Porsche 911 GT3 Cup 2018 Techical Manual

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911 GT3 Cup (991 II) MY 2018

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Page 1 Technical manual 911 GT3 Cup (991 II) MY 2018...
Page 2 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 II). Customer Sport Dr. Ing. h.c. F. Porsche Inc. Motorsport Sales 911 GT3 Cup (991 II)
Page 3 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: Preface
Mr. Tobias Hütter Tel. +49 (0)711 911 82616 Mr. Christoph Hewer Tel. +49 (0)711 91186774 Fax. +49 (0)711 911 82920 Porsche Mobil 1 Supercup Mr. Oliver Schwab Tel. +49 (0)711 911 84042 Assistent Mrs. Tamara Falkenstein Tel. +49 (0)711 911 84096 Fax.
Page 5: Race
Warnings and safety instructions Preface The warning notes and safety instructions are classified by the respective signal word (Danger, Warning, Caution) beside the warning symbol. DANGER Warns against death or very serious injury which will certainly occur if the instructions are ignored. WARNING Warns against death or very serious injury which may occur if the instructions are ignored.
Page 6 Preface instructions carefully and observe them fully. It is not possible for Dr. Ing. h.c. F. Porsche AG to give a detailed evaluation of all danger situations for the persons carrying out the work. It is therefore imperative that all persons carrying out repair and maintenance work on Porsche vehicles use their...
Page 7: Table Of Contents
Contents Preface Preface 1 Engine General information Technical data Engine lubrication 1.3.1 Oil level measurement 1.3.2 Filling capacities 1.3.3 Engine oil 1.3.4 Engine oil circuit 1.3.5 Central oil supply 1.3.6 Oil mist separator Engine cooling system 1.4.1 Schematic diagram 1.4.2 Thermostat 1.4.3 Coolant...
Page 8 1.12 Running time of engine 1.12.1 Behavior if the maximum engine speed is exceeded 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...
Page 9 2.8.1 Dismantling of hang-on parts 2.8.2 Gear housing dismantling Preface 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 Connecting shaft dismantling 2.8.12...
Page 10 3.1.1 Wheel bearing 3.1.2 Wheel hub Preface 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 11 4 Bodywork Preface General Front and side view Rear view Body shell 4.4.1 General 4.4.2 Weight distribution 4.4.3 Weight percentage of the Body -in-White 4.4.4 Body aluminum parts 4.4.5 Body features 4.4.6 Body steel parts 4.4.7 Materials overview 4.4.8 Roll cage 4.4.9 Recovery device Aerodynamics...
Page 12 4.14.1 Fuel 4.14.2 Defueling Preface 4.14.3 Tank installation 4.15 Repairing the body 4.15.1 Repairing the front section 4.15.2 Replacing the front strut mount 4.15.3 Repairing the rear end Protective measures 4.15.4 Reinforcement plates cast carrier 4.15.5 Side panel repair – flange edge wheel arch 4.16 Thread repair kit 4.16.1 Thread repair of chassis bolt connections...
Page 13 6.4.1 DME control unit 6.4.2 DME diagnosis Preface 6.4.3 Error codes 6.4.4 Carburation 6.4.5 Ignition system Transmission 6.5.1 Error codes Sensors 6.6.1 Sensor rated values 6.6.2 View online sensor values 6.6.3 Calibrating sensors Display ICD 6.7.1 General information 6.7.2 Race page 1 6.7.3 Race page 2 6.7.4...
Page 14 6.13.1 Steering wheel 6.13.2 Center console Preface 6.13.3 Windscreen wiper 6.13.4 Interior fan switch 7 Maintenance Engine 7.1.1 Oil level measurement 7.1.2 Oil level measurement with display (optional) 7.1.3 Changing engine oil 7.1.4 Refilling engine oil 7.1.5 Oil specification 7.1.6 Engine cooling system 7.1.7 Engine tightening torques...
Page 15 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) Special tools 911 GT3 Cup (991) Partner contacts 8.
Page 16 8.11 Battery charging cable Preface 8.12 Suspension travel sensor 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 17 Preface 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 18: Engine
1 Engine Engine Engine 1.1 General information The engine of the new 911 GT3 Cup (991 II) is an enhancement of the unit in the road- approved 911 GT3 RS with displacement of 3,996 cc. New features compared with the previous Cup engine are the direct fuel injection, camshaft control for the intake and exhaust valves, and rigidly mounted valve levers for valve actuation.
Page 19: Technical Data
1.2 Technical data Engine Engine Full load curves 1.2.1 Technical engine specifications Number of cylinders Type Flat-six engine Valves per cylinder Displacement 3,996 cc Bore 102.0 mm (4 inches) Stroke 81.5 mm (3.2 inches) Compression Approx. 13.3 : 1 Max. engine speed 8,500 rpm Cooling Water-cooled...
Page 20: Engine Lubrication
Oil change without change of oil filter: 6.0 liters (6.3 qts) 1.3.3 Engine oil The engine oil is always changed when the engine is overhauled at Porsche AG. The following oil specification is used for this: Mobil 1 FS 0W-40 ...
Page 21: Engine Oil Circuit
1.3.4 Engine oil circuit Engine Engine 1.3.4.1 1 – Dry-sump oil pan 12 – Piston oil spray jet switching valve 24 – Camshaft controller 2 – Extraction point 13 – Crankshaft 25 – Oil filler neck 3 – Oil pump 14 –...
Page 22: Central Oil Supply
1.3.5 Central oil supply Engine Engine The engine of the 911 GT3 Cup features a central engine oil supply to the crankshaft to ensure lubrication of the connecting-rod bearings all the way up to the highest engine speeds. The oil for the connecting-rod bearings is not routed to the connecting rod via the main bearings here in the conventional way, but rather supplied centrally from the main oil gallery to the crankshaft via a line.
Page 23: Engine Cooling System
1.4 Engine cooling system Engine Engine The cooling system is used to control the engine temperature. The heat generated during combustion is dissipated to the environment in a controlled manner via three radiators arranged in the front end, thereby protecting the combustion engine against overheating. The cooling system also has two oil/water heat exchangers.
Page 24: Coolant
This provides protection against cold/freezing down to -30°C (-22°F). Porsche Motorsport recommends replacing the factory-filled coolant with 20 liters (21.1 qts) of water and 2 liters (2.1 qts) of anti-corrosion agent (Porsche spare part no.: 997.106.907.90) for all racing events. The anti-corrosion agent protects the water-carrying parts against corrosion, reduces cavitation, lubricates the water pump, and increases the boiling point of the cooling water.
Page 25: Intake System
1.5 Intake system Engine Engine 1.5.1 The new intake bridge has been made from plastic to save weight and lower the center of gravity. 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 26: Throttle Valve
1.5.1 Throttle valve Engine Engine The electronic throttle valve controls the air supply to the engine using an integrated electric motor. 1.5.1.1  Electronic throttle valve  Redundant design through the use of two potentiometers Adjusting the throttle valve There is no mechanical connection between the throttle valve and gas pedal. The electrical signal from the gas pedal is converted into an opening angle by an electrical servo motor in the throttle valve.
Page 27: Working On The Engine
1.6 Working on the engine Engine Engine 1.6.1 Tightening specification for the flywheel The following procedure must be observed when installing the flywheel. Use new screws Tighten the screws in diagonally opposite sequence to 60 Nm (44.3 ft-lb) Tighten the screws in diagonally opposite sequence with a 90° angle of rotation. 1.6.2 Valve timing The valve timing does not need to be adjusted;...
