshaft but I would like to verify TDC

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[Cloud9...68]

The opening in the bell housing is very hard to find (I've never been able to see it), but from what everybody says, it's there. Apparently, you have to really lean over the fender to the point where you're practically inside the engine bay, and then look down at the top of the bell housing for an opening, inside which the alleged mark lives. If you've lined up the rotor to the #1 plug wire in the distributor cap, and confirmed that the mark on the camshaft sprocket lines up with the mark on the casing (or whateve it's called), you're 100% certain to be at TDC. This being the case should make it easier to find the mark in the bell housing opening, since it should be lined up to the mark in the opening. Maybe some dirt is covering it up. Can you get a rag down there to wipe it up?

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[PorscheDude]

Careful, with the cam sprocket mark, it's possible to be 180 off.

Check the position of the #1 cylinder using a long wooden dowel.

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[Cloud9...68]

<!--quoteo(post=78453:date=Aug 22 2009, 06:46 PM:name=PorscheDude)-->QUOTE (PorscheDude @ Aug 22 2009, 06:46 PM) <{POST_SNAPBACK}><!--quotec-->Careful, with the cam sprocket mark, it's possible to be 180 off.

Check the position of the #1 cylinder using a long wooden dowel.<!--QuoteEnd--><!--QuoteEEnd-->
That's true, but if you've carefully checked to make sure the rotor is pointing to the #1 plug wire's connector on the distributor cap, AND the cam sprocket's mark lines up, you should be pretty sure you're at TDC. But the dowel method is a good check as well.

I took a look in my engine bay, and actually found the bell housing opening very easily - don't know why I couldn't see it before. You don't get a really good line of site to it, since there is some stuff in the way, but between the rotor position, cam sprocket marks, the dowel method, and the opening in the bell housing, you should have no trouble confirming you're at TDC.

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[kwikt]

Easiest way is with a makeshift extention using a dial indicator. I did not have much luck with the top bell housing marks. Using the dial indicator verified the lower(starter area) flywheel marks.

Kevin

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[Cloud9...68]

I forgot about the simplest, most obvious TDC check. Directly above the top distributor cap bolt is a rubber cap that covers a window. Pull the cap out, and you'll see the cam sprocket. All you have to do is turn the engine until the mark on the sprocket lines up with the mark in the window. Then, take off the distributor cap, and see if the rotor is pointing to the #1 plug wire connector on the cap.

Or, probably a better way is to remove the #1 spark plug (you may want to remove all of them to make the engine easier to turn), stick a dowel into the spark plug hole, and watch the movement of the dowel as you're turning the engine to line up the sprocket mark with the mark in the window above the distributor. Once you've found TDC with either of these methods, go ahead and look in the window in the bell housing; the marks should be lined up there as well.

To turn the engine, I have always used the method of putting the car in 6th gear, and rolling it forward.

Like I said, there are many different ways to find TDC on this engine.

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[MikeVT]

I couldn’t ever see the marks on the flywheel. Too dirty and rusty I guess. Used my compression gage to verify that the piston was up when the cam mark is aligned.

Belts didn’t look bad but some wear on the balance belt. I'm replacing both.

Darn clip ring on the tensioner arm is sprung so I can’t finish until latter in the week. Have to order a clip, cost of living in the country.

Also, the two allen head bolts on the lower balance belt guide are getting worn. I'm going to replace but the PET calls them a 6X12 cheese head. What is a cheese head bolt? I have never heard that one.

Part Number N 0124 761 2

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[flash]

it's real name is "triple square" - basically a 12 pt, that looks like a torx, but with 12 points

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[Cloud9...68]

Yeah, those bolts can be a bit of a bear to get out. Have you removed them yet? If not, I would spray some penetrating fluid on them and let it soak overnight. Then clean out the bolt heads as best you can, and make sure your socket is well seated in the bolt head. I would use the longest wrench you can, and press against the bolt as you are turning the wrench to minimize the chance of rounding the bolt. Mine popped out without a problem, but it was surprisingy tight for such a little bolt.

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[MikeVT]

Bolts stuff including cheese head info

http://en.wikipedia.org/wiki/Screw

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[MikeVT]

All done

New belts, anti-freeze, tranny oil, brake fluid, and complete wash. Its ready for fall and some nice convertable weather.

FYI ... my timing marks can be seen under the car on the front of the flywheel. Easy to see once I figured out where. Not sure that cars are from the top. Maybe autos.

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[Cloud9...68]

<!--quoteo(post=79132:date=Aug 29 2009, 06:52 PM:name=MikeVT)-->QUOTE (MikeVT @ Aug 29 2009, 06:52 PM) <{POST_SNAPBACK}><!--quotec-->All done

New belts, anti-freeze, tranny oil, brake fluid, and complete wash. Its ready for fall and some nice convertable weather.

FYI ... my timing marks can be seen under the car on the front of the flywheel. Easy to see once I figured out where. Not sure that cars are from the top. Maybe autos.<!--QuoteEnd--><!--QuoteEEnd-->
Congrats on getting the job done. Very satisfying once it's all buttoned up, isn't it?

Marks on the bottom, at the front of the flywheel, huh? Sheesh, how many different places, present in different combinations on some cars and not others, did Porsche see fit to make? I guess this is what happens with a hand-built car. Werner says, "Do it this way!", while Klauss bellows in retort, "You dumbkoff, don't you know THIS is the only way it must be done!"

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[Ryan]

Here is a shot of the location from below. A small 3/4" plug may be covering the hole. I thought I would put this in at this time so if people are doing a search, they would have a good reference

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