Porsche 911 GT3 R Technical Manual
  1. Manuals
  2. Brands
  3. Porsche Manuals
  4. Automobile
  5. 911 GT3 R 2012
  6. Technical manual
Porsche 911 GT3 R Technical Manual

Porsche 911 GT3 R Technical Manual

Hide thumbs Also See for 911 GT3 R:
Table of Contents

Advertisement

Quick Links

Technical Manual
Model 2013

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 911 GT3 R and is the answer not in the manual?

Questions and answers

Related Manuals for Porsche 911 GT3 R

Summary of Contents for Porsche 911 GT3 R

  • Page 1 Technical Manual Model 2013...
  • Page 2 This technical information will give you the possibility to reference data, adjustment values and working procedures and make the maintenance and repair work on the vehicle easier. We wish you every success with your GT3 R Dr. Ing. h.c. F. Porsche Aktiengesellschaft Vertrieb Sonder- und Rennfahrzeuge...
  • Page 3 German road traffic regulations. Illustrations, descriptions and schematic drawings serve exclusively as presentation for the text. Porsche Motorsport accepts no liability for the completeness and conformity of the contents of this brochure with respect to the legality of the current regulations.

  • Page 4: Table Of Contents

    Contents CONTACTS GENERAL TECHNICAL DATA 2.1. Dimensions 2.2. Weight ENGINE 3.1. Engine technical data 3.2. Fuel specs 3.3. Engine power and torque curves 3.4. Engine lubrication 3.5. Engine cooling system 3.6. Induction system 3.7. Throttle butterfly 3.8. Working on the engine 3.9.

  • Page 5: Table Of Contents

    5.7. Clutch 5.8. Working on the gearbox 5.9. Gearbox component tightening torques SUSPENSION 6.1. Front suspension 6.2. Rear suspension 6.3. Basic wheel alignment 6.4. Working on the suspension 6.5. Tightening torques suspension 6.6. Sachs damper service information WHEELS 7.1. Wheel nuts BRAKE SYSTEM 8.1.

  • Page 6: Table Of Contents

    10.3. Steering wheel 10.4. Centre console 10.5. Shift Light Module 10.6. MoTeC Dash 10.7. Car sensors 10.8. Engine Control Unit (ECU) 10.9. EGas 10.10. 10.11. Traction control 10.12. Relay- and fuse assignment CAR MAINTENANCE 11.1. After approx. 200 km and/or first test 11.2.

  • Page 7: Contacts

    1. Contacts Technical Support Mr Rainer Sauter 0711 911 84994 0170 911 3436 Mr Steffen Höllwarth 0711 911 89922 0170 911 3989 Fax: 0711 911 89535 Sport parts sales Mr Christian Müller 0711 911 89175 Mr Robert Hirrig 0711 911 82687 Mr Klaus Lenzner 0711 911 82423 Mr Salvatore Scozzaro...

  • Page 8: General Technical Data

    2. General technical data Engine type M 97/79 Gearbox type G 97/72 Numbers of gears sequential 6 2.1. Dimensions Length (w/o spoiler edge) [mm] see homologation papers Width across front axle [mm] see homologation papers Width across rear axle [mm] see homologation papers Wheelbase [mm]...

  • Page 9: Engine

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

  • Page 10: Engine Power And Torque Curves

    3.3. Engine power and torque curves...

  • Page 11: Engine Lubrication

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

  • Page 15: Engine Cooling System

    3.5. Engine cooling system The GT3 R cooling system is a standard cooling system optimised for use in a race car. 3.5.1. Scheme drawing...
  • Page 16 3.5.2. Thermostat The stock GT3 R is not equipped with a thermostat. As an option a thermostat is available for cooler driving conditions (see parts catalog). When competing under warmer conditions the car should be driven without the thermostat in order to reduce the temperature level of the cooling system.
  • Page 17 The coolant remains fluid to temperatures of -30°C in delivery specification. For all race events Porsche Motorsport recommends that the factory filled engine coolant is replaced by 24.3 litres of water and 2 litres of anti- corrosion additive (part number. 997.106.907.90), which protects the...
  • Page 18 3.5.4. Filling the cooling system A quick-release coupling is integrated in the area of the expansion tank. The water system can be filled and bled quickly and safely via this coupling – after an engine change for example. Quick-release coupling Attention: When the water system has reached its operating temperature, expansion...
  • Page 19 A valve in the expansion tank allows the exhaust of steam at a pressure of 1.4 bars, and the release of water at a pressure of 1.8 – 2.0 bars. Air is drawn through the valve as the cooling system cools down. The bleed valve in the standard production car improves the initial reaction from the heating system;...
  • Page 20 Filling the system should be carried out as follows: • Disconnect the quick release fittings in the engine bay and connect the corresponding fittings with those of the filling system. Scavenge Pressure • Switch on the pump. The system will be filled. The device must run for ten minutes to guarantee that the system •...
  • Page 21 3.5.4.1. Filling the cooling system with engine at normal operating temperature: A special filling system to fill the engine water system when the engine is at normal operating temperature is also available from Sobek. This appliance consists of a fluid reservoir with a coupling. The reservoir is charged with a pressure of 2.5 –...

  • Page 22: Induction System

    3.6. Induction system Vacuum actuator Reso 1 (su) Vacuum actuator Reso 2 (su2) 4 stage resonance induction system • • Activated by vacuum actuator resonance valve 3.6.1. Under pressure routing...

