Installing Porsche Doppelkupplung (PDK)

Information 

After replacing the Porsche Doppelkupplung (PDK) or after carrying out repairs in the Porsche Doppelkupplung (PDK), the transmission control unit must be calibrated using PIWIS Tester II 9818  .

Information 

• Check the diaphragm spring on the flywheel for mechanical damage before installing it. 
• A damaged flywheel must not be installed! 

1. Check diaphragm spring -1-  on the flywheel for damage.

   There must be no dents or mechanical damage! 

   1. 1.1. The flywheel must be replaced if the diaphragm spring is damaged -arrow-  .
      Fig 1: Locating Spring On Flywheel

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      NOTE: Engine housing overload.

      • Risk of engine damage if housing breaks.

      → Observe specified loosening and tightening sequence!

      → Loosening sequence: Loosen screws from the bottom up.

      → Tightening sequence: Tighten screws from top to bottom.

      Information 

      Replace flange screws if necessary.

2. Install Porsche Doppelkupplung (PDK).
   1. 2.1. Lift the Porsche Doppelkupplung (PDK).
      1. 2.1.1. Make sure that the guide sleeves are located in the engine flange.
      2. 2.1.2. When lifting the transmission, make sure that no connectors or cables are trapped.
   2. 2.2. Connect the top multiple plug connection -1-  and cable plug -2-  to the control valve.
      Fig 2: Connecting Plug Connection And Solenoid Valve Cable Plug (Top Multiple)

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   3. 2.3. Lift the Porsche Doppelkupplung (PDK) further and fit it.
      1. 2.3.1. Adjust the angle of the transmission jack so that the transmission flange and engine flange are parallel.
      2. 2.3.2. Make sure that no lines are trapped between the transmission flange and engine flange.
      3. 2.3.3. Fit the Porsche Doppelkupplung (PDK).
   4. 2.4. Connect the bottom multiple plug connection -1-  and cable plug -2-  to the control valve.
      Fig 3: Connecting Plug Connection And Solenoid Valve Cable Plug (Bottom Multiple)

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   5. 2.5. Fit transmission on the engine flange by screwing in screws in the following sequence: -3, 4, 5, 6, 1, 2-  .
      Fig 4: Identifying PDK Screws

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   6. 2.6. Tighten screws in the specified sequence.

      Tightening torque 85 Nm (63 ftlb.) 

3. Connect vent line and vacuum line.
   1. 3.1. Connect vent line to the cable holder -arrows-  .
      Fig 5: Disconnecting Vent Line

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   2. 3.2. Connect vacuum line -1-  to the cable holder -arrows-  .
      Fig 6: Disconnecting Vacuum Line

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4. Connect rpm sensor -1-  .
   Fig 7: Connecting RPM Sensor

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5. Fit cable duct for B+ line.
   1. 5.1. Position cable duct -A-  .
   2. 5.2. Fit external Torx screws -1-  .
   3. 5.3. Tighten external Torx screws.

      Tightening torque 10 Nm (7.5 ftlb.) 

      Fig 8: Fitting Cable Duct For B+ Line

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      Information 

      • The coolant hoses must lock with an audible click when pushed into the plug-in couplings. 
6. Connect coolant hoses.
   1. 6.1. Connect coolant hose -1-  .
      Fig 9: Connecting Coolant Hose 1

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      1. 6.1.1. Fit coolant hose and close the safety clip on the Henn coupling -arrow-  .

         The coolant hose must engage with an audible click.

   2. 6.2. Connect coolant hose -2-  .
      Fig 10: Connecting Coolant Hose 2

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      1. 6.2.1. Fit coolant hose and close the safety clip on the Henn coupling -arrow-  .

         The coolant hose must engage with an audible click.

7. Engage parking lock cable on the Porsche Doppelkupplung (PDK).
   1. 7.1. Check that the selector lever on the selector support is in position "P" and is not locked.
   2. 7.2. Check that the transmission lock is fully engaged.
   3. 7.3. Fit the parking lock cable on the support -2-  , press on it and engage it.
   4. 7.4. Press the ball joint of the parking lock cable -1-  onto the parking lock lever.
      Fig 11: Securing Lock Cable On Transmission

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      Information 

      When lowering and lifting the Porsche Doppelkupplung, make sure that the sharp cooling fins on the ATF cooler do not damage the left cooling water hose. Move left cooling water hose into position when lowering and lifting the PDK.

