Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Porsche 2015 911 GT3 Cup
Summary of Contents for Porsche 2015 911 GT3 Cup
- Page 1 Technical manual 911 GT3 Cup (991) MY 2015...
-
Page 2: Preface
This document should give you the opportunity to look up data, settings, und operating regulations, and to facilitate maintenance or repair of the vehicle. We wish you many sporting successes with your 911 GT3 Cup (991). Customer Sport Dr. Ing. h.c. F. Porsche Inc. Motorsport Sales 911 GT3 Cup (991) Version: 16.12.2014... -
Page 3: Version: 16.12.2014
Due to the constant improvement of our products and the related documentation at the time of your purchase, a new version of this technical manual could be available. The latest Version is always accessible at the "Porsche Motorsport race car service information" database (PMRSI), and can be downloaded on the following homepage. -
Page 4: Gt3 Cup (991 My 2015
Mr. Christoph Werner Tel. + 49 (0) 711 911 82690 Hr. Stefan Rometsch Tel. +49 (0)711 911 89946 Fax. + 49 (0) 711 911 89535 Porsche Mobil 1 Mr. Jonas Krauss Tel. + 49 (0) 711 911 84042 Supercup Assistent Fr. -
Page 5: Table Of Contents
Contents Preface Preface 1 Engine General Specifications Engine lubrication 1.3.1 Engine oil circuit 1.3.2 Oil level measurement 1.3.3 Refilling engine oil 1.3.4 Engine oil Engine cooling system 1.4.1 Schematic diagram 1.4.2 Thermostat 1.4.3 Coolant 1.4.4 Filling the cooling system 1.4.5 Races at low temperatures Intake system 1.5.1... - Page 6 1.10 Engine run time 1.10.1 Behavior when exceeding the maximum speed Preface 2 Powertrain General Clutch 2.2.1 Installation instructions 2.2.2 Clutch wear 2.2.3 Fluid for clutch actuation 2.2.4 Central release mechanism Sequential six-speed gearbox 2.3.1 Overview 2.3.2 Technical specifications 2.3.3 Gear set 2.3.4 Drive...
- Page 7 Transmission dismantling 2.8.1 Dismantling of hang-on parts Preface 2.8.2 Gear housing dismantling 2.8.3 Gear set removal 2.8.4 Dismantling the shift drum 2.8.5 Dismantling the locking sleeve 2.8.6 Oil supply 2.8.7 Cross shaft dismantling 2.8.8 Pinion shaft dismantling 2.8.9 Differential removal 2.8.10 Central clutch operator removal 2.8.11...
- Page 8 3 Chassis Preface General 3.1.1 Wheel bearing 3.1.2 Wheel hub 3.1.3 Wheel nut 3.1.4 Locking piece Front axle 3.2.1 Front axle cross member 3.2.2 Front axle transverse control arm 3.2.3 Longitudinal control arm 3.2.4 Front axle wheel mount 3.2.5 Front axle shock absorber 3.2.6 Front axle anti-roll bar Rear axle...
- Page 9 Brake pressure distribution 3.8.1 Balance beam basic setting Preface 3.8.2 Calculating the brake power Balance bar replacement kit 3.9.1 Replacing the trunnion 3.9.2 Replacing the balance bar 3.10 Performance setup 4 Bodywork General Front and side view Rear view Body shell 4.4.1 General 4.4.2...
- Page 10 4.10 Trunk and engine lid 4.10.1 Trunk lid Preface 4.10.2 Engine lid 4.11 Windows 4.11.1 Installing and removing the windshield 4.11.2 Preparing the window cutout for installation 4.11.3 Preparing the windshield for installation 4.11.4 Installing the windshield 4.12 Fenders 4.13 Wheel cover 4.14 Fuel system 4.14.1 Fuel...
- Page 11 6 Electrical system Preface General Power supply 6.2.1 Battery 6.2.2 Generator 6.2.3 Battery master switch Electrical system protection 6.3.1 Electrical system control unit IPS32 6.3.2 Fuse holder hydraulic pump DME engine electronics 6.4.1 DME control unit 6.4.2 DME diagnosis 6.4.3 Carburation 6.4.4 Ignition system...
- Page 12 6.12 Driver Control Systems 6.12.1 Steering wheel Preface 6.12.2 Center console 6.12.3 Windscreen wiper 6.12.4 Interior fan switch 7 Maintenance Engine 7.1.1 Oil level measurement using the dipstick 7.1.2 Oil level measurement with display 7.1.3 Changing the engine oil 7.1.4 Refilling engine oil 7.1.5 Oil specification...
- Page 13 Electrical system 7.6.1 Checks after wet races Preface Maintenance intervals 7.7.1 After 200 km (124 mi) or first test drive 7.7.2 After each session 7.7.3 After each weekend (sprint race) 7.7.4 After 3 – 4 race weekends (sprint races) 7.7.5 After 30 hours run time 7.7.6 After 50 hours run time...
-
Page 14: Engine
Engine Engine General The engine of the new 911 GT3 Cup (991) is based on the proven drive unit of the street-legal 911 GT3 RS and has been redesigned especially for use in motor sports. New features include the electronic accelerator and the accompanying throttle. Furthermore, the Bosch Motronic MS4.6 controller has been used as engine control. -
Page 15: Specifications
Specifications Engine Full load curves (key: red=torque, blue=power) 1.2.1 Engine specifications Number of cylinders Type six-cylinder boxer engine Valves/cylinders Displacement 3,797 cm Hole 102.7 mm Stroke 76.4 mm Compression approx. 12 : 1 Maximum speed 8,500 rpm Intake valve diameter 41 mm Intake valve stroke 12.0 mm... -
Page 16: Engine Lubrication
Engine lubrication Engine The 911 GT3 Cup (991) is provided with dry sump lubrication. This type of lubrication system design ensures a consistant pressure oil supply to the engine components requiring lubrication in any driving situation. The oil tank, which is installed separately on the front side of the engine, always contains enough oil to supply the oil pump. -
Page 17: Engine Oil Circuit
1.3.1 Engine oil circuit Engine 1.3.1.1 1 – Oil tank 9 – Injector 2 – Positive displacement pump 10 – Chain tensioner 3 – Safety valve 11 – Camshaft 4 – Oil filter 12 – Hydraulic valve lifter 5 – Pressure sensor 13 –... -
Page 18: Oil Level Measurement
Without oil filter change: 8.1 liter (8.8 qts.) • 1.3.4 Engine oil When the engine is inspected by Porsche, the engine oil is always changed. The following specification is used for this purpose: • Mobil 1 0W – 40 911 GT3 Cup (991) Version: 16.12.2014... -
Page 19: Engine Cooling System
Engine cooling system Engine The cooling system ensures the engine’s temperature during operation. The heat produced by combustion is released in a controlled way to the environment via three water radiators installed in the front, thus protecting the engine from overheating. Furthermore, two oil/water-heat exchangers are installed in the cooling circuit. -
Page 20: Coolant
(11.6 qts.) of low temperature/freezing protection, ensuring a low temperature/freezing protection up to -30° C (-22° F). For all racing events, Porsche Motorsport recommends substituting the factory filled coolant with 20 liters (21 qts.) of water and 2 liters (2.1 qts.) of corrosion protection (spare part no. -
Page 21: Intake System
Intake system Engine 1 – Vacuum cell (large flap) 2 – Vacuum cell (small flap) 1.5.1 1.5.1 Resonance flaps • Four-stage resonance intake system • Resonance flaps controlled by vacuum cells (2x) The resonance flaps open and close depending on the speed of the engine and thereby have a positive influence on the airflow within the intake system, thus contributing to a power/torque increase. -
Page 22: Throttle
1.5.2 Throttle Engine The electronic throttle controls the air supply to the engine by means of an integrated electric motor. The use of a mechanical operator such as throttle cable is therefore not required. 1.5.2.1 • Electronic throttle • Redundant design by using 2 potentiometers Throttle Setting There is no mechanical connection between the throttle and accelerator pedal. -
Page 23: Work On The Engine
Work on the engine Engine 1.6.1 Cylinder head installation Follow the steps below for cylinder head installation: Lightly oil the threads and contact surfaces Pre-tighten to 30 Nm (22 ft-lb) in the specified order Wait for 15 minutes 1.6.1.1 Completely untighten the bolts in the reverse order Tighten all bolts first to 20 Nm (14.75 ft-lb), then with 120°... -
Page 24: Flywheel Tightening Instructions
Setting the valve timing Cylinder base plate 1: 996.721.549.90 Cylinder base plate 2: 996.721.550.90 Porsche Motorsport recommends using the special tools indicated on the right for Guide element intake/ setting the valve timing on the 911 GT3 Cup (991). exhaust valve lobe center line 110/110: 996.721.551.9A... -
Page 25: Removing And Installing The Crankshaft Seal - Pulley Side
1.6.4 Removing and installing the crankshaft seal – pulley side Engine Special tools Porsche Motorsport recommends using the following special tools for installing or removing the crankshaft seal on the pulley side: • Pulley holding key: Porsche ET-No.: 000.721.973.20 Pulley holding key insert: Porsche ET-No.: 000.721.973.21... -
Page 26: Version: 16.12.2014
Drill holes at the punch-marked locations using a drill (Ø 2 mm) Engine 1.6.4.2 Screw in the screw head of a commercially available slide hammer puller (1) alternately into the holes and carefully in an alternating way remove the sealing ring (2). -
Page 27: Version: 16.12.2014
Create a drilling template according to the sketch below (cardboard or thick paper), all dimensions indicated in millimeters (50=1.97”, 30=1.18”, 23=0.91”, Engine 2=0.08”) 1.6.4.4 Push and position the template on the crankshaft flange up to the sealing ring Wet the drill (Ø 2mm) sufficiently with heavy-duty grease Drill holes at the specified locations 10. -
Page 28: Version: 16.12.2014
Installation Engine Put together fitting tool (1) Porsche ET-No.: 000.721.216.40 with spacer ring (2) 000.721.979.71 1.6.4.5 Always dry mount the crankshaft seal, do not use grease Push protective cap (1) Porsche ET-No.: 000.721.979.70 onto crankshaft flange 1.6.4.6 911 GT3 Cup (991) Version: 16.12.2014... -
Page 29: Version: 16.12.2014
Slide the new crankshaft seal (1) on the crankshaft flange (mounting position: steel disk towards belt side) Engine 1.6.4.7 Slide the fitting tool (see 1.) on the crankshaft flange and screw in hexagon bolt (3) (wrench width SW17) Tighten hexagon nut (4) until spacer ring (2) fits snugly on the crankshaft flange 1.6.4.8 Leave the tool mounted for approx. -
Page 30: Removing And Installing The Crankshaft Seal - Flywheel Side
1.6.5 Removing and installing the crankshaft seal – flywheel side Engine Special tools Porsche Motorsport recommends using the following special tools for installing or removing the crankshaft seal on the flywheel side: • Pressure piece: Porsche ET-No.: 000.721.912.60 Seal fitting tool: Porsche ET-No.: 000.721.971.90... -
Page 31: Version: 16.12.2014
Alternately screw in the screw head of a commercially available slide hammer puller in the holes and uniformly pull out the metal ring. Engine 1.6.5.2 After removing the metal ring, the real seal remains in the crankcase. Never pry it out! NOTE Thoroughly remove the drilling shavings Drill two more holes (arrows) using a 0.2 mm drill. -
Page 32: Version: 16.12.2014
Remove the seal. Use one of the two procedures Engine a.) Alternately screw in the screw head of the slide hammer puller in the holes and uniformly pull out the seal. 1.6.5.3 b.) Screw in two tapping screws and pull out the seal using the claw-type sleeve of a slide hammer puller. -
Page 33: Version: 16.12.2014
Remove corrosion on the crankshaft flange only using a special metal-polishing pad. Then clean the crankshaft flange thoroughly with acetone or cleaning solvent. Uniformly attach (hand-tight) the fitting tool base plate Porsche ET-No.: 000.721.971.90 to the crankshaft flange using the socket head screws 1.6.5.5 Only dry mount the crankshaft seal. -
Page 34: Version: 16.12.2014
Engine 1.6.5.6 Remove the magnetic cone and slide the crankshaft seal in a plane-parallel position using the pressure piece Porsche ET-No.: 000.721.912.60 1.6.5.7 911 GT3 Cup (991) Version: 16.12.2014... -
Page 35: Version: 16.12.2014
Attach the fitting tool mounting bell Porsche ET-No.: 000.721.971.90 to the base plate by tightening the mounting bell hexagon bolt (hand-tight) Engine 1.6.5.8 Pull the crankshaft seal on the crankshaft flange by turning clockwise the fitting nut until the mounting bell fits snugly and completely on the crankcase contact surface 1.6.5.9... -
Page 36: Version: 16.12.2014
Check the seal mounting position. For this purpose, measure at four points from the crankshaft flange to the steel ring flat surface (arrows) using a vernier Engine caliper 1.6.5.10 Measuring depth approx. 5 mm (0.2”) NOTE Maximum allowable tilt is 0.5 mm (0.2”) If the comparative values exceed the maximum difference, press in the seal again using the fitting tool 911 GT3 Cup (991) -
Page 37: Engine Tightening Torque Overview
Engine tightening torque overview Engine Screw Tighening torque Component dimensions [Nm] Engine Engine mount to body 65 (48 ft-lb) Crankshaft and crankcase Connecting rod M10 x 1.25 Oil pump 23 (17 ft-lb) Crankcase bolt/nut 23 (23 ft-lb) Pulley to crankshaft M14 x 1.5 170 (125.4 ft-lb) Sealing screw, pressure control and... -
Page 38: Version: 16.12.2014
Auxiliary Units Engine Pulley on generator 55 (40.6 ft-lb) Lambda sensor M18 x 1.5 50 (37 ft-lb) Flywheel coupling M8 x 45 33 (24.3 ft-lb) Oil drain plug on oil tank M20 x 1.5 60 (44.3 ft-lb) *1= Pre-tightening 30 +/- 3 Nm (22.1 ± 2.2 ft-lb) Final tightening 62 (45.7 ft-lb) +/-2°... -
Page 39: Exhaust System
Exhaust system Engine In the course of the different engine modifications, the exhaust system has also been refined. A version with muffler and a version without muffler are available. Both versions are equipped with exhaust manifold including catalysts (100 cells). System with muffler: 1.8.1 System without muffler:... -
Page 40: Fixation Pre-Silencer
Make use of an air gun to proper refill the insulation material (figure 1.8.5) Torque service bolt: 60 Nm Fixation pre-silencer 1.8.4 Porsche Motorsport points out that the fixation of the pre silencers makes the following changes necessary. Part list: Part number Name... -
Page 41: Engine Run Time
