Porsche 911 GT3 Cup 2008 Technical Handbook
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Porsche 911 GT3 Cup 2008 Technical Handbook

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911 GT3 Cup
Technical Handbook, 2008 Model

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  • Page 1 911 GT3 Cup Technical Handbook, 2008 Model...
  • 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 911 GT3 Cup. Dr.Ing.h.c. F. Porsche Aktiengesellschaft Vertrieb Sonder- und Rennfahrzeuge...
  • Page 3 For obvious reasons, measurements referring to bodywork dimensions of the production cars cannot be used as reference. Porsche accepts no guarantee that the vehicle conforms to the regulations. The car can not be registered for road use and does not comply with German road traffic regulations.
  • Page 4 For guarantee refer to sales contract Project Management Manager Porsche Michelin Supercup Mr. Jens Walther Tel. 0711 911-84042 Assistant Fr. Jennifer Biela 0711 911-84096 Fax:0711 911-82920 Service Mr. Stefan Rometsch Tel:0711 911-84613 Fax:0711 911-82052 Manager International Cup Mr. Gerd Schmid Tel.

  • Page 5: Table Of Contents

    Contents General technical data Technical engine data Engine Valve train / cam timing Throttle reset Engine tightening torques Clutch Gearbox Gear ration chart Gearbox disassembly Gearbox assembly Gear lever Gearbox special tools . Fluid capacities Suspension Maintenance and settings Steering Chassis tightening torques Cooling system Brake system...

  • Page 6: General Technical Data

    General Technical Data Chassis number: from WPO ZZZ 99 Z8S 7 98001 Car model: 997 830 Engine model: M 97/75 Gearbox model: G 97/ 60 Number of gears: Weight Dry weight: approx. 1170 kg Dry weight Supercup (PCCB) approx. 1130 kg Dimensions Overall length (mm) 4450...

  • Page 7: Engine

    Engine Technical Data Engine model M97/75 Construction Six-cylinder boxer Type of cooling water cooled Number of cylinders Cylinder bore (mm) 99.98 Stroke (mm) 76.4 Actual cubic capacity 3598 cm³ Compression ratio 12.0 (- 0.4):1 Maximum power 309 kW / 420 PS Maximum power at 7500 r.p.m.
  • Page 8 Valve timing Inlet valve diameter (mm) Inlet valve lift (mm) 12.5 Exhaust valve diameter (mm) 35.5 Exhaust valve lift (mm) 11.1 Maximum inlet valve lift 105° after TDC Maximum exhaust valve lift 115° before TDC Camshaft adjustment: Set the camshaft timing with the camshaft timing and adjustment tools.
  • Page 9 Connecting rod: Because the connecting rods have a shot peened surface care must be taken that no visible damage occurs when removing or fitting. The connecting rod must not be polished. Connecting rod bolts: Attention: The connecting rod bolts must always be renewed when the engine is completely overhauled.
  • Page 10 Engine lubrication: The 911 GT3 Cup engine is fitted with a dry sump lubrication system. The oil tank is mounted to the engine. An oil/water heat-exchanger is mounted to the engine (production GT3 RS). 1 – Oil tank 9 – Piston cooling 2 –...
  • Page 11 Cylinder head mounting: The following procedure must be adhered to when fitting the cylinder head. The nut mounting faces and threads must be lightly oiled when tightening. 1. Initial tightening to 30 Nm in accordance with tightening sequence given below. Wait fifteen minutes before step 2. 2.
  • Page 12 Valve timing Inlet valve diameter 41 mm Inlet valve lift 12.5 mm Exhaust valve 35.5 mm Exhaust valve lift 11.1mm Maximum inlet valve lift 105° after TDC Maximum exhaust valve lift 115° before TDC Adjusting the valve timing on the GT3 Cup engine model 2008.
  • Page 13 Set the cylinder 1 to exhaust / inlet valve overlap TDC. Fit the special tool and, if necessary, correct the camshaft position. After tighten the timing chain sprockets as instructed 30 Nm + 90° torque angle. Rotate the crankshaft 360° Set the cylinder 4 to exhaust / inlet valve overlap TDC.
  • Page 14 Valves: The exhaust valves are sodium filled standard GT3 production specification. Exhaust system: Exhaust system with cat-manifold (integrated catalytic converte) and silencer. Noise emissions are subject to country specific regulations. Delivery version without presilencer Delivery version including presilencer Supercup version...
  • Page 15 Engine cooling: The engine cooling is made by a water/oil heat-exchanger fitted to the water cooling system. Induction system: Multi-stage – resonance – induction channel Central air intake plenum Replaceable air filter in boot lid Attention: The rubber sleeve in the connecting part must be removed when racing in the rain.
  • Page 16 Throttle cable adjustment: The throttle cable adjustment is made on the connecting part The two throttle cables are joined with the connecting piece in the cockpit behind the drivers’ seat. This connection part removes the play from the cables by means of a spring. The adjustment of the connection part is carried out as described in step 1.
  • Page 17 Re-setting the throttle Re-setting the throttle is always necessary if the ECU or the throttle sensor were changed or replaced. Disconnect throttle cable • idle adjusting srew Rotate the knurled screw (idle adjustment screw) anti-clockwise • till a gap is visible between the cam-disc and the idle adjustment screw (throttle completely closed).