Page 28: Removing And Installing The Crankshaft Sealing Ring (Flywheel Side)
Engine Engine Special tools Porsche Motorsport recommends using the following special tools to install and remove the crankshaft sealing ring on the flywheel side: Press-in tools for crankshaft sealing ring: Porsche spare part no.: 9699/3 This tool can be ordered in the Porsche Dealership.
Page 29 Screw the threaded tip of a commercially available impact pull-off device alternately into the bore holes and pull the metal ring off evenly Engine Engine 1.6.3.2 Part of the sealing ring remains in the crankcase after the metal ring is pulled off. Removal of the remaining sealing ring NOTE Damage to the crankshaft/engine block...
Page 30 Remove the sealing ring; there are two ways of doing this: a.) Screw the threaded tip of the impact pull-off device alternately into the bore Engine Engine holes and pull the sealing ring off evenly. 1.6.3.3 b.) Screw in two tapping screws and pull the sealing ring off evenly using the claw sleeve from a slide hammer kit.
Page 31 Then clean the crankshaft flange carefully using acetone or solvent naphtha.  Unscrew the press-in tool (Porsche spare part no.: 9699/3) (Figure 1.6.3.5). 1.6.3.5  Slide the sealing ring with red assembly protection onto the base plate. Grease the outside of the sealing ring (Figure 1.6.3.6 and Figure 1.6.3.7).
Page 32  Check the installation position of the sealing ring by using a caliper gauge to take measurements at four points from the crankcase flange to the flat part of Engine Engine the steel ring (arrows) 1.6.3.8 Measured depth is approx. 4.5 mm (0.18 inches) •...
Page 33: Changing The Poly-V-Belt
1.6.4 Changing the poly-V-belt Engine Engine Preliminary work:  Remove the rear apron  Remove the heat shield Damage to the central oil supply NOTE Major engine damage The oil line of the central oil supply must not be • dismantled to change the belt.
Page 34: Fuel High-Pressure Line
1.6.5 Fuel high-pressure line Engine Engine Installation of the fuel line WARNING Danger of fire due to leakage The high-pressure line must always be replaced • following disassembly. Mounting specification for the high-pressure line: The assembly specification is the same for both cylinder banks. Fit the line (always use a new line) ...
Page 35: Tightening Torques For Engine
1.7 Tightening torques for engine Engine Engine Screw Tightening torque [Nm Component dimension (ft-lb)] Engine Retaining bracket at central oil supply line M6x16 13 Nm (9.6 ft-lb) 20 Nm (14.8 ft-lb) +90° Pulley on crankshaft M8x1.25 crossed Pulley on alternator 55 Nm (40.6 ft-lb) Oil filter 1"-12 UNF...
Page 36 Engine Engine Exhaust system Restraining strap on muffler M8x50 18 Nm (13.3 ft-lb) 50 Nm (36.9 ft-lb) ± 8 Nm Oxygen sensor M18x1.5 (6 ft-lb) Muffler ball clamp on manifold M8x50 18 Nm (13.3 ft-lb) Engine mount Engine strut on body M10x130 60 Nm (44.3 ft-lb) Engine strut on crankcase...
Page 37: Exhaust System
1.8 Exhaust system Engine Engine The exhaust system was also enhanced as part of the engine redevelopment. Variants with a muffler, with additional front mufflers as well as without any muffler are available. All variants have exhaust manifolds with catalytic converters (each 100 cells). The exhaust system is always mounted on the engine.
Page 38 Engine Engine 991 II) are measured by Porsche AG as guide values and are to inform about the different available exhaust configurations. The guide values can differ from the actual values measured by any race track through technical tolerances (wear and tear, deterioration of filling material, etc.) and environmental influences (weather, ambient...
Page 39: Mounting Front Muffler
1.9 Mounting front muffler Engine Engine 1.9.1 Prelimnary work: Remove rear cover Let the exhaust system cool down Hot components Caution Risk of burns Allow hot components to cool down • Wear protective clothing • 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 40 Pre-mount the holder of the front muffler. Tighten the screw 1 (Figure 1.9.2). Torque: 20 Nm Engine Engine 1.9.2 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 41 Installation: Engine Engine Before fitting the front muffler, an adaption oft he NOTE heat shiled below the rearlight is required.. For this purpose, an additional heat shield 1 (Figure 1.9.3) must be attached to the body. 1.9.3 Drill the marked points (Figure 1.9.4) with a drill (Ø 9 mm/0,358 inch). Insert the blind rivet nuts with the rivet tool..
Page 42 Insert the new heat shield 1 and mark the drill points 2 (Figure 1.9.4/View Engine Engine from below). 1.9.4 Drill the marked points (Figure 1.9.4) with a drill (Ø 9 mm/0,35 inch). Insert the blind rivet nuts with the rivet tool. 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 43 Position the heat shiled 1 to secure with two torx screws 2 (Figure 1.9.5). Torque: Engine Engine 10 Nm 1.9.5 After the screws are tightened, an additional heat protection (yellow marking) must be glued over the screw 1 (Figure 1.9.6) 1.9.6 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 44 Position the holder on the cylinder head. Tighten the screws 1 by hand. The Engine Engine holder must remain displaceable. Pess the holder with slight force in thre direction of the motor (Figure 1.9.7/arrow), so that it rests evenly on both screw shafts. Tighten the two screws 1.
Page 45 The front silencer is attached to the vehicle and has Engine Engine Information little freedom of movement due to the decoupling elements. 1.9.8 Install the lower connecting pipe with the ball clamp on the exhaust manifold. Attach the ball clamp only hand-tight. The connecting pipe must still move freely (Figure 1.9.9).
Page 46 Attach the connecting pipe cleanly tot he front muffler Place the v-band clamp on the front and rear. Engine Engine Tigthen both halves evenly (Figure 1.9.10). Observe the orientation oft he v-band clamp. NOTE 1.9.10 Tigthen the screws oft he v-band clamp. Torque: 5Nm 1.9.11 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 47 Insert the upper connecting pipe into the rear muffler. Fit the connecting pipe upper on the front muffler (Figure 1.9.12/arrows). Engine Engine 1.9.12 Align the connecting pipe parallel tot he connection oft he front muffler and install the clamp (Figure 1.9.13) 1.9.13 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 48 Observe the orientation of the ball clamp. NOTE Engine Engine 1.9.14 Tighten the two screws oft the ball clamp by hand. The front muffler must be movable (Figure 1.9.15) 1.9.15 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 49 Prior to aligning and fixing the front muffler, the NOTE Engine Engine conditions of the connections should be observed (Figure 1.9.16) The rear muffler is firmly connected to the engine bracket.. Ball clamp: loose V-band-clamp: fixed Ball clamp: loose Connection: loose Fron muffler bracket: fixed 1.9.16 911 GT3 Cup (991 II)
Page 50 Press the front muffler in the upper area with slight force in the direction oft he engine (Figure 1.9.17/arrow). Engine Engine Fully eliminate the freedom of movement and hold the front muffer in position. Tighten the screw (1) of the ball clamp, torque: 18 Nm Tighten the screw (2) of the ball clamp, torque: 13 Nm Tighten the nuts (3) on the connecting flange, torque: 23 Nm.
Page 51 The clearance of the front muffler to the heat NOTE Engine Engine protection parts must not be less than 6 mm/0,23 inch If the muffler comes into contact with the heat shield during travel, the insulation can be damaged. The insulation effect is reduced.
