Opening And Fitting Plug-In Couplings

Information 

Do not use other (commercially available) loosening tools.

• They may damage the plug connection, making it necessary to replace the line. 

1. Open the plug-in coupling using loosening tool (special tool 9780). 
   Fig 1: Identifying Special Tool (9780)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   1. 1.1. To do this, fit the special tool loosening tool 9780  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-  )!

      Fig 2: Releasing Plug-In Coupling

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 1.2. Once you have released the plug-in coupling (by inserting the loosening tool), pull the lines apart -arrow-  .

      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 Lines

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   3. 1.3. Pull special tool loosening tool 9780  off the line -1-  (off the connector).
      Fig 4: Identifying Special Tool (9780)

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2. Fit the plug-in couplings. 
   1. 2.1. Carry out a close visual inspection of all parts. Replace the O-ring -7-  and axial spring -5-  if necessary. Then fit -(arrow)-  the plug-in couplings -1 and 2-  .
      Fig 5: Connecting Lines/Available Spare Parts

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   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 to 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.