Technical Service Bulletin # 343/10 Date: 120524
PDK Transmission - Diagnosis/Symptoms & Repair
43/10 ENU 3730 3
May 24, 2012
The present document was valid at the time of print. A later version may be available online
PDK Transmission Diagnosis, Symptoms and Repair Procedures (43/10)
Tools
Model year: as of 2010
Information
This bulletin replaces bulletin Group 3, #43/10, dated April 6, 2011.
Changes/additions compared to the previous Technical Information:
New PDK Diagnostic Flow Charts dated 8/2011.
Vehicle Type: Panamera/Panamera S/Panamera 4/Panamera 4S/Panamera Turbo
Equipment: Porsche Doppelkupplung (PDK) - I-no. 250
Concerns:
PDK transmission/control unit for PDK transmission
Information:
Procedure and repair measures in the event of complaints relating to PDK:
^ Gearbox emergency operation/other warning messages
^ Fault memory entries in the fault memory of the PDK control unit
^ Leaks on the PDK transmission
^ Complaints relating to comfort
^ Complaints relating to noises
This Technical Information is divided into the following sections:
^ Procedure and repair measures in the event of fault entries in the fault memory of the PDK control unit
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^ Repair measures in the event of leaks on the PDK transmission
^ Remedial action and repair measures in the event of complaints relating to comfort and noise
Information
^ Always create a Vehicle Analysis Log (VAL) before starting any measures --> 0X03IN Creating Vehicle Analysis Log (VAL).
^ When evaluating faults, also bear in mind the detailed information contained or stored in the relevant fault code (measured values, etc.).
^ Make sure the version of the PIWIS Tester II 9818 software you are using is the latest version.
^ If components are replaced: Return components to the Porsche and document all measures in PIWIS/PQIS.
Information
Information on PDK calibration and engine torque loss adaptation
Engine torque loss adaptation
Engine torque loss adaptation must always be performed before calibrating PDK. Engine torque loss adaptation is also required after carrying out
control unit programming (DME/PDK - with or without part replacement).
Conditions/procedure for engine torque loss adaptation:
^ Engine temperature is at least 176°F. (80°C.) (read out the temperature from the PDK control unit by selecting "Actual values/Input signals" >
"CAN input signals - Engine temperature").
^ All loads switched off.
^ PDK selector lever in position P.
^ Allow engine to run at idle speed for 3 minutes with air conditioning switched off.
^ Then allow engine to run at idle speed for 3 minutes with air conditioning switched on.
^ Switch off ignition and wait 15 seconds (adaptation values are stored).
PDK calibration
Essentially, PDK calibration is required only after replacing parts (of the PDK control unit, hydraulic switch unit, PDK transmission) or if you are
expressly instructed to do so during troubleshooting.
PDK calibration can be started by selecting the PDK control unit under > "Maintenance/repairs" >> "Calibration (complete process)" using PIWIS
Tester II. Shift travel, hydraulics and clutches are calibrated during calibration. It is not possible to perform a "minor" calibration routine
("Calibration without previous part replacement") -which you may be familiar with from the Boxster, Cayman and Carrera sports cars - on the
Panamera.
Engine torque loss adaptation must always be performed before carrying out calibration.
The preconditions for engine torque loss adaptation and PDK calibration are summarized again in the overview above.
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References
Model Year as of 2010
C02, C36
Work Procedure 1
Procedure and repair measures in the event of fault entries in the fault memory of the PDK control unit
Work Procedure:
1 Procedure and repair measures in the event of fault entries in the fault memory of the PDK control unit.
The required procedure for correcting faults for the groups of fault memory entries listed below is described using flow charts.
A separate flow chart is used for each of the fault groups specified below.
Information
You will find the flow charts under the heading "3730 - Flow charts of PDK fault codes (970)" in the information medium TI - Technical
Information releases, main group 3 - Transmission.
In addition to the flow charts, Guided Fault Finding in PIWIS Tester II must always be used during troubleshooting for existing fault memory
entries. In some cases, you are directed to the required guided fault finding from the flow charts. The procedure for required electric testing is
stored only under Guided Fault Finding in PIWIS Tester II.
Sequence for correcting faults if various fault entries from various fault groups are present:
1) Electrical faults
2) Sensor faults/software faults
3) Gear selection faults
Fault correction for complaints relating to comfort and noise must only be carried out after the faults listed above (if present) have been found
and corrected.
1.1 Electrical faults
Electrical faults include all fault memory entries relating to fault type
- Short circuit to ground
- Short circuit to B+
- Shunt
- Open circuit
- Incorrect voltage (operating limit, low-voltage, over-voltage).
Correct faults as shown in Flow chart EF - Electrical faults.