8,500 rpm so that an inspection interval of 50 hours is recommended. If an engine speed above 8,500 rpm is recorded, NOTE Porsche Motorsport will not accept any good-will claims. 1.10.1 Behavior when exceeding the maximum speed When the maximum speed of 8,500 rpm is exceeded, the insepction interval changes according to the table below. -
Page 42: Powertrain
Powertrain Powertrain General The 911 GT3 Cup (991) integrates a sequential six-speed gearbox specially developed for use in motor sports. The shift mechanism has been designed for optimal efficiency, taking into account the pneumatic actuation by means of the compressed air system. In addition, the gearbox is equipped with a limited-slip differential, an oil filter and an oil/water heat exchanger for cooling. -
Page 43: Clutch
Clutch Powertrain A Sachs three-disk sintered metal clutch is used in the 911 GT3 Cup (991). The clutch has been designed particularly for the loads in motor sports and combines high performance and temperature durability with reduced weight and low moment of inertia. -
Page 44: Clutch Wear
Fluid for clutch actuation Racing Brake Fluid-325° from Performance Friction Brakes is used as clutch fluid. Porsche spare part No.: 991.355.960.8A Porsche recommends to vent the system after each session and to change the fluid after each race weekend. Venting: •... -
Page 45: Central Release Mechanism
2.2.4 Central release mechanism Powertrain The hydraulically actuated piston is controlled by the clutch pedal and the master cylinder and thereby acts as a slave cylinder. The thrust bearing integrated into the release piston transfers the force to the diaphragm spring of the clutch housing, thereby separating the positive engagement between engine and gearbox. -
Page 46: Sequential Six-Speed Gearbox
Sequential six-speed gearbox Powertrain 2.3.1 Overview Limited-slip differential Connecting shaft Drive shaft Gear shift drum Cross shaft Pinion shaft Gear shift cylinder 2.3.1.1 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 47: Technical Specifications
2.3.2 Technical specifications Powertrain Gearbox type G91/72 Design sequential Number of forward gears Fill quantity 3.0 l (3.17 qt.) Weight 70 kg (154 lb.) Gear Teeth i_gear i_const. i_bevel/crown i_total gear 13 / 41 3.154 2.412 1.571 11.951 17 / 40 2.353 2.412 1.571... -
Page 48: Gear Set
2.3.3 Gear set Powertrain 2.3.3.1 The gear set consists of the drive shaft (3) with fixed gears, the pinion shaft (6) with idlers, a cross shaft with constant ratio (5) and the limited-slip differential (1). Connecting shaft The connecting shaft (1) is the element that connects the clutch to the drive shaft. It transfers the torque generated by the engine directly to the fixed gears of the drive shaft. -
Page 49: Version: 16.12.2014
Drive shaft design The drive shaft is located above the pinion shaft and is mounted with two bearings in Powertrain the gearbox housing. As typically found in motor sports, the fixed gears of the gear pairs are all located on this shaft. Fixed gear, 1st gear Fixed gear, 2nd gear Fixed gear, 3rd gear... -
Page 50: Version: 16.12.2014
Cross shaft design Powertrain The cross shaft (1), offset by 90°, is located behind the pinion shaft and is used for changing the direction of the torque. The crown gear of the cross shaft is driven by the bevel gear of the pinion shaft. The torque is transmitted by means of the opposing spur gear teeth to the limited-slip differential located above it. -
Page 51: Drive
2.3.4 Drive Powertrain Direction of rotation, traction Shaft movement, traction Shaft movement, coast Driving direction 2.3.4.1 The torque is transmitted from the engine through the connecting shaft and drive shaft to the gearbox and then through the corresponding gear ratio from the drive shaft to the pinion shaft. -
Page 52: Version: 16.12.2014
Limited-slip differential Powertrain The limited-slip differential is provided with 12 friction disks. The ramp angle of the pressure pieces is 52° on the traction side and 30° on the coast side. When fitting, pay attention to the correct orientation of the pressure pieces (illustration No. 2.3.4.2). -
Page 53: Oil Circuit
2.3.5 Oil circuit Powertrain Oil grades and fill quantity The gearbox fill quantity is 3.0 liters (3,17 qts) of Mobilube 1SHC75W90. When filling, make sure that the gearbox is placed on a flat surface. Viewed in the driving direction, the inclined oil filler neck (1) is located on the right side of the gearbox. Oil cooling The gearbox is provided with a separate oil/water heat exchanger (2) for heating and cooling the gear set oil. -
Page 54: Gear Shift Mechanism
Gear shift mechanism Powertrain The G91/72 is a sequential gearbox with six forward gears and one reverse gear. Gear shifting is performed using two shift paddles located on the steering wheel and a pushbutton on the instrument panel connected to the steering wheel. Pull the right paddle to up-shift and the left paddle to down-shift. -
Page 55: Gear Shifting
Advantages of the system Powertrain • Gear shifting with both hands on the steering wheel Automatic double de-clutching when down-shifting • • Focusing on braking and steering Over-revving of the engine is less probably* • • Gearbox protection due to consistent gear shifting *Blocking of the rear wheels during the braking process, may still allow over-revving. -
Page 56: Version: 16.12.2014
Gear shift conditions Powertrain Observe the following handling conditions to ensure the correct operation of the gear- shift system. Example of how to read the diagram: Engaging the reverse gear • No actuation of the shift paddle • The throttle must be < 17% (neutral position) •... -
Page 57: Gear Recognition
2.4.2 Gear recognition Powertrain For electronic recognition of the engaged gear, a potentiometer is installed on the gearbox. The potentiometer outputs a defined voltage depending on the gear currently engaged. Gear recognition is necessary for the interruption of the power flow when up-shifting. -
Page 58: Maintenance
2.4.4 Maintenance Powertrain Small Service: • Once p.a. • Max. 10.000 km • Max. 10 h compressor run time Big Service: • Every two years • Max. 20.000 km • Max. 20 h compressor run time Contact data MEGA-Line Racing ELECTRONIC GmbH Haunersdorf Str. -
Page 59: Drive Shafts
Do not interchange used drive shafts left-right Grease quantity for joint on wheel side: 150 g (5.3 ounces) Grease quantity for joint on gearbox side: 120 g (4.2 ounces) Porsche spare part No. (100 g (3.5 ounce) tube): 000.043.110.01 2.5.1 Tightening instructions 2.5.1 Tighten all bolts to 30 Nm (22.1 ft-lb) in the specified order... -
Page 60: Gearbox Run Time
Gearbox run time Powertrain The gearbox running time is 30 hours. Gearbox tightening torques Place Designation Number per Tightening gearbox torque/Comment pre-tightening8 Nm Coupling on engine/flywheel ZYL-SHR M8x45 final tightening 33 Nm Gearbox on engine 6KT-MU M10 Gearbox on body/carrier3/top 6KT-SHR AM10X75 65 Nm Gearbox on body/carrier3/bottom... -
Page 61: Version: 16.12.2014
Powertrain Place Designatio Number per Tightening gearbox torque/Comment 30 Nm +60°, then lock nut M32x1.25 Pinion shaft-shaft end untighten 30 Nm + 60° Reverse gear-intermediate gear-thrust bearing 6KT-SHR AM8x75 25 Nm with stop Gear shift drum-shaft end groove nut M30x1.25 60 Nm 50 Nm +60°, then Cross shaft-shaft end 4-point bearing... -
Page 62: Transmission Dismantling
Transmission dismantling Powertrain General: After dismantling, the individual components should be cleaned thoroughly and inspected visually for damage. The transmission is generally dismantled in the opposite order to that described for mounting. But some procedures and work steps are different and will be addressed in detail in the following. Any changes to the sequence can lead to component damage. -
Page 63: Gear Housing Dismantling
By twisting the pinion shaft, engage gear 1 and fix the drive shaft in place with tool no. 19 (Figure 2.8.2.2) 2.8.2.2 Loosen the pinion shaft nut with socket SW 38 Porsche spare part No.: 9R6.450.304.00 (do not remove the pinion shaft nut) 2.8.2.3 911 GT3 Cup (991) Version: 16.12.2014... -
Page 64: Gear Set Removal
Loosen the nuts of the gear housing flanging Powertrain Remove the gear housing. Use a rubber hammer, if necessary (Figure 2.8.2.4) 2.8.2.4 2.8.3 Gear set removal Remove the O ring from the shift rod (Figure 2.8.3.1) Pull out the shift rod toward the top; ensure that the shift forks do not drop out of the sleeves. -
Page 65: Dismantling The Shift Drum
Remove the shift drum (7) with the bushing (4) 2.8.4.1 Secure the shift drum against twisting with an open-end wrench and loosen the shift drum nut with socket Porsche spare part No.: 997.450.306.00 (Figure 2.8.4.2) 2.8.5 Dismantling the locking sleeve 2.8.4.2... -
Page 66: Oil Supply
2.8.6 Oil supply Powertrain Suction tube Loosen the nut (1) and remove the suction tube (3) (Figure 2.8.6.1) Injection tube 2.8.6.1 Loosen the nut (4) and remove the injection tube (2) with the panel puller (M6) (Figure 2.8.6.2) The injection tube must be removed before taking out NOTE the shift module because the shift module cannot be pulled out otherwise... -
Page 67: Cross Shaft Dismantling
2.8.7 Cross shaft dismantling Powertrain Remove the locking ring of the cross shaft lid (Figure 2.8.7.1) Pull the closure cap with the panel puller (Figure 2.8.7.1) Remove the cross shaft lid catch 2.8.7.1 Open the cross shaft lid with the assembly lever (Figure 2.8.7.2) 2.8.7.2 Remove adjusting disk P2 of the anti-lash plate (Figure 2.8.7.3) 2.8.7.3... -
Page 68: Version: 16.12.2014
Take out locking ring and rotation prevention (3) Powertrain Loosen the nut of the cross shaft with socket Porsche spare part No.: 2.8.7.5 9R6.450.304.00 Be careful when removing the cross shaft nut. The NOTE bearing shell of the four-point bearing is behind it. -
Page 69: Version: 16.12.2014
Insert the cross shaft in tool no. 44. Ensure the correct seat of the two insert washers! The insert washers are supported by the cylinder rolls of the bearing (Figure Powertrain 2.8.7.7) 2.8.7.7 Push the cage out of the cylinder roll bearing (cross shaft) with tool no. 44 (Figure 2.8.7.8) 2.8.7.8 Heat the cross shaft lid (1) at 130 °C (266 F) for 30 minutes... -
Page 70: Pinion Shaft Dismantling
2.8.8 Pinion shaft dismantling Powertrain Remove locking ring and mounting lid (arrow) of the pinion shaft in the transmission shell (Figure 2.8.8.1) Take out the pinion shaft through the assembly opening 2.8.8.1 Press out the cylinder roll bearing of the pinion shaft with tool no. 44 (Figure 2.8.8.2) See 2.8.7 cross shaft dismantling 2.8.8.2 911 GT3 Cup (991) -
Page 71: Differential Removal
2.8.9 Differential removal Powertrain Loosen the differential lid catch evenly using a crisscross pattern and remove it Remove the differential lid with the assembly lever (Figure 2.8.9.1) 2.8.9.1 Remove the locking ring of the cylinder roll bearing differential lid Heat the differential lid at 130 °C (266 F) for 30 minutes Remove the bearing (2) without applying great force 2.8.9.2 Remove the differential from the gearbox housing (Figure 2.8.9.3) -
Page 72: Central Clutch Operator Removal
Remove snap ring and needle cage from the differential housing (Figure 2.8.9.5) Powertrain 2.8.9.1 2.8.10 Central clutch operator removal Remove the central clutch operator (Figure 2.8.10.1) 2.8.10.2 2.8.11 Connecting shaft dismantling Drive out the connecting shaft with the panel puller (Figure 2.8.11.1) 2.8.11.1 911 GT3 Cup (991) Version: 16.12.2014... -
Page 73: Drive Shaft Dismantling
2.8.12 Drive shaft dismantling Powertrain Take out the drive shaft locking ring (1) Use the shortened locking ring pliers (Figure 2.8.12.2). The handles of the pliers are shortened so that the pliers can be used inside the gearbox housing. Take out the thrust plate (2) Remove the drive shaft (3) from the gearbox housing 2.8.12.1 2.8.12.2... -
Page 74: Bearing Dismantling
2.8.13 Bearing dismantling Powertrain Gearbox housing Remove the needle bearing of the cross shaft with puller HAZET 788-37 (Figure 2.8.13.1) The pulling off motion requires the utmost care. The NOTE gearbox housing could be damaged in the process! 2.8.13.1 Clean the gearbox housing and remove any oil Heat the gearbox housing at 130 °C (266 F) for 30 minutes Remove the outer rings of the bearings in the housing. -
Page 75: Version: 16.12.2014
Outer ring of the axle shaft flange needle bearing, left side (arrow) Powertrain Drive out the differential cylinder roll bearing (Figure 2.8.13.5) with removal tool 2.8.13.5 HAZET 788 – 70 (3) and panel puller 2.8.13.6 Press out the connecting shaft needle bush in the direction of the arrow with tool no. 46 (Figure 2.8.13.7) 2.8.13.7 Gear housing... -
Page 76: Transmission Assembly
130°C (266 F) for approx. 40 minutes. The heat of the housing can be 2.9.1.1 used for the next work step (inserting the bearings). Cross shift lid studs Dimensions: M8x30 Porsche spare part No.: 999.062.044.01 Projection: 30 mm (1.18”) Adhesive: Loctite 2701 green 2.9.1.2... -
Page 77: Version: 16.12.2014
Differential lid studs (red) Powertrain Dimensions: M8x30 Porsche spare part No.: 999.062.044.01 Projection: 30 mm (1.18”) Adhesive: Loctite 2701 green Thread position: Screw in short thread Starter studs (1) Dimensions: M10x22 2.9.1.3 Porsche spare part No.: 999.062.014.01 Projection: 24 mm (0.94”) -
Page 78: Version: 16.12.2014
Retaining frame pinion shaft studs (light blue) Powertrain Dimensions: M8x26 Porsche spare part No.: 999.062.311.01 Projection: 14.5 mm (5.71”) Adhesive: Loctite 2701 green Thread position: Screw in long thread Oil pump studs (2) Dimensions: M6x28 Porsche spare part No.: 999.062.100.02 Projection: 27 mm (1.06”) -
Page 79: Version: 16.12.2014
999.062.001.01 Projection: 11 mm (0.43”) Adhesive: Loctite 2701 green Thread position: Screw in long thread Shift drum stud (2) Bushing Porsche spare part No.: 991.303.498.9B NOTE must first be pressed in. Dimensions: M6x35 2.9.1.7 Porsche spare part No.: 999.062.093.01 Projection: 29 mm (1.14”) -
