Porsche 911 GT3R 2010 Technical Manual
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Porsche 911 GT3R 2010 Technical Manual

Porsche 911 GT3R 2010 Technical Manual

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Summary of Contents for Porsche 911 GT3R 2010

  • Page 1 Technical Manual Model 2010...
  • Page 2 This technical information will give you the possibility to reference data, adjustment values and working procedures and make the maintenance and repair work on the vehicle easier. We wish you every success with your GT3 R Dr. Ing. h.c. F. Porsche Aktiengesellschaft Vertrieb Sonder- und Rennfahrzeuge...
  • Page 3 German road traffic regulations. Illustrations, descriptions and schematic drawings serve exclusively as presentation for the text. Porsche Motorsport accepts no liability for the completeness and conformity of the contents of this brochure with respect to the legality of the current regulations.

  • Page 4: Table Of Contents

    Contents CONTACTS GENERAL TECHNICAL DATA 2.1. Dimensions 2.2. Weight ENGINE 3.1. Engine technical data 3.2. Fuel specs 3.3. Engine power and torque curves 3.4. Engine lubrication 3.5. Engine cooling system 3.6. Induction system 3.7. Throttle butterfly 3.8. Working on the engine 3.9.
  • Page 5 5.7. Gearbox component tightening torques SUSPENSION 6.1. Front suspension 6.2. Rear suspension 6.3. Basic wheel alignment 6.4. Working on the suspension 6.5. Tightening torques suspension 6.6. Sachs damper service information WHEELS 7.1. Wheel nuts BRAKE SYSTEM 8.1. Technical data brake system 8.2.
  • Page 6 10.6. MoTeC Dash 10.7. Car sensors 10.8. Engine Control Unit (ECU) 10.9. EGas 10.10. 10.11. Traction control 10.12. Relay- and fuse assignment CAR MAINTENANCE 11.1. After approx. 200 km and/or first test 11.2. After every session 11.3. After every race weekend (sprint) 11.4.

  • Page 7: Contacts

    1. Contacts Technical Support Mr Rainer Gohl 0711 911 82685 0170 911 1999 Mr Marcus Stolzenthaler 0711 911 82498 0170 911 2996 Mr Rainer Sauter 0711 911 84994 0170 911 3436 Fax: 0711 911 89535 Sport parts sales Mr Friedrich Weseler 0711 911 89854 Mr Karlheinz Kienle 0711 911 82923...

  • Page 8: General Technical Data

    2. General technical data Engine type M 97/79 Gearbox type G 97/71 Numbers of gears sequential 6 2.1. Dimensions Length (w/o spoiler edge) [mm] see homologation papers Width across front axle [mm] see homologation papers Width across rear axle [mm] see homologation papers Wheelbase [mm]...

  • Page 9: Engine

    3. Engine 3.1. Engine technical data Engine type M97/79 Design Six-cylinder boxer Cylinders Bore [mm] 102.7 Stroke [mm] 80.4 Cubic capacity [cm³] 3996 Compression ratio approx. 14.5 Maximum revs [rpm] 9,400 [mm] Inlet valve diameter [mm] Inlet valve lift Point of maximum [°] after TDC inlet valve lift...

  • Page 10: Engine Power And Torque Curves

    3.3. Engine power and torque curves...

  • Page 11: Engine Lubrication

    3.4. Engine lubrication The 911 GT3 R is equipped with a dry sump lubrication system. The oil tank is mounted to the engine. The engine oil is cooled by an oil-water heat-exchanger mounted on the engine. 3.4.1. Engine oil Mobil 1 0W - 40 Mobil 1 5W - 40...
  • Page 12 3.4.2. Engine oil system 1 – Oil tank 9 – Piston cooling 2 – Pressure pump 10 – Timing chain tensioner 3 – Safety valve 11 – Camshaft 4 – Oil filter 12 – Camshaft housing scavenge pump 5 – Pressure sensor 13 –...
  • Page 13 3.4.3. Checking the oil level The engine oil temperature must be over 80°C and the engine running at idle speed (approx 2,200 rpm) to measure the oil level correctly. The oil level must be between the two marks on the dip-stick. The distance between the two marks corresponds to 1 litre of engine oil.
  • Page 14 3.4.5. Digital oil level display An optional oil level display is available (997.641.139.9A): The car wiring loom is already prepared for use of this display. The connector for the display is located in the area of the rear side-window on right-hand side of the car.