1.2 Sensor faults/software faults
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"Sensor faults" include all fault memory entries relating to the components
^ Distance sensor
^ Speed sensor
^ Pressure sensor
^ Temperature sensor.
Correct faults as shown in Flow chart SF0 - SF5.
Overview of fault memory entries for distance sensor (Flow chart SF1)
- P1731 ... to P1734: Distance sensor information/shift rod faults (outside of validity range)
Overview of fault memory entries for speed sensor (Flow chart SF2)
- P0730: Transmission monitoring symptom - incorrect gear ratio
- P1743: Plausibility of transmission input shaft speed sensor clutch 1
- P1744: Plausibility of transmission input shaft speed sensor clutch 2
- P1745: Input shaft overspeed
Overview of fault memory entries for pressure sensor (Flow chart SF3)
- P0841, P0846 and P0871: Pressure sensor fault (measured value implausible)
- P17B1 and P17B2: Clutch fault (activation pressure implausible)
- P17B3 and P17B4: Clutch valve fault (valve pressure stays too high mechanically during overlap switching after quick filling)
- P17BB ... to P17BE: Clutch fault (clutch cannot be opened)
Overview of fault memory entries for temperature sensor (Flow chart SF4)
- P0711: Transmission temperature sensor implausible
- P172D: Transmission temperature sensor gradient fault
- P17F0 to P17F2: Transmission over temperature
Overview of fault memory entries for software faults (Flow chart SF5)
- P0602: PDK control unit not programmed
- P0603 ... to P605: PDK control unit, internal fault
- P0614: Data status does not match engine
- P0702: PDK control unit, internal fault
- P1715: PDK control unit, internal fault
- P1749: PDK control unit, variant coding invalid
- P174B: PDK control unit, interchange detected
- P174C: BIN file does not match software version
- P174E: EEPROM content at system start incorrect/implausible
- P186F ... to P1872: PDK control unit, internal fault (electric synchronization data, shift rod compensation, clutches and hydraulics)
- P1897, P189A, P189C, P189D: PDK control unit, internal fault (software monitoring)
- P18A0 ... to P18B5: PDK control unit, internal fault (software monitoring)
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- P18D0: Clutch, BIN file implausible
- Uxxxx: CAN fault
1.3 Overview of fault memory entries for gear selection
- P17D0 ... to 17D9: Hydraulic gear selection, system fault
- P1779, P177A ... to P177F: Synchronization fault - gear cannot be disengaged (disengagement block)
Other fault entries relating to the fault memory entries specified above that can be entered in the fault memory of the PDK control unit.
- P18B4: PDK control unit, internal fault (software monitoring) with fault type $36/$37/$38
Correct faults as shown in Flow chart GS.
Repair measures in the event of leaks on the PDK transmission
Information
General information on how to deal with leaks on the PDK transmission
The exact site of the leak must be determined in order to be able to define the required repair measures. If this is not possible at first, carry out
the following steps one after the other:
- Clean the transmission
- Perform a test drive
- Check the transmission for leaks and find the leak.
Once you have found the leak, carry out the required repair measures in accordance with the following overview.
Once you have repaired the leak, always check the transmission fluid level and correct it if necessary --> 370235 Checking and topping up
ATF.
Work Procedure 2
Work Procedure:
2 Repair measures in the event of leaks on the PDK transmission
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Work Procedure 3
Remedial action and repair measures in the event of complaints relating to comfort and noise
Work Procedure: 3
3. Remedial action and repair measures in the event of complaints relating to comfort (gearshift and drive-off quality).
3.1 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
3.2 Find and correct any faults that are present in other control units (DME, PSM, air conditioning, etc.).
3.3 Check oil level in PDK transmission and correct it if necessary --> 370235 Checking and topping up ATF.
3.4 Teach the throttle valve using the PIWIS Tester:
Select PIWIS Tester II > DME control unit >> "Maintenance/repairs" menu >>> menu item "Adaptations" >>>> "Throttle valve adaptation"
function. Follow the instructions on the PIWIS Tester.
3.5 Perform engine torque loss adaptation.
Conditions/procedure for engine torque loss adaptation:
^ Engine temperature is at least 176°F. (80°C.) (read out the temperature from the PDK control unit by selecting "Actual values/Input
signals" > "CAN input signals - Engine temperature").
^ All loads switched off.
^ PDK selector lever in position P.
^ Allow engine to run at idle speed for 3 minutes with air conditioning switched off.
^ Then allow engine to run at idle speed for 3 minutes with air conditioning switched on.
^ Switch off ignition and wait 15 seconds (adaptation values are stored).
3.6 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
3.7 Perform adaptation drive.
WARNING
Driver steers off course during adaptation drive
^ Increased risk of accidents
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^ Danger to other people on the roads
--> Get another person to accompany the driver and give him the relevant instructions for carrying out the adaptation drive.