Page 80: Version: 16.12.2014
Central clutch operator screw connection stud (arrow) Powertrain Dimensions: M6x18 Porsche spare part No.: 999.062.003.01 Projection: 19 mm (0.75”) Adhesive: Loctite 2701 green Thread position: Screw in long thread 2.9.1.8 Injection tube stud Dimensions: M6x10 Porsche spare part No.: 999.062.001.01 Projection: 10 mm (0.39”) -
Page 81: Version: 16.12.2014
Heat-resistant gloves must be worn for any work with WARNING hot items because of the risk of burning. Drive shaft bearing Dimensions: 34x62x17 Type: Cylinder roll bearing Porsche spare part No.: 991.302.283.9A Tool: No. 1 2.9.1.10 Pinion shaft cylinder roll bearing (outer ring) Dimensions: 40x90x23... -
Page 82: Version: 16.12.2014
Type: Needle bearing Porsche spare part No.: 991.302.491.9A Tool: No. 5 Insert locking ring (37x1.5) Porsche spare part No.: 991.302.781.9A Insert locking ring (1) at a 180° offset to the opening NOTE 2.9.1.13 (2)! Outer ring of cross shaft bearing... -
Page 83: Version: 16.12.2014
Type: Cylinder roll bearing Porsche spare part No.: 991.332.645.9A Tool: No. 8b With locking ring Porsche spare part No.: 999.152.138.01 2.9.1.16 Insert locking ring at a 90° offset to the opening! NOTE 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 84: Version: 16.12.2014
Pinion shaft retaining frame locating pins Porsche spare part No.: 991.301.645.9B Press in up to the limit Attach perforated panel of clutch bleeding Porsche spare part No.: 991.116.710.9A and secure with locking ring Porsche spare part No.: 991.302.781.9A 2.9.1.8 911 GT3 Cup (991) Version: 16.12.2014... -
Page 85: Version: 16.12.2014
Oil hole closure Dimensions: M12x1.5 alu Porsche spare part No.: 900.219.006.30 2.9.1.19 Torque: 9 Nm (6.6 ft-lb) Attach with sealing ring Porsche spare part No.: 900.123.101.30 (12x18). Plug without pressure sensor Dimensions: M10x1 Porsche spare part No.: 900.219.007.01 2.9.1.20 Torque: 9 Nm (6.6 ft-lb) -
Page 86: Version: 16.12.2014
Mounting hydraulic connections for the clutch: Powertrain Use Loctite 574 orange. NOTE Bleeding (2) Porsche spare part No.: 962.355.522.00 Sealing ring Porsche spare part No.: 900.123.003.20 Pressure line (1) Porsche spare part No.: 999.105.027.30 Sealing ring Porsche spare part No.: 900.123.003.30 2.9.1.21... -
Page 87: Gear Housing Pre-Assembly
Heat-resistant gloves must be worn for any work with WARNING hot items because of the risk of burning. Screwing in the gear housing studs Heat exchanger studs (green) Dimensions: M6x15 Porsche spare part No.: 999.062.002.02 Projection: 14 mm (0.55”) Adhesive: Loctite 2701 green Thread position: Screw in long thread 2.9.2.1... -
Page 88: Version: 16.12.2014
Bearing baffle studs Powertrain Dimensions: M5x10 Porsche spare part No.: 999.062.136.01 Projection: 10 mm (0.39”) Adhesive: Loctite 2701 green Thread position: Screw in long thread 2.9.2.1 Threaded pin of the baffle Dimensions: M5x20 12.9 Porsche spare part No.: 999.069.005.09 Projection: 7 mm (0.27”) -
Page 89: Version: 16.12.2014
Porsche spare part No.: 900.060.107.01 Projection: 45 mm (1.77”) Adhesive: Loctite 2701 green Thread position: Screw in short thread Press in fitting sleeve (1) Porsche spare part No.: NOTE 991.301.641.9B up to the limit 2.9.2.5 • Bottom: Dimensions: M10x45 10.9 Porsche spare part No.:... -
Page 90: Version: 16.12.2014
Labels of outer and inner bearing rings generally point in the direction of the pressing tools during the pressing in process! Gearbox bleeding bushing Porsche spare part No.: 02A.301.473 Adhesive: Loctite 638... -
Page 91: Version: 16.12.2014
Pinion shaft cylinder roll bearing (3) Powertrain Dimensions: 44x72x17 Porsche spare part No.: 991.302.291.9A Tool: No. 4 Grooved ball bearing of the shift drum (1) Dimensions: 50x65x7 Porsche spare part No.: 900.052.225.00 2.9.2.7 Tool: No. 31 Screw connection of baffle M5 Porsche spare part No.:... -
Page 92: Version: 16.12.2014
Dimensions: M16x1.5 Porsche spare part No.: 900.219.004.30 2.9.2.9 Torque: 20 Nm (14.8 ft-lb) Adhesive: Loctite 574 orange Sealing ring Porsche spare part No.: 900.123.018.30 Sealing plug Dimensions: M12x1.5 Porsche spare part No.: 900.219.006.30 Torque: 9 Nm (6.6 ft-lb) Adhesive: Loctite 574 orange Sealing ring Porsche spare part No.: 900.123.101.30... -
Page 93: Differential Lid Pre-Assembly
2.9.3.1 Tool: No.8/8a Point the label to the top and secure with snap ring NOTE Porsche spare part No.: 999.152.117.01. Mount the locking ring at a 180° offset to the housing opening. 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 94: Pinion Shaft Bearing Assembly
2.9.4 Pinion shaft bearing assembly Powertrain Place spacing washer (1) H1 2 mm on the gearbox housing with the oil grooves; the oil grooves must be on the side of the four-point bearing (2). The oil grooves serve to lubricate the bearing. A NOTE reversal of the installation direction leads to bearing damage from lack of lubrication. -
Page 95: Pinion Shaft
2.9.5 Pinion shaft Powertrain Heat the interior of the cylinder roll bearing at 130° C (266 F) for 20 minutes Press the inner ring on the pinion shaft up to the limit (Figure 2.9.5.1) Insert the base adjusting disk (1) (2.00 mm P1) (Figure 2.9.5.1) Put on the bottom inner ring of the four-point bearing Insert the pinion shaft through the gearbox housing Put on the top inner ring of the four-point bearing... -
Page 96: Version: 16.12.2014
Pre-tightening: 30 Nm (22 ft-lb) + 60° angle of rotation Loosening Final tightening: 30 Nm (22 ft-lb) + 60° angle of rotation 2.9.5.4 Tighten the pinion shaft retaining frame with 11 nuts using a crisscross pattern Porsche spare part No.: 900.817.002.02 Torque: 33 Nm (24.3 ft-lb) Adhesive: Loctite 243 The four-point bearing is now centered. -
Page 97: Pinion Shaft Position Adjustment
2.9.6 Pinion shaft position adjustment Powertrain Adjustment is done in two steps. In the first step, the distance between the top of the bevel gear and the projection of the gearbox housing opening (blue arrow) is determined. This is the measurement that the pinion shaft must ultimately be set to. The actual distance between gearbox housing opening and the top of the bevel gear is measured in the second step. -
Page 98: Version: 16.12.2014
Measurement process Powertrain Put the transmission in an upright position Put magnetic disc (Figure 2.9.5.4) (5 mm) no. 28 on the pinion shaft head (bevel gear). Put measuring plate (1) (20 mm) no. 23 on the gearbox housing. With the depth gauge (2), measure the distance (green arrow in the diagram) e.g. -
Page 99: Assembly Of Gear Sets
Lubricate the drive shaft bearing running surfaces (3) well Insert the drive shaft (3) in the gearbox housing Push on thrust plate (2) Porsche spare part No.: 991.302.381.9C Secure with locking ring (1) (30x1.5) Porsche spare part No.: 900.041.015.01; use the shortened snap ring pliers (Figure 2.9.6.2). 2.9.7.1 2.9.7.2... -
Page 100: Version: 16.12.2014
Powertrain 2.9.7.5 Push the spur gear of the reverse gear (2) on pinion shaft Porsche spare part No.: 991.302.225.9A. In doing so, point the labeled side in the direction of idler gear 1 gear, the conically beveled side points in the direction of the gearbox housing (Figure 2.9.7.4... -
Page 101: Version: 16.12.2014
Powertrain 2.9.7.8 2.9.7.9 Insert selector sleeve (6) Porsche spare part No.: 991.304.631.9A with the label facing outward (Figure 2.9.7.10) 2.9.7.10 Insert the 2 gear idler gear (8) with the idler gear bearing (7), the claws point toward the selector sleeve (6) here (Figure 2.9.7.11) Push the fixed gear 3 gear (B) on the drive shaft (A) (Figure 2.9.7.11) -
Page 102: Version: 16.12.2014
Powertrain 2.9.7.12 2.9.7.13 Push the idler gear 3 gear (9) with idler gear bearing (10) on the guide sleeve (11) (claws toward 4 gear) and thread onto the pinion shaft (Figure 2.9.7.14). Please ensure in doing so that the oil holes of pinion shaft and guide sleeve are not directly on top of each other (extensive oil supply). -
Page 103: Version: 16.12.2014
Put on the selector sleeve (18) (Figure 2.9.7.18) Push the spacer sleeve (E) between 5 and 6 gear fixed gears Porsche spare part No.: 991.302.268.9B (Figure 2.9.7.18) Push on idler gear 6 gear (20) with idler gear bearing (19) (claws pointing toward 5 gear) (Figure 2.9.7.19) -
Page 104: Version: 16.12.2014
Powertrain 2.9.7.20 2.9.7.21 Secure locking ring (G) Porsche spare part No.: 900.041.039.01 of the drive shaft (Figure 2.9.7.22) Put on the inner ring of the pinion shaft (21) Put the nut (22) loosely on the pinion shaft Do not tighten the nut (22), final tightening is not done NOTE until step 2.9.20 Putting on the gear housing . -
Page 105: Vormontage Schaltwalze
2.9.8 Vormontage Schaltwalze Powertrain 2.9.8.2 Put adjusting disk (6) Basic Porsche spare part No.: 991.303.297.09 (1.4 mm) on the shift drum (7) Insert the grooved ball bearing (5) Put on the bushing (4) (observe installation position) Insert the gearshift shaft spacing washer (3) 2.9.8.1... -
Page 106: Oil Pump Assembly
Remove the drive gear Put on the oil pump and four nuts Porsche spare part No.: 900.817.001.02 and then tighten with 4 Nm (3 ft-lb) using a crisscross pattern. Check whether the shaft can be spun smoothly at that. -
Page 107: Reverse Idler Gear
2.9.10 Reverse idler gear Powertrain The needle bearing sleeve (2) must be assembled first during reconstruction. Heat the reverse idler gear (3) to 130° (266 F) C for 30 minutes and press in the needle bearing sleeve with tool no. 32 Heat-resistant gloves must be worn for any work with WARNING hot items because of the risk of burning. -
Page 108: Locking Sleeve
2.9.11 Locking sleeve Powertrain Abutment assembly: Insert the lever (1) into bearing spindle abutment (4) Porsche spare part No.: 991.303.493.9A Press in bushing (2) Porsche spare part No.: 991.303.497.9A Insert the compression spring (3) between housing and lever The bushing (2) must be flush with the housing (4) 2.9.11.1... -
Page 109: Shift Rod And Shift Forks
Powertrain Put the shift drum in the neutral position Insert shift forks Porsche spare part No.: 991.303.111.9A Grease two O rings (1) (11x2) Porsche spare part No.: 999.701.948.40 with Optimol Paste MP3 and put on the shift rod (1) 2.9.12.1... -
Page 110: Suction Tube Assembly
Suction tube assembly Powertrain Put greased suction tube (2) and O ring (1) Porsche spare part No.: 999.701.809.40 (15x2.5) on the gearbox housing Put on nut (4) Porsche spare part No.: 900.817.001.02 and tighten with 10 Nm (7,4 ft-lb) Oil filter 2.9.13.1... -
Page 111: Version: 16.12.2014
Center the snap ring (Figure 2.9.13.3) with grease to facilitate shaft assembly Insert the connecting shaft in the drive shaft until it engages clearly 2.9.13.3 Put guide ring (connecting shaft) Porsche spare part No.: 991.301.119.9B on the bearing 2.9.13.4 Grease shaft sealing ring (connecting shaft) (26x41x6) Porsche spare part No.: 997.302.351.9A with Optimol and drive in with tools no. -
Page 112: Central Clutch Operator Assembly
Central clutch operator assembly Powertrain Put in grease O rings (1) Tighten the central clutch operator with 10 Nm (7.4 ft-lb) on the gearbox housing, use nut Porsche spare part No.: 900.817.001.02. 2.9.14.1 2.9.15 Cutted gear housing assembly The cutted gear housing is assembled to check the NOTE backlash of bevel gear to ring gear. -
Page 113: Version: 16.12.2014
Check the gearshift clearance Powertrain Put the transmission in the installation position The selector sleeves must be centered and move freely Check the shifting of all gears while rotating drive shaft / pinion shaft Check the clearance of the reverse gear shift fork Check the backlash of the gearwheel pairings Check the position of the gearwheel pairings Check the free movement of the shift fork... -
Page 114: Determining Cross Shaft Bearing Adjusting Disk Q1
Insert measurement device Porsche spare part No.: 991.450.348.9A in the cross shaft lid. The touching surfaces of the components must be free from dirt. The measurement device is clamped in with locking ring Porsche spare part No.: 900.042.049.01. The locking ring that is also ultimately used for installation must be 2.9.16.1... -
Page 115: Cross Shaft Setup
2.9.17 Cross shaft setup Powertrain Heat the cylinder roll bearing inner ring on a hot plate for 30 minutes at 130° C (266 Heat-resistant gloves must be worn for any work with WARNING hot items because of the risk of burning. Lubricate the shaft Press the heated bearing (1) quickly onto the shaft. -
Page 116: Cross Shaft Assembly
2.9.18 Cross shaft assembly Powertrain In the first step, the four-point bearing must be centered in the housing lid. Housing lid and four-point bearing are pre-assembled with an auxiliary shaft (tool no. 36) for that. The four-point bearing is fixed in place with the locking ring. The cross shaft is inserted in the housing lid in the second step. -
Page 117: Version: 16.12.2014
Insert the calculated adjusting disk Q1 (4) Powertrain Insert the locking ring (5). The oil hole must stay open (Figure pos.) Drive in ring with copper drift (four-point bearing is fixed in place) Use compressed air to blow out any chippings Loosen the nut and take the housing lid of the centering tool (auxiliary shaft) Lubricate the inner bearing ring of the cylinder roll bearing Put the housing lid on the cross shaft... -
Page 118: Version: 16.12.2014
Powertrain Attach locking ring (3) Porsche spare part No.: 991.302.793.9A for the nut Attach locking ring Porsche spare part No.: 999.042.313.01 Place the greased O ring (130x2.5) on the lid, Porsche spare part No.: 999.701.580.40 Visually check the gearbox housing 2.9.18.7... -
Page 119: Version: 16.12.2014