Page 52 The clearance between the connecting pipes, at the NOTE Engine Engine narrowest point, should not be less than 8mm / 0.31 inch (Figure 1.9.19). If the pipes touch during the ride, the insulation may be damaged. The insulation effect is reduced. Thermal overloading of surrounding components may occur.
Page 53 Remove the old seals (1) from the side heat shield (Figure 1.9.20). Engine Engine 1.9.20 Fit the new seal (2) (Figure 1.9.21). 1.9.21 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 54 Mount the side heat protection (Figure 1.9.22 / View from the rear). Engine Engine 1.9.22 When installing the side heat protection (1), make NOTE sure that the edge of the vehicle - safe heat protection (2) is not folded or damaged. The correct fit of the two heat shields is important for the function of the overall system (Fig.
Page 55 Press the heat shield (1) upwards until it rests against the seal (2) (Figure 1.9.24). Engine Engine 1.9.24 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 56 The clearance between the front silencers and the NOTE Engine Engine heat protection should not be less than 6 mm/0,23 inch! If the muffler comes into contact with the heat shield during travel, the insulation can be damaged. The insulation effect is reduced. Thermal overloading of surrounding components may occur.
Page 57: Mounting Wheel Arch
1.10 Mounting wheel arch Engine Engine 1.10.1 15mm 1.10.2 Cut away the red marked area. 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 58 Engine Engine 1.10.3 Position the wheel arch, mark centre of bore (1). Drill hole using a 9.0-mm drill bit. Insert blind rivet nut in the frame. 1.10.4 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 59 Engine Engine 1.10.5 Position the wheel arch. Mark centre of bore (1). Drill hole using a 9.0-mm drill bit. Insert blind rivet nut in the rear bodywork. 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 60 Engine Engine 1.10.6 Fasten wheel arch. SELF-TAPPING SCREW ST4, 8x19 3 Nm IN-6RD-FLSH_SHR M6x12 3 Nm IN-6RD-FLSH_SHR M6x12 3 Nm 6KT-MU M6-S 10 Nm 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 61: Sensors
1.11 Sensors Engine Engine Lambda probe Phase Sensor outlet Phase Sensor intake Fuelpress. Sensor Crankcasepress.-sensor Manifold pressure and temp. Sensor Knock Sensor 2 Cooling water temp. Sensor Lambda probe 2 1.11.1 Knock Sensor Fuel press rail Sensor (high pressure) Engine oil temp. and pressure Sensor Oil level (tank) Fuel press rail Sensor (high pressure) 1.11.2...
Page 62: Running Time Of Engine
Engine speed of 8,500 rpm exceeded NOTE Serious damage to the engine Porsche warranty voided Do not exceed an engine speed of 8,500 rpm. • The engine of the 911 GT3 Cup (991 II), which is based on the 991 GT3 RS standard- production unit, is designed for a maximum engine speed of 8,500 rpm.
Page 63: Behavior If The Maximum Engine Speed Is Exceeded
1.12.1 Behavior if the maximum engine speed is exceeded Engine Engine The overhaul interval changes in accordance with the table below if the maximum engine speed of 8,500 rpm is exceeded. Engine speed Duration Overhaul 8,500 – 9,000 rpm After 60 hours 9,000 –...
Page 64: Powertrain
2 Powertrain Powertrain 2.1 General The 911 GT3 Cup (991 II) 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.
Page 65: Clutch
2.2 Clutch Powertrain A Sachs three-disk sintered metal clutch is used in the 911 GT3 Cup (991 II). 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 66: Clutch Wear
2.2.3 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 67: Central Release Mechanism
2.2.4 Central release mechanism Powertrain The hydraulically actuated piston is controlled by the clutch pedal and the master 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 68: Sequential Six-Speed Gearbox
2.3 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 mechanisms 2.3.1.1 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 69: Technical Specifications
2.3.2 Technical specifications Powertrain Gearbox type G91/70 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/ i_total crown gear 13/41 3.154 2.412 1.571 11.951 17/40 2.353 2.412 1.571 8.916 19/36...
Page 70: 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 71 Drive shaft design Powertrain The drive shaft is located above the pinion shaft and is mounted with two bearings in 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 72 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 73: 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 74 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). Operation The pressure pieces (1) driven by the differential cage transmit the torque to the two cross pin bolts (2).
Page 75: Oil Circuit
2.3.5 Oil circuit Powertrain Oil grades and fill quantity Hot fluid WARNING Danger of scalding  Let the fluid cool down. Wear personal protective equipment.  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.
Page 76: Gear Shift Mechanism
2.4 Gear shift mechanism Powertrain The G91/70 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 77: 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 78 Gear shift conditions Powertrain Observe the following handling conditions to ensure the correct operation of the gear- shift system. Up-shifting Down-shifting R -> N N -> 1 1 -> 6 6 -> 1 1 -> N N -> R Paddle/ Reverse Right Right...
Page 79: 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 80: Maintenance Shift System
2.4.4 Maintenance shift system Powertrain The maintenance includes the compressor, the valve block and the shift cylinder. Small Service: • Once p.a. • Max. 10.000 km • Max. 10 h compressor run time Big Service: • Every two years • Max.
Page 81: Drive Shafts
2.5 Drive shafts Powertrain It is recommended to run in drive shafts on new vehicles or newly fitted drive shafts for about 50 km (31 miles) with reduced load and at max. 200 km/h (124 mph). Only use HT 1 LF grease for lubrication when overhauling the drive shafts ...
Page 82: Gearbox Run Time
2.6 Gearbox run time Powertrain The gearbox running time is 60 hours. 2.7 Gearbox tightening torques Place Designation Number per Tightening gearbox torque/Comment pre-tightening 8 Nm Coupling on engine/flywheel ZYL-SHR M8x45 final tightening 33 Nm Gearbox on engine 6KT-MU M10 85 Nm Gearbox on body/carrier3/top 6KT-SHR AM10X92...
Page 83 Powertrain Place Designatio Number per Tightening gearbox torque/Comment 30 Nm +60°, then Pinion shaft-shaft end lock nut M32x1.25 untighten 30 Nm + 60° Reverse gear-intermediate gear-thrust bearing with 6KT-SHR AM8x75 25 Nm stop Gear shift drum-shaft end groove nut M30x1.25 60 Nm 50 Nm +60°, then Cross shaft-shaft end 4-point bearing...
Page 84: Transmission Dismantling
2.8 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 85: 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...
Page 86: Gear Set Removal
Loosen the nuts of the gear housing flanging Remove the gear housing. Use a rubber hammer, if necessary (Figure 2.8.2.4) Powertrain 2.8.3 Gear set removal 2.8.2.4 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 87: Dismantling The Shift Drum
Remove the shift drum (7) with the bushing (4) Secure the shift drum against twisting with an open-end wrench and loosen the shift 2.8.4.1 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 Loosen the nut (2) and (3) and the screw (1) of the locking sleeve and remove the locking sleeve (Figure 2.8.5.1)
Page 88: 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 Loosen the nut (4) and remove the injection tube (2) with the panel puller (M6) (Figure 2.8.6.1 2.8.6.2) The injection tube must be removed before taking out Information the shift module because the shift module cannot be pulled out otherwise...
Page 89: 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 90 Take out locking ring and rotation prevention (3) Powertrain Loosen the nut of the cross shaft with socket Porsche spare part No.: 9R6.450.304.00 2.8.7.5 Be careful when removing the cross shaft nut. The Information bearing shell of the four-point bearing is behind it.