  • Page 23: Throttle Butterfly

    3.7. Throttle butterfly • Electronically actuated single throttle butterfly Redundant system (two potis) • • For information on the EGAS system refer to 10.9 3.7.1. Throttle butterfly setting There is no mechanical connection between the throttle butterfly and the throttle pedal. The signal of the pedal is transferred to the throttle butterfly via an electro motor.

  • Page 24: Working On The Engine

    3.8. Working on the engine 3.8.1. Connecting-rod bolt mounting instructions • Thoroughly clean the mating faces, bolt threads and the tapped bores with cleaning grade petrol and nylon brush • Smear PLB 07 (997.103.803.8A) grease on the bolt threads and mating faces Tightening procedure: •...
  • Page 25 120° torque angle 3.8.3. Set valve timing 3.8.3.1. Special tools Porsche Motorsport recommends use of the following special tools to adjust and set the valve timing of the 911 GT3 Cup Base plate cylinder 1: 996.721.549.90 Base plate cylinder 2: 996.721.550.90...
  • Page 26 3.8.4. Valve clearance The valve clearance is measured between the cam follower and the cam lobe heel when the engine is cold. Inlet valve clearance [mm] 0.22 – 0.25 Exhaust valve clearance [mm] 0.22 – 0.25 3.8.5. Valve spring adjustment The valve springs are set based on spring travel.
  • Page 27 3.8.6. Removing and fitting the crankshaft seal – pulley-side 3.8.6.1. Special tools Porsche Motorsport recommends use of the following special tools to remove and fit the pulley-side crankshaft seal: Retaining key pulley: 000.721.973.20 Adapter retaining key pulley: 000.721.973.21 Press tool crankshaft seal: 000.721.216.40...
  • Page 28 4. Drill two holes (Ø 2 mm) at the centre punched points 5. Screw the threaded-end of a commercially available slide hammer -1- into the drilled holes. Carefully remove the seal -2- by swapping the slide hammer alternatively between the drilled holes 6.
  • Page 29 7. Slide the drill jig up to the seal on the crankshaft flange and position correctly 8. Coat the drill bit (Ø 2 mm) with extremely viscous grease 9. Drill at the specified points 10. Screw the pointed end of a commercially available slide hammer alternatively into the two holes and pull-out the seal.
  • Page 30 4. Push the new crankshaft seal -1- onto the crankshaft flange (mounting position: steel disc to pulley) 5. Push the press tool (see 1) onto the crankshaft flange and fit the hexagon-head bolt -3- (17 mm AF) 6. Tighten the hexagon-head nut -4- till the spacer -2- touches the crankshaft flange 7.
  • Page 31 3.8.7. Removing and fitting the crankshaft seal – crankshaft side 3.8.7.1. Special tools Porsche Motorsport recommends use of the following special tools to remove and fit the flywheel side crankshaft seal: Pressure pad: 000.721.912.60 Seal extractor jig: 000.721.971.90 3.8.7.2. Removal 1.
  • Page 32 3. After extracting the metal ring the actual seal remains in the crankcase. Under no circumstances whatsoever must this be levered out. 4. Carefully remove the drill swarf 5. Carefully drill two further 2.0 mm holes (arrows) as close as possible to the corners (metal body) of the seal.
  • Page 33 3.8.7.3. Fitting If visible carefully remove small edges or burrs from the crankshaft flange chamfer with an oil stone, afterwards carefully clean the crankshaft journal and the crankcase bore (use cleaning solvent or acetone with a clean, lint- free cloth). The crankshaft flange sealing face must not, under any circumstances, be treated with emery cloth, polish compounds or wire brushes.
  • Page 34 2. Fit the insertion-jig magnetic cone to the base plate, fit the crankshaft seal to the cone and carefully push it onto the base plate 3. Fit the seal dry 4. Remove the magnetic cone and using the pressure piece 000.721.912.60 push the crankshaft seal in a coplanar position.
  • Page 35 6. Push the crankshaft seal onto the crankshaft flange by rotating the insertion nut clockwise till the mounting dome butts completely on the crankshaft flange mounting surface. 7. Leave the assembly tools for one or two minutes in the final position, the seal and sealing lip position themselves as a result.
  • Page 36 Measurement depth is approximately 5 mm Maximum permissible misalignment is 0.5 mm 10. If the comparable values exceed the maximum difference use the insertion jig again to press home...

  • Page 37: Engine Component Tightening Torques

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

  • Page 38: Engine Mileage

    3.10. Engine mileage The engine in the 2012 911 GT3 R is designed to rev to a maximum of 9,400 rpm, in this case the rebuild interval is 35 hours...

  • Page 39: Fuel And Exhaust System

    4. Fuel and exhaust system 4.1. Fuel system Pressure Engine supply regulator Fuel filter Safety valve Preliminary filter vane pumps Tank vent Main pump Reserve pump • Returnless fuel system FT3 safety fuel cell • • Fuel cell volume: 104 l •...