Checking the backlash of the angle drive Powertrain Clamp tool no. 15 onto the shaft Screw tool no. 26 onto the housing Attach the probe indicator; the needle (1) must touch tool no. 26 pre-tightened Block the pinion shaft in the position „drive“ with tool no. 18, fix the tool well in place on the cutted gear housing to allow a precise measurement. -
Page 120: Differential Setup
2.9.19 Differential setup Powertrain The differential can be replaced even if the transmission is filled with oil. The oil level should still always be checked after working on the transmission. Friction disks, bevel gears, bevel pinions, axial bearings, and ramps must be lubricated well before the assembly. -
Page 121: Version: 16.12.2014
Powertrain 2.9.19.5 2.9.19.4 Insert the pressure piece (11); keep in mind rotational direction and 0 mark (Figure 2.9.19.4) Insert bevel gear (12) Insert cross pin (13) with bevel pinion (14) Insert bevel gear (12) Insert pressure piece (11), keep in mind rotational direction / mark! Disk package (10): Insert inner disk 3 Insert outer disk 3... -
Page 122: Version: 16.12.2014
Measure the friction package Powertrain Measurement of the differential housing depth from the bottom surface to the top face of the gearing (A) - measurement of the step within the diff cap (B) = C + tolerance (0.1 - 0.3 mm) Measurement: A –... -
Page 123: Version: 16.12.2014
Symmetry of the cross pin Powertrain During the assembly of the friction package please note, that the cross pin has to be in symmetric position of the friction package as otherwise the axle flanges might be pushed out of their latching position within the thrust pieces. Therefore the layered arrangement of the friction package has to be measured from the differential housing face / the differential housing cap face to the cross pin (marked red) and the difference between the sides may not exceed 0.2 mm. -
Page 124: Version: 16.12.2014
Check the differential lid / differential housing pairing! Powertrain Lubricate the edge and put on the lid (2) The inner threads must be free from residue of the screw locking device agent. All screws (1) and threads must be degreased. Bolting differential lid (2): Tighten lid with 4 assembly bolts with 15 Nm Sequence 1, 11, 6, 16 •... -
Page 125: Version: 16.12.2014
Insert needle cage (3) Porsche spare part No.: 999.201.128.00 Dimensions: 35x40x17 Put on snap ring (4) Porsche spare part No.: 999.332.997.9A Insert the differential in the gearbox housing (Figure 2.9.19.13) Put on differential lid with greased O ring and tighten with 25 Nm (18.4 ft-lb) 2.9.19.12... -
Page 126: Version: 16.12.2014
Checking the backlash of cross shaft / differential Powertrain The backlash of cross shaft / differential cannot be adjusted due to the design. It must still be checked though whether the clearance is within the specified measurement value. Attach tool no. 16 on the lateral differential lid Attach the probe indicator Attach stop no. -
Page 127: Gear Housing Assembly
2.9.20 Gear housing assembly Powertrain Insert the greased top O ring of the shift rod into the groove (Figure 2.9.20.1) 2.9.20.1 Grease the O ring (1) and insert it in the gearbox housing (Figure 2.9.20.2) 2.9.20.2 The cutted gear housing can be replaced with the gear housing after all settings have been made. -
Page 128: Version: 16.12.2014
Tighten the pinion shaft nut with 30 Nm (22 ft-lb)+60°, loosen and then tighten again with 30 Nm (22 ft-lb) +60° (Figure 2.9.20.4) Powertrain 2.9.20.4 Put on the pinion shaft lid (23) with greased sealing ring (24) and tighten the nuts (25) with 10 Nm (7.4 ft-lb) (Figure 2.9.20.5) 2.9.20.5 Put on the cross shaft lid cover with greased O ring and fix in place with a locking... -
Page 129: Version: 16.12.2014
Put on the transmission shell assembly opening cover (arrow) with greased O ring and fix in place with a locking ring (Figure 2.9.20.6) Powertrain 2.9.20.7 Put on the shift control (3) and tighten with 10 Nm (7.4 ft-lb) Put the shift control potentiometer (2) on the shift control Calibrate the shift control potentiometer (6 gear, 4.5 V) 2.9.20.8... -
Page 130: Version: 16.12.2014
Insert the greased sealing rings (2) of the oil / water heat exchanger, put on reinforcement plate (3) and heat exchanger (1) Powertrain Tighten the heat exchanger with 10 Nm (7.4 ft-lb) 2.9.20.11 Insert the oil injection tube (2) for the pinion shaft into the gearbox housing with greased sealing ring (1) and tighten the nut (4) with 10 Nm (7.4 ft-lb) tightening torque and Loctite 2701 2.9.20.12... -
Page 131: Overview Gearbox Settings
2.10 Overview gearbox settings Powertrain Pinion shaft Preload 4-point-bearing Set valve: 0.03 – 0.05 mm (Figure 2.9.4.2) via adjustment disk H1 Axial backlash 4-point-bearing Set valve: 0.02 – 0.05 mm via adjustment disk H2 Pinion shaft position Offset: 0.00 - 0.02 mm via adjustment disk P1 2.9.4.2 Cross shaft Preload 4-point-bearing... -
Page 132: Chassis
Chassis Chassis General The front and rear axles have been overhauled to suit the requirements of competition and to allow for easy and accurate setting of camber, toe, and vehicle height. Compared to the previous model, the shock absorber and spring characteristics have once more been optimized. -
Page 133: Wheel Bearing
3.1.1 Wheel bearing Chassis The wheel bearing is attached separately on the wheel mount using four bolts. Compared to the pressed-in variant, this advanced bearing integration has the advantage that the bearing can be replaced faster and easier on the vehicle. Moreover, the wheel bearing is insensitive to temperature changes. -
Page 134: Wheel Hub
3.1.2 Wheel hub Chassis The wheel hub is a reinforced racing wheel hub with central lock. The central lock nut is protected by a locking mechanism integrated in the hub to prevent it from accidental loosening. The correct functioning of the retaining keys has to be checked regularly. -
Page 135: Wheel Nut
(after approx. 6 hours running time) to verify and regenerate them. Clean the threads, judge them by visual inspection and re-grease them with Optimol Paste TA Porsche spare part no.: 000.043.020.00. Also grease the contact surface nut-rim. Proceed as follows in order to prevent the wheel nuts from settling: Tighten the new part 3 to 4 times using an impact wrench (500 –... -
Page 136: Locking Piece
3.1.4 Locking piece Chassis The locking pieces are used as wheel nut locking mechanism and to prevent the wheel from loosening. Locking Piece 3.1.4.1 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 137: Front Axle
Front axle Chassis 3.2.1 A MacPherson strut with gas pressure shock absorbers is installed on the front axle and attached to the body by a Uniball joint in the strut bearing. A blade-type anti-roll bar that is adjustable on both ends has a controlled impact on the vehicle’s rolling behavior. -
Page 138: Front Axle Cross Member
3.2.1 Front axle cross member Chassis The cross member made of cast aluminum is used as connecting element between the transverse control arms and the body. Transverse control arm, anti-roll bar bearing, longitudinal control arm and steering unit are attached to the cross member. 3.2.1.1 3.2.1.2 List of tightening torques for front axle cross member... -
Page 139: Front Axle Transverse Control Arm
For fine adjustment of the camber, slots in the front axle dome allow displacement of the strut mount. The following adjustment washers can be purchased at Porsche Motorsport: 0.30 mm 996.341.543.96... -
Page 140: Longitudinal Control Arm
When working on the suspension, care must be taken NOTE to see that the wheel mount is not inclined when Chassis abutting the transverse control arm joint, as this might damage the joint. Adjust the strut mount inwardly in order to ensure a NOTE sufficient screwing depth of the tie rod threads for high camber values (>4.5°). -
Page 141: Front Axle Wheel Mount
3.2.4 Front axle wheel mount Chassis The aluminum wheel mount is still made of torsion-proof and bending-resistant hollow casting. To optimize the cooling air supply to the brake, the geometry in the area of the “steering arms” has been significantly improved. 3.2.4.1 List of tightening torques front axle wheel mount Item... -
Page 142: Front Axle Shock Absorber
M14 x 1,5 75 Nm (55 ft-lb) 33 Nm (24 ft-lb) Spring characteristic values (spring rate/diameter/length): Helper spring 75/60/43 Porsche spare part No.: 996.343.537.90 Main spring 240/60/120 Porsche spare part No.: 991.343.531.8C 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 143: Front Axle Anti-Roll Bar
3.2.6 Front axle anti-roll bar Chassis The adjustable double blade-type anti-roll bar on the front axle can be adjusted in seven positions each on both ends, any position resulting in a 15° change of the bending lever. Maximum stiffness is achieved when the bending lever is arranged parallel to the anti-roll bar link. -
Page 144: Version: 16.12.2014
When rotating the bending levers (7), do not damage NOTE them by using improper tools. Notches or other damages may result in breakage of the bending lever. Chassis The following chart shows the wheel-related stiffness of the anti-roll bar depending on the blade position. -
Page 145: Rear Axle
Rear axle Chassis 3.3.1 The longitudinal and transverse control arms of the multi-link rear axle are attached separately to the wheel mount. The beads attached to the mounting points of the upper transverse control arm identify the correct mounting position. When installed, they should be facing upwards. -
Page 146: Rear Axle Control Arm And Tie Rod
65 Nm (48 ft-il) The rear screw of the trailing arm bracket, consisting NOTE 3.3.1.2 of the screw Porsche spare part no.: 999.072.836.01 and the spacer sleeve Porsche spare part no.: 999.331.781.8A (figure 3.3.1.2) must be tightened to 65 Nm (48 ft-lb). -
Page 147: Fixation Trailing Arm Bracket
Fixation trailing arm bracket Chassis Porsche Motorsport points out that a technical change of the sub frame 3 makes it necessary to use different bolts to attach the bracket for the trailing arm on both sides, according to the version of the sub frame 3. -
Page 148: Rear Axle Transverse Control Arm
The camber is adjusted on the transverse control arm (1) using spacers. The maximum permitted spacer width is 15 mm (0.59 inches) on the rear axle. 3.3.3.1 The following adjustment washers can be purchased at Porsche Motorsport: 0.50 mm 996.341.543.80 1.00 mm... -
Page 149: Rear Axle Wheel Mount
3.3.4 Rear axle wheel mount Chassis The aluminum rear axle wheel mount is still made as a torsion-proof and bending- resistant hollow casting part. 3.3.4.1 List of tightening torques rear axle wheel mount Item Dimensions Tightening torque in Nm/Comments M12 x 1,25 x 45 170 Nm (125 ft-lb) M8 x 32 35 Nm (26 ft-lb) -
Page 150: Rear Axle Shock Absorber
(29.5/25.8 ft-lb) When tightening the upper nut (13), the lower nut (13) should be locked. Spring characteristic values (spring rate/diameter/length): Helper spring 80/60/60 Porsche spare part No.: 997.333.537.90 Main spring 260/60/130 Porsche spare part No.: 991.333.531.8C 911 GT3 Cup (991) Version: 16.12.2014... -
Page 151: Rear Axle Anti-Roll Bar
3.3.6 Rear axle anti-roll bar Chassis Like the front anti-roll bar, the rear anti-roll bar can be adjusted in seven positions, each position resulting in a 15° change of the bending lever. Maximum stiffness of the anti-roll bar is achieved when the bending lever is arranged parallel to the anti-roll bar link. -
Page 152: Version: 16.12.2014
A distance of 12 mm (0.47 inches) towards the control arm is 3.3.6.4 recommended when the axle is decompressed (figure 3.3.5.3). Axial clearance compensation In order to counteract a possible backlash of the stabilizer, Porsche Motorsport offer two different spacers (pink). 991.343.761.8A 3.3.6.5 Spacer 1mm Porsche spare part No.:... -
Page 153: Rear Axle Side Part
Items 16 and 19 are cooling air ducts that lead to the drive shafts. Wheel alignment Precise wheel alignment is essential for achieving the optimum vehicle performance. Porsche Motorsport recommends proceeding as described below. 911 GT3 Cup (991) Version: 16.12.2014... -
Page 154: Preparatory Measures
3.4.1 Preparatory measures Chassis The conditions prevailing while driving have to be produced as far as possible under static conditions. Porsche Motorsport recommends using the set up wheels mentioned below for the 911 GT3 Cup (991). Part number Description Pcs per car 997.450.230.91... -
Page 155: Vehicle Ride Height Measuring Points
3.4.2 Vehicle ride height measuring points Chassis For ride height measuring, the vehicle should be on a flat surface (setup plate). Front and rear axle have to be compressed and decompressed several times. Measuring point, front axle: The vehicle front ride height is measured on the front mounting screw of the front axle cross member. -
Page 156: Steering System
Steering system Chassis The hydraulic power steering is derived from the 911 GT3 Cup (997) while the power steering pump has its origins in the 911 GT3 R. The power steering pump unit is located in the front-end and consists of an electrically driven pressure pump and an integrated hydraulic oil tank installed on top of it. -
Page 157: Version: 16.12.2014
The components and the assembly sequence of the steering wheel quick release are shown in the illustration below. Chassis 3.5.3 List of tightening torques Item Dimensions Tightening torque in Nm/Comments M5 x 16 6 Nm (4.4 ft-lb) M5 x 35 6 Nm (4.4 ft-lb) M18 x 26 50 ±5 Nm (37 ±... -
Page 158: Bleeding The Steering System
The fluid level in the container drops rapidly and it must be ensured that “Pentosin” Porsche spare part No.: (000.043.206.56) is continuously replenished while the engine is running. During this procedure, the reservoir should never run dry. -
Page 159: Rims And Tire