  • Page 15: Engine Cooling System

    3.5. Engine cooling system The GT3 R cooling system is a standard cooling system optimised for use in a race car. 3.5.1. Scheme drawing...
  • Page 16 3.5.2. Thermostat The stock GT3 R is not equipped with a thermostat. As an option a thermostat is available for cooler driving conditions (see parts catalog). When competing under warmer conditions the car should be driven without the thermostat in order to reduce the temperature level of the cooling system.
  • Page 17 The coolant remains fluid to temperatures of -15°C in delivery specification. For all race events Porsche Motorsport recommends that the factory filled engine coolant is replaced by 24.3 litres of water and 2 litres of anti- corrosion additive (part number. 997.106.907.90), which protects the...
  • Page 18 3.5.4. Filling the cooling system A quick-release coupling is integrated in the area of the expansion tank. The water system can be filled and bled quickly and safely via this coupling – after an engine change for example. Quick-release coupling Attention: When the water system has reached its operating temperature, expansion...
  • Page 19 A valve in the expansion tank allows the exhaust of steam at a pressure of 1.4 bars, and the release of water at a pressure of 1.8 – 2.0 bars. Air is drawn through the valve as the cooling system cools down. The bleed valve in the standard production car improves the initial reaction from the heating system;...
  • Page 20 Filling the system should be carried out as follows:  Disconnect the quick release fittings in the engine bay and connect the corresponding fittings with those of the filling system. Scavenge Pressure  Switch on the pump. The system will be filled. ...
  • Page 21 3.5.4.1. Filling the cooling system with engine at normal operating temperature: A special filling system to fill the engine water system when the engine is at normal operating temperature is also available from Sobek. This appliance consists of a fluid reservoir with a coupling. The reservoir is charged with a pressure of 2.5 –...

  • Page 22: Induction System

    3.6. Induction system Vacuum actuator Reso 2 (su2)  2 stage resonance induction system  Activated by vacuum actuator resonance valve 3.6.1. Under pressure routing...

  • Page 23: Throttle Butterfly

    3.7. Throttle butterfly  Electronically actuated single throttle butterfly  Redundant system (two potis)  For information on the EGAS system refer to 10.9...
  • Page 24 3.7.1. Throttle butterfly setting There is no mechanical connection between the throttle butterfly and the throttle pedal. The signal of the pedal is transferred to the throttle butterfly via an electro motor. An adjustment of the throttle butterfly is not necessary. After turning on ignition the throttle butterfly opens and closes automatically in order to determine its setting.

  • Page 25: Working On The Engine

    3.8. Working on the engine 3.8.1. Connecting-rod bolt mounting instructions  Thoroughly clean the mating faces, bolt threads and the tapped bores with cleaning grade petrol and nylon brush  Smear PLB 05 grease on the bolt threads and mating faces Tightening procedure: ...
  • Page 26 4. Initially tighten the bolts to 20 Nm, before finally tightening to 120° torque angle 3.8.3. Set valve timing 3.8.3.1. Special tools Porsche Motorsport recommends use of the following special tools to adjust and set the valve timing of the 911 GT3 Cup Base plate cylinder 1: 996.721.549.90 Base plate cylinder 2: 996.721.550.90...
  • Page 27 3.8.4. Valve clearance The valve clearance is measured between the cam follower and the cam lobe heel when the engine is cold. Inlet valve clearance [mm] 0.22 – 0.25 Exhaust valve clearance [mm] 0.22 – 0.25 3.8.5. Valve spring adjustment The valve springs are set based on spring travel.
  • Page 28 3.8.6. Removing and fitting the crankshaft seal – pulley-side 3.8.6.1. Special tools Porsche Motorsport recommends use of the following special tools to remove and fit the pulley-side crankshaft seal: Retaining key pulley: 000.721.973.20 Adapter retaining key pulley: 000.721.973.21 Press tool crankshaft seal: 000.721.216.40...
  • Page 29 4. Drill two holes (Ø 2 mm) at the centre punched points 5. Screw the threaded-end of a commercially available slide hammer -1- into the drilled holes. Carefully remove the seal -2- by swapping the slide hammer alternatively between the drilled holes 6.
  • Page 30 7. Slide the drill jig up to the seal on the crankshaft flange and position correctly 8. Coat the drill bit (Ø 2 mm) with extremely viscous grease 9. Drill at the specified points 10. Screw the pointed end of a commercially available slide hammer alternatively into the two holes and pull-out the seal.
  • Page 31 4. Push the new crankshaft seal -1- onto the crankshaft flange (mounting position: steel disc to pulley) 5. Push the press tool (see 1) onto the crankshaft flange and fit the hexagon-head bolt -3- (17 mm AF) 6. Tighten the hexagon-head nut -4- till the spacer -2- touches the crankshaft flange 7.
  • Page 32 3.8.7. Removing and fitting the crankshaft seal – crankshaft side 3.8.7.1. Special tools Porsche Motorsport recommends use of the following special tools to remove and fit the flywheel side crankshaft seal: Pressure pad: 000.721.912.60 Seal extractor jig: 000.721.971.90 3.8.7.2. Removal 1.
  • Page 33 3. After extracting the metal ring the actual seal remains in the crankcase. Under no circumstances whatsoever must this be levered out. 4. Carefully remove the drill swarf 5. Carefully drill two further 2.0 mm holes (arrows) as close as possible to the corners (metal body) of the seal.
  • Page 34 3.8.7.3. Fitting If visible carefully remove small edges or burrs from the crankshaft flange chamfer with an oil stone, afterwards carefully clean the crankshaft journal and the crankcase bore (use cleaning solvent or acetone with a clean, lint- free cloth). The crankshaft flange sealing face must not, under any circumstances, be treated with emery cloth, polish compounds or wire brushes.
  • Page 35 2. Fit the insertion-jig magnetic cone to the base plate, fit the crankshaft seal to the cone and carefully push it onto the base plate 3. Fit the seal dry 4. Remove the magnetic cone and using the pressure piece 000.721.912.60 push the crankshaft seal in a coplanar position.
  • Page 36 6. Push the crankshaft seal onto the crankshaft flange by rotating the insertion nut clockwise till the mounting dome butts completely on the crankshaft flange mounting surface. 8. Leave the assembly tools for one or two minutes in the final position, the seal and sealing lip position themselves as a result.
  • Page 37 Measurement depth is approximately 5 mm Maximum permissible misalignment is 0.5 mm 11. If the comparable values exceed the maximum difference use the insertion jig again to press home...

