Opening And Closing Plug-In Couplings - As Of Model Year 2009

Information

The new plug-in couplings (as of model year 2009) are precision components, just like the previous plug connections.
These precision components must be handled carefully during repairs. Excess force during assembly work, damage to the sealing surface and soiling can cause leaks.
Perform preparations carefully when handling plug-in couplings as repairs are possible only by replacing the affected line in most cases.
Only use loosening tool 9780 for opening (releasing) the plug-in couplings! If a different (commercially available) loosening tool is used, the plug-in connection can become damaged if it is not handled properly, e.g. as a result of incorrect positioning or levering.
Only the O-ring (item 7) and the axial spring (item 5) are available as spare parts (repair kit).

Fig 1: Identifying Plug-In Couplings Components
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Open plug-in coupling using loosening tool (special tool 9780).

Fig 2: Disconnecting Plug-In Couplings
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 1.1. Release plug-in coupling using loosening tool 9780 .
  To do this, fit the special tool on the loosening sleeve plate -3- and insert it as far as it will go over the 60° chamfer -(in direction of arrow)- .
  
  If the tool is turned 180° before fitting, it cannot be inserted.
  
  The 60° chamfer on the loosening tool must be facing the 60° chamfer from the connector (line -1- )!
2. 1.2. Once you have released the plug-in coupling (by inserting the loosening tool), pull the lines apart -arrows- .
  Collect hydraulic fluid in a container. Close off lines with suitable stoppers (e.g. from new lines) to prevent damage in the sealing area. Alternatively, cover the plug-in couplings using a clean, lint-free cloth.
  
  Fig 3: Disconnecting Plug-In Coupling Lines
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. Pull special tool 9780 off the line -1- (off the connector).
  
  Fig 4: Identifying Special Tool 9780
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Close plug-in couplings.
1. 2.1. Replace the O-ring -7- and axial spring -5- if necessary. Then connect the lines (plug-in coupling) -1 and 2- (-(arrow)- ).
  
  Fig 5: Closing Plug-In Couplings
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Check that the plug-in coupling is locked correctly.
  Pull on the connector -1- to check that the plug-in coupling is locked (push and pull slightly in axial direction).
  
  Counter at the plug-in sleeve -2- while doing this.
  
  If the plug-in coupling is locked correctly, you should be able t↓o feel slight axial play between the connector -1- and plug-in sleeve -2- . A plug-in coupling cannot be partly locked.
  
  Another sure sign of a correctly locked plug-in coupling is the bulbous shape of the axial spring -5- .
  
  Fig 6: Identifying Locked Plug-In Coupling
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.