Page 91 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 2.8.7.7) Powertrain Mechanical, hydraulic or pneumatic press WARNING Risk of crush injuries ...
Page 92: 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 Mechanical, hydraulic or pneumatic press WARNING Risk of crush injuries 2.8.8.1 ...
Page 93: 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 Hot components Caution Danger of burns ...
Page 94: Central Clutch Operator Removal
Remove snap ring and needle cage from the differential housing (Figure 2.8.9.5) Powertrain 2.8.10 Central clutch operator removal 2.8.9.5 Corrosive fluids WARNING Danger of chemical burns  Wear personal protective equipment. Ensure good ventilation.   Avoid contact with corrosive fluid. ...
Page 95: 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 96: 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 Information gearbox housing could be damaged in the process! 2.8.13.1 Clean the gearbox housing and remove any oil Hot components Caution Danger of burns...
Page 97 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 HAZET 788 – 70 (3) and panel puller 2.8.13.5 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) Gear housing Remove the baffle of the bearings (4)
Page 98: Transmission Assembly
Transmission assembly Powertrain 2.9.1 Gearbox housing pre-assembly Before putting together the transmission, all components of the transmission must be cleaned and degreased thoroughly. In addition, a visual inspection must be carried out. Especially the visual check of the oil holes is necessary to ensure perfect function of the transmission.
Page 99 Differential lid studs (red) Powertrain Dimensions: M8x30 Projection: 30 mm (1.18") Adhesive: Loctite 2701 green Thread position: Screw in short thread Starter studs (1) Dimensions: M10x22 2.9.1.3 Projection: 24 mm (0.94") Adhesive: Loctite 2701 green Thread position: Screw in short thread 2.9.1.4 Gear housing connection studs (green) Dimensions:...
Page 100 Retaining frame pinion shaft studs (light blue) Powertrain Dimensions: M8x26 Projection: 14.5 mm (5.71") Adhesive: Loctite 2701 green Thread position: Screw in long thread Oil pump studs (2) Dimensions: M6x28 2.9.1.6 Projection: 27 mm (1.06") Adhesive: Loctite 2701 green Thread position: Screw in short thread Screw in suction tube screw stud (1) Dimensions:...
Page 101 Shift drum stud (1) Powertrain Dimensions: M6x10 Projection: 11 mm (0.43") Adhesive: Loctite 2701 green Thread position: Screw in long thread Shift drum stud (2) Bushing must first be pressed in. Information 2.9.1.7 Dimensions: M6x35 Projection: 29 mm (1.14") Adhesive: Loctite 2701 green Thread position: Screw in long thread...
Page 102 Central clutch operator screw connection stud (arrow) Powertrain Dimensions: M6x18 Projection: 19 mm (0.75") Adhesive: Loctite 2701 green Thread position: Screw in long thread 2.9.1.8 Injection tube stud Dimensions: M6x10 Projection: 10 mm (0.39") Adhesive: Loctite 2701 green 2.9.1.9 Thread position: Screw in long thread 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 103 Bearing assembly Powertrain Inserting the bearings requires the heating of the gearbox housing analogous to the setting of the adhesive connection (see above). All bearings must be inserted quickly before the housing has cooled off. To ensure the proper seat of the bearings, all bearings must be tapped with an appropriate tool after the housing has cooled off.
Page 104 Cross shaft bearing Powertrain Dimensions: 28x37x30 Type: Needle bearing Tool: No. 5 Insert locking ring (37x1.5) Insert locking ring (1) at a 180° offset to the opening Information (2)! 2.9.1.13 Outer ring of cross shaft bearing Dimensions: 50x90x20 Type: Cylinder roll bearing Tool: No.
Page 105 Differential cylinder roll bearing in the gearbox housing Powertrain Dimensions: 59,5x90x23 Type: Cylinder roll bearing Tool: No. 8b With locking ring Insert locking ring at a 90° offset to the opening! Information 2.9.1.16 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 106 Pressing in the bushings Powertrain Hot components Caution Danger of burns Wear personal protective equipment.  Pressing in the bushings requires heating the housing (see 2.9.1 Pre-assembly/bearing assembly). Pressing in the bushing for the oil filter (1) Adhesive: Loctite 638 Press in up to the limit 2.9.1.17 Gearbox housing-gear housing screw connection bushing (12x6x16)
Page 107 Screwing in the sealing plug: Powertrain General All sealing plugs must be sealed with surface sealant Loctite 574. Apply sealant thinly on the thread surface for this. Oil hole closure Dimensions: M12x1.5 alu Torque: 9 Nm (6.6 ft-lb) 2.9.1.19 Attach with sealing ring (12x18). Plug without pressure sensor Dimensions: M10x1...
Page 108 Mounting hydraulic connections for the clutch: Powertrain Use Loctite 574 orange. Information Bleeding (2) With Sealing ring Pressure line (1) With Sealing ring 2.9.1.21 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 109: Gear Housing Pre-Assembly
2.9.2 Gear housing pre-assembly Powertrain General Before assembling the gear housing, all components must be cleaned and degreased thoroughly. Furthermore, a visual inspection must be carried out. Especially all oil holes must be checked to ensure the perfect running of the transmission. The gear housing must finally be blown out with compressed air.
Page 110 Bearing baffle studs Powertrain Dimensions: M5x10 Projection: 10 mm (0.39”) Adhesive: Loctite 2701 green Thread position: Screw in long thread 2.9.2.2 Threaded pin of the baffle Dimensions: M5x20 12.9 Projection: 7 mm (0.27”) Adhesive: Loctite 2701 green 2.9.2.3 Shift module screw connection stud (26) Dimensions: M6x18 Projection:...
Page 111 M10x52 10.9 2.9.2.5 Projection: 45 mm (1.77”) Adhesive: Loctite 2701 green Thread position: Screw in short thread Press in fitting sleeve (1) Porsche spare part No.: Information 991.301.641.9B up to the limit Bottom: 2.9.2.6 Dimensions: M10x45 10.9 Projection: 45 mm (1.77”)
Page 112 Pressing in gear housing bearings and bushings Powertrain Hot components Caution Danger of burns Wear personal protective equipment.  After the studs are inserted, the gear housing has to set in an oven for approx. 40 minutes at 130°C (266 F). The heat is also required for the next work step (inserting the bearings).
Page 113 Pinion shaft cylinder roll bearing (3) Powertrain Dimensions: 44x72x17 Tool: No. 4 Grooved ball bearing of the shift drum (1) Dimensions: 50x65x7 Tool: No. 31 2.9.2.8 Screw connection of baffle M5 Torque: 6 Nm (4.4 ft-lb) Shift module bushing (27) Dimensions: 6x8x8 Press in up to the limit...
Page 114 Gearbox bracket bushing (1) Powertrain Dimensions: 13x6x13.5 Press in up to the limit Top sealing plug Dimensions: M16x1.5 2.9.2.10 Torque: 20 Nm (14.8 ft-lb) Adhesive: Loctite 574 orange Sealing ring Sealing plug Dimensions: M12x1.5 Torque: 9 Nm (6.6 ft-lb) Adhesive: Loctite 574 orange Sealing ring Temperature sensor (arrow)
Page 115: Differential Lid Pre-Assembly
2.9.3 Differential lid pre-assembly Powertrain Hot components Caution Danger of burns  Wear personal protective equipment. Heat the lid in the oven to 130°C (266 F) for 40 minutes Cylinder roll bearing (2) Dimensions: 54,5x85x19 Tool: No.8/8a 2.9.3.1 Point the label from the bearing to the top and secure Information with snap ring.