  • Page 40: Fuel Cell

    4.2. Fuel cell Attention: The fuel tank volume must be measured and adjusted before the first competition to ensure that the capacity does not exceed that stated by the relevant regulations. Both the main and reserve fuel pumps are of the electrical vane type. The fuel filter is located in the front luggage compartment and should be replaced after approximately every 24 hours of use.
  • Page 41 Attention: The fuel pumps should not be activated under any circumstances tank-engine quick release couplings disconnected. Fuel pressure peaks in the system can cause leakage, and in the worst case the system pressure can exceed the burst pressure of the fuel filter. 4.2.1.
  • Page 42 4.2.2. Pressure regulator The 911 GT3 R is equipped with a returnless fuel system. Due to this design fluctuation in fuel pressure is possible. The average fuel pressure over one complete lap should not be lower than 4.8 bar...
  • Page 43 4.2.3. Fuel 98 ROZ DO NOT drill holes in the area of the fuel cell. DO NOT use sharp objects when removing the fuel cell from the car. 4.2.4. Reserve pumps A reserve fuel pump is fitted as standard and is activated from a switch mounted on the dashboard.

  • Page 44: Exhaust System

    4.3. Exhaust system 4.3.1. Configuration with exhaust pre-silencer It is possible to change the exhaust system’s configuration by fitting either an optional unit with catalytic converter or a unit with additional silencing effect in the silencer.
  • Page 45 4.3.2. Configuration without exhaust pre-silencer In addition to the above mentioned exhaust system configuration the possibility exists to use a version without pre-silencer. With this configuration the unit with the catalytic converter must be mounted in the rear silencer. 4.3.3. Catalytic converter Unit to mount in rear silencer 100 cells...
  • Page 46 When mounting the exhaust manifold the correct nut tightening sequence must be observed. 4.3.5. Stop-Choc Elements Porsche Motorsport emphasizes that the maximum service life for the 5 Stop-Choc elements (997.111.228.8A) in the rear silencer and pre- silencer retainer is: 35 hours...

  • Page 47: Gearbox

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

  • Page 48: Gear Ratio Diagram

    5.2. Gear ratio diagram Ratios 997 GT3 R 2013 Ratios 997 GT3 R 2012 9000 8000 7000 6000 5000 4000 3000 2000 1000 V [km/h] 5.3. Connection scheme gearbox heat exchanger vom Vorlauf Motorkühlkreislauf / from supply engine cooling circuit vom Rücklauf Motorkühlkreislauf / from return engine cooling circuit...

  • Page 49: Paddle Shift Mega-Line

    5.4. Paddle Shift MEGA-Line The paddle shift system eases and simplifies the procedure of changing gear for the driver and also protects the drivetrain from misuse. 5.4.1. System advantages • Shift gear with both hands on the steering wheel Automatic throttle blip when down shifting •...
  • Page 50 5.4.4. Component position in car The position of the individual components is illustrated in the following image.
  • Page 51 5.4.5. Instructions for use To guarantee the correct function of the shift system the following conditions of use must be observed. Example for reading the diagram: Shifting from NEUTRAL to REVERSE • DO not touch or activate the paddles • The throttle must be closed (engine at idle speed) •...
  • Page 52 5.4.6. Emergency Mode (EM) The emergency mode should only be activated for function check purposes when the car is stationary (gearbox check by mechanics). When the emergency mode is active the LEDs shown below blink in the gear shift display module as warning. All safety functions are deactivated when the Emergency Mode is active! When shifting gear in Emergency Mode the car must be moved and/or...
  • Page 53 The service intervals stipulated for the individual components must be observed. service plan 997 GT3 RSR Megaline system 997 GT3 R interval (the first event reached) part no. Porsche no. MEGA no. description extent of work km-level time interval operating time 7608 997.618.401.8A...
  • Page 54 It is important to prevent dirt and dust from finding its way into the components during assembly / disassembly. When working on the air pressure system during disconnected fittings, it is necessary to cover the openings by means of plugs. The fittings of the air hoses as well as the fittings at the component cases have to be covert with a safety cap.

  • Page 55: Gear Position Recognition

    5.5. Gear position recognition To determine the gear selected electronically a potentiometer, in which a defined current drops subject to the gear selected, is mounted to the gearbox. The gear recognition is required for the power interruption when shifting gear. 5.5.1.

  • Page 56: Differential

    5.6. Differential The limited-slip differential has a locking torque of 45 % / 65 % (power / overrun) (dynamic locking value). The differential is checked by means of a friction test in which the preload and wear of the clutch disc plates are determined. 5.6.1.

  • Page 57: Clutch

    5.7. Clutch A 3 disc carbon/carbon clutch is used in the 911 GT3 R MY 2013. The vehicles of model year 2013 are standard equipped with a ZF-Sachs clutch. The use of the present Tilton clutch is still possible. 5.7.1. Mounting of ZF-Sachs clutch The following points should be observed when mounting the clutch: •...
  • Page 58 • Place pressure ring and base plate in the clutch housing. The mark on the base plate (arrow) must lie on the left-hand side of the reference lug with the label “ZF Sachs Race Engineering”. Arrow has to point towards flywheel. Place intermediate and drive plates alternately in the clutch •...
  • Page 59 • The hub has to be inserted after the third intermediate plate. The arrow marking on the hub has to point towards the flywheel and has to align with the reference lug of the clutch housing. Arrow mark on Dot mark on third intermediate plate...
  • Page 60 No greasy or oily substances should contaminate the clutch plates. The splined section of the gearbox input shaft must mesh over the entire length of the drive hub. The gearbox input shaft bearing-journal must be smeared lightly with copper grease (Porsche part number 000.043.004.00) before assembly.
  • Page 61 5.7.2. Mounting the clutch The following points should be observed when mounting the clutch: • Place pressure plate on first intermediate plate • Place pressure plate and first carbon disc in the cage. The mark on the intermediate plate (arrow) must lie on the left-hand side of the cage foot with the serial number Arrow mark Serial number...
  • Page 62 • Place intermediate and drive plates alternately in the cage • The “FS” (Flywheel Side) mark on the drive plates must point towards the engine. Furthermore the “FS” mark of each drive plate should lie on top of each other “FS” mark FS - Mark •...
  • Page 63 • Then insert drive plate 3 and intermediate plate 4 Attention: The clutch plates should be refitted in the original sequence and orientation. Please observe the markings on the edges.
  • Page 64 The gearbox input shaft bearing-journal must be smeared lightly with copper grease (Porsche part number 000.043.004.00) before assembly. 5.7.3. Clutch wear It is possible to service the carbon/carbon clutch to achieve a longer service life. To compensate for the carbon disc wear compensation pressure plates can be fitted.