  • Page 38: Engine Component Tightening Torques

    3.9. Engine component tightening torques Bolt Tightening torque Component dimensions [Nm] Crankshaft and crankcase Connecting rod M10 x 1.25 see 3.8.1 V-belt pulley to crankshaft M14 x 1.5 Plug screw for pressure release valve M18 x 1.5 Oil drain bolt, crankcase M20 x 1.5 Water drain bolt, cylinders M10 x 1...

  • Page 39: Engine Mileage

    3.10. Engine mileage The engine in the 2010 911 GT3 R is designed to rev to a maximum of 9,400 rpm, in this case the rebuild interval is 30 hours...

  • Page 40: Fuel And Exhaust System

    4. Fuel and exhaust system 4.1. Fuel system Pressure regulator Engine supply Fuel filter Main pump Reserve pump  No return fuel system FT3 safety fuel cell   Fuel cell volume: 100 l  Integrated 10 l catch tank (double tank: 6,5 + 3,5 l) ...

  • Page 41: Fuel Cell

    4.2. Fuel cell Attention: The fuel tank volume must be measured and adjusted before the first competition to ensure that the capacity does not exceed that stated by the relevant regulations. Both the main and reserve fuel pumps are of the electrical vane type. The fuel filter is located in the front luggage compartment and should be replaced after approximately every 24 hours of use.
  • Page 42 Attention: The fuel pumps should not be activated under any circumstances if tank-engine quick release couplings are disconnected. Fuel pressure peaks in the system can cause leakage, and in the worst case the system pressure can exceed the burst pressure of the fuel filter. 4.2.1.
  • Page 43 4.2.2. Fuel 98 ROZ DO NOT drill holes in the area of the fuel cell. DO NOT use sharp objects when removing the fuel cell from the car. 4.2.3. Reserve pumps A reserve fuel pump is fitted as standard and is activated from a switch mounted on the dashboard.

  • Page 44: Exhaust System

    4.3. Exhaust system 4.3.1. Standard system 4.3.2. Catalytic converter 100 cells...

  • Page 46: Gearbox

    5. Gearbox The six-speed sequential gearbox fitted to the GT3 R is fitted with a limited slip differential, an oil filter and a water / oil heat-exchanger for cooling purposes. The gear pairs are uniquely matched and should never be mixed.

  • Page 47: Gear Ratio Diagram

    5.2. Gear ratio diagram 9000 8000 7000 6000 5000 4000 3000 2000 1000 v (km/h)

  • Page 48: Gear Position Recognition

    5.3. Gear position recognition To determine the gear selected electronically a potentiometer, in which a defined current drops subject to the gear selected, is mounted to the gearbox. The gear recognition is required for the power interruption when shifting gear. 5.3.1.

  • Page 49: Differential

    5.4. Differential The limited-slip differential has a locking torque of 45 % / 65 % (power / overrun) (dynamic locking value). The differential is checked by means of a friction test in which the preload and wear of the clutch disc plates are determined. 5.4.1.

