Removing and Mounting Porsche Doppelkupplung (PDK)

Removing and mounting Porsche Doppelkupplung (PDK)








Preliminary work

1. Remove engine and transmission unit.

Removing Porsche Doppelkupplung (PDK)

1. Remove B+ cable duct on the Porsche Doppelkupplung.





B+ cable routing on transmission

Unscrew screws -2- for B+ cable duct -1- and move B+ cable duct -1- into position.

2. Remove cooling water tubes on the Porsche Doppelkupplung.





Removing and installing cooling water tubes

2.1. Unscrew screws -2- for cooling water tubes -1-.
2.2. Open bracket -3- for coolant pipes.
2.3. Press clamps -4- on the cooling water hoses together and pull cooling water hoses off the cooling water tubes -2-. Remove cooling water tubes -2-.
3. Remove speed sender on the Porsche Doppelkupplung.





Removing and fitting speed sender

Unscrew screw -1-, remove speed sender -2- and place it safely aside.

4. Disconnect cooling water hoses.

Close off coolant lines -2- by releasing and pulling off the safety clips -1- on the Henn couplings.





Disconnecting cooling water hoses

Caution
Mechanical overload of components
Component will be damaged irreparably

- Observe guidelines for assembly and disassembly

5. Remove Porsche Doppelkupplung.





Removing Porsche Doppelkupplung

5.1. Fit restraining strap.

Fit the restraining strap -1- around the transmission bell housing and front transmission cover. Get another person to help lift the front transmission cover and guide the restraining strap through. Fit the restraining strap in such a way that the load is distributed uniformly.

5.2. Remove Porsche Doppelkupplung.

Loosen and unscrew M12 screws first -1, 2-, then -6, 5, 3- and finally -4-.





Porsche Doppelkupplung screws

Mounting Porsche Doppelkupplung (PDK)

Caution
Mechanical overload of components
Component will be damaged irreparably

- Observe guidelines for assembly and disassembly

1. Mount the Porsche Doppelkupplung.

Information
After replacing the Porsche Doppelkupplung or after carrying out repairs in the Porsche Doppelkupplung, the transmission control unit must be programmed and calibrated using the PIWIS Tester 9718.

Information
Always replace flange screws.

1.1. Mount the Porsche Doppelkupplung.

Screw in and tighten screws -4- first, then -3, 5, 6- and finally -1, 2-.





Porsche Doppelkupplung screws

- Tightening torque: 85 Nm (63 ftlb.)

1.2. Remove restraining strap.





Removing Porsche Doppelkupplung

2. Connect cooling water hoses.





Connecting cooling water hoses

Connect cooling water hoses -2- by attaching the Henn couplings and engaging the safety clips -1-.

Information
The coolant hoses must engage audibly when pushed into the flanges (Henn coupling).

3. Fit the speed sender.





Removing and fitting speed sender

Insert speed sender -2- and screw in and tighten screw -1-.

- Tightening torque: 10 Nm (7.5 ftlb.)

4. Install cooling water tubes on Porsche Doppelkupplung.





Removing and installing cooling water tubes

4.1. Fit cooling water tubes -2-. Slide cooling water hoses onto the cooling water tubes -2- and fit clamps -4- on the cooling water hoses.
4.2. Screw in and tighten screws -2- for cooling water tubes -1-.

- Tightening torque: 10 Nm (7.5 ftlb.)

4.3. Close bracket -3- for cooling water tubes.
5. Fit B+ cable duct.





B+ cable routing on transmission

Fit B+ cable duct -1- by screwing in and tightening the M6 screws -2-.

- Tightening torque: 10 Nm (7.5 ftlb.)

Subsequent work

1. Install engine and transmission unit.

Information
After replacing the Porsche Doppelkupplung or after carrying out repairs in the Porsche Doppelkupplung, the transmission control unit must be programmed and calibrated using the PIWIS Tester 9718.