  • Page 65: Working On The Gearbox

    In the event of more comprehensive damage, which necessitates the replacement of gearbox housings, we strongly recommend that this is undertaken Porsche Motorsport. Complex measurement adjustment, which could not be included in these instructions, are necessary to guarantee that the gearbox works perfectly.
  • Page 66 (approx. 3 litres for a newly build gearbox) Close the oil overflow pipe and add 1.0 litre of oil • Filler plug Oil drain plug Overflow pipe Porsche Motorsport recommends the use of Mobil Mobilube SHC.
  • Page 67 5.8.3. Changing gear ratios • Lock the gearbox Open closure plate on gear ratio housing • • Remove circlip from the M32 x 1.25 nut • Remove anti-rotational safety • Loosen M32 x 1.25 nut • Completely remove gear ratio housing •...
  • Page 68 • To change the 1 and 2 gear shaft remove the differential Remove reverse-gear shaft support • • Remove oil pump drive gear Remove 35x1.5 circlip from input shaft • (differential side) Input shaft circlip Ensure that the washer under the circlip (part of bearing inner race) is seated correctly when fitting the input shaft.
  • Page 69 5.8.5. Gearbox maintenance The following work should be carried out regularly: • Check gear ratio teeth, dogs and dog-rings • Check the shift collars • Check the gear hub and gear roller bearings for signs of wear and pitting Check the oil for signs of metallic debris •...
  • Page 70 5.8.6. Starter motor maintenance The starter motor maintenance includes the following work: After each race: Shell Stamina Grease HDS ET.Nr.: 997.605.920.9A (400 g)

  • Page 71: Gearbox Component Tightening Torques

    Every 6,000 km it is recommended to send the starter for a complete overhaul to the below mentioned companies: Bosch Engineering GmbH Motorsport Robert Bosch Allee D - 74232 Abstatt Tel.: 0711 811 3981 www.bosch-motorsport.com BSA Motorsport Industriestraße 30 D – 68519 Viernheim Tel.: 06204 929090 Email: info@bsa-motorsport.com...

  • Page 72: Suspension

    6. Suspension Both the front and rear suspension have been modified to suit the demands of competition and to enable the accurate and easy adjustment of camber, wheel alignment and ride height. The front suspension is of the independent McPherson strut type with aluminium wishbones and the rear suspension is multi-link with ‘LSA –...
  • Page 73 When changing the existing dampers for those of another manufacturer, it is necessary to ensure that the recommended ride height and spring travel values are retained. Porsche AG does not accept any liability for any subsequent damage to the suspension or related components.
  • Page 74 6.1.2.3. Damper curves (F2T1) 4000 3500 3000 2500 2000 1500 1000 -500 -1000 -1500 -2000 -2500 -3000 -3500 -4000 -4500 -5000 0,131 0,262 0,393 0,524 piston speed [m/s]...
  • Page 75 6.1.3. Front anti-roll bar The front anti-roll bar has a 7 position adjustment range on both sides, each position results in the blade being adjusted by an angle of 15°. The maximum stiffness of the anti-roll bar is achieved when the blade is aligned parallel to the anti-roll bar link.
  • Page 76 6.1.4. Steering system The 911 GT3 R is fitted with an electrical servo assisted rack and pinion steering system. 6.1.4.1. Servo pump control Control of the electrical servo pump is made via an MoTec output channel. This means that the servo pump only operates when the engine is running.
  • Page 77 Bleeding the steering system: This procedure is best carried out by two people. To fill the complete steering system after fitting a new steering rack, oil lines or because of excessive hydraulic fluid loss, start and then immediately stop the engine several times. This procedure causes the fluid level in the reservoir to sink rapidly, therefore ensure that the reservoir is refilled constantly with ‘Pentosin’...

  • Page 78: Rear Suspension

    6.2. Rear suspension Multi-link suspension • • Adjustable main spring • Adjustable anti-roll bar • Two way adjustable dampers 6.2.1. Rear springs The rear coil spring has a four-step adjustment range, the corresponding spring rates are listed in the table below: Colour Part number Stiffness Range [N/mm]...
  • Page 79 Changing the spring rate (spring stiffness) directly affects the vehicle ride height as well as the toe. The ride height must be adjusted by four revolutions to compensate for one step in spring rate change. For example, when the spring rate is softened by one step the ride height must be lowered four turns to compensate.
  • Page 80 When changing the existing dampers for those of another manufacturer, it is necessary to ensure that the recommended ride height and spring travel values are retained. Porsche AG does not accept any liability for any subsequent damage to the suspension or related components.
  • Page 81 6.2.2.3. Damper curves (NFB2T1) 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 -500 -1000 -1500 -2000 -2500 -3000 -3500 -4000 -4500 -5000 -5500 -6000 -6500 0,131 0,262 0,393 0,524 piston speed [m/s]...
  • Page 82 6.2.3. Rear anti-roll bar The rear anti-roll bar has a 7 position adjustment range on both sides, each position results in the blade being adjusted by an angle of 15°. The maximum stiffness of the anti-roll bar is achieved when the blade is aligned parallel to the anti-roll bar link.