  • Page 18: Clutch

    Engine component tightening torques All component tightening torques listed are given in Newton metres. Please ensure that your torque wrench is calibrated correctly! Crankshaft and crankcase: Connecting rod (see section connecting rod) M10 x 1.25 30Nm +60° Oil pump Crankcase studs M10 x 1.25 Crankcase nuts &...
  • Page 19 With multi-plate clutches care should be taken that the splined hub is as well aligned as possible with the sintered plates. (Special alignment tool, Porsche Nr. 996.450.335.90) Smear the splines lightly with grease and slide the clutch plates along the splined input shaft till the hub moves easily on the shaft. Remove excess grease.

  • Page 20: Gearbox

    Gearbox G 97 / 63 The Porsche six-speed sequential gearbox is fitted with a limited slip differential, and oil filter and a water / oil heat-exchanger for cooling purposes. All gear ratio pairs can be changed individually to suit driver preference, engine and the circuit characteristics.
  • Page 21 Gear ratio chart 911 GT3 Cup Type 997 model 2008 9000 8000 7000 6000 5000 4000 3000 2000 1000 Standard GT3 Cup Model 2008; vmax = 282,22 km/h; rdyn = 0,34 m V [km/h]...

  • Page 22: Gearbox Disassembly

    In the event of more comprehensive damage, which requires the replacement of castings, we recommend that this work is carried out by Porsche Motorsport. Intricate measurement and adjustment work, which is not described in these instructions, is required to ensure that the gearbox works perfectly.
  • Page 23 Dismantling the gearbox: Clamp the input shaft using the special tool Remove the gearbox cover nuts and then slide off the cover. Remove the oil pipe retaining screws before pulling out the oil pipe. Engage 1 gear Drive out the 5 gear selector fork roll-pins with a suitable drift.
  • Page 24 Remove the gear housing nuts and take off the housing. Remove roller bearing. Remove the 1 gear ratio wheel. Remove the 1 gear dog-ring hub. Remove the selector rod including the 1 gear selector fork. Remove the 5 gear selector rod and reverse gear. Remove all gear ratios, hubs etc from the pinion gear shaft.
  • Page 25 Loosen the mounting plate (7x M8 cap head socket screws) and remove completely. Pull the pinion gear shaft out of the mounting plate. After the removing the mounting plate, remove the selector rod with the 3 gear selector fork. Remove the circlip and sliding sleeve from the input shaft. Clamp the input shaft with the special tool and loosen the collared nuts.
  • Page 26 Separate input shaft Pull the input shaft out of the mounting plate. Limited slip differential: The limited slip differential has a basic locking torque of 40% (power) and 60% (braking). (Locking rate dynamic). Notice: In the event of repair work being carried out always replace the complete clutch pack.