Page 116: 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). Incorrect installation of spacers NOTE Lack of lubrication Damage to the gearbox ...
Page 117: Pinion Shaft
2.9.5 Pinion shaft Powertrain Hot components Caution Danger of burns  Wear personal protective equipment. 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...
Page 118 Put on the cutted gear housing and fix it in place with 4 nuts (Figure 2.9.5.5) Powertrain Tightening the pinion shaft nut: The counter torque wrench no. 27 touches the cutted Information gear housing and thus fixes the pinion shaft in place. (Figure 2.9.5.5) 2.9.5.4 Tightening instructions:...
Page 119: 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 120 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 121: Assembly Of Gear Sets
2.9.7 Assembly of gear sets Powertrain During the fitting of the gear sets, the gearbox housing is in the position where the upper side of the transmission points to the right. Lubricate the drive shaft bearing running surfaces (3) well Insert the drive shaft (3) in the gearbox housing Push on thrust plate (2) Secure with locking ring (1) (30x1.5);...
Page 122 Powertrain 2.9.7.5 Push the spur gear of the reverse gear (2) on pinion shaft. 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 2.9.7.5) 2.9.7.4 Insert idler gear 1 gear (3) without the bearing, the claws then point away from the...
Page 123 Powertrain 2.9.7.8 2.9.7.9 Insert selector sleeve (6) with the label facing outward (Figure 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) 2.9.7.10 Push the fixed gear 3 gear (B) on the drive shaft (A) (Figure 2.9.7.11) 2.9.7.11 911 GT3 Cup (991 II)
Page 124 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 125 Powertrain 2.9.7.16 2.9.7.17 Push on guide sleeve 5 gear (17) with idler gear 5 gear (15) and idler gear bearing (16) (claws pointing toward 6 gear) (Figure 2.9.7.18) Push on fixed gear (D) gear 5 (installation direction: label of fixed gear (D) and idler gear (15) on the same side) (Figure 2.9.7.18).
Page 126 Powertrain 2.9.7.20 2.9.7.21 The Secure locking ring (G) of the drive shaft (Figure 2.9.7.20) has a sharp-edged and a rounded edge. The sharp edge of the secure locking ring must point outwards (shaft end)  Fixate secure locking ring by hand and then install it. ...
Page 127: Premounting Shift Drum
2.9.8 Premounting shift drum Powertrain 2.9.8.1 Put adjusting disk (6) Basic (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) Insert the grooved ball bearing (2) Screw on the nut (1) (flattened side in the direction of the grooved ball bearing (2)) and 2.9.8.2 tighten with 60 Nm (44.3 ft-lb) with tool no.
Page 128: Oil Pump Assembly
2.9.9 Oil pump assembly Powertrain Grease O rings (1) and insert them in the oil pump housing Remove the drive gear Put on the oil pump and four nuts and then tighten with 4 Nm (3 ft-lb) using a crisscross pattern.
Page 129: Reverse Idler Gear
2.9.10 Reverse idler gear Powertrain Hot components Caution Danger of burns  Wear personal protective equipment. 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.
Page 130: Locking Sleeve
2.9.11 Locking sleeve Powertrain Abutment assembly: Insert the lever (1) into bearing spindle abutment (4) Press in bushing (2) Insert the compression spring (3) between housing and lever The bushing (2) must be flush with the housing (4) 2.9.11.1 Tension the lever with a slot screwdriver and insert the locking sleeve in the gearbox housing 2.9.11.2 Put on Simmonds nuts (3) and tighten with 10 Nm (7.4 ft-lb)
Page 131: Shift Rod And Shift Forks
2.9.12 Shift rod and shift forks Powertrain Put the shift drum in the neutral position Insert shift forks Grease two O rings (1) (11x2) with Optimol Paste MP3 and put on the shift rod (1) 2.9.12.1 Lubricate the shift rod and put it in all the way to the stop Do not insert the upper O ring (arrow) of the shift rod Information until the final assembly.
Page 132: Suction Tube Assembly
2.9.13 Suction tube assembly Powertrain Put greased suction tube (2) and O ring (1) (15x2.5) on the gearbox housing Put on nut (4) and tighten with 10 Nm (7,4 ft-lb) Oil filter 2.9.13.1 Insert the oil filter element (2) in the gear housing (without a specific installation direction), put on closure cap (3) with greased O ring (4) and secure with the locking ring (5) 2.9.13.2...
Page 133 Inserting the connecting shaft Powertrain Press snap ring onto the shaft 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) on the bearing Grease shaft sealing ring (connecting shaft) (26x41x6) with Optimol and drive in with 2.9.13.4 tools no.
Page 134: Central Clutch Operator Assembly
2.9.14 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. 2.9.15 Cutted gear housing assembly 2.9.14.1 The cutted gear housing is assembled to check the Information backlash of bevel gear to ring gear.
Page 135 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 136: Determining Cross Shaft Bearing Adjusting Disk Q1
Determining adjusting disk Q1 requires measurement device. Measurement process 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. The locking ring that is also ultimately used for installation must be used (Figure 2.9.16.1)
Page 137: Cross Shaft Setup
2.9.17 Cross shaft setup Powertrain Hot components Caution Danger of burns  Wear personal protective equipment. Heat the cylinder roll bearing inner ring on a hot plate for 30 minutes at 130° C (266 F) Lubricate the shaft Press the heated bearing (1) quickly onto the shaft. It must be possible to mount the bearing without applying great force.
Page 138: 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 139 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 140 Check the ease of movement of the bearing Powertrain Attach locking ring (3) for the nut Attach locking ring Place the greased O ring (130x2.5) on the lid Visually check the gearbox housing 2.9.18.7 Put on the adjusting disk (basic 1.4) P2 Insert the shaft with the lid (rotate shaft slightly to prevent two teeth of ring gear and bevel gear from touching directly) Tighten the lid with every second nut using a crisscross pattern (25 Nm (18.4 ft-lb))
Page 141 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 142: 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 (see 7.3.1). Friction disks, bevel gears, bevel pinions, axial bearings, and ramps must be lubricated well before the assembly.
Page 143 Powertrain 2.9.19.4 2.9.19.5 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 144 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 145 Measurement of pressure plates/clutch discs/ramp/cross pin package Powertrain Measurement without springs! 2.9.19.8 The measurement of the friction package has to be 0.1- 0.3 mm less than the measurement (A-B). In case the measurement of the friction package is not within the tolerance it must be corrected by reassembling with pressure plates of different thickness.
Page 146 Meassurement: Powertrain D = E ± 0.2 mm 2.9.19.9 Check the differential lid/differential housing pairing! 2.9.19.10 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.
Page 147 Differential installation Powertrain Insert needle cage (3) Dimensions: 35x40x17 Put on snap ring (4) Insert the differential in the gearbox housing (Figure 2.9.19.14) Put on differential lid with greased O ring and tighten with 25 Nm (18.4 ft-lb) 2.9.19.13 2.9.19.14 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 148 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 149: Mounting Gearhousing
2.9.20 Mounting gearhousing Powertrain Insert the upper O-ring of the shift rod into the notch (Bild 2.9.20.1) O-ring (1) and insert into gearbox housing (Bild 2.9.20.2) 2.9.20.1 Once all adjustments have been made, the cut housing can be replaced by the wheel housing.