3.6.1.1 3.6.2 Tires The new 911 GT3 Cup (991) is delivered by Porsche Motorsport only with rain tires. A sticker provided on the windshield (figure 3.6.2.1) will indicate this restriction in use of the tires upon delivery of the vehicle. -
Page 160: Brake System
Porsche Motorsport. Six piston fixed calipers are provided on the front axle, four piston fixed calipers in monoblock design on the rear axle. Brake pistons of different sizes are in use on the brake caliper, which prevent diagonal wear of the brake pads. -
Page 161: Version: 16.12.2014
This is indicated by 3.7.1.3 sluggishly moving wheels or stuck pistons. Repair kits can be purchased at Porsche Motorsport. Refer to the maintenance section, chapter 7.4.7 „Replacing the piston seal rings”... -
Page 162: Front Axle Brake
3.7.2 Front axle brake Chassis 3.7.2.1 3.7.2.2 List of tightening torques for front axle brake Item Dimensions Tightening torque in Nm/Comments 20 Nm (14.75 ft-lb) 20 Nm (14.75 ft-lb) 5 Nm (3,7 ft-lb) 16 Nm (11.8 ft-lb) 65 Nm (48 ft-lb) M6X12 10 Nm (7.4ft-lb) + Loctite 243 911 GT3 Cup (991) -
Page 163: Rear Axle Brake
3.7.3 Rear axle brake Chassis 3.7.3.1 3.7.3.2 List of tightening torques for rear axle brake Item Dimensions Tightening torque in Nm/Comments 20 Nm (14.75 ft-lb) 20 Nm (14.75 ft-lb) 5 Nm (3,7 ft-lb) 16 Nm (11.8 ft-lb) 65 Nm (48 ft-lb) M6 x 12 10 Nm (7.4 ft-lb) + Loctite 243 911 GT3 Cup (991) -
Page 164: Master Cylinders
Both master cylinders supplied by AP Racing have a diameter of 17.8 mm (0.7 inches). An AP Racing ID-Number on the master cylinder can be used to designate the cylinder. Porsche spare part No.: 991.355.170.8C 3.7.4.1 List of tightening torques for master cylinders... -
Page 165: Changing The Brake Fluid
3.7.5 Changing the brake fluid Chassis Racing Brake Fluid-325° (DOT 4) supplied by Performance Friction Brakes should be used. Proceed as follows when changing the brake fluid. Remove the brake fluid from the brake fluid reservoir of the two master •... -
Page 166: Brake Pressure Distribution
Brake pressure distribution Chassis The brake pressure distribution between front and rear axle is set by means of a balance beam adjustment. Turning the dial below the dashboard changes the balance beam lever ratio. The rotations of the knob are recorded using a potentiometer and stored in the display. -
Page 167: Balance Beam Basic Setting
3.8.1 Balance beam basic setting Chassis In the basic position, the potentiometer should be in position “zero”. The distance between the push rod and master cylinders is symmetrical and amounts to 11.8 mm (0.465 inches). In the default setting, the balance beam should be perpendicular to the push rod at a pedal load of 40 bar (580 psi). -
Page 168: Version: 16.12.2014
Set a clearance of approx. 5 mm between joint thread base and master cylinder threaded rod at the connection of the balance beam to the front axle master cylinder. Chassis This ensures that the balance beam is perpendicular to the push rod under load. The thread length to the lock nut can be between 56 mm to 64 mm. -
Page 169: Calculating The Brake Power
3.8.2 Calculating the brake power Chassis The braking power of the front axle brake and the rear axle brake can be calculated as follows: Key: Pedalkraft = pedal force, Bremskraft = brake power HA = rear axle Front Axle Rear Axle VA = front axle 3.8.2.1 •... -
Page 170: Balance Bar Replacement Kit
Balance bar replacement kit Chassis Replacing the trunnion 3.9.1 • Remove balance bar see chapter 3.9.2 • Remove both circlipses from either end • Remove the trunnion and both bearings by using a light press • Clean the bore of any dirt •... -
Page 171: Performance Setup
3.10 Performance setup Chassis Fuel 50 liters (13.2 gal) Tires Slick Air pressure Front axle left 1.85 bar (26.8 psi) Front axle right 1.85 bar Rear axle left 1.9 bar (27.6 psi) Rear axle right 1.9 bar Height in Front axle left 78 mm (3,07“) Front axle right 78 mm... -
Page 172: Bodywork
Bodywork Bodywork General The exterior of the 911 GT3 Cup (991) is characterized by a clear distinction from the previous models, taking into account the typical 911 design. As its predecessor to reduce weight, the 911 GT3 Cup (991) is provided with a reduced sealing and sound insulation package. -
Page 173: Front And Side View
Front and side view Bodywork Front bumper The lateral air intakes of the front bumper have been redesigned and enlarged. The newly developed daytime running lights are integrated and include LED direction indicators. The front bumper is made of PUR GF 18 (polyurethane). 4.2.1 911 GT3 Cup (991) Version: 16.12.2014... -
Page 174: Version: 16.12.2014
Side view Bodywork At first glance, it is striking that the wheel base has been extended by 100 mm (3.94”). At the same time, the typical compact exterior dimensions of a sports car were retained. The increase in length is only +56 mm (2.2”). To achieve this, the overhangs were shortened by 32 mm (1.26”) at the front and by 12 mm (0.47”) at the rear. -
Page 175: Rear View
Rear view Bodywork The rear end cover has been redesigned, taking into account the aerodynamic and thermodynamic requirements: • The tail lights are completely designed in LED technology • The narrower shape integrates perfectly in the rear panel The rear end cover is made of PUR GF18 (polyurethane). 4.3.1 911 GT3 Cup (991) Version: 16.12.2014... -
Page 176: Body Shell
Body shell Bodywork 4.4.1 General In the development of the body of the new 911 GT3 Cup (991), the following objectives were pursued, in order to further enhance the safety and performance: • Weight reduction combined with improved strength/stiffness • Intelligent multi-material selection •... -
Page 177: Version: 16.12.2014
When looking in detail at the body of the 911 GT3 Cup (991), the following material mix can be found: Bodywork Material Scope Aluminum Trunk lid and fender, roof, front section, floor assembly, rear section Steel Rear side panels and side wall structure Front and rear roof cross members Reinforced dash panel cross member Reinforcements in the side skirts... -
Page 178: Weight Distribution
4.4.2 Weight distribution Bodywork The body shell is divided into the body-in-white and the attachment parts. The following chart illustrate the respective percentages of weight of the individual components. 4.4.3 Weight percentage of the Body -in-White 36.2 % aluminum 63.8 % steel 4.4.3.1 911 GT3 Cup (991) Version: 16.12.2014... -
Page 179: Body Aluminum Parts
4.4.4 Body aluminum parts Bodywork In addition to the extensive use of aluminum sheet parts in the assemblies of the platform (front section, floor center, rear section), more cast aluminum parts and extruded sections are specifically used. 4.4.4.1 Sheet aluminum Cast aluminum Aluminum extruded section Sheet steel... -
Page 180: Body Features
4.4.5 Body features Bodywork In addition to a very good power to weight ratio, the body stiffness also contributes significantly to the driving performance. Increased stiffness usually means more weight and is consequently in conflict with the goal of reducing weight. The intelligent lightweight construction in multi-material design is the solution to this problem: •... -
Page 181: Body Steel Parts
4.4.6 Body steel parts Bodywork A further challenge in the body development of the new 911 GT3 Cup (991) consisted in connecting the floor assembly largely made up of aluminum parts to the steel assemblies of the body. Bonded joints are used in addition to pierce-riveted, clinch and flow drill connections. -
Page 182: Materials Overview
4.4.7 Materials overview Bodywork Plastic parts Aluminum parts CFRP 4.4.7.1 Modified series parts New parts Carry-over parts 4.4.7.2 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 183: Roll Cage
4.4.8 Roll cage Bodywork The roll cage is firmly welded into the body. Any WARNING modifications to the roll cage will result in non- certification or disqualification of the vehicle. In the event of an accident, an inspection of the rollcage and an approval by a technical scrutineer is mandatory. -
Page 184: Recovery Device
4.4.9 Recovery device Bodywork One tow hook is provided both at the front and the rear NOTE section (4.4.9.1 and 4.4.9.2). When towing, make sure to avoid any jerky towing, otherwise there is a risk of damaging the body. Two connections for attaching recovery eyebolts (4.4.9.3) are provided on the top of the rollcage. -
Page 185: Aerodynamics
Aerodynamics Bodywork 4.5.1 General Compared to the previous models, the new 911 GT3 Cup (991) has been significantly improved in terms of its aerodynamic performance. 4.5.2 Rear wing The rear wing is 1,800 mm (5’11”) wide and adjustable in nine steps; its support brackets are directly attached to the body. -
Page 186: Exterior Mirrors
Exterior mirrors Bodywork The streamlined design of the exterior mirrors benefit the aerodynamics. Electric mirror adjustment and mirror heating are not installed. Roof The roof skin is made of aluminum sheet and connected to the body via a bonded joint. A rescue opening made of CFRP that may be released by camlock bolts is provided above the driver’s seat. -
Page 187: Air Jack System
Air jack system Bodywork The air jack system is supplied by Krontec. The vehicle has three lifting jacks, one in the middle of the front section and two in the area of the B-pillars, firmly attached to the body. The lifting jacks are not adjustable for height and must not be adjusted to a ride height change. -
Page 188: Version: 16.12.2014
• Never use mineral oil-based cleaning agents. • Porsche Motorsport recommends having an overhaul carried out by Krontec after two years or 2,000 lifts. • Check the tightening torque of the grooved nut (air jack tightness) during normal vehicle checks. -
Page 189: Doors
Doors Bodywork To further reduce vehicle weight, the doors are made of CFRP. 4.10 Trunk and engine lid Greatest care should be taken when closing the quick WARNING releases (4.10.2.1) of the trunk and engine lids. The lid pins must be inserted and locked (4.10.2.1). There is a risk that the hood or trunk lid might accidentally open when driving and tear off! Gas pressure springs are mounted on trunk and engine lids. -
Page 190: Windows
Cut system for glued panes - VAS 6452 ASE 481 261 01 000 The tools can be ordered at your Porsche Center. As an alternative for the cut system VAS 6452 (4.11.1.1), KSA Toolsystems offer a cutting device “Single Cut System”... -
Page 191: Version: 16.12.2014
Preparation Bodywork Remove the windshield wiper arm Remove the interior rear-view mirror • Improper installation and removal of vehicle WARNING windows may cause cuts and (eye) injuries Wear your personal protective equipment • Only change cutting blades when the power •... -
Page 192: Version: 16.12.2014
The cutting cord has to be below the window edge, as NOTE Bodywork otherwise the seal will be damaged. Insert the cutting wire into the window gap, WE1480 cutting system for glued windows - VAS 6452. • Wet the windshield sealing (1) with soapy water on the entire circumference. -
Page 193: Version: 16.12.2014
Cut out the windshield. Bodywork Introduce the cutting wire (1) in the hole of the rewinding device (2). • • Align the rewinding device (2) in the window center and press the suction lifter firmly against the windshield (3). • Fix the suction lifter on the windshield by moving the operating lever. -
Page 194: Preparing The Window Cutout For Installation
4.11.2 Preparing the window cutout for installation Bodywork Remove glue on the body. • Remove residual glue (1) with (electric special cutter) WE1137 electric special cutter Fein and scraper (U shape 639.031.130.22) on the body so that a glue residue remains on the entire area (2). The area-wide glue residue serves as primer for the NOTE new glue material. -
Page 195: Preparing The Windshield For Installation
4.11.3 Preparing the windshield for installation Bodywork (new windshield) Clean and prime the gluing surface. • Clean the window with cleaning solution. • Apply primer on the window flange around the marking. A flash-off time of at least 10 minutes should be NOTE observed between cleaning the window and application of the primer! The window must be free of any cleaning... -
Page 196: Installing The Windshield
4.11.4 Installing the windshield Bodywork Risk of material damage if the predetermined curing CAUTION time of the glue is not observed! In order to ensure proper bonding, the following conditions have to be met: • Do not put the vehicle into operation before the end of the curing time! •... -
Page 197: Version: 16.12.2014
When applying the glue material, make sure that the NOTE Bodywork adhesive bead overlaps by approx. 30 mm (1.2”) at the beginning and end. Apply glue on the windshield using the double cartridge gun VAS 5237. • Use the glue gun and apply two-component glue on the windshield along the pre-coating or on the primer in form of a triangular adhesive bead with dimension (X) application height: 15 mm (0.6”). -
Page 198: Fenders
Set the windshield gap dimension. Bodywork Move the windshield to set gap dimension (X). Gap dimension: 3.0 mm • (0.12“) on the entire circumference. • Remove the suction lifter. • Secure the windshield with adhesive tape (1) to prevent it from slipping. 4.11.4.4 Clean the vision areas. -
Page 199: Fuel System
4.14 Fuel system Bodywork A FT3 safety fuel tank (100 liters (26.4 gal) with return-free fuel system is used in the 911 GT3 Cup (991). The tank consists of a fuel cell which provides maximum safety and meets the current FIA standard, and a protective shell made of carbon. The tank integrates two fuel pumps. -
Page 200: Fuel
4.14.1 Fuel Bodywork Superplus unleaded (at least 98 ROZ) The ethanol content in the fuel may not exceed 26 % (E26). 4.14.2 Defueling A defueling valve is installed to empty the fuel tank. To start the procedure, the fuel pump switch located in the central console must be in position "Fuel Pump Service". The fuel pump is then activated for 120 seconds. -