  • Page 83: Basic Wheel Alignment

    Maximum running time: 30 hrs Grease quantity outer joint: 100 g Grease quantity inner joint: 140 g Porsche part number: 996.332.897.9A 6.3. Basic wheel alignment In the event of an accident or any other damage occurring to the suspension every component, including...
  • Page 84 Porsche Motorsport parts sales offers a cord alignment tool: 997.450.351.90 Bracket front left: 997.450.561.90 Bracket front right: 997.450.562.90 The following points must be followed before alignment can begin: • Set the front and rear tyre pressures to hot running pressure, if...
  • Page 85 6.3.1. Front axle 6.3.1.1. Ride height The car must be placed on a level surface (set-up platform) to check the ride height. The front and rear suspension should be loaded and unloaded (compressed) several times to allow the suspension to settle. Min ground clearance: 65mm Reference surface The ride height is adjusted by rotating the lower spring platform.
  • Page 86 6.3.1.2. The toe-rod length can be set using the clamping screw. Clamp screw Porsche Motorsport provides a special tool to remove the trunnion pin: 997.450.349.9B 2 mm spacer 2x 4 mm spacer The steering gear is shimmed on the two mounting points by a 3 mm...
  • Page 87 1 mm adjustment in length equates to a camber change of approximately 13’. • Trailing arm mounting hole: The mounting position of the trailing arm should not be changed (wheel clearance) Porsche Motorsport provides a special tool to remove the • trunnion pin: 997.450.345.9B)
  • Page 88 6.3.1.4. Trailing arm 28 mm Buchse 8 mm Buchse 6.3.1.5. Upper mount The upper-mount position can be adjusted by using the slots in the car body.
  • Page 89 6.3.2. Rear axle 6.3.2.1. Ride height The car must be placed on a level surface (set-up platform) to check the ride height. The front and rear suspension should be loaded and unloaded (compressed) several times to allow the suspension to settle. reference plane Ride height adjustment is made by rotating the spring perch.
  • Page 90 6.3.2.2. The length of the toe-rod can be adjusted using the clamp bolt. Bearing journal Spacers Clamp bolt 1x 6 mm Scheibe 2 mm Scheibe...
  • Page 91 1 mm adjustment in length equates to a camber change of approximately 10’. • Trailing arm mounting hole: The mounting position of the trailing arm should not be changed (wheel clearance) • Porsche Motorsport provides a special tool to remove the trunnion pin: 997.450.345.9B...
  • Page 92 6.3.2.4. Trailing arm 16 mm spacer 16 mm spacer...
  • Page 93 6.3.2.5. Upper wishbone Upper rear-wishbone front Upper rear-wishbone rear Rear upright, left 6.3.3. Summary of suspension geometry adjustment components Front Part number Rear Part number Lower wishbone + spacer shims [mm] 996.341.543.95 996.341.543.95 996.341.543.93 996.341.543.93 996.341.543.92 996.341.543.92 996.341.543.91 996.341.543.91 996.341.543.90 996.341.543.90 996.341.543.98 996.341.543.98...
  • Page 94 6.3.4. Suspension set-up The basic settings for the suspension are listed in the following table. These settings can be used as the basic set-up for the majority of race tracks. Performance Setup Front Rear Remark left / right left / right Ride Height 70 mm 90 mm...

  • Page 95: Working On The Suspension

    Tighten the wheel bearing cover to the stipulated torque • • A maximum of one wheel bearing change per upright (bearing seat) recommended by Porsche Motorsport Re-tighten the wheel bearing cover to the stipulated torque after approximately 200 km.