--> Only drive the vehicle to achieve the rpm and speed ranges required for the adaptation drive in accordance with road traffic regulations
and if the road, weather and traffic conditions are conducive to such driving.
Observe and meet the following conditions for the adaptation drive:
^ Transmission fluid temperature is > 140°F. (60°C.) (read out the temperature from the PDK control unit by selecting "Actual values/Input
signals" > "CAN output signals - Transmission sump temperature").
^ Perform adaptation drive on a level stretch of road.
^ Once the transmission fluid temperature is > 140°F. (60°C.), switch off the engine and ignition and wait at least 20 seconds.
^ Switch on ignition, wait at least three seconds and then start the engine.
^ After you have switched the ignition off and then on again, there should be no error messages displayed in the instrument cluster.
^ Perform adaptation drive in shift program "M".
3.7.1 Start the adaptation drive, accelerate to rpm range 1,000 - 1,200 rpm in 5th gear and maintain this range for two minutes.
3.7.2 Then change gear several times (in any target gear) and switch between traction and deceleration mode while driving in the selected gears.
3.7.3 Then, change to 5th gear again and repeat steps 3.7.1 to 3.7.3 twice. The procedure must be done three times in total.
3.7.4 Continue the adaptation drive, accelerate to rpm range 1,000 - 1,200 rpm in 6th gear and maintain this range for two minutes.
3.7.5 Then change gear several times (in any target gear) and switch between traction and deceleration mode while driving in the selected gears.
3.7.6 Then, change to 6th gear again and repeat steps 3.7.4 to 3.7.6 twice. (The procedure must be carried out three times in total.)
3.7.7 Stop the vehicle, switch off the engine and ignition and wait at least 20 seconds.
3.7.8 Switch on ignition, wait at least three seconds and then start the engine.
There should be no error messages displayed in the instrument cluster.
3.7.9 Carry out adaptation drive once more as described in steps 3.7.1 to 3.7.6.
3.7.10 Stop the vehicle, switch off the engine and ignition and wait at least 20 seconds.
3.7.11 Switch on ignition, wait at least three seconds and then start the engine.
There should be no error messages displayed in the instrument cluster.
3.7.12 Continue the adaptation drive, accelerate to rpm range 2,000 - 2,500 rpm in 5th gear and maintain this range for two minutes.
3.7.13 Then change gear several times (in any target gear) and switch between traction and deceleration mode while driving in the selected gears.
3.7.14 Then, change to 5th gear again and repeat steps 3.7.12 to 3.7.14 twice. The procedure must be carried out three times in total.
3.7.15 Continue the adaptation drive, accelerate to rpm range 2,000 - 2,500 rpm in 6th gear and maintain this range for two minutes.
3.7.16 Then change gear several times (in any target gear) and switch between traction and deceleration mode while driving in the selected gears.
3.7.17 Then, change to 6th gear again and repeat steps 3.7.15 to 3.7.17 twice. (The procedure must be carried out three times in total.)
3.7.18 Stop the vehicle, switch off the engine and ignition and wait at least 20 seconds.
3.7.19 Switch on ignition, wait at least three seconds and then start the engine.
There should be no error messages displayed in the instrument cluster.
3.7.20 Carry out adaptation drive once more as described in steps 3.7.12 to 3.7.17.
3.7.21 Stop the vehicle, switch off the engine and ignition and wait at least 20 seconds.
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3.7.22 Switch on ignition, wait at least three seconds and then start the engine.
3.7.23 End the adaptation drive.
3.7.24 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
3.7.25 Leave the vehicle overnight if necessary and evaluate it again with regard to gearshift/drive-off quality the next day.
^ If the vehicle checks out OK with regard to gearshift/drive-off quality --> End of remedial action.
^ If the vehicle does not show any improvement with regard to gearshift/drive-off quality, please contact Porsche to find out what to do
next.
Work Procedure 4
4 Procedure in the event of noises on the PDK transmission.
If a complaint is received in relation to noises from the PDK transmission, please complete the following steps initially:
4.1 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
4.2 Find and correct any faults that are present in other control units (DME, PSM, air conditioning, etc.).
4.3 Check to see if the noise is actually coming from the transmission.
Also check other possible noise sources, such as:
^ Engine (e.g. adjacent damping parts)
^ Rear-axle differential
^ Wheels, wheel bearings
^ Cardan shaft bearing
^ Power-steering pump
4.4 Check the oil level in the PDK transmission and correct it if necessary --> 370235 Checking and topping up ATF.
4.5 If the data version of the PDK control unit is not up-to-date, re-program the PDK control unit. To do this, select "Programming" > "Automatic
programming" in the PDK control unit using the PIWIS Tester and confirm with [>>].