  • Page 50: Working On The Gearbox

    In the event of more comprehensive damage, which necessitates the replacement of gearbox housings, we strongly recommend that this is undertaken by Porsche Motorsport. Complex measurement and adjustment, which could not be included in these instructions, are necessary to guarantee that the gearbox works perfectly.
  • Page 51 (approx. 3 litres for a newly build gearbox)  Close the oil overflow pipe and add 1.0 litre of oil Filler plug Oil drain plug Overflow pipe Porsche Motorsport recommends the use of Mobil Mobilube SHC.
  • Page 52 5.6.3. Changing gear ratios  Lock the gearbox  Open closure plate on gear ratio housing  Remove circlip from the M32 x 1.25 nut Remove anti-rotational safety   Loosen M32 x 1.25 nut Completely remove gear ratio housing ...
  • Page 53  To change the 1 and 2 gear shaft remove the differential  Remove reverse-gear shaft support  Remove oil pump drive gear Remove 35x1.5 circlip from input shaft  (differential side) Input shaft circlip Ensure that the washer under the circlip (part of bearing inner race) is seated correctly when fitting the input shaft.
  • Page 54  Place intermediate and drive plates alternately in the cage  The “FS” (Flywheel Side) mark on the drive plates must point towards the engine. Furthermore the “FS” mark of each drive plate should lie on top of each other “FS” mark FS - Mark ...
  • Page 55  Then insert drive plate 3 and intermediate plate 4 Attention: The clutch plates should be refitted in the original sequence and orientation. Please observe the markings on the edges.
  • Page 56 The gearbox input shaft bearing-journal must be smeared lightly with copper grease (Porsche part number 000.043.004.00) before assembly. 5.6.5. Release bearing Under no circumstances whatsoever must gearbox come into contact with the clutch release bearing seal otherwise the seal can swell which, in the worst case, can result in the seal not functioning correctly.
  • Page 57 5.6.6. Gearbox maintenance The following work should be carried out regularly:  Check gear ratio teeth, dogs and dog-rings Check the shift collars   Check the gear hub and gear roller bearings for signs of wear and pitting  Check the oil for signs of metallic debris The following work should be carried out after a total running time of approximately 30 hours:...
  • Page 58 5.6.7. Starter motor maintenance The starter motor maintenance includes the following work: After each race: Shell Stamina Grease HDS ET.Nr.: 997.605.920.9A (400 g)

  • Page 59: Gearbox Component Tightening Torques

    Every 6,000 km it is recommended to send the starter for an complete overhaul to Bosch Motorsport: Bosch Engineering GmbH Motorsport An der Bracke 9 D - 71706 Markgröningen Tel.: 0711 811 3981 www.bosch-motorsport.com 5.7. Gearbox component tightening torques Tightening torque Component Bolt dimensions [Nm]...

  • Page 60: Suspension

    6. Suspension Both the front and rear suspension have been modified to suit the demands of competition and to enable the accurate and easy adjustment of camber, wheel alignment and ride height. The front suspension is of the independent McPherson strut type with aluminium wishbones and the rear suspension is multi-link with ‘LSA –...
  • Page 61 When changing the existing dampers for those of another manufacturer, it is necessary to ensure that the recommended ride height and spring travel values are retained. Porsche AG does not accept any liability for any subsequent damage to the suspension or related components.
  • Page 62 6.1.2.3. Damper curves (F2T1) 4000 3500 3000 2500 2000 1500 1000 -500 -1000 -1500 -2000 -2500 -3000 -3500 -4000 -4500 -5000 0,131 0,262 0,393 0,524 piston speed [m/s]...
  • Page 63 6.1.3. Front anti-roll bar The front anti-roll bar has a 7 position adjustment range on both sides, each position results in the blade being adjusted by an angle of 15°. The maximum stiffness of the anti-roll bar is achieved when the blade is aligned parallel to the anti-roll bar link.
  • Page 64 6.1.4. Steering system The 911 GT3 R is fitted with an electrical servo assisted rack and pinion steering system. 6.1.4.1. Servo pump control Control of the electrical servo pump is made via terminal 61. This means that the servo pump only operates when the engine is running and the alternator is charging..
  • Page 65 Bleeding the steering system: This procedure is best carried out by two people. To fill the complete steering system after fitting a new steering rack, oil lines or because of excessive hydraulic fluid loss, start and then immediately stop the engine several times. This procedure causes the fluid level in the reservoir to sink rapidly, therefore ensure that the reservoir is refilled constantly with ‘Pentosin’...

  • Page 66: Rear Suspension

    6.2. Rear suspension Multi-link suspension   Adjustable main spring Adjustable anti-roll bar   Two way adjustable dampers 6.2.1. Rear springs The rear coil spring has a four-step adjustment range, the corresponding spring rates are listed in the table below: Colour Part number Stiffness Range [N/mm]...
  • Page 67 When changing the existing dampers for those of another manufacturer, it is necessary to ensure that the recommended ride height and spring travel values are retained. Porsche AG does not accept any liability for any subsequent damage to the suspension or related components.
  • Page 68 6.2.2.3. Damper curves (N FB2T1) 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 -500 -1000 -1500 -2000 -2500 -3000 -3500 -4000 -4500 -5000 -5500 -6000 -6500 0,131 0,262 0,393 0,524 piston speed [m/s]...
  • Page 69 6.2.3. Rear anti-roll bar The rear anti-roll bar has a 7 position adjustment range on both sides, each position results in the blade being adjusted by an angle of 15°. The maximum stiffness of the anti-roll bar is achieved when the blade is aligned parallel to the anti-roll bar link.