  • Page 27: Gearbox Assembly

    Gearbox assembly: Fit the splined 2 gear and the 3 and 4 idler gear wheels etc to the input shaft before pushing the complete shaft through the mounting plate. Clamp the input shaft using the special tool. Tighten the collared input shaft nut to 220 Nm. Bolt together the split input shaft and fit the sliding sleeve and circlip.
  • Page 28 Fit the complete mounting plate to the differential housing and tighten (7x M8 cap head screws). Lightly coat the threads with Loctite 243. Attention: The gearbox must be positioned vertically before fitting the mounting plate. Rotate the selector barrel to the 1 gear position.
  • Page 29 Fit 1 gear dog-ring hub. Push the 1 gear idler wheel onto the shaft. Fit the 5 gear selector rod with cam follower. Fit the roller bearing. Fit the axial needle roller bearing and spacer ring to the selector barrel.
  • Page 30 Mount away gear cluster housing. Part 996.450.319.9A Fit the splined 6 gear spacer hub and the 6 gear idler wheel, guide hub, dog-ring, selector fork and 5 gear idler wheel to the pinion gear shaft. Fit the splined 5 gear wheel to the input shaft.
  • Page 31 Check the free play of the 1 and 5 gear dog-ring guide hubs. Select the gears and bring the dog-ring into position by hand. There should be 0.1mm play, on each side, between the dog- ring and selector fork. Attention: Insufficient gear-selector fork play can be adjusted by fitting the spacer ring H3.
  • Page 32 Smear the gearbox cover mounting faces lightly with sealing compound. Tighten the gearbox cover (M8 spring washers and nuts). Fit the drive shaft and gear recognition potentiometer as marked during removal. Attention: The potentiometer MUST be adjusted after the gearbox been fitted (refer...
  • Page 33 Changing the selector barrel: To remove the locking pawl neutral latch and alignment pawl, unscrew the selector barrel and lock. Raise the selector barrel. Attention: When removing the barrel, make sure that the locking pawls, springs etc do not fall out. Attention: When replacing the selector barrel, the position of the barrel track must be fitted in exactly same position.
  • Page 34 Set the new selector barrel in position and determine the dimension as above. Calculate the spacers required, place in the new selector barrel and check the dimension. Replacing the selector barrel alignment pawl. When replacing the selector barrel alignment pawl bolt it must be secured with Loctite 243.

  • Page 35: Gear Lever

    Gear shift mechanism: Gear lever with gear shift force sensor to cut engine propulsion Function: The sensor is only active at engine speeds greater than 2800 rpm. Up shift Down shift Sensor is not speed dependent. 6–neutral – reverse gear Ignition cut only occurs under power.
  • Page 36 Gearbox component tightening torques All component tightening torques listed are given in Newton metres. Please ensure that your torque wrench is calibrated correctly! Oil fill plug M22 x 1.5 Oil drain plug M22 x 1.5 Gearbox casing nut Input shaft nut M22 x 1.5 Input shaft nut M30 x 1.5...
  • Page 37 Special tools Gear ratio housing tool Part number 996.450.310.9A Reverse gear tool Part number 996.450.311.9A Inner shift rod tool Part number 996.450.315.9A Shift grip Part number 996.450.313.9A...

  • Page 38: Fluid Capacities

    Approximately 10 litres Engine cooling fluid Approximately 22 litres The car is delivered with 11 litres of Porsche cooling fluid and approximately 11 litres of water. It is recommended that 4 litres of Porsche cooling fluid and approximately 18 litres of water are used when refilling the cooling system.

  • Page 39: Suspension

    Suspension Front axle • Independent suspension • Centre lock wheels • McPherson strut with double clamped upright • Multi adjustable anti-roll bar • Non-adjustable dampers • Rack & pinion steering with electro-hydraulic assistance. Main spring: 100 - 60 - 260 •...