The name of the control unit to be programmed (in this case: PDK) as well as the data record to be programmed and the Porsche part number
and status will be displayed.
If "not current" is displayed in the status display, re-program the PDK control unit. If the data record is already up-to-date ("current" in the
status display), there is no need to program the PDK control unit.
4.6 Teach the throttle valve using the PIWIS Tester:
Select PIWIS Tester II > DME control unit >> "Maintenance/repairs" menu >>> menu item "Adaptations" >>>> "Throttle valve adaptation"
function. Follow the instructions on the PIWIS Tester.
4.7 Perform engine torque loss adaptation.
Conditions/procedure for engine torque loss adaptation:
^ Engine temperature is at least 176°F. (80°C.) (read out the temperature from the PDK control unit by selecting "Actual values/Input
signals" > "CAN input signals - Engine temperature").
^ All loads switched off.
^ PDK selector lever in position P.
^ Allow engine to run at idle speed for 3 minutes with air conditioning switched off.
^ Then allow engine to run at idle speed for 3 minutes with air conditioning switched on.
^ Switch off ignition and wait 15 seconds (adaptation values are stored).
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4.8 Perform a test drive.
If, after carrying out tests and/or correcting faults, the vehicle still has definite symptoms in relation to transmission noises, please document
the information specified below in PIWIS/PQIS
^ Create and save a sound file of the noise
^ Provide a detailed description of the noise (e.g. rattling, grinding, whining, whistling, singing, )
^ In which rpm range does the noise occur?
^ In which drive and shift program does the noise occur (D, M, Sport, Sport Plus)?
^ In which gear does the noise occur?
^ At what speed does the noise occur?
^ In which load condition does the noise occur (acceleration, deceleration, partial load, full load)?
^ In which operating state does the noise occur (cold, warm)?
^ Who noticed the noise (customer, workshop)?
^ What work has already been done?
^ How do comparable vehicles behave?
Contact Porsche to find out what to do next.
Work Procedure 5
5 Procedure in the event of noises on the PDK transmission.
If a complaint is received in relation to noises from the PDK transmission, please complete the following steps initially:
5.1 Create and save the Vehicle Analysis Log (VAL) using the PIWIS Tester.
5.2 Find and correct any faults that are present in other control units (DME, PSM, air conditioning, etc.).
5.3 Check to see if the noise is actually coming from the transmission.
Also check other possible noise sources, such as:
^ Engine (e.g. adjacent damping parts)
^ Rear-axle differential
^ Wheels, wheel bearings
^ Cardan shaft bearing
^ Power-steering pump
5.4 Check the oil level in the PDK transmission and correct it if necessary --> 370235 Checking and topping up ATF.
5.5 If the data version of the PDK control unit is not up-to-date, re-program the PDK control unit. To do this, select "Programming" > "Automatic
programming" in the PDK control unit using the PIWIS Tester and confirm with [>>].
The name of the control unit to be programmed (in this case: PDK) as well as the data record to be programmed and the Porsche part number
and status will be displayed. If "not current" is displayed in the status display, re-program the PDK control unit. If the data record is already
up-to-date ("current" in the status display), there is no need to program the PDK control unit.
5.6 Teach the throttle valve using the PIWIS Tester:
Select PIWIS Tester II > DME control unit >> "Maintenance/repairs" menu >>> menu item "Adaptations" >>>> "Throttle valve adaptation"
function. Follow the instructions on the PIWIS Tester.
5.7 Perform engine torque loss adaptation.
Conditions/procedure for engine torque loss adaptation:
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^ Engine temperature is at least 176°F. (80°C.) (read out the temperature from the PDK control unit by selecting "Actual values/input
signals" > "CAN input signals - Engine temperature").
^ All loads switched off.
^ PDK selector lever in position P.
^ Allow engine to run at idle speed for 3 minutes with air conditioning switched off.
^ Then allow engine to run at idle speed for 3 minutes with air conditioning switched on.
^ Switch off ignition and wait 15 seconds (adaptation values are stored).
5.8 Perform a test drive.
If, after carrying out tests and/or correcting faults, the vehicle still has definite symptoms in relation to transmission noises, please document
the information specified below in PIWIS/PQIS:
^ Create and save a sound file of the noise
^ Provide a detailed description of the noise (e.g. rattling, grinding, whining, whistling, singing,)
^ In which rpm range does the noise occur?
^ In which drive and shift program does the noise occur (D, M, Sport, Sport Plus)?
^ In which gear does the noise occur?
^ At what speed does the noise occur?
^ In which load condition does the noise occur (acceleration, deceleration, partial load, full load)?
^ In which operating state does the noise occur (cold, warm)?
^ Who noticed the noise (customer, workshop)?
^ What work has already been done?
^ How do comparable vehicles behave?
Contact Porsche to find out what to do next.