Page 201: Tank Installation
4.14.3 Tank installation Bodywork A steel underride protection is provided beneath the tank, protecting it against external impacts. Part Item Dimensions Tightening torque in Nm Hexagon nut 10 Nm (7.4 ft-lb) Combi SHR M8X40 20 Nm (14.75 ft-lb) Hexagon nut 10 Nm (7.4 ft-lb) 4.14.3.1 4.15... -
Page 202: Repairing The Front Section
4.15.1 Repairing the front section Bodywork A tool kit has been set up especially for performing repair work on the aluminum parts. The tool kit may only be used on aluminum parts. Required tools by Wieländer+Schill Description Item No. Body saw WPS 2010 230V 120020 W+S special central punch F2 (for self-pierce rivets) -
Page 203: Version: 16.12.2014
Consumables Bodywork Solid carbide drill ø 6.7 mm 627010 3M 2K glue DP 490 (Porsche) 999.915.323.40 Blind rivet (long) 5.0-8.5 (Porsche) 999.190.230 Blind rivet (short) 3.0-6.5 (Porsche) 999.190.227.01 Wieländer + Schill Siederstr. 50 78054 Villingen-Schwenningen Phone: +49 (0)7720-83 17 0 E-Mail: info@wielanderschill.com... -
Page 204: Version: 16.12.2014
HAZET Bodywork Designation Item No. Tool trolley 179-6-RAL 4000896148851 Door RAL 9006 179-21 4000896146246 Can holder 179-35 4000896141074 Attachable box 179-28 400089141234 Paper roll holder 180-34 4000896120840 Set of separating plates 173-31/5 4000896090150 Set of separating plates 173-32/5 400089120796 Cable drum 161-3D 4000896048878 Anti-slip mat 180-38 400089120819... -
Page 205: Version: 16.12.2014
Preparation for repairing the front section Bodywork These instructions describe how to repair the front section. Individual operations are shown on one side and have to be carried out inversely on the other side. In case of deviations, the steps are described separately. The estimated time for the described repair is approximately five hours. -
Page 206: Version: 16.12.2014
Removing the front section Bodywork The front section (Z front section Cup) is available as spare part. Porsche spare part number: 991.501.991.8A 4.15.1.1 Together with the front section are consumables such as glue and blind rivets. Where possible, drill out the self-pierce rivets (1) from the rivets head. -
Page 207: Version: 16.12.2014
Heat the glued joint (2) with the heating gun and pry apart the sheet to the top using a separating chisel. Bodywork 4.15.1.3 Bore the marked rivets (1) only through the first sheet. Aluminum extruded sections are in the carrier frame. The aluminum profile is behind the saw line (2). This cut allows removing the front section, a more precise cut will follow in a later step. -
Page 208: Version: 16.12.2014
The illustration shows the saw line on the right outside. Bodywork Cut through the carrier frame at the line (1) using the electric saw (saw blade 14). Starting from the center of the oval cutout, carry out the separation cut directly behind the two threads. -
Page 209: Version: 16.12.2014
Together with a second person, remove the front section towards the front of the vehicle, using the slide hammer with hook if necessary. Bodywork The illustration shows the cut off front section from the right. Adapting carrier frame to new part 4.15.1.7 Carry out grinding operations using a stainless steel wire brush. -
Page 210: Version: 16.12.2014
Sawing template, left Bodywork The three threaded holes (1) are used as fixing point. 4.15.1.9 Transfer the saw line (1) on the template’s front end onto the carrier from the top to the bottom and align centrally to the rivet hole. The saw cut is described for the right carrier frame. -
Page 211: Version: 16.12.2014
Heat the upper section (hatched) of the two carrier sheets and open with the separating chisel. Bodywork 4.15.1.12 Carry out the inner saw cut (hatched) A = outer sheet B = inner sheet 4.15.1.13 Saw the carrier upper section (1). Remove glue residues in the hatched area. -
Page 212: Version: 16.12.2014
The illustration shows the new part’s right outside. Bodywork The new part is riveted to the old carrier frame. Item (1) shows where the holes for the rivets have to be provided. 4.15.1.15 The illustration shows the right carrier from the inside. Transfer the three holes onto the old carrier stub (1). -
Page 213: Version: 16.12.2014
Mounting the new part Bodywork The bottom cross member and the rivets at the upper end next to the strut dome are used for positioning. All surfaces that are riveted have also to be bonded with two-component glue. Place and rivet the blind rivets connecting the new part to the body. Make sure that two different rivet lengths are available. -
Page 214: Version: 16.12.2014
The illustration shows the new front section and the old carrier stub Bodywork 4.15.1.19 The illustration shows the front section on the left side 4.15.1.20 The illustration shows left inside of the front section 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 215: Version: 16.12.2014
Bodywork 4.15.1.21 The illustration shows the front section from the top, near the strut dome 4.15.1.22 The illustration shows the front section’s left rear panel from below 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 216: Replacing The Front Strut Mount
4.15.2 Replacing the front strut mount Bodywork Safety measures Always wear the indicated protective equipment to prevent injuries caused by heat or flying debris. • Goggles • Safety shoes • Protective gloves • Hearing protection 4.15.2.1 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 217: Version: 16.12.2014
Required tools by Wieländer+Schill Bodywork Designation Item No. Body saw WPS 2010 230 V 120020 W+S special central punch F2 (for self-pierce rivets) 628006 Slide hammer with hook 5 kg 511300 Dead blow bumping hammer 511029 Separating chisel incl. handle, body 512001 Anvil dolly, half-round 511113... -
Page 218: Version: 16.12.2014
Consumables Bodywork Solid carbide drill ø 6.7 mm 627010 3M 2K glue DP 490 (Porsche) 999.915.323.40 Blind rivet (long) 5.0-8.5 (Porsche) 999.190.230 Blind rivet (short) 3.0-6.5 (Porsche) 999.190.227.01 Wieländer + Schill Siederstr. 50 78054 Villingen-Schwenningen Phone: +49 (0)7720-83 17 0 E-Mail: info@wielanderschill.com... -
Page 219: Version: 16.12.2014
HAZET Bodywork Designation Item No. Tool trolley 179-6-RAL 4000896148851 Door RAL 9006 179-21 4000896146246 Can holder 179-35 4000896141074 Attachable box 179-28 400089141234 Paper roll holder 180-34 4000896120840 Set of separating plates 173-31/5 4000896090150 Set of separating plates 173-32/5 400089120796 Cable drum 161-3D 4000896048878 Anti-slip mat 180-38 400089120819... -
Page 220: Version: 16.12.2014
Preparation for replacing the strut dome Bodywork These instructions describe how to remove the left front strut dome. Perform the operations on the right side inversely. The estimated time for the described repair is approximately three hours. Remove the following parts: •... -
Page 221: Version: 16.12.2014
Deeply mark the self-pierce rivets and pierce them using a solid carbide drill (Ø 6.7 mm). Bodywork • Saw the defective dome using an air saw (2) • Pierce the rivet in the direction of the arrow • Heat the glued joints between dome and body using a hot air blower Remove the damaged dome. -
Page 222: Version: 16.12.2014
Do not remove the beads on the carrier inside; they are part of the body! Bodywork Debur the bore holes on both sides of the body. Creating a drilling template Only a drilling template ensures exact positioning of the holes. Make a drilling template from the defective strut mount. -
Page 223: Version: 16.12.2014
Riveting the new part Bodywork The hidden row of rivets (1) should be riveted from the bottom, as the row is hidden by the body. 4.15.2.9 Rivet the first row of rivets (1). 4.15.2.10 Drill the holes for the rivets using a solid carbide drill (Ø 6,7 mm). On the bottom part of the dome, another rivet is fitted in addition to the existing one. -
Page 224: Repairing The Rear End
4 parallel clamps body grip pliers Body saw WPS 2010 220V Item No. 120020 Hot air blower 3000 W Item No. 801200 Consumable supplies Porsche Rivets (short) 3.0-6.5 Item No. 999.190.227.01 Rivets (long) 5.0-8.5 Item No. 999.190.230 3M 2K glue DP 490 Item No. -
Page 225: Version: 16.12.2014
Removing the rear section Bodywork The standard bolts will be replaced by rivets. Remove the Torx bolts from the carrier frame. Fit the clamping claw to the carrier frame assembly and knock it loose from the body. Carry out grinding operations using a stainless steel wire brush. Always use special grinding wheels for grinding aluminum. -
Page 226: Version: 16.12.2014
Installing the new part Bodywork Apply evenly two-component glue on the old bonded joints. The illustration shows the rivets (1) from the outside on the left. Place the new part, fit the rivets and rivet them. 4.15.3.2 The illustration shows the rivets (1) from the inside on the right. 4.15.3.3 The illustration shows the rivets (1) from below on the right. -
Page 227: Version: 16.12.2014
The illustration shows the rivets (1) on the rear engine mount (bumper) on the left. Bodywork The curing time of two-component glue is 2-3 hours at 60 °C (140 °F). 4.15.3.5 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 228: Thread Repair Kit
Helicoil thread by a new Helicoil. Two systems are available for thread repair. The Helicoil repair system supplied by Böllhoff and Time-Sert thread inserts supplied by Würth. Porsche recommends special thread repair kits for particular thread sizes. It is important that the corresponding tightening torque of the bolted connection can be achieved after repair. -
Page 229: Germany
Basic method for repairing threads with thread inserts: Bodywork Remove the defective thread insert Drill a core hole using a special core hole drill Cut a thread using a tap (two-piece/three-piece), use a cutting agent. Insert the new thread insert with a special inserter Thread repair kits can be ordered at the following companies: Wilhelm Böllhoff GmbH &... -
Page 230: Thread Repair Of Chassis Bolt Connections
4.16.1 Thread repair of chassis bolt connections Bodywork Threaded bushings without collar Tools: Hot air blower V.A.G. 1416 (WE1119) • • Thread repair kit 9843 • Thread repair kit 9843/1 • Thread repair kit 9843/2 • Thread repair kit 9843/3 •... -
Page 231: Version: 16.12.2014
Repair of threaded bushings without collar Bodywork • Remove standard wire thread inserts/Helicoil before drilling • Release the wire thread insert /Helicoil (1) with a suitable screwdriver 4.16.1.5 Pull out the wire thread insert/Helicoil (1) • 4.16.1.6 • Drill out the old thread completely using a special three-fluted drill (included in the kit) (B) 4.16.1.7 911 GT3 Cup (991) -
Page 232: Version: 16.12.2014
Cut the thread to the dimension (Y) with a cutting tool Bodywork 4.16.1.8 • Clean the thread: Blow out chips from the thread with compressed air, flush the thread with brake cleaner, dry the thread with compressed air • Screw the threaded bushing (1) on the inserter (2) 4.16.1.9 Unscrew the inserter (E) from the threaded bushing (A) •... -
Page 233: Version: 16.12.2014
Make sure that the threaded bushing (1) is screwed completely on the inserter (2) – arrows Bodywork 4.16.1.11 • Insert the threaded bushing (1) completely with the inserter (2) • Briefly heat the thread insert with a WE1119 hot air blower, Leister- Electron/V.A.G. -
Page 234: Version: 16.12.2014
Threaded bushings with collar Bodywork • Remove the standard wire thread inserts (Helicoil) before drilling • Drill out the old thread completely using the drill (included in the kit) (B) 4.16.1.13 The repair bushing has to be fitted more deeply. Use the tool included in the tool kit for milling the appropriate recess •... -
Page 235: Version: 16.12.2014
Cut the thread to the dimension (Y) with a cutting tool Bodywork 4.16.1.15 • Place the threaded bushing on the inserter • Oil the inserter (E) • Manually screw the threaded bushing (A) on the inserter (E) During press fitting in the basic thread, forming the internal thread requires perceptibly more force on the inserter. -
Page 236: Version: 16.12.2014
Repair positions – overview Bodywork 4.16.1.18 Trunk cross member Strut mount, left Strut mount, right Rear beam, left Rear beam, right Engine mount left & right Bumper mount (impact absorber) left & right 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 237: Version: 16.12.2014
Threads – cross member Bodywork Thread 1; front axle mounting (Helicoil) M12x1.5x30 Thread 2; axle support mounting (Helicoil) M12x1.5x30 Threads 1 / 2: Explanation Type Basic value Threads 1 and 2 Dimension Y Length 33 mm Threads 1 and 2 Dimension X Length 5 mm... -
Page 238: Version: 16.12.2014
Threads – strut mount Bodywork Thread 1; diagonal brace mounting (Helicoil) M8x16 Thread 2; alarm horn mounting M8x16 (only on the left strut mount) (Helicoil) Thread 3, sensor mounting Thread M6 Thread 1: 4.16.1.21 Explanation Type Basic value Thread 1 Dimension Y Length 20 mm... -
Page 239: Version: 16.12.2014
Thread 2: Bodywork Explanation Type Basic value Thread 2 Dimension Y 20 mm Length Dimension X 5 mm Length Thread 2 Use repair kit 9843/3 with threaded bushing 999.504.262.01. 4.16.1.23 Thread 3: Explanation Type Basic value Thread 3 Dimension Y Length 9.4 mm Use repair kit No.122-1 Item 1 Time-Sert with short threaded bushing. -
Page 240: Version: 16.12.2014
Longitudinal beam, rear Bodywork Left beam: Thread 1; chassis mounting (Helicoil) M12x1.5x24 (3x) Thread 2; chassis mounting (Helicoil) M10x20 (3x) Thread 3; (Helicoil) M10x20 (4x) Thread 4; gearbox mounting (Helicoil) M10x20 (1x) Thread 5; M10 (1x) 4.16.1.25 Right beam: Thread 1; chassis mounting (Helicoil) M12x1.5x24 (3x) Thread 2;... -
Page 241: Version: 16.12.2014