  • Page 40: Steering

    General maintenance and adjustments Work on the front or rear axles Repair In the event of an accident or any other damage occurring to the suspension, every component NOT directly affected MUST be inspected. In this case, inspected means measured, crack detected replaced where...
  • Page 41 Working on the rear axle Driveshafts: It is recommended that new driveshafts are run in for 100 kilometres at a maximum speed of 200 km/h and at low torque. Driveshafts that have already been fitted and run in a particularly direction must not be swapped from left to right or vice versa.
  • Page 42 Inspection and mounting of the servo steering Important notice: The rack and pinion steering and servo pump must not be repaired and/or dismantled. Checking the hydraulic fluid level: The fluid level of the servo steering is measured using the dip stick fitted to the servo oil reservoir cap.
  • Page 43 Miscellaneous: Measuring and aligning the front and rear 911 GT3 Cup suspension is similar to the alignment procedure for a standard road-going Porsche. The suspension alignment can be made with any suitable optical or electronic system or the optional Porsche Motorsport alignment system (part nr.
  • Page 44 To prevent damage occurring to the internal cylinder end stops never pressurise the system without the car being on the ground (never without the air jack having to lift the vehicle). The air jacks can be overhauled by Porsche Motorsport when required.
  • Page 45 Suspension component tightening torques All component tightening torques listed are given in Newton metres. Please ensure that your torque wrench is calibrated correctly! Front suspension: Shear plate on subframe, front M10 x 30 Shear plate on subframe, rear M10 x 30 Shear plate on chassis M12 x1.5 x 25 Sub frame to chassis, rear...
  • Page 46 Rear suspension: Stud on chassis, front M12 x 1.5 Stud on chassis, centre M12 x 1.5 Stud on chassis, rear M12 x 1.5 Side part on chassis, front M12 x 1.5 Side part on chassis, centre M12 x 1.5 Side part on chassis, rear M12 x 1.5 Side member on wishbone, lower M14 x 1.5 x 75...
  • Page 47 Steering: Steering rack on subframe M10 x 45 Track rod on steering rack M16 x 1.5 Universal joint on steering rack M8 x 35 Steering column to frame, upper M10 x 100 Steering column to frame, lower M14 x 1 Steering wheel to column M16 x 1.5 Steering column lateral support...

  • Page 48: Cooling System

    Cooling system maintenance General information: The cooling system can be filled, bleed and emptied from a quick release coupling fitted in the bleed line leading from the front mounted side coolers, rearwards to the expansion tank in the engine bay. The valve in the expansion tank allows the exhaust of steam at a pressure of 1.4 bar (+/- 0.1 bar), and the release of water at a pressure of 1.8 –...
  • Page 49 Filling the cooling system (engine cold) with an electronic filling system To fill the cooling system when the engine is cold, open the quick release coupling and connect the electronic filling system. • Switch on the pump and fill the cooling system with the cooling fluid valve open.

