Installing Porsche Doppelkupplung (PDK)

Information 

• The coolant hoses must lock with an audible click when pushed into the plug-in couplings  .

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  .

1. Install Porsche Doppelkupplung (PDK).
   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.

   1. 1.1. Lift the Porsche Doppelkupplung (PDK).
      1. 1.1.1. Make sure that the guide sleeves are located in the engine flange.
      2. 1.1.2. When lifting the transmission, make sure that no connectors or cables are trapped.
   2. 1.2. As soon as the Porsche Doppelkupplung (PDK) is raised far enough:
      1. 1.2.1. Fit bracket with change-over valves, screw in fastening screw -3-  and tighten to Tightening Torque 13 Nm (9.5 ft. lbs.)  until secure.
      2. 1.2.2. Attach vacuum hose -2-  to the vacuum line -1-  .
      Fig 1: Securing Change-Over Valves

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   3. 1.3. Lift the Porsche Doppelkupplung (PDK) further and fit it.
      1. 1.3.1. Adjust the transmission jack bracket so that the transmission flange and engine flange are parallel.
      2. 1.3.2. Make sure that no lines are trapped between the transmission flange and engine flange.
      3. 1.3.3. Fit the Porsche Doppelkupplung (PDK).
   4. 1.4. Screw the transmission flange to the engine flange.

      Information 

      Replace flange screws if necessary.

      1. 1.4.1. Screw in all screws in the following sequence:

         First -1-  and -2-  ,

         then -4-  ,

         and finally -3-  and -5-  .

         Fig 2: Identifying PDK Transmission Bolt Loosening Sequence

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      2. 1.4.2. Tighten screws from top to bottom.

         Tightening torque 85 Nm (63 ft. lbs.) 

2. Fit transverse strut -2-  , screw in fastening screws -1-  and tighten to Initial Tightening 35 Nm (26 ft. lbs.) Final tightening +60°  until secure.
   Fig 3: Installing Transverse Strut

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3. Fit coolant hoses -1-  and fasten the locks -2-  (-arrows-  ).
   Fig 4: Securing Coolant Hoses

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4. Position electric wire harness, clip fixing clip -2-  onto the transmission and connect electric plug connections -1, 3-  .
   Fig 5: Securing Electric Plug Connections At Right

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5. Fit the housing of the electric plug connections -1-  (-B-  ) and turn it -A-  .
   Fig 6: Securing Electric Plug Connections At Left

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6. Connect electric plug connection -1-  on the crankshaft hall sender -2-  .
   Fig 7: Securing Electric Plug Connection On Crankshaft Sensor

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