Flywheel Lock Installation

Overview

This procedure installs a flywheel lock on your Porsche 944 S2’s 3.0L engine to secure the flywheel in place. It’s a critical step when working on tasks like timing belt replacement, ensuring the engine stays at top dead center (TDC) and doesn’t rotate. This keeps your engine timing precise and prevents damage during repairs.

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Tools Required

• Jack stands and floor jack (or ramps)
• 8mm socket and ratchet
• 17mm (11/16 inch) combination wrench
• 19mm (3/4 inch) socket and ratchet or combination wrench
• Flywheel Lock tool (P9206)
• Nut to fit one of the starter mounting bolts (typically M10)
• Shock cords or bailing wire

Parts Required

• Flywheel Lock (P9206)
• Nut to fit one starter mounting bolt (M10 recommended for the Porsche 944 S2)

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1

Step-by-Step Procedure

Step 1: Lift and Secure the Vehicle

1. Use a floor jack to raise your Porsche 944 S2, then place it securely on jack stands. Alternatively, drive it onto ramps. Ensure the car is stable before proceeding.

Step 2: Disconnect the Battery

2. Locate the battery in the engine compartment (front of the car). Use a 13mm wrench to loosen and remove the positive (+) cable from the battery terminal. This prevents any electrical shorts while you work.

Step 3: Set the Engine to Top Dead Center (TDC)

3. Follow this link to ensure this step – Locating and Setting Engine to Top Dead Center (TDC), Cylinder 1 – of the process is followed accurately. This positions the engine correctly for the flywheel lock.

Step 4: Loosen and Remove the Heat Shield

4. Locate the starter heat shield on the back of the starter (near the clutch housing). Use an 8mm socket and ratchet to remove the mounting nut holding the shield in place.
5. Find the two bolts securing the heat shield to the clutch housing. Use a 17mm (11/16 inch) combination wrench to loosen these bolts. You don’t need to remove them fully—just loosen enough to slide the heat shield off, then set it aside.

Step 5: Remove the Starter

6. Use a 19mm (3/4 inch) socket and ratchet or combination wrench to remove the two starter mounting bolts from the clutch housing. Carefully pull the starter out and hang it to the side using shock cords or bailing wire to keep it out of the way.

Step 6: Install the Flywheel Lock

7. Take the flywheel lock (P9206) and position it so its teeth engage with the flywheel’s teeth. Check that it sits flush and secure against the flywheel.
8. Bolt the flywheel lock to the clutch housing using the two starter mounting bolts you removed earlier. For one bolt, thread it directly into the housing. For the other, use the extra nut (M10) to secure it, tightening both to 50 Nm (37 ft-lbs) with a 19mm (3/4 inch) wrench.

Step 7: Verify Engine Position

9. Double-check that the engine is still at TDC on cylinder 1. Look through the timing mark window on the camshaft housing to confirm the TDC mark aligns. If it’s off, remove the lock, reposition the engine, and reinstall.

Post Procedure Checklist

• Ensure the flywheel lock teeth are fully engaged with the flywheel and don’t slip when you gently try to rotate the crankshaft.
• Check that the starter mounting bolts holding the lock are tightened to 50 Nm (37 ft-lbs).
• Verify the engine remains at TDC by checking the timing marks on the camshaft.
• Inspect the work area for loose tools or parts before lowering the car.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• Youtube