  • Page 70: Basic Wheel Alignment

    Maximum running time: 30 hrs Grease quantity outer joint: 90 g Grease quantity inner joint: 100 g Porsche part number: 000.043.110.01 6.3. Basic wheel alignment In the event of an accident or any other damage occurring to the suspension every component, including those not directly affected, should be measured, checked for cracks and, where necessary, replaced (e.g.
  • Page 71 Porsche Motorsport parts sales offers a cord alignment tool: 997.450.351.90 Bracket front left: 997.450.561.90 Bracket front r ight: 997.450.562.90 The following points must be followed before alignment can begin: Set the front and rear tyr e pressures to hot running pressure, if ...
  • Page 72 6.3.1. Front axle 6.3.1.1. Ride height The car must be p laced on a level surface (set- up platform) to check the ride height. The fron t and rea r suspension shoul d be loaded and unloaded ompressed) several times to allow the suspension to settle. reference plane The ride height is adjusted by rotating the lower spring platform.
  • Page 73 6.3.1.2. Toe The toe-rod length can be set using the clamping screw. Clamp screw Porsche Motorsport provides a special tool to remove the trunnion pin: 997.450.349.9B 2 mm spacer 2x 4 mm spacer The steering gear is shimmed on the two mounting points by a 3 mm...
  • Page 74 1 mm adjustment in length equates to a camber change of approximately 13’.  Trailing arm mounting hole: The mounting position of the trailing arm should no t be changed (wheel clearance)  Porsche Motorsport provides a special tool to remove the trunnion pin: 997 .450.345.9B)
  • Page 75 6.3.1.4. Trailing a 28 mm Buchse 8 mm Buchse 6.3.1.5. Upper mount The upper-mount position can be adjusted by using the slots in the car body.
  • Page 76 6.3.2. Rear axle 6.3.2.1. Ride height The car must be placed on a level surface (set-up platform) to check the ride height. The front and rear suspension should be loaded and unloaded (compressed) several times to allow the suspension to settle. reference plane Ride height adjustment is made by rotating the spring perch.
  • Page 77 6.3.2.2. Toe The length of the toe-rod can be adjusted using the clamp bolt. Bearing journal Spacers Clamp bolt 2x 4 mm Scheibe 2 mm Scheibe...
  • Page 78 1 mm adjustment in length equates to a camber change of approximately 10’. Trailing arm mounting hole: The mounting position of the trailing  arm should not be changed (wheel clearance)  Porsche Motorsport provides a special tool to remove the trunnion pin: 997.450.345.9B...
  • Page 79 6.3.2.4. Trailing a 8 mm Buchse 28 mm Buchse...
  • Page 80 6.3.2.5. Upper wishbo Upper rear-wishbone front Upper rear-wishbone rear Rear upright, left 6.3.3. Summary of suspension geometry adjustment components Front Part number Rear Part number Lower wishbone + spacer shims [mm] 996.341.543.95 996.34 1.543.95 996.341.543.93 996.341.543.93 996.341.543.92 996.341.543.92 996.341.543.91 996.341 .543.91 996.341.543.90 996.341.543.90...
  • Page 81 6.3.4. Suspension set he basic settings for the suspension are listed in the following table. hese settings can be used as the basic set-up for the majority of race acks. Performance Setup Front Rear Remark left / right left / right Ride Height 67 mm 87 mm...

  • Page 82: Working On The Suspension

    6.4. Working on the s uspension 6.4.1. Changing wheel bearings ollow the following points when changing defect wheel bearings:  Heat the upright to 110°C to remove or fit the wheel bearing  ss the w heel bearing out of t he upright ...

  • Page 83: Tightening Torques Suspension

    6.5. Tightening torques suspensi 6.5.1. Front axle Tightening Torque Position Dimension [Nm] M14 x 1.5 x50 M12 x 1.5 x30 M12 x 1.5 M10 x 1.5 45 with Loctite 243 M12 x 1.5 75 (replace after dismounting) M14 x 1.5 M14 x1.5x120 M12 x 95 10.9...
  • Page 84 6.5.2. Front upright Tightening Torque Position Dimension [Nm] Coppe r paste thin n: thread, ge aring, front side M6 x 16 8.8 M8 x 35 10.9 Grease b with l ongtime grease 31 w ith Lo ctite 270 470 (retig ten after 100 km when r eassembled) , Cop...
  • Page 85 6.5.3. Anti roll bar fro Tightening Torque Position Dimension [Nm] M8 LH...
  • Page 86 6.5.4. Suspension stut fro Tighteni ng T orque Position Dimension [Nm] M6 x 12...
  • Page 87 6.5.5. Steering gear Tightening Torque Position Dimension [Nm] M10 x 45 10.9 M18 x15 90 (track rod on steering gear) M14 x 1,5 M6 x 20 M14 x 1 ,5 12 x 1.5 10.9 75 (replace afte r dismounting)
  • Page 88 6.5.6. Steering colum Tightening Torque Position Dimens M8 x 35 1 M5 x M16 x 50 +5...
  • Page 89 6.5.7. Side part rear Tightening Torque Position Dimension [Nm] M12 x 97 75 with Loctite 270 M12 x 1.5 10.9 M12 x 80 M12 x 1.5...
  • Page 90 6.5.8. Rear axle Tightening Torque Position Dimension [Nm] 45 with Loctite 243 M12 x 1.5 75 (replace after dismounting) M14 x 1.5 M14 x 1.5 M12x1.5 M12 x 70 M12 x 1.5 M6 x 20 M14 x 1.5 75 (replace after dismounting)
  • Page 91 6.5.9. Upright rea Tightening Torque Position Dimension [Nm] M8 x 35 31 with Loc tite 270 Grease hu b with longtime greas 470 (retighten after 100 km when reassembled), Copper paste on contact surface 500 + 25 M6 x 16 M6 x 12 M6 x 1 Replace...
  • Page 92 6.5.10. Anti roll bar r Position Dimension Tightening Torque [Nm] M4 x 10 M8 LH M8 x 25 M6 x 12...
  • Page 93 6.5.11. Suspension strut r Tighteni ng T orque Position Dimension [Nm] 3 upper M12 x 1 3 lo wer M12 x 1...