Page 150 Tighten pinion shaft nut with 30 Nm + 60 °, then loosen and tighten again with 30 Nm + 60 ° (Bild 2.9.20.4) Powertrain Fit cover pinion shaft (23) with greased sealing ring (24) and tighten nuts (25) to 10 2.9.20.4 Nm (Bild 2.9.20.5) Cover Install the cross shaft cover with a greased O-ring and fix it with the retaining...
Page 151 Cover Installation opening Insert the coupling housing (arrow) with a greased O-ring and fix it with a securing ring Powertrain Connect switch actuator (3) and tighten with 10 Nm 2.9.20.7 Connect switching actuator potentiometer (2) to switching actuator Calibrate potentiometer operation (6th gear 4.5 V) Gearbox holder to gearbox screw 45 Nm Shift cylinder on gearbox holder and shift actuation screws 12 Nm 2.9.20.8...
Page 152 Seal rings (2) Place oil / water heat exchanger greasy, place heat exchanger (1) Apply heat exchanger to 10 Nm Powertrain Insert the oil injection pipe (2) for the pinion shaft with a greased sealing ring (1) into the gearbox housing and tighten the nut (4) to 10 Nm tightening torque and Loctite 2701 2.9.20.11 Fill the gearbox with 3 liters of oil (see chapter 2.3.5 Oil circuit)
Page 153 Porsche Motorsport points out that the mounting of the sprengren on the articulated flange has to be carried out by the following procedure. The assembly is carried out Powertrain with the support of an O-ring in the sprengren groove, the instruction applies to both joint flanges.
Page 154 Sprengring is centered by O-ring, grease axle flange teeth. Powertrain 2.9.20.17 Insert drive shaft flanges (arrow) 2.9.20.18 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 155: Rolex Assembly
2.10 Rolex assembly Powertrain Disassemble Rolex old stock, clean the parts and carefully place all parts. These old stock parts are for reuse in Rolex-Status 4.0:Gehäuse (Deckel): 2* Sliding Sleeve 2* Compression Spring 2* Spring Mount 1* Bracket (Potentiometer) 1* Potentiometer 1* Connecting Tube 2* Fillister Screw Potentiometer 2* Fillister Screw Bracket...
Page 156 Required new parts Powertrain Following new parts must be present and replaced: 1* Rolex Housing 1* Shaft Sealing Ring 1* Stud Holder (Potentiometer) 2* Sealing Ring Spring Mount 1* Needle Bush for Coupling Part 2* Pin 1* O-Ring for Rolex Housing 1* Bearing Sleeve 1* Stop Guide Plate 3* Torx Screw...
Page 157 Assembly Powertrain Technical aids to use: Loctite 574; Loctite 243 blue; Loctite 2701 green; Optimol- MP3-Grease; Gearbox Oil; Porsche Special-Tools; Standard Tools as shown in Picture; Heating Plate; Torque- Wrench Important: Use only a Rubber hammer! Clean all components with benzine and arrange the old and new parts as follows.
Page 158 Hot components Caution Powertrain Danger of burns  Wear personal protective equipment.  Heat up the rolex housing and the additional grooved ball bearing with the heating plate to 100°C – 120°C (212-248 °F). 2.10.2  As these parts are heating up, install the grooved ball bearing for the coupling part in the shifting element.
Page 159 Take the rolex housing from the heating plate, lay the needle bush for the  coupling part into the housing and fix it with the special tool no. 30 and the Powertrain rubber hammer. Important: Do not use the hammer directly on the bearing! 2.10.4 2.10.5 911 GT3 Cup (991 II)
Page 160  Countersink the pins into the rolex housing. Let the housing cool down.  Powertrain Coat the sliding sleeve and the compression spring with oil and put it into  the housing. Important: The oil should not contact the thread of the housing. Place the shaft sealing ring and the spring mount on the housing, secure it with Loctite 574 and screw it into the housing.
Page 161 Insert the stop disk with the writing face down into the housing as shown in  the picture. Powertrain 2.10.8  Lay in the stop guide plate with the sinkings facing up into the housing. Use the three torx screws and Loctite 243 to secure and fix the stop guid plate. Torque: 4 Nm (3 ft-lb).
Page 162 Hot components Caution Powertrain Danger of burns  Wear personal protective equipment.  Heat up the rolex housing again to 100°C - 120°C (212-248 °F) and insert the bearing sleeve for the additional grooved ball bearing. Important: Ensure that the bearings sleeve is seated correctly. Let the housing cool down.
Page 163 Put together the coupling part, the compression springs and the drivers and  carefully guide the parts into the shifting element. Secure the coupling part Powertrain immediately with the securing ring and check on free movement. Important: Check the neutral position as shown in the picture! 2.10.13 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 164 The additional grooved ball bearing and all the moving parts in the housing  have to be coated with oil and checked on free movement. Powertrain 2.10.14  The next step is, to put the potentiometer driver and the washer into the coupling part and subsequently into the shifting element.
Page 165 Turn over the rolex housing and make sure that the coupling parts don’t  fall out. Powertrain  Important: Check the neutral position as shown in the picture! 2.10.16  Check the function and free movement. Rotate the coupling part once to the right and once to the left side.
Page 166 Use the special tools (sleeve and mandrel no. 29) to mount the shaft  sealing ring. Important: Use only the rubber hammer! Powertrain 2.10.17 Secure the coupling part and the shaft sealing ring with the locking ring as  shown in the picture. Important: Ensure that the locking ring is seated correctly! 2.10.18 911 GT3 Cup (991 II)
Page 167 Mount the paddle shift control lever as shown in the picture and secure it  with the locking ring. Important: Ensure that the locking ring seats correctly! Powertrain 2.10.19  Perform a shifting test. Important: Shifting operations must be easy to carry out and the control lever has to return automatically to its neutral position.
Page 168 Mount the bracket fillister screws (M5x15) and the spring lock washers with  Loctite 243 into the rolex housing. Torque: 6 Nm (4,4 ft-lb). Powertrain  Potentiometer fillister screws (M4x10) and the related spring lock washers also has to be mounted as shown in the picture below. Torque: 4 Nm (3 ft- lb).
Page 169: Overview Gearbox Settings
2.11 Overview gearbox settings Powertrain Pinion shaft Preload 4-point-bearing Set valve: 0.03 – 0.05 mm (Figure 2.11.1) 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 2.11.1 2.11.3 2.11.2...
Page 170: Chassis
3 Chassis Chassis 3.1 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 been unchanged.
Page 171: 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 172: 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. 3.1.2.1 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 173 The wheel bolts must be checked and • regenerated after 6 hours of use. Porsche Motorsport recommends also replacing the wheel nuts during a long-distance race (after approx. 6 hours running time) to verify and regenerate them. Clean the threads, judge them by visual inspection.
Page 174: 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 II) Version: 4/20/2018 MY 2018...
Page 175: Front Axle
3.2 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. The double shear connection of the control arm and tie rod to the wheel mount as well as a stiffer shock absorber clamp increase the wheel mount’s overall stiffness.
Page 176: 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 177: 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 2.00 mm...
Page 178 Screw-in depth of tie rod thread WARNING Chassis Tie rod breaks off Loss of control over the vehicle To ensure the tie rod thread is screwed in to a sufficient depth in the case of high camber values (>4.5 degrees), the supporting mount must be adjusted inwards.