  • Page 50: Brake System

    Brake system 911 GT3 Cup The Porsche 911 Cup car has a twin-circuit hydraulic brakes system with two separate main cylinders. The front to rear brake balance can be changed by adjusting the brake balance adjuster bar. Vehicles which are intruded to be used at the Porsche Michelin Supercup will be equipped with ceramic brake discs (PCCB).
  • Page 51 Brake master cylinders and balance bar: The two brake master cylinders supplying each brake circuit have different bore diameters: - Front axle 20.6 mm (orange marking) - Rear axle 19.05 mm (green marking) The front to rear brake balance can be adjusted by turning the adjuster shaft.
  • Page 52 Brake balance display and brake force distribution The brake force distribution is shown in the Motec – Display. Display Setup “Practice” The adjustment range is from - 7 to + 7 Attention: • The potentiometer is set initially to zero. •...
  • Page 53 Brake system 911 GT3 Cup PCCB The Porsche 911 Cup car has a twin-circuit hydraulic brakes system with two separate main cylinders. The front to rear brake balance can be changed by adjusting the brake balance adjuster bar. The brake discs are made of Ceramic Composite (PCCB –...
  • Page 54 The dust covers can be removed form the brake calipers when driving. It is possible to overhaul the brake calipers, the necessary spare parts can be purchased from Porsche Motorsport sales department. Brake fluid: Only Endless RF - 650 Racing Super Fluid brake fluid should be used.
  • Page 55 Brake balance display and brake force distribution The brake force distribution is shown in the Motec – Display. Display Setup “Practice” The adjustment range is from - 7 to + 7 Attention: • The potentiometer is set initially to zero. •...
  • Page 56 Chassis Construction • Weight optimised road going 2004 911 GT3 RS shell. • Interior without insulation. • Integral roll-cage in accordance with DMSB guidelines • CFC boot lid with integrated RAM – Box and engine air filter • Adjustable CFC rear wing •...
  • Page 57 Dashboard: Dashboard with Motec Display. The Motec Display can be programmed freely and has a 1 Mb memory for data recording. (Optional 4 Mb memory) Driver cooling / windscreen ventilation: The fan has three possible settings: “Pushed in” position: 100% foot well, ventilation ducts and driver cooling “Pulled out”...
  • Page 58 Motec – Display Analogue freely programmable CAN blocked Race: • Engine revs • Vehicle speed • Lap time • Water temperature Oil temperature • Oil pressure • Fuel pressure • • Gearbox oil temperature • Lap consumption • Total consumption •...
  • Page 59 Standard sensors fitted in car: • 4 x wheel speed sensors Clutch system pressure sensor • Acceleration sensor • Fuel level • • Lap Trigger • Fuel pressure sensor • Oil pressure sensor • Engine speed sensor • Water pressure sensor Centre console:...