Thread 1: Bodywork Explanation Type Basic value Thread 1 Dimension Y Length 27 mm Thread 1 Dimension X Length 5 mm Use thread repair kit 9843 with threaded bushing 999.504.263.01. 4.16.1.27 Thread 2/3: Explanation Type Basic value Thread 2 and 3 Dimension Y Length 25 mm... -
Page 242: Version: 16.12.2014
Thread 4: Bodywork Explanation Type Basic value Thread 4 Dimension Y 25 mm Length Thread 4 Dimension X Length 5 mm Use repair kit 9843/1 with THREADED BUSHING 999.504.268.01. 4.16.1.29 Thread 5: Explanation Type Basic value Thread 5 Dimension Y Length 37 mm Length... -
Page 243: Version: 16.12.2014
Thread 6: Bodywork Explanation Type Basic value Thread 6 Dimension Y Length 16.2 mm Thread repair 6 only for the right beam. Use repair kit No. 122-1 Item 2 Time-Sert thread repair with long threaded bushing. 4.16.1.31 Cross beam, rear (engine mount) Thread 1;... -
Page 244: Version: 16.12.2014
Thread 1: Bodywork Explanation Type Basic value Thread 1 Dimension Y Length 16.2 mm Use repair kit No. 122-1 Item 2 Time-Sert with long threaded bushing. Thread 2: 4.16.1.33 Explanation Type Basic value Length Thread 2 Dimension Y 9.4 mm Use repair kit No.122-1 Item 1 Time-Sert with short threaded bushing. -
Page 245: Version: 16.12.2014
Longitudinal beam, rear (impact absorber mount) Bodywork Thread M8 in cast part Explanation Type Basic value Thread 1 Dimension Y Length 16.2 mm Use repair kit No. 122-1 Item 2 Time-Sert with long threaded bushing. 4.16.1.36 4.16.1.35 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 246: Installing Roof Assembly
4.17 Installing roof assembly Bodywork Preparation measure Danger of material damage if specified curing time of NOTE adhesive is not observed! In order to ensure that the bonded joint is sufficiently strong, the following conditions must be adhered to: • The vehicle must not be used until the curing time has •... -
Page 247: Version: 16.12.2014
Installation: Bodywork Two people are needed in order to insert, position and NOTE secure the roof assembly. Clean bonding surfaces (1) with cleaning solution. Prime bonding surfaces (1). Apply adhesive on the primer. Do not apply adhesive in areas (A) 50 mm and (B) 30 mm. 4.17.2 Apply a triangular bead of adhesive measuring X = approx. -
Page 248: Interior
Interior Interior General The interior design of the new 911 GT3 Cup (991) focuses on ergonomics and driver´s safety. The center console is tilted towards the driver in order to improve accessibility of the control elements. Appearance improvements feature colored controls and a Cosworth data logger with colored display. -
Page 249: Drivers Safety
Drivers safety Interior The substantial occupant safety system of the 911 GT3 Cup (991) primarily includes the following components: • Certified safety cage • FIA homologated racing bucket seat with longitudinal adjustment Six-point safety belt connected to safety cage • •... -
Page 250: Seat Rail Tightening Torques
5.2.2 Seat rail tightening torques Interior Tighten all bolts to a tightening torque 28 Nm ±2 Nm. Use medium-strength thread locker. M10x16 7/16“ UNFx16 5.2.2.1 911 GT3 Cup (991) Version: 16.12.2014 MJ 2015... -
Page 251: Bucket Seat Tightening Torques
5.2.3 Bucket seat tightening torques Interior Tighten all bolts to a tightening torque 23 Nm ±2 Nm. Use medium-strength thread locker. M10x16 7/16“ UNFx16 5.2.3.1 911 GT3 Cup (991) Version: 16.12.2014 MJ 2015... -
Page 252: Padding System
5.2.4 Padding system Interior Different seat pads are available and may be ordered in three sizes (S, M, L). The seat pads can be purchased at Recaro. On delivery, the bucket seat is equipped with standard padding in medium size (M). Seat pad thickness S = 30 mm (1.2“) M = 20 mm (0.8“) -
Page 253: Steering Wheel
Steering wheel Interior Particular attention was paid to the steering wheel as a central control element. All necessary functions which are typical used during driving may be operated by switches and pushbuttons on the steering wheel, without removing the hands from the steering wheel. -
Page 254: Cockpit Ventilation
Cockpit ventilation Interior Two NACA air intakes have been integrated into the front bonnet in order to ensure a fresh air supply to the vehicle interior. The left intake – as seen in the driving direction – provides fresh air through a flexible aluminum hose directly onto the driver (yellow arrow). -
Page 255: Version: 16.12.2014
Interior 911 GT3 Cup (991) Version: 16.12.2014 MJ 2015... -
Page 256: Electrical System
Electrical system Electrical System General The 911 GT3 Cup (991) has been significantly improved in terms of operating comfort and functionality. Compared to previous models, the electrical equipment has been upgraded and new and attractive features are available. The integration of an electro-pneumatic gear shift system, the innovative electrical system control unit, and the color display all improve the operating comfort. -
Page 257: Battery Master Switch
6.2.3 Battery master switch Electrical System The battery master switch (6.2.3.1) cuts off all electrical circuits (battery, generator, lights, ignition and electrical controls, etc.) as well as the engine. 6.2.3.1 The battery master switch (Pos.2 in picture 6.2.3.2) is installed right next to the battery. -
Page 258: Electrical System Protection
Electrical system protection Electrical System 6.3.1 Electrical system control unit IPS32 In the 911 GT3 Cup (991), the IPS32 electrical system control unit takes over the functions of fuses and relays. The IPS32 also ensures the power supply to the electrical consumers. -
Page 259: Fuse Holder Hydraulic Pump
Part name Pin No. Part name Pin No. Display & option plug Windscreenwiper Transponder Electrical System ID-Lights Flasher right (front & rear) Frontlight Generator Option AC Unit Low beam left LED daytime driving light Low beam right Flasher left (front & rear) Starter Brakelight (right &... -
Page 260: Dme Control Unit
Device programming is carried out exclusively at Porsche Motorsport. The sensor Error engine oil E_toil online fault diagnosis functionality is only available for the engineers of Porsche AG. If temperature sensor Error gearbox oil an engine overhaul is to be performed at Porsche Motorsport, the corresponding... -
Page 261: Dme Diagnosis
Error clutch pressure E_pclutch sensor Error fuel pressure E_pfuel RaceCon (USB drive): sensor Error gearbox pressure E_pgear sensor Porsche part number: 991.618.815.8A Error reverse gear E_brev switch E_psdia_fpump Error fuel pump Error MIL (malfunction 6.4.3 Carburation E_psdia_mil indicator lamp) -
Page 262: Sensors
Sensors Electrical System Upon delivery, the following sensors are used in the vehicle: 104 E_etccal Error calibration throttle E_canmsg_ Parameter Label in the PI Label in Bosch Error can message dyno_0 Cosworth ICD Display RaceCon E_canmsg_ Error can message dyno_1 Engine E_canmsg_ Error can message... -
Page 263: Sensor Rated Values
6.5.1 Sensor rated values Electrical System Parameter Bosch label Rated value Comment Engine idle speed nmot 2000 +/-100 rpm At operating temperature (oil 80 °C (176 °F) Throttle angle idle 6.5 +/- 1.0° Throttle angle full 80 +/- 2 ° Bosch value =>... -
Page 264: Optional Sensors
6.5.2 Optional sensors Electrical System Porsche Motorsport optionally offers a steering angle sensor and brake pressure sensors. In addition, a memory extension is recommended when fitting optional sensors. See chapter 6.6.1 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 265: Icd Display
ICD Display Electrical System 6.6.1 General 6.6.1.1 The ICD (Intelligent color display) supplied by PI Cosworth is a universal display unit with integrated data storage. The 6.2” TFT color display provides the driver with substantial information. 8 LEDs acting as shift lights (green - yellow - red) are located on top of the display. -
Page 266: Version: 16.12.2014
The yellow button (1) on the right side of the steering wheel is used to navigate through the different pages. A long press changes the page number; a short press Electrical System navigates to the main page (Race). 6.6.1.3 When adjusting the brake bias, activating the pit speed or when an alarm is active, the corresponding displays have priority and overlay other pages. -
Page 267: Race Page
6.6.2 Race page Electrical System The “Race” page configured for races is divided into three information areas. 6.6.2.1 Engine speed Channel information Alarm information Engine speed is sent from the Bosch ECU to the display and is displayed from 1500 to 10,000 rpm. -
Page 268: Version: 16.12.2014
The display is divided into three main areas. Electrical System 6.6.2.3 Channel pairs to be selected by a switch on the steering wheel Fixed display of RPM, gear number and speed Fixed display of Fuel level (after power on), if you start the engine you see the Fuel Press for 3 seconds and after 3 seconds the Fuel Press switches to Fuel Cons. -
Page 269: Version: 16.12.2014
Center panel/fixed display Electrical System The top value is related to the engine speed. The large “N” in the middle indicates the gear number and the lower number displays the vehicle speed. Display Description Indicates a gear position between 2 valid gear numbers Reverse Neutral An unrecognized value is being sent from the Bosch ECU... -
Page 270: Practice Page
6.6.3 Practice page Electrical System The relevant practice data are configured on the “Pract” page of the display. The layout is similar to the “Race” page but with different channel information. 6.6.3.1 Engine speed Channel information Alarm information Left panel Two different times can be displayed on the left panel (6.6.3.2). -
Page 271: Version: 16.12.2014
Right panel Electrical System Time Diff: This is the time difference calculated in “qualifying mode“ between the current lap and a reference lap. The upper image (6.6.3.3) shows a negative value, indicating that the driver is currently 0.11 seconds faster than the reference lap. The green bar also shows the same value. -
Page 272: Warmup Page
6.6.4 Warmup page Electrical System Enlarged letters and numbers of Rpm, water temperature, and oil temperature are displayed on the “warmup” page (6.6.4.1). This allows the page and the different parameters to be visible from outside the car. 6.6.4.1 Engine speed Channel information Alarm information The engine warmup speed range is shown in a smaller scale on the bargraph. -
Page 273: Vitals Page
6.6.5 Vitals page Electrical System The „Vitals“ page (6.6.5.1) gives an overview of the vital functions of the engine and the vehicle. The important channels are all displayed on one page. The displays and values on this page are fixed and cannot be changed. 6.6.5.1 Channel information Alarm information... -
Page 274: Version: 16.12.2014
Odometer (6.6.5.4) Electrical System To reset the Odometer press and hold the Mark button for more than 1.5 seconds. Label Resolution Unit Scale Description Total 0 - 999999.9 Cumulative channel Distance (0-621371 mi) Trip 0.001 0 - 9999.999 Trip resets Distance (0-6213.71 6.6.5.4... -
Page 275: Version: 16.12.2014
Right panel Electrical System Gear Pot (6.6.5.7) Label PI Toolbox Resolution Unit Scale channel Gear MS4 ugearp 0.001 65.535 Voltage 6.6.5.7 Battery display (6.6.5.8) Label PI Toolbox Resolution Unit Scale Description channel Battery Voltage 0 - 99.9 Voltage seen Voltage by the ICD 6.6.5.8 Power system (6.6.5.9) -
Page 276: Pedals Page
6.6.6 Pedals page Electrical System The “Pedals” page (6.6.6.1) displays all important pedal information. Brake pressures as well as the position/function of the accelerator pedal and the electronic throttle can be checked. 6.6.6.1 Left panel A graphical interpration of front and rear brake pressures and of the balance and the brake bias is displayed (6.6.6.2) Display PI Toolbox... -
Page 277: Version: 16.12.2014
Middle panel Electrical System Shows numerical values for brake and throttle Display PI Toolbox Resolution Unit Scale Description channel Brake P Brake Press Front 0 – 280 (0- 250 bar sensor Front 4,061 psi) Brake P Brake Press Rear 0 – 280 (0 – 250 bar sensor Rear 4,061 psi) -
Page 278: Additional Information
6.6.7 Additional information Electrical System Overlays Additional information of higher priority will overlay all other displays for a limited period. Brake bias: While adjusting the mechanical brake bias, values in steps of 0.25 will be displayed. The display will keep this setting change one second and returns afterwards to the previous display (6.6.7.1). -
Page 279: Version: 16.12.2014
Pit speed Electrical System “Pit Speed” is enabled with the orange switch (1) on the steering wheel (6.6.7.2). Activating the “Pit speed” mode only possible above 10 kph (6.2 mph) There are two types of pit speed display: The green background is displayed as long as the target speed of 60 kph (37 mph) is not exceeded (6.6.7.3). -
Page 280: Version: 16.12.2014
Alarm displays Electrical System There are three types of alarm displays: Alarm Where Text Lights level Middle display panel ALARM 4 flashing lights Lower information area ALARM/WARN Continuous lights Lower information area ALARM/WARN Continuous lights Level 1 alarms The main alarm page is triggered by only a few parameters. This alarm page has the highest priority and will always be displayed in the foreground. -
Page 281: Version: 16.12.2014
Level 2 alarms Electrical System Every level 2 ALARM is labeled as ALARM. If the message has lower priority “WARN” appears in the display, together with the error description. 6.6.7.8 Priority Alarm Channel Conditions Description Fuel MS4 pfuel <2.5 bar (36 psi) Engine speed 6.6.7.7 pressure... -
Page 282: Version: 16.12.2014
Level 3 alarms Electrical System Any additional level 3 warning or information message is shown in the display with a short description. Priority Alarm Channel Conditions Description SW03 Pit Active for 0.5 Speed Speed sec. Button Gearbox MS4 B Active for 1 sec. Gearbox emergency emsw switch for manual shift... -