  • Page 96: Tightening Torques Suspension

    6.5. Tightening torques suspension 6.5.1. Front axle Tightening Torque Position Dimension [Nm] M14 x 1.5 x50 M12 x 1.5 x30 M12 x 1.5 M10 x 1.5 45 with Loctite 243 M12 x 1.5 75 (replace after dismounting) M14 x 1.5 M14 x1.5x120 M12 x 95 10.9...
  • Page 97 6.5.2. Front upright Tightening Torque Position Dimension [Nm] Copper paste thin on: thread, gearing, front side M6 x 16 8.8 M8 x 35 10.9 Grease hub with longtime grease 31, replace after dismounting 470 (retighten after 100 km when reassembled), Copper paste on contact surface 500 + 25 M6 x 16 Exchange after disassembling...
  • Page 98 6.5.3. Anti roll bar front Position Dimension Tightening Torque [Nm] M8 LH...
  • Page 99 6.5.4. Suspension stut front Position Dimension Tightening Torque [Nm] M6 x 12...
  • Page 100 6.5.5. Steering gear Tightening Torque Position Dimension [Nm] M10 x 45 10.9 M18 x15 90 (track rod on steering gear) M14 x 1,5 M6 x 20 M14 x 1,5 M12 x 1.5 10.9 75 (replace after dismounting)
  • Page 101 6.5.6. Steering column Tightening Torque Position Dimension [Nm] M8 x 35 10.9 M5 x 35 M16 x 1.5 50 +5...
  • Page 102 6.5.7. Side part rear Tightening Torque Position Dimension [Nm] M12 x 97 75 with Loctite 270 M12 x 1.5 10.9 M12 x 80 M12 x 1.5...
  • Page 103 6.5.8. Rear axle Tightening Torque Position Dimension [Nm] 45 with Loctite 243 M12 x 1.5 75 (replace after dismounting) M14 x 1.5 M14 x 1.5 M12x1.5 M12 x 70 M12 x 1.5 M6 x 20 M14 x 1.5 75 (replace after dismounting)
  • Page 104 6.5.9. Upright rear Tightening Torque Position Dimension [Nm] M8 x 35 max 40 hrs 31, replace after dismounting Grease hub with longtime grease 470 (retighten after 100 km when reassembled), Copper paste on contact surface 500 + 25 M6 x 16 M6 x 12 M6 x 16 Replace after disassembling ...
  • Page 105 6.5.10. Anti roll bar rear Position Dimension Tightening Torque [Nm] M4 x 10 M8 LH M8 x 25 M6 x 12...
  • Page 106 6.5.11. Suspension strut rear Position Dimension Tightening Torque [Nm] 3 upper M12 x 1 3 lower M12 x 1...

  • Page 107: Sachs Damper Service Information

    6.6. Sachs damper service information Service partners for Germany: ZF Sachs Race Engineering GmbH Ernst-Sachs-Straße 62 97424 Schweinfurt Phone +49 9721 983258 Fax: +49 9721 984299 Gallade Technologiezentrum am Nürburgring Rudolf-Diesel-Straße 11 – 13 53520 Meuspath Phone +49 2691 9338-54 +49 2691 9338-50 Service partner for the UK: BG Motorsports Ltd...
  • Page 108 Oceanshore Motorsports David Glenn 5892 John Anderson Highway 32136 Flagler Beach, FL Phone +1 386 6731936 +1 386 6731184 Service partner for Asia: Enable Inc. Technical center 1 – 36 Ootsuzaki Ogakie-cho Kariya-shi, Aichi-ken, 448-0813 Japan Phone +81 566 62 86 05 +81 566 62 86 07...

  • Page 109: Wheels

    Left-hand side of car = right-hand thread, colour red Porsche recommends that the wheel nuts are also changed during a long distance race (after approximately 6 hours running) and to inspect and service them, which means cleaning the thread, visual inspection and re- grease with Klüber Nontrop RB3 999.917.507.00.
  • Page 110 Please check the setting (tightening torque) of the wheel gun. Tests have shown that the centre-lock threads can be damaged if the wheel gun is incorrectly set. The above mentioned procedure must be strictly adhered to. A control test must also be carried out to ensure that the required tightening torque is also achieved (also different wheel guns supplied by a different manufacturer and specification).

  • Page 111: Brake System

    8. Brake system The GT3 Cup is fitted with a dual circuit brake system incorporating two separate brake master cylinders. The front to rear brake balance ratio is set by rotating the brake balance knob. 8.1. Technical data brake system Front axle Rear axle Master cylinder...
  • Page 112 8.2.1. Brake balance system If the brake balance potentiometer is rotated the lever ratio (dimension x) on the balance bar is adjusted directly by a adjuster cable Balance bar rod Spacer Balance bar...
  • Page 113 Pedal force Brake Brake force VA force HA • pedalforce brakeforce rear − brakeforce front pedalforce brakeforce rear 8.2.1.1. Basic setting balance bar The following dimensions must be set in the basic setting (0). Adjuster cable fitting...
  • Page 114 In addition one has to take care for sufficient axial play of the balance bar. Thererfore a play of 0.9 … 1.5 mm between the plastic spacer and the fork end hast to be set. The adjustment of the play is performed by altering the difference between the two fork ends.
  • Page 115 In addition, it should also be noted that with the maximum positive rotation in the anti-clockwise direction (+7) there must be a 2 mm gap between the adjuster cable lock-nut and the front brake master cylinder pushrod clevis to prevent the clevis colliding with the lock-nut. 2 mm Under all circumstances avoid the system being fitted with preload.
  • Page 116 The following parts in the system should be cleaned and re-greased regularly: Balance bar bearing Balance bar rod floating bearing Porsche Motorsport recommends the used of Autol Top 2000 grease.
  • Page 117 8.2.1.4. Runtime master cylinder Due to the usage of an ABS brake system (antilock braking system) in the 911 GT3 R, it´s recommended to replace the master cylinders after 10.000 km.

  • Page 118: Brake Caliper

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

  • Page 119: Brake Disc Screwing

    8.5. Brake disc screwing Porsche Motorsport recommend to secure the fixation bolts of the front and rear brake disc with silicone. 1. The countersink in the brakepot as well as the bolt head have to be free from grease Tighten both fixation bolts 900.075.010.030 with 5 Nm (no Loctite) 3.