  • Page 60: Modas

    The lamp indicates MS3.1 system errors. A special software programme is required to delete the errors (Bosch Modas), which must be purchased form Porsche Motorsport. Fuel pump switch: Position “Service”...
  • Page 61 Steering wheel: Steering wheel with buttons to activate pit lane speed limiter and to reset the alarm display in the Motec display Pit lane speed limiter is programmed to 50 km/h, but can be re- programmed with the Bosch Modas system. Battery main relay: Only operate the master switch approximately 10 seconds after having switched off the engine with the ignition switch.
  • Page 62 Relay and fuse layout...
  • Page 63 Location of main fuse for steering hydraulic Boot, front right (80 Amp)
  • Page 64 Modas operating instructions Application use: Modas is an application tool that represents measured variables (RAM variables) and adjustable variables (parameters and graphs) in various used displays. It was developed to recall standard measured values and to adjust the most important adjustable values quickly. To install the software, load the enclosed CD and start the SETUP.EXE file.
  • Page 65 Log file: This is a protocol file with the following entries: • Date and time of the MODAS request • Loading of the Binary file • Project names Configuration file name • Name of the A2L file loaded • • Number of measured variables and adjustable variables •...
  • Page 66 Upload PAR-File to MODAS: Retrieves the current parameter files from the control unit. Copy PAR-File to MODAS: Copies any *.par parameter file from disc to the Modas sub-directory \Modas\Parameter\ Copy PAR-File to A: Copies any *.par parameter file to disc. Open LOG-file: Opens the protocol file MODAS.LOG Programme start:...
  • Page 67 Measurement and adjustable variables: Measured values, parameters and indices can be represented in a display. A maximum of 20 measured or adjustable variables can be displayed or 10 measures and 10 adjustable variables. The parameter and graph values are displayed in the adjustable fields. The corresponding calibration points are displayed to the right-hand side of the graphs.
  • Page 68 Views Displays and pages: Displays and pages are distinguished as follows: A display is limited to the representation of measured and adjustable variables, and the Macro buttons. One page can contain up to 10 displays with their display choice buttons. The display choice buttons remain the same only when the choice of displays is changed.
  • Page 69 Bosch Modas Start page Bosch Modas Porsche GT3 Cup Mj 2008...
  • Page 70 Crankcase pressure Engine revs Battery voltage Throttle angle Lambda cylinder 4-6 Lambda cylinder 1-3 Regulation factor 4-6 Regulation factor 1-3 Water pressure Water temperature Oil pressure Engine oil temperature Gearbox oil temperature Fuel pressure Intake air temperature Ambient pressure Clutch pressure Relative air mass Engine oil tank level...
  • Page 71 Raw voltage throttle Throttle angle. Re-set Throttle angle Resoklappe1 Resoklappe2 Error throttle poti. Engine stopped Error throttle position sensor: Throttle sensor defect -> Display TRUE uwdk_w Voltage must increase with throttle angle wdkba-w is zero (0) when throttle reset, wdk_w and wdklm are equal after reset Check Reso 1 Function reset throttle 1 Check Reso 2...
  • Page 72 Min. map position Max map position Run time ECU ECU number Max. throttle angle Max speed Min. ambient press Max ambient press Max fuel pressure Min. fuel pressure Vehicle mileage Min oil temp Vehicle mileage Max oil temp Min intake temp Max intake temp Max water temp Min water temp...
  • Page 73 Cylinder 1 sensor Diagnostic lamp Customer diagnostic lamp Angle cyl 1 and TDC Oil pressure warning lamp Map-position B-mil Display TRUE if diagnostic lamp is activated, engine not running always TRUE B-milspec Display TRUE if customer specific parameter exceeded GT3 RSR -> fuel pressure, water temperature, oil temperature B-oellamp Display TRUE if oil pressure warning lamp is activated phase test...
  • Page 74 Real time year Set real time year Real time month Set real time month Real time day Set real time day Real time hour Set real time hour Real time minute Set real time minute Real time second Set real time second Flag memory Flag flashcard detect.
  • Page 75 Error flag speed Number of pulses FR Vehicle speed Wheel circumference FR Vehicle speed ERROR wheel speed error speed detection = display TRUE E-vradxx error...
  • Page 76 Shift light Voltage shift sensor Error flag shift sensor NSHLAMPG shift light ugs_w neutral shows 2.5 V upshift = voltage rises (to 3.5 - 4.0 V) cut off starts at 2.9 V E - GSH error gearshift sensor = display TRUE BUTTON SYNCHRO code for synchronised gearbox must be flashed to reference page by using: Action/Flashing / Workingpage to reference...
  • Page 77 Code gear detection Detected gear Det. Gear from ratio Gear from gearpoti Voltage gearpoti Offset gear poti callib . corr. volt. gera poti Flag gear det. by poti Threshold ratio1 - 2 Threshold ratio2 - 3 Threshold ratio3 - 4 Threshold ratio4 - 5 Threshold ratio5 - 6 CWGANG...
  • Page 78 Lap counter Track length Flag Lap trigger f . ECU Flag Lap trigger Factor min. tr. length Factor max. tr. length Min. speed...
  • Page 79 Pitspeed limit. speed Code speed limit. Pitspeed limit. speed Error flg speed Switch pit speed CWVMAX code for pitspeed-Limit 0 for km/h or Button Pitlane (km/h) 1 for mph or Button Pitlane (mph) must be flashed to reference page by using:Action/Flashing/Working Page to Reference Page Error wheel speed:Error vehicle speed = display shows TRUE Pitlane Button switch pressed = display1...
  • Page 80 Loading data files (hex. files) 1. Action 2. Datapart 3. Download to ECU 4. Open in corresponding file window...
  • Page 81 Fire extinguisher system: The car is equipped with an FIA homologated fire extinguishing system. AFFF extinguishing agent is used. The cylinder has two separate chambers each with a capacity of two litres. The extinguishing agent is discharged through three nozzles located in the engine bay and a further three located within the cockpit.
  • Page 82 Battery installation: Attention: The toggle switch on the trigger box must be set in the ‘System Inactive’ position. Remove the trigger box cover and change the battery. Ensure that the battery poles are connected correctly. Only Alkaline batteries should be used.
  • Page 83 We undertake no liability for the completeness and conformity of the contents with respect to the legality of the current sporting regulations. We reserve the right for technical changes. © Copyright by Dr. Ing. h. c. F. Porsche AG...

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