8. Install transmission brackets.
   1. 8.1. Raise the transmission.
      Fig 12: Installing Transmission Bracket Elements

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   2. 8.2. Position transmission support -C-  and fit the nuts -4-  only on the threaded bolts initially.
   3. 8.3. Position the transmission bracket -A-  and hold it loosely in your hand.
   4. 8.4. Insert transmission mount screw -1-  through the transmission support and transmission bracket into the transmission mount.

      Fit collar nut -2-  only on the transmission mount screw initially.

   5. 8.5. Attach water tube holder -B-  to the transmission bracket.
   6. 8.6. Position brace plate -A-  and only fit all screws -1-  initially.
      Fig 13: Positioning Brace Plate

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   7. 8.7. Fit screws -3-  on the transmission bracket -A-  .
      Fig 14: Installing Transmission Bracket Elements

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   8. 8.8. Tighten nut on the transmission mount screw -1-  .

      Tightening torque 120 Nm (89 ftlb.) 

   9. 8.9. Tighten screws on the brace plate.

      Tightening torque 30 Nm (22 ftlb.) +90 Grad 

   10. 8.10. Tighten screws on the transmission bracket.

       Tightening torque 65 Nm (48 ftlb.) 

   11. 8.11. Tighten nuts -4-  used to secure the transmission support -C-  to the body.

       Tightening torque 65 Nm (48 ftlb.) 

9. Remove transmission jack from under the transmission and engine.
   1. 9.1. Loosen restraining strap.
   2. 9.2. Lower and remove the transmission jack -1-  .
      Fig 15: Removing Transmission Jack

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   3. 9.3. Lower and remove the transmission jack -2 -  .
10. Secure the rear-axle cross member.

    → 420609 LOOSENING AND SECURING REAR-AXLE CROSS MEMBER .

11. Connect and fit cable plug for temperature switch.
    1. 11.1. Connect cable plug for temperature switch -A-  .
       Fig 16: Connecting Cable Plug For Temperature Switch

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    2. 11.2. Attach cable holder -1-  .
    3. 11.3. Attach cable holder -2-  .
12. Fit drive shafts on the transmission side.
    1. 12.1. Remove tie-wrap.
    2. 12.2. Fit and tighten screws -arrows-  on the drive shaft flange with the plates -1-  .

       Counter at the wheel to prevent it from turning as well. Get another person to help if necessary.

       Tightening torque 90 Nm 

       Fig 17: Locating Drive Shafts Screws

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13. Only for vehicles with PDCC: 
    1. 13.1. Position bracket for PDCC lines -A-  .
       Fig 18: Identifying Bracket For PDCC Lines

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    2. 13.2. Screw in and tighten screws -1-  .

       Tightening torque 13 Nm (9.5 ftlb.) 

    3. 13.3. Clip PDCC lines -A-  into the brackets -1-  .
       Fig 19: Identifying Bracket For PDCC Lines

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    4. 13.4. Screw on and tighten union nuts -1-  .

       Tightening torque 28 Nm (21 ftlb.) 

       Fig 20: Identifying Threaded Joint For Lines

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14. Install diagonal braces.
    1. 14.1. Position diagonal braces -A-  .
    2. 14.2. Screw in and tighten screws -1-  on the mounting for the longitudinal arm.

       Tightening torque 65 Nm (48 ftlb.) 

    3. 14.3. Screw in and tighten screws -2-  on the body.

       Initial tightening 90 Nm (67 ftlb.) Final tightening +90° 

       For Cabriolet vehicles:  Diagonal brace on outer body

       Tightening torque 30 Nm (22 ftlb.) 

    4. 14.4. Screw in and tighten screws -3-  on the rear-axle cross member.

       Initial tightening 30 Nm (22 ftlb.) Final tightening +90° 

       Fig 21: Installing Diagonal Braces

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