  • Page 94: Sachs Damper Service Information

    6.6. Sachs damper servi ce information Service partners for Germany: ZF Sachs Race Engineering GmbH Ernst-Sachs-Straße 62 97424 Schweinfurt Phone +49 9721 983258 Fax: +49 9721 984299 Gallade Technologiezentrum am Nürburgring Rudolf-Diesel-Straße 11 – 13 53520 Meuspath Phone +49 2691 9338-54 +49 2691 9338-50 Service partner for the UK: BG Motorsports Ltd...
  • Page 95 Oceanshore Mo torsports avid Glenn 5892 John Anderson Highway 32136 Flagler Beach, FL Phone +1 386 67319 +1 386 673 1184 Service partner for Asia: nable Inc. Technical center 1 – 36 Ootsuzaki Ogakie-cho Kariya-shi, Aichi-ken, 448-081 Japan Phone +81 566 62 86 05 +81 566 62 86 07 After 2,500 km the d ampers should be overhauled.

  • Page 96: Wheels

    Left-hand side of car = right-hand thread, colour red Porsche recommends that the wheel nuts are also changed during a long distance race (after approximately 6 hours running) and to inspect and service them, which means cleaning the thread, visual inspection and re- grease with Klüber Nontrop RB3 999.917.507.00.
  • Page 97 Please check the setting (tightening torque) of the wheel gun. Tests have shown that the centre-lock threads can be damaged if the w heel gun is correctly set. The above mentioned procedure must be strictly adhered to. A contro l test must also be carried out to ensure that the required ghtening torque is also achie...

  • Page 98: Brake System

    8. Brake system The GT3 Cup is fitted with a dual circuit brake system incorporating two separate brake master cylinders. The front to rear brake balance ratio is set by rotating the brake balance knob. 8.1. Technical data brake system Front axle Rear axle Master cylinder...
  • Page 99 8.2.1. Brake balance system If the brake balance potentiometer is rotated the lever ratio (dimension x) on the balance bar is adjusted directly by a adjuster cable Balance bar rod acer Balance bar...
  • Page 100 Pedal force Brake Brake force VA force HA  pedalforce  brakeforce rear   brakeforce front pedalforce brakeforce rear 8.2.1.1. Basic setting balance bar The fo llowing dimensions must be set in the basic setting (0). Adjuster cable fitting...
  • Page 101 In addition one has to take care fo r sufficient axial play o f the balance bar. Thererfore lay of 0.9 … 1.5 mm between the plastic spacer and the fork end hast to be set. The adjustment of the play is performed by altering the difference between the two fork ends.
  • Page 102 In addition, it should also be noted that with the maximum positive rotation in the anti-clockwise direction (+7) there must be a 2 mm gap between adjust er cable lock-nut and the front brake master cylinder pushrod clevis to pr event the clevis colliding with the lock-nut.
  • Page 103 The following parts in the system should be cleaned and re-greased regularly: Balance bar bearing Balance bar rod floating bearing Porsche Motorsport recommends the used of Autol Top 2000 grease.
  • Page 104 AP Racing provides a repair kit for the brake master cylinder The repair kit includes the following parts: 4 -- Main seal 5 -- Piston shim 7 -- Secondary seal 10 -- Circlip 11 -- Rubb er boot Repair kit installation: 1.

  • Page 105: Brake Caliper

    Porsche Motorsport provides a repair kit for brake calipers which includes new pistons and seals. There are two bleed nipples on each brake caliper. If a pressure manometer is connected to the caliper it should be noted that the system including manometer is bled.

  • Page 106: Chassis

    DO NOT under any circumstances modify the roll-cage as its struct ural integrity will be compromised. DO NOT weld additional rackets, or drill holes in the tubes. If in doubt please contact Porsche Motorsport. All unnecessary panels and sound proofing materials have been removed to reduc e weight.

  • Page 107: Exterior

    9.2. Exterio 9.2.1. Front bumper...

  • Page 108: Rear Wing

    9.3. Rear wing Left wing support Gurney 10mm ...

  • Page 109: Fire Extinguisher System

    9.4. Fire extingu isher system he car is equipped with an FIA homologated fire extinguishing system using AFFF as extinguishing agent. The extinguishant cylinder has two separate chambers each with a two kilogram capacity. The extinguishing agent is discharged through three nozzles located in the engine bay and a further three located within the cockpit.
  • Page 110 9.4.2. Extinguisher system error ana lysis Battery check:  Hold the toggle switch on the trigger box in the “Battery Check” position  If the battery charge state is good the trigger box warning lamp will blink Warning lamp does not glow: ...