Page 179: Longitudinal Control Arm
3.2.3 Longitudinal control arm Chassis The longitudinal control arms are stiffness-optimized forged control arms. 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 180: 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 181 Incorrect handling of safety-relevant bolts WARNING Chassis Injuries Loss of torque  Always use new fastening bolts and nuts following removal.  Observe specified tightening torques.  Carry out a visual inspection of all re-used parts. Mechanical, hydraulic or pneumatic press WARNING Risk of crush injuries ...
Page 182: Front Axle Shock Absorber
3.2.5 Front axle shock absorber Chassis Preloaded or pressurized components WARNING Risk of crush injuries or contusions  Do not reach into the danger area.  Relieve the tension on components before starting work.  Secure components to prevent them from loosening suddenly.
Page 183 Chassis 3.2.5.1 Damage to the intermediate ring (item 5) NOTE The ends of main springs and helper springs should not lie opposite one another. Arrange so they are offset • List of tightening torques for front axle shock absorber Item Dimensions Tightening torque in Nm/Comments M14 x 1,5...
Page 184: Front Axle Anti-Roll Bar
3.2.6 Front axle anti-roll bar Chassis Warning about components falling down when the WARNING vehicle is raised Risk of personal injury, particularly head injuries, if the front-axle cross member or steering gear falls down. Never loosen the front-axle cross member ...
Page 185 Chassis 3.2.6.1 Damage to the bending lever (item 7) NOTE Fracture of the bending lever  Do not cause notches or other damage.  Use a suitable tool only. List of tightening torques front axle anti roll bar Item Dimensions Tightening torque in Nm/Comments 10 Nm (7 ft-lb) M8 x 18...
Page 186 The following chart shows the wheel-related stiffness of the anti-roll bar depending on the blade position. The left and the right blade are always in the same position: Chassis Overall stiffness related to blade angle, front axle 3.2.6.3 Coupling rod setting 3.2.6.2 Adjusting the coupling rod NOTE...
Page 187: Rear Axle
3.3 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 188: Rear Axle Control Arm And Tie Rod
3.3.1 Rear axle control arm and tie rod Chassis The use of high-performance joint bearings in all control arms minimizes play and greatly reduces unwanted elastokinematic effects. 3.3.1.1 List of tightening torques and tie rod Item Dimensions Tightening torque in Nm/Comments Stud: 10 Nm + Loctite 276 65 Nm (48 ft-lb) 8 (7)
Page 189: 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. 3.3.2.1 The following adjustment washers can be purchased at Porsche Motorsport: 0.50 mm 1.00 mm 2.00 mm...
Page 190 Chassis When inserting the spacers, it´s important to use as NOTE less spacers as possible to get to the desired length. This prevents potential clamping force loss caused by settling process. Thinner shims have to be mounted on the inside of the wishbone (side of the fixed bearing).
Page 191: Rear Axle Wheel Mount
3.3.3 Rear axle wheel mount Chassis Incorrect handling of safety-relevant bolts WARNING Injuries Loss of torque  Always use new fastening bolts and nuts following removal.  Observe specified tightening torques.  Carry out a visual inspection of all re-used parts.
Page 192 Chassis 3.3.3.1 List of tightening torques rear axle wheel mount Item Dimensions Tightening torque in Nm/Comments M12 x 1,25 x 45 80 Nm (60 ft-lb) + 120° M8 x 32 35 Nm (26 ft-lb) 470 Nm (347 ft-lb) then free (ca.90°) then M22 x 1,5 470 Nm (347 ft-lb) 500-525 Nm (369/387 ft-lb ft-lb) (lubricate with...
Page 193: Rear Axle Shock Absorber
3.3.4 Rear axle shock absorber Chassis Preloaded or pressurized components WARNING Risk of crush injuries or contusions  Do not reach into the danger area.  Relieve the tension on components before starting work.  Secure components to prevent them from loosening suddenly.
Page 194 Chassis 3.3.4.1 Damage to the intermediate ring (item 9) NOTE The ends of main springs and helper springs should not lie opposite one another.  Arrange so they are offset List of tightening torques for rear axle shock absorber Item Dimensions Tightening torque in Nm/Comments N12x1,5x80...
Page 195: Rear Axle Anti-Roll Bar
3.3.5 Rear axle anti-roll bar Chassis Adjusting the anti-roll bar WARNING Changed vehicle handling The anti-roll bar must only be adjusted symmetrically. • 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 196 Damage to the bending lever (Figure 3.3.5.1, item 7) NOTE Fracture of the bending lever Chassis Do not cause notches or other damage. • Use a suitable tool only. • The following chart shows the wheel-related component stiffness of the anti-roll bar depending on the blade position.
Page 197 A distance of 12 mm (0.47 inches) towards the control arm is recommended when the axle is decompressed (figure 3.3.5.4). Axial clearance compensation To counteract any possible axial play of the rear stabilizer, Porsche Motorsport offers two differently sized spacers (pink). 3.3.5.3...
Page 198: Rear Axle Side Part
3.3.6 Rear axle side part Chassis The side parts made of cast aluminum are used as connecting elements between control arms and body. 3.3.6.1 List of tightening torques for rear axle side part Item Dimensions Tightening torque in Nm/Comments M12 x 1.5 x 95 120 Nm (88.5 ft-lb) 120 Nm (88.5 ft-lb) M10 x 45...
Page 199: Wheel Alignment
Porsche Motorsport recommends proceeding as described below. 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...
Page 200: Preparatory Measures
3.4.1 Preparatory measures Chassis For this purpose, the following measures have proven to be extremely helpful:  Place driver’s compensation weight on the driver’s seat  Set air pressure to 2.0 bar (29 psi)  Fill the tank with 50 % of the fuel quantity necessary for the race/practice The following work order is recommended when performing a complete vehicle alignment: Unhook the anti-roll bars...
Page 201: 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 202: Steering System
3.5 Steering system Chassis Screw-in depth of tie rod thread WARNING Tie rod breaks off Loss of control over the vehicle To ensure the tie rod thread is screwed in to a  sufficient depth in the case of high camber 3.5.1 values (>4.5 degrees), the supporting mount must be adjusted inwards.
Page 203 The hydraulic power steering is derived from the 911 GT3 Cup (997 II) while the power steering pump has its origins in the 911 GT3 R (997 II). The power steering pump unit Chassis 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 204 The components and the assembly sequence of the steering wheel quick release are shown in the illustration below. Chassis 3.5.4 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 205: Bleeding The Steering System
Under no circumstances should the rack and pinion NOTE steering and the power steering pump be repaired or Chassis dismantled. Damage to the steering system can occur due to a lack of oil in the circuit of the hydraulic system. Even small oil leaks may cause damage to the power steering pump due to the high system pressure.
Page 206: Rims And Tire
3.6 Rims and tire Chassis Risk of accidents if the air pressure in the tires falls WARNING below the minimum, if the tread depth is insufficient or if there are foreign bodies, cuts, cracks, and bulges in the sidewall (ply breakage). Modified handling behavior can cause accidents and major material damage.
Page 207: Rim
3.6.1.1 3.6.2 Tires The new 911 GT3 Cup (991 II) 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. Furthermore the transport tires are marked by the manufacturer.
Page 208: 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 209 60 hours before they have to be replaced. Under extreme temperature load, they may have to be replaced even earlier. This is indicated by sluggishly moving wheels or stuck pistons. Repair kits can be purchased at Porsche Motorsport.