Page 283: Version: 16.12.2014
Wheel lock lights Electrical System This function is provided to help the driver to prevent unnecessary tire wear caused by locking front wheels. A potential lock up of the front wheels are indicated by a flashing LED on the display. If the front brake pressure is more than 10 bar (145 psi) and the speed of the left front wheel is less than that of the left rear wheel by 20 kph (12 mph), the top left warning light comes on (6.6.7.10). -
Page 284: Lights
Lights Electrical System The 911 GT3 Cup (991) is equipped with xenon headlights and front lights incl. daytime running lights, position, and indicator lights in LED technology. The headlight leveling control is without function. The headlight leveling control motor is only used for fixing the xenon lens. -
Page 285: Data Bus System
Data bus system Electrical System Four CAN bus systems and two LIN bus systems are used in the vehicle. Data bus overview: 6.8.1 CAN 1 (highspeed) Communication between engine ECU and display (1Mbit/s) CAN 2 (highspeed) Communication between electrical system control unit and display (1 Mbit/s) CAN 3 (lowspeed) Communication... -
Page 286: Wiring Harness
The wiring harness is separated as follows: Engine Porsche Spare part number: 997 607 012 99 Vehicle cable harness Porsche Spare part number: 991 612 101 8A Front axle wheel carrier... -
Page 287: Fire Extinguisher
6.11 Fire extinguisher Electrical System The fire-extinguishing system uses a liquid extinguishing agent. It consists of a two- chamber reservoir that stores the liquid extinguishing agent and turns it into gas when it is activated. This allows residue-free extinguishing. Two gas cartridges that are activated by a control unit are used as propellant. -
Page 288: Testing The Trigger Switch
6.11.1 Testing the trigger switch Electrical System The switch test is performed on the fire extinguishing system control unit. Always follow the steps below to prevent unintended triggering of the system. The switch (2) has three positions. Upper position: = Battery/Circuit test Central position: = (OFF) The system is switched off Lower position: = (ARMED if ON) The system is armed if the red LED will be ON. -
Page 289: Driver Control Systems
6.12 Driver Control Systems Electrical System 6.12.1 Steering wheel The most important functions can be comfortably carried out with the press of a button directly from the steering wheel. 6.12.1.2 6.12.1.1 The steering wheel is attached to the steering column by means of a quick release coupling. -
Page 290: Center Console
6.12.2 Center console Electrical System Switches and pushbuttons are located in the center console. Their functions are described below. Main = Power supply 4 to 6 sec. overrun Fuel Pump Service = High pressure pump switch Intank Pump Service = Intank pump switch Ignition = Ignition Light... -
Page 291: Windscreen Wiper
6.12.3 Windscreen wiper Electrical System The wiper motor is activated by the display via the LIN. A green push button is provided on the steering wheel. The wiper motor has two stages: slow and fast. Switching logic: Press once short: one time on Press once longer 1,5 second: continuity wiping... -
Page 292: Maintenance
Maintenance Maintenance Engine 7.1.1 Oil level measurement using the dipstick Conditions for the correct measurement: The vehicle should be on a flat, even surface • • Engine at operating temperature, oil temperature 80 °C (176 °F) Idle speed • 7.1.1.1 Follow the steps below for correct measuring: •... -
Page 293: Oil Level Measurement With Display
7.1.2 Oil level measurement with display Maintenance A digital oil level indicator (7.1.2.1) is optionally available Porsche spare parts number: 997.641.139.9A. Adapter cable Porsche spare parts number: 991:612:334.8A The vehicle cable harness is already prepared for this indicator. On the vehicle itself, the connector for the oil level indicator is provided near the rear side window on the right side of the vehicle. -
Page 294: Refilling Engine Oil
Incl. oil filter change: 8.3 l (8.8 qt) • Without oil filter change: 8.1 l (8.6 qt) Consumables: Porsche spare part number: 996.107.225.53 Oil filter element Porsche spare part number: 900.123.010.20 Oil tank seal ring Porsche spare part number: 900.123.118.30 Crankcase seal ring 7.1.5... -
Page 295: Engine Cooling System
Allow the coolant to run into suitable containers Provide the drain plugs with new seal rings and screw tight (10 Nm (7.4 lb- • ft) tightening torque) Consumables: Porsche spare part number: 900.123.144.30 Coolant circuit seal ring 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 296: Version: 16.12.2014
Filling the cooling system Maintenance • Disconnect the quick coupling in the engine compartment and connect the open ends to the two couplings of the filling device • Switch on the pump; the system is being filled • The device should be turned on for ten minutes to ensure proper filling and venting •... -
Page 297: Setting The Valve Timing
Checking the coolant level Maintenance If possible, open the compensating tank cap (1) only when the engine is cold. When opening the system while the engine is hot, air may penetrate into the system and impair the function. A float (2) indicating the fluid level is provided behind the cap. When the engine is cold, the fluid level should be between min and max. -
Page 298: Engine Tightening Torques
7.1.8 Engine tightening torques Maintenance Component Screw Tightening torque dimensions [Nm] Engine Engine mount to body 65 (48 lb-ft) Crankshaft and crankcase Connecting rod M10 x 1.25 Oil pump 23 (17 lb-ft) Crankshaft bolt/nut 23 (17 lb-ft) Pulley to crankshaft M14 x 1.5 170 (125.4 lb-ft) Sealing screw, pressure control and... -
Page 299: Fuel System
Fuel system Maintenance 7.2.1 Fuel Superplus, unleaded (min. 98 ROZ) The ethanol content in the fuel may not exceed 26 % NOTE (E26). 7.2.2 Fuel pump The fuel pump is located in the tank. 7.2.3 Fuel extraction A defueling valve is provided close to the tank filler neck to empty the fuel tank. Use a special hose with a quick disconnect coupling for defueling. -
Page 300: Version: 16.12.2014
Switch position down Normal operation Auxiliary material: Porsche spare part number: 997.110.355.91 Fuel extraction hose The fuel pump should not run dry as this may cause NOTE damage to the pump. Ensure that the coupling fits tightly. The hose end has NOTE to lead into a suitable container. -
Page 301: Power Transmission
Power transmission Maintenance 7.3.1 Gearbox The running time is 30 hours. Transmission oil fill quantity For a rebuild, the fill quantity is 3 liters (3.2 qt). Filling: Place the gearbox on a flat and even surface • • Slowly fill transmission oil in the inclined filler neck Oil specifications 7.3.1.1 Mobilube 1SHC75W90... -
Page 302: Clutch
7.3.2 Clutch Maintenance Check the following during any inspection: • Check clutch basket, hub, sintered disk for cracks • Check spring tongues for wear • Check housing lugs for wear • New sintered lining 3.40 mm (0.13”) • Replace at 3.00 mm (0.12”) Installation •... -
Page 303: Version: 16.12.2014
Racing Brake Fluid-325° from Performance Friction Brakes is used as clutch fluid. Consumables: Porsche spare part number: 991.355.960.8A Brake fluid Porsche recommends bleeding the system after each practice and changing the fluid after each race. Fill quantity: approx. 500 ml (17 oz) •... -
Page 304: Paddle Shift
Central release mechanism Maintenance When handling the central release mechanism seal, be NOTE sure to avoid any contact with transmission oil. Otherwise, the seal may swell, which, in the worst case, may cause a loss of function. Only use the Sachs special tool to fit the seal. -
Page 305: Drive Shafts
150 g (5.3 oz) Grease quantity for joint on gearbox side: 120 g (4.2 oz) Porsche spare part no.: 000.043.110.01 grease (100 g / 3.5 oz) Torque Tightening Specifications Tighten all bolts to 30 Nm (22.1 lb-ft) in the specified order Tighten all bolts to 60 Nm (44.3 lb-ft) in the specified order... -
Page 306: Chassis
Maintenance 7.4.1 Wheel nut Porsche Motorsport also recommends replacing the wheel nuts during a long distance race (approx. 6 hours run time). The replacement is required for checking and regenerating the used wheel bolts. Regenerating includes cleaning of the threads, visual inspection for damage and re-greasing with aluminum paste. Also grease the nut-rim contact surface. -
Page 307: Locking Piece
The locking pieces are used as the locking mechanism for the wheel nuts. Make sure that they can be moved freely. Grease the mechanism using “Optimol Paste”. Consumables: Porsche spare part no.: 000.043.004.00 Optimol Paste HAT The locking mechanism may be removed from the hub for maintenance and cleaning. -
Page 308: Wheel Bearings
7.4.3 Wheel bearings Maintenance Regularly check the tolerance in the wheel bearings. While one person holds the steering wheel, a second person turns the wheel as shown in the illustration below. Horizontal tolerance • • Vertical tolerance Proceed in the same way to check the dome bearing and the suspension arm. Check the dome bearing by means of vertical movements. -
Page 309: Brake System
7.4.6 Brake system Maintenance Brake pad wear limit: The wear limit is reached when the pad has been worn down to the bottom of the slot (7.4.6.1). Brake Disk Wear Limit: The wear limit is reached when the disk has been worn down to the bottom of the slot (7.4.6.2). -
Page 310: Version: 16.12.2014
Installation Maintenance • The brake fluid can be used as assembly lubricant; wet pistons and seals with brake fluid • When inserting the pistons into the holes, a slight resistance is caused by the seals (normal) • Place the piece of wood again in the caliper •... -
Page 311: Shock Absorber/Spring
Proceed as follows for changing the brake fluid: Maintenance Remove the brake fluid from the brake fluid reservoir of the two master cylinders using a syringe Pour in new brake fluid Flushing: Build up pressure with the brake pedal Open the front axle and rear axle brake bleeder valves simultaneously and close them again Only release the brake pedal when the bleeder valves have been closed. -
Page 312: Steering System
7.4.10 Steering system Maintenance Reservoir capacity: 0.65 liter (0.7 qt) Bleeding the steering system Venting should be performed by two persons. For filling the entire system, e.g. after replacing the steering system, lines or a high loss of fluid, start the engine and stop it again immediately. The fluid level in the container drops rapidly and it should be ensured that “Pentosin”... -
Page 313: Version: 16.12.2014
Quick release coupling Maintenance • Check the steering wheel for play Clean and grease the mounting points of the quick release coupling • The picture (7.4.10.1) shows the locking pins of the quick release coupling. 7.4.10.1 The picture (7.4.10.2) shows the open quick release coupling (coupling ring pulled out). -
Page 314: Body
• Check seat and seat rail for damage, tightness and function 7.5.1 Airjack system Porsche Motorsport recommends overhauling after two years or 2,000 strokes. • Only clean air jack piston with silicone grease or spray • Regularly check the air jacks for mechanical damage 7.5.1... -
Page 315: Electrical System
Electrical system Maintenance • Regularly check connectors for tight fit and corrosion 7.6.1 Checks after wet races • Remove moisture from the interior • Check electrical connectors for moisture, remove if required 911 GT3 Cup (991) Version: 16.12.2014 MY 2015... -
Page 316: Maintenance Intervals
Maintenance intervals Maintenance 7.7.1 After 200 km (124 mi) or first test drive • Visual inspection of all systems, lines, etc. for leaks, damage or chafing • Check the specified tightening torque of all safety critical bolts • Check all wheel suspension bolts •... -
Page 317: After Each Weekend (Sprint Race)
7.7.3 After each weekend (sprint race) Maintenance In addition to 7.7.2: • Engine oil and filter change (after „heat race“ engine oil temperature > 140 °C (284 °F)) • Check compression and pressure loss of the individual cylinders Clean/replace air filter •... -
Page 318: Special Tools 911 Gt3 Cup (991)
Special tools 911 GT3 Cup (991) Maintenance Designation Company Part number Motor Angle-controlled wrench 3-60 Stahlwille 96501606 Nm (2.2 – 44.25 lb-ft) Angle-controlled wrench 20-200 Hazet 7292-2eTAC Nm (14.75 – 147.5 lb-ft) Angle-controlled wrench 40-400 Hazet 7294-2eTAC Nm (29.5 -295 lb-ft) Cooling system adapter Cooling Hazet... -
Page 319: Version: 16.12.2014
Front axle Carlift Vehicle Krontec LL-30_CL_PP lifting Maintenance Rear axle Carlift Vehicle Krontec LL-20_CL lifting Air gun Krontec LL-03 Tank filler neck Sobek Fuel bottle Krontec Windshield cutting tool KSA SCS-500 Toolsystem Riveting tongs M5 + M6 Threaded Förch nuts, threaded pins Rivet tongs 9399/1 threaded... -
Page 320: Partner Contacts
Partner contacts Maintenance EDUARD WILLE GmbH & Co.KG Lindenallee 27 42349 Wuppertal Phone: +49 (0)202-47 91-0 Fax: +49 (0)202-47 91-200 E-Mail: info@stahlwille.de HAZET-WERK Postfach 100461 42804 Remscheid Phone: +49 (0)21 91-79 23 75 E-Mail: info@hazet.de SOBEK Motorsporttechnik GmbH & Co.KG Industriestraße 8 68542 Heddesheim Phone: +49 (0)62 03-40 43 90 0... -
Page 321: Version: 16.12.2014
CB24 8PS United Kingdom Telefon: Porsche UK Support (Mobil Team): +44 1604 598814 Porsche UK Support (Non Business Hours): +44 1604 598809 Porsche US Support: +1 (424) 250-1290 X 1290 Fax: +44 (0)19 54-25 36 01 E-Mail: Porsche.support@cosworth.com MEGA-Line Racing ELECTRONIC GmbH Haunersdorf Str.
Need help?
Do you have a question about the 2015 911 GT3 Cup and is the answer not in the manual?
Questions and answers