  • Page 111: Air-Jack System

    Never open the air jacks: There is residual pressure in the system ev en when jacks are retracted!  Porsche Motorsport recommends that the system is overhauled after 2000 lifts or two years  The torque setting for the grooved nut (air-jack fixed mount) must...
  • Page 112  If a loose or incorrectly tightened air-jack is discovered this must be changed immediately  Please refer to the manufacturer’s product description (Krontec) for further safety measures KRONTEC Maschinenbau GmbH Pommernstraße 33 D - 93073 Neutraubling www.krontec.de 9.5.1. Car lift system Never u se a th ird party product as this can lead to damage to the air-jack...

  • Page 113: Electric

    10. Electric 10.1. Alternator  TAG 140 A 0.2. Battery  V, 80 Ah 10.3. Steering wheel  Quick-release ra ce steering wheel The two parts of the release coupling are balanced  together and therefore have to be used in only one combination (numbers on steering wheel and hub must match) Steering wheel...
  • Page 114 DO, UP Adjust traction control setting RADIO Radio SPEED Speed limit HIGHBEAM Headlight flash, if the button is pressed for about 1 second the headlights stay on till the next time the button is presse WIPER Wiper DISPLAY Change MoTeC display pages ALARM Reset MoTeC Alarm Change engine characteristics...

  • Page 115: Centre Console

    10.4. Centre console MAIN SWITCH: Main power supply IGNITION: Ignition FIRE: Fire extuingisher LIGHT: Head light ABS: ABS on / off WINDSCR Pulled: 100% windscreen Pushed: floor, air vents, driver ventilation FUEL PUMPS: Fuel pump Bosch: Pump runs when engine runs Middle position: Fuel pumps off Service: Pumps run with ignition (o nly to...

  • Page 116: Shift Light Module

    INTANK PUMPS: same as FUEL PUMPS for the Intank pumps FAN: Driver cooling (on or off) DRY/WET Traction control mode MOTEC MODE: Switch through the different MoTeC display setups (practice, warmup, race) HAZARD Hazard lights FOG REAR: Fog lights 10.5. Shift Light Module The Shift Light Module (SLM) is located above the MoTeC dash.

  • Page 117: Motec Dash

    10.6. MoTeC Dash The M oTeC Dash fitted has a 1 MB memory. This has a recording capacity of approximately 15 minutes. The Cup MoTeC system is sold exclusively worldwide by Brückle– Motorsport. If information and/or a system is required please contact Brückle–Mot orsport directly.
  • Page 118 10.6.1.1. Race mode Centre Left Right Bottom The lower (bottom) display line can be changed via the steering wheel mounted ‘Displ ay’ switch. Left: Speed Brake balance Centre: Gear Top: Traction control setting Throttle valve angle ight: Actual lap time Previous lap-time Bottom: Engine temperature...
  • Page 119 10.6.1.2. Practice mod Left: Speed / Wheel Speed Brake bias Centre: Gear Top: Traction control setting Throttle valve angle Right: Engine speed Previous lap time Bottom: Engine temperature Engine oil temperature Engine oil pressure Fuel pressure Gearbox oil temp ient temp Battery voltage on dash VOLTS Distance covered...
  • Page 120 Vertical acceleration G-Vert Lateral acceleration Longitudinal acceleration Odometer TRIP_D Trip distance STANG_W Steering angle SW_ANG Steering wheel ang Gearbox potentiomete GEARS...
  • Page 121 10.6.2. MoTeC Dash configuration The existing configuration can be modified with the software ‘ADL2 Dash Manager’. The following version is required: DM2_450Y6_P Communication PC - MoTeC Dash only function with this version. Delivered with the car is a CD with the p rogramme and the con figuratio n used.

  • Page 122: Car Sensors

    10.7. Car sensors Sensor MoTeC Modas Nominal value Engine < 100°C Oil temp Oil Temp toil < 90°C Water temp Water Temp tmot Oil pressure Oil Pressure poil > 3 bar ATTENTION: ABSOLUTE PRESSURE ng Coolant Pres - Water pressure System pwat >...

  • Page 123: Engine Control Unit (Ecu)

    GT3 R is equipped with a Bosch MS 4.0 ECU specially developed for motorsport applications. The Bosch MS 4.0 can be programmed with special software. The ECU is programmed exclusively by Porsche Motorsport. If an engine is overhauled by Porsche Motorsport the ECU should be delive...