  • Page 120: Chassis

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

  • Page 121: Exterior

    9.2. Exterior 9.2.1. Front bumper...

  • Page 122: Rear Wing

    9.3. Rear wing & engine cover • Gurney 10mm...

  • Page 123: Fire Extinguisher System

    9.4. Fire extinguisher system The car is equipped with an FIA homologated fire extinguishing system using AFFF as extinguishing agent. The extinguishant cylinder has two separate chambers each with a two kilogram capacity. The extinguishing agent is discharged through three nozzles located in the engine bay and a further three located within the cockpit.
  • Page 124 9.4.2. Extinguisher system error analysis Battery check: • Hold the toggle switch on the trigger box in the “Battery Check” position If the battery charge state is good the trigger box warning lamp • will blink Warning lamp does not glow: Check battery charge state (refer to ‘Battery Installation’) •...

  • Page 125: Air-Jack System

    Never use mineral oil based cleaning agents Never open the air jacks: There is residual pressure in the • system even when jacks are retracted! Porsche Motorsport recommends that the system is overhauled • after 2000 lifts or two years •...
  • Page 126 Assembly instructions: 1. Evenly coat the threads of all ventilation screws and Crimp Collar connections with copper paste (Porsche No.: 000.043.004.00) 2. Screw together the ring connector and ventilation screw into each of the three lifting cylinders, supporting the lid of the lifting cylinder with an additional wrench across the flats.
  • Page 127 9.5.1. Car lift system Never use a third party product as this can lead to damage to the air-jack cover or piston tube. KRONTEC Maschinenbau GmbH Pommernstraße 33 D - 93073 Neutraubling www.krontec.de...

  • Page 128: Electric

    10. Electric 10.1. Starter button The electrical connector of the starter button shall be checked on damage and proper electrical connection regularly. Furthermore, it has to be ensured that there is no tension on the two connector cables.

  • Page 129: Alternator

    10.2. Alternator TAG 140 A • 10.3. Battery • 12 V, 80 Ah 10.4. Steering wheel Quick-release race steering wheel • • The two parts of the release coupling are balanced together and therefore have to be used in only one combination (numbers on steering wheel and hub must match) Steering wheel...
  • Page 130 DO, UP Adjust traction control setting RADIO Radio SPEED Speed limit HIGHBEAM Headlight flash, if the button is pressed for about 1 second the headlights stay on till the next time the button is pressed WIPER Wiper DISPLAY Change MoTeC display pages ALARM Reset MoTeC Alarm Change engine characteristics...

  • Page 131: Centre Console

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

  • Page 132: Shift Light Module

    INTANK PUMPS: same as FUEL PUMPS for the Intank pumps FAN: Driver cooling (on or off) DRY/WET Traction control mode MOTEC MODE: Switch through the different MoTeC display setups (practice, warmup, race) HAZARD Hazard lights FOG REAR: Fog lights 10.6. Shift Light Module The Shift Light Module (SLM) is located above the MoTeC dash.

  • Page 133: Motec Dash

    10.7. MoTeC Dash The MoTeC Dash fitted has a 1 MB memory. This has a recording capacity of approximately 15 minutes. The Cup MoTeC system is sold exclusively worldwide by Brückle– Motorsport. If information and/or a system is required please contact Brückle–Motorsport directly.
  • Page 134 10.7.1.1. Race mode Centre Left Right Bottom The lower (bottom) display line can be changed via the steering wheel mounted ‘Display’ switch. Left: Speed Brake balance Centre: Gear Top: Traction control setting Throttle valve angle Right: Actual lap time Previous lap-time Bottom: Engine temperature Oil temperature...
  • Page 135 10.7.1.2. Practice mode Left: Speed / Wheel Speed Brake bias Centre: Gear Top: Traction control setting Throttle valve angle Right: Engine speed Previous lap time Bottom: Engine temperature Engine oil temperature Engine oil pressure Fuel pressure Gearbox oil temp Ambient temp Battery voltage on dash VOLTS Distance covered...
  • Page 136 Vertical acceleration G-Vert Lateral acceleration Longitudinal acceleration Odometer TRIP_D Trip distance Steering angle STANG_W Steering wheel angle SW_ANG Gearbox potentiometer GEARSEN...
  • Page 137 10.7.2. MoTeC Dash configuration The existing configuration can be modified with the software ‘ADL2 Dash Manager’. The following version is required: DM2_450Y6_P Communication PC - MoTeC Dash only function with this version. Delivered with the car is a CD with the programme and the configuration used. Under NO circumstances should the USB connection cable PC - MoTeC Dash be removed or the power supply cut during the up or downloading of configurations and/or measurement data.

  • Page 138: Car Sensors

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

  • Page 139: Engine Control Unit (Ecu)

    The Bosch MS 4.0 can be programmed with special software. The ECU is programmed exclusively by Porsche Motorsport. If an engine is overhauled by Porsche Motorsport the ECU should be delivered with the engine to run them both together on the dynamometer.