Page 210 Increased wear of brake pads 3.7.1.2 Only use the type-specific brake pads listed in the • Porsche spare parts catalog. Replace the brake discs on each axle upon • reaching the wear limits. Old mounting parts fitted on the brake caliper...
Page 211: Front Axle Brake
Longer braking distance More wear on brake pads Only use the type-specific brake pads listed in the Porsche spare parts catalog. Replace the brake pads on each axle upon reaching • the wear limits. 911 GT3 Cup (991 II)
Page 212: Rear Axle Brake
Increased braking distance Increased wear of brake pads  Only use the type-specific brake pads listed in the Porsche spare parts catalog.  Replace the brake pads on each axle upon reaching the wear limits. 911 GT3 Cup (991 II)
Page 213: Master Cylinders
3.7.4 Master cylinders Chassis 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. Lifetime master cylinder: 5000 km (3106 mi) or 30 hours 3.7.4.1 List of tightening torques for master cylinders Item...
Page 214: Changing The Brake Fluid
3.7.5 Changing the brake fluid Chassis Corrosive fluids WARNING Danger of chemical burns Wear personal protective equipment. • Ensure good ventilation. • Avoid contact with corrosive fluid. • If you do come into contact, wash off immediately • with plenty of warm water and contact a doctor if necessary.
Page 215: Brake Pressure Distribution
3.8 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 216: Balance Beam Basic Setting
3.8.1 Balance beam basic setting Chassis Changing the setting of the balance bar WARNING Changed braking behaviour Loss of control over the vehicle Adjusting the weather condition • Adjust settings to vehicle setup • Test new setting carefully • 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).
Page 217 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 and 64 mm.
Page 218: 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: Front Axle Rear Axle 3.8.2.1 Key:  Pedalkraft Pedalkraft = pedal force,  Bremskraft Bremskraft = brake power ...
Page 219: Balance Bar Replacement Kit
3.9 Balance bar replacement kit Chassis 3.9.1 Replacing the trunnion  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 220: Replacing The Balance Bar
3.9.2 Replacing the balance bar Chassis  Remove the R-clips, spacers, circlips and clevises from the balance bar  Remove the balance bar Retaining rings and snap rings DANGER Snap ring or retaining ring drops out Failure of brake system Loss of control over the vehicle ...
Page 221: Performance Setup
After each race or training to prevent from dirt the NOTE needle bearing should be covered with a doughy fat Chassis 3.10 Performance setup 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...
Page 222: Bodywork
Bodywork Bodywork General The exterior of the 911 GT3 Cup (991 II) 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 II) is provided with a reduced sealing and sound insulation package.
Page 223: Front And Side View
Front and side view Bodywork Front bumper The lateral air intakes of the front bumper have been redesigned. The newly developed daytime running lights are integrated and include LED direction indicators. The front bumper is made of PUR CF3/GK 10 (polyurethane). 4.2.1 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 224 Side view Bodywork 4.2.2 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 225: 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 CF3/GK 10 (polyurethane). 4.3.1 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 226: Body Shell
Body shell Bodywork 4.4.1 General In the development of the body of the new 911 GT3 Cup (991 II), the following objectives were pursued, in order to further enhance the safety and performance:  Weight retention combined with improved strength/stiffness ...
Page 227 When looking in detail at the body of the 911 GT3 Cup (991 II), 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 228: 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 II) Version: 4/20/2018...
Page 229: 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 230: 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: Increased torsional stiffness ...
Page 231: 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 232: 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 II) Version: 4/20/2018 MY 2018...
Page 233: Roll Cage
4.4.8 Roll cage Bodywork Damaged safety cell WARNING Reduced occupant protection  After an accident, the safety cell must be inspected by an independent expert. The roll cage is permanently welded in the body. Any Information modifications to the roll cage will result in non-approval or disqualification of the vehicle.
Page 234: Recovery Device
4.4.9 Recovery device Bodywork Floating load WARNING Injury due falling parts  Use oley intact recovery bar/ ball locking bolts  Ball locking pin must audibly engage, make sure he is locked Towing using a towing hook (Figures 4.4.9.1 and 4.4.9.1 NOTE 4.4.9.2)
Page 235: Aerodynamics
Aerodynamics Bodywork 4.5.1 General Compared to the previous models, the new 911 GT3 Cup (991 II) use the same significantly improved in terms of its aerodynamic performance. The aerodynamic of the front cover were further improved. 4.5.2 Rear wing Damaged, worn or missing aerodynamic WARNING components.
Page 236: 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 237: Air Jack System
Air jack system Bodywork The air jack system is made 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 238  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 239: Doors
Doors Bodywork To further reduce vehicle weight, the doors are made of CFRP. 4.10 Trunk and engine lid Trunk or hood lid opening while driving WARNING Trunk lid bangs against the windshield Visual obstruction for the driver Push lid pins fully through and carefully close •...
Page 240: 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 241 Preparation Bodywork Remove the windshield wiper arm Remove the interior rear-view mirror Removal and installation of vehicle windows WARNING Risk of eye injuries Risk of cuts Wear personal protective equipment. • Cutting blades must only be changed with the • power supply turned off.
Page 242 The cutting cord has to be below the window edge, NOTE as otherwise the seal will be damaged. Bodywork 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 243 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 244: 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). ...
Page 245: Preparing The Windshield For Installation
4.11.3 Preparing the windshield for installation Bodywork (new windshield) Toxic substances WARNING Poisoning or suffocation Burns to the eyes and skin Ventilate the work area well. • Never ingest or inhale. • Read specific information on the Hazard Sheet. • Do not smoke, eat, or drink in the work area.
Page 246: Installing The Windshield
4.11.4 Installing the windshield Bodywork Application of adhesive NOTE Poor adhesive bond Window becomes detached Fixing time: Approx. 1 hour. • The vehicle must not be used until a curing time • of 2 hours has elapsed. Processing temperature at least 10°C (50°F). •...
Page 247 When applying the glue material, make sure that the Information 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 248: 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. ...
Page 249: 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 II). 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 250: 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 "Intank Pump Service". The fuel pump is then activated for 120 seconds.
Page 251: Repairing The Body
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 6 Nm (4.4 ft-lb) Combi SHR M8X40 23 Nm (17 ft-lb) Hexagon nut 6 Nm (4.4 ft-lb) 4.14.3.1 4.15...
Page 252: Repairing The Front Section
Removing stoppers Note Bodywork Risk of corrosion Uncontrolled water leakage Body apertures that are sealed with stoppers at • the factory must be re-sealed with the stoppers provided following disassembly or repair work. 4.15.1 Repairing the front section Safety measures The protective equipment listed must always be worn to prevent injuries caused by heat or flying parts.
Page 253 Pointed or sharp objects Caution Bodywork Risk of lacerations, puncture wounds, or cuts Wear personal protective equipment. Hot components Caution Danger of burns Let hot components cool down. Wear personal protective equipment. Voltage peaks NOTE HINWEIS Damage to the control unit ...
Page 254 Chassis jig Bodywork 4.15.1.3 The chassis jig is required to check the mounting points for dimensional accuracy and tolerance. This jig is also required to adjust and fix in position a new front chassis section before all the rivets are inserted and seated. Overview Strut brace for fixation and checking purpose, 2 x M10x35...
Page 255 Bodywork 116 mm (4.5 inch) 244.02 mm (9.6 inch) 4.15.1.5 Position mounting plate and bolt with 