  • Page 124: Egas

    10.9. EGas The following points have to be observed when dealing with the system Egas: 10.9.1. Hardware requirements The EGas system can only function if the hardware requirements specified in points 10.9.2 to 10.9.6 are observed. If one of more of the constraining conditions are violated the system must not be operated further.
  • Page 125 10.9.5. Emerge ncy-stop switch The system must have an emergency-stop switch which, when actuated, must a t least isolate the throttle butterfly actuator from the power supply. olation of the control unit primary power supply is also permitted. The emergency-stop switch in the car must be clearly visible, and be easily activated by the driver.
  • Page 126 10.9.12. Transfer to third par ties Cars equipped with a motorsport EGas system from Bosch Engineering GmbH must not be transferred to third parties by Porsche AG without reference to these operating regulations. 10.9.13. Damage to the system If the hardware components described in 10.9.2 to 10.9.6 are damaged...
  • Page 127 10.9.14. Operating principle There is no mechanical connection between the accelerator pedal the the throttle valve. The pedal as well as the throttle valve are equipped with two potentiometers (redundancy) 10.9.14.1. Pedal characteristics The characteristics of the accelerator pedal (ratio pedal angle - throttle valve angle) can be adjusted by the Bosch Modas system.

  • Page 128: Abs

    10.10. ABS The ABS function is realised as a compromise between driveability and break performance. Driveability is of big importance on a street car. The ABS is supposed to allow the driver to control the car under each ircumstances. For motorsport purposes this compromise has been shifted towards the optimum brake performance.
  • Page 129 10.10.2. Mea suring vehicle dynamics The ABS allows the driver to brake near the locking limit of the wheels. By preventing the locking of a wheel the systems ensures braking in the optimum deceleration range. o determine the vehicle’s driving state the following data is permanently measured: ...
  • Page 130 10.10.3. Usage of different tires The application of the ABS System of the 911 GT3 R has been carried out with Michelin tires. Therefore, the stored tire circumference is valid for the actual Michelin tires. This circumference is 037 mm on the front and 2230 mm on the rear If different tires are used o ne has the possibility to adapt a different...
  • Page 131 10.10.4. Hydraulic control unit Hydraulic control unit with integrated ECU Connecting cable Rear brake circuit Front brake circuit Front left brake line Rear right brake line Front right brake line Rear left brake line...
  • Page 132 10.10.4.1. Characteristics  Integrated analogical valves for an optimised controllability  5 integrated pressure sensores (front brake circuit, wheel specific brake pressures)  Directly wired wheel speed sensors (transmitted to MoTeC via CAN) 10.10.5. Turn off ABS Due to the optimum brake performance it is not recommended to turn the system off.
  • Page 133 In case a wheel speed sensor is disconnect and the ABS is activ e. The ABS error gets active. When the sensor is connected and works properly the error message disappears wh en a ground speed of 20 kmph is achieved.

  • Page 134: Traction Control

    10.11. Traction control The 911 GT3 R is equipped with a traction control. The application of the system is carried out by Bosch Modas. comparison of desired and actual slip is the basic principle of the traction control. A PID controller takes care of the necessary torque corrections.
  • Page 135 10.11.1.1. Target slip FSLSV is the base factor for the calculation of the target slip. It reflects the tyre/racetrack characteristics. FSL SV affects a 3D map which is ddressed by TC switch position and ground speed. This parameter works like a multiplier on the complete TC calculation. If problems w ith the TC occur, first try to work on this map in order to ne traction control to your (and the drivers) liking!
  • Page 136 10.11.1.4. PID controle FPASR is the amplification factor of the P-component of the TC controller. The P-component (proportional component) of the controller can be adjusted via this value. This controller component works proportionally on the deviation. This controller determines the effectiven ess of the control t the start of regulation.
  • Page 137 10.11.1.5. Driver influenc KLMIFAASR (dry condition) and KLMIFAASR_WET (wet condition) are factors to calibrate the driver influence to the TC controller. Both are 2D maps with breakpoints addressed by the TC switch position. This factor is included to give the driver the opportunity to influence the TC intervention with „his right foot“.
  • Page 138  If you are not sure about your calibration, go back to the neutral values.  Watch the recorded data and compare to this manual to find solutions to your problem! If the TC does n‘t work fine, first check the incoming signals: ...

  • Page 139: Relay- And Fuse Assignment

    10.12. Relay- and fuse ass ignment 10.12.1. Fuse holder...
  • Page 140 10.12.2. Hydraulic control unit ABS The fuse for the pump of the hydraulic control unit is situated in the front trunk on the left side. The fuse has to be secured by a tie wrap. 10.12.3. Power steering pump The fuse for the power steering pump is situated in the front trunk on the right side.
  • Page 141 10.12.4. MS4 sensor system...

  • Page 142: Car Maintenance

    11. Car maintenance Porsche Motorsport recommends that following minimum maintenance work is carried out after the corresponding mileage: 11.1. After approx. 200 km and/or first test  Visual inspection of all systems. hoses and cables etc. for leakage. damage or chafing ...

  • Page 143: After Every Race Weekend (Sprint)

    11.3. After every race wee kend (sprint) In addition to points in 11.2:  Engine oil and filter change (after ‘hot races’  engine oil > 110°  Check compression and pressure loss of each cylinder  Clean/replac e air filter ...
  • Page 144 Porsche AG reserves the right for te chnical changes. © Copyright by Dr. Ing. h. c. F. Porsche AG...

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