  • Page 140: Egas

    10.10. EGas The following points have to be observed when dealing with the system Egas: 10.10.1. Hardware requirements The EGas system can only function if the hardware requirements specified in points 10.9.2 to 10.9.6 are observed. If one of more of the constraining conditions are violated the system must not be operated further.
  • Page 141 10.10.5. Emergency-stop switch The system must have an emergency-stop switch which, when actuated, must at least isolate the throttle butterfly actuator from the power supply. Isolation of the control unit primary power supply is also permitted. The emergency-stop switch in the car must be clearly visible, and be easily activated by the driver.
  • Page 142 10.10.12. Transfer to third parties Cars equipped with a motorsport EGas system from Bosch Engineering GmbH must not be transferred to third parties by Porsche AG without reference to these operating regulations. 10.10.13. Damage to the system If the hardware components described in 10.9.2 to 10.9.6 are damaged...
  • Page 143 10.10.14. Operating principle There is no mechanical connection between the accelerator pedal the the throttle valve. The pedal as well as the throttle valve are equipped with two potentiometers (redundancy) 10.10.14.1. Pedal characteristics The characteristics of the accelerator pedal (ratio pedal angle - throttle valve angle) can be adjusted by the Bosch Modas system.
  • Page 144 10.11. ABS The ABS function is realised as a compromise between driveability and break performance. Driveability is of big importance on a street car. The ABS is supposed to allow the driver to control the car under each circumstances. For motorsport purposes this compromise has been shifted towards the optimum brake performance.
  • Page 145 10.11.2. Measuring vehicle dynamics The ABS allows the driver to brake near the locking limit of the wheels. By preventing the locking of a wheel the systems ensures braking in the optimum deceleration range. To determine the vehicle’s driving state the following data is permanently measured: Brake pressure at each wheel •...
  • Page 146 10.11.3. Usage of different tires The application of the ABS System of the 911 GT3 R has been carried out with Michelin tires. Therefore, the stored tire circumference is valid for the actual Michelin tires. This circumference is 2037 mm on the front and...
  • Page 147 10.11.4. Brake master cylinder For cars equipped with genuine Porsche Motorsport ABS brakes (antilock braking system), it is recommended to replace the brake master cylinder after 10.000 km. Pos Part number Description Amount / Car 996.355.017.9C Brake master cylinder front 996.355.017.9A...
  • Page 148 10.11.5. Hydraulic control unit Hydraulic control unit with integrated ECU Connecting cable Rear brake circuit Front brake circuit Front left brake line Rear right brake line Front right brake line Rear left brake line...
  • Page 149 10.11.5.1. Characteristics • Integrated analogical valves for an optimised controllability • 5 integrated pressure sensores (front brake circuit, wheel specific brake pressures) • Directly wired wheel speed sensors (transmitted to MoTeC via CAN) 10.11.6. Turn off ABS Due to the optimum brake performance it is not recommended to turn the system off.
  • Page 150 System errors can be caused by either a malfunction of the acceleration / yaw sensor or a failure of one of the wheel speed sensors. The breakdown of a wheel speed sensor leads to the deactivating of the ABS. In case a wheel speed sensor is disconnect and the ABS is active. The ABS error gets active.
  • Page 151 10.11.7.2. Clearing the error memory • Mark „00_clear_error_s“ (left display side) • Click on „Conn-2 write“ Rightclick on „00_clear_error_s“  execute • • Check the error memory one more time to ensure that the previous detected errors are not present anymore...

  • Page 152: Traction Control

    10.12. Traction control The 911 GT3 R is equipped with a traction control. The application of the system is carried out by Bosch Modas. A comparison of desired and actual slip is the basic principle of the traction control. A PID controller takes care of the necessary torque corrections.
  • Page 153 10.12.1.1. Target slip FSLSV is the base factor for the calculation of the target slip. It reflects the tyre/racetrack characteristics. FSLSV affects a 3D map which is addressed by TC switch position and ground speed. This parameter works like a multiplier on the complete TC calculation.If problems with the TC occur, first try to work on this map in order to tune traction control to your (and the drivers) liking! FSLSV =1.0 is the basic calibration...
  • Page 154 10.12.1.5. PID controler FPASR is the amplification factor of the P-component of the TC controller. The P-component (proportional component) of the controller can be adjusted via this value. This controller component works proportionally on the deviation. This controller determines the effectiveness of the control at the start of regulation.
  • Page 155 10.12.1.6. Driver influence KLMIFAASR (dry condition) and KLMIFAASR_WET (wet condition) are factors to calibrate the driver influence to the TC controller. Both are 2D maps with breakpoints addressed by the TC switch position. This factor is included to give the driver the opportunity to influence the TC intervention with „his right foot“.
  • Page 156 10.12.2. Traction control hints If problems with the TC occur, first try to get rid of them by • altering the target slip. The target slip is dependant on the race track. • Under normal conditions, the controller does not need to be recalibrated.

  • Page 157: Relay- And Fuse Assignment

    10.13. Relay- and fuse assignment 10.13.1. Fuse holder...
  • Page 158 10.13.2. Hydraulic control unit ABS The fuse (40 A) for the pump of the hydraulic control unit is situated in the front trunk on the left side. The fuse has to be secured by a tie wrap. 10.13.3. Power steering pump The fuse (80 A) for the power steering pump is situated in the front trunk on the right side.
  • Page 159 10.13.4. MS4 sensor system...
  • Page 160 10.13.5. Paddle Shift MEGA-Lline The paddle shift system is protected by a separate fuse block in the passenger side footwell. Control of the fan for cooling the compressor / control unit is made via a relay. This is located on the right in the rear on the ECU mounting bracket.

  • Page 161: Car Maintenance

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

  • Page 162: After Every Race Weekend (Sprint)

    11.3. After every race weekend (sprint) In addition to points in 11.2: • Engine oil and filter change (after ‘hot races’  engine oil > 110° • Check compression and pressure loss of each cylinder • Clean/replace air filter • Change brake fluid •...
  • Page 163 We undertake no liability for the completeness and conformity of the contents with respect to the legality of the current sporting regulations. Porsche AG reserves the right for technical changes. © Copyright by Dr. Ing. h.c. F. Porsche AG...

Table of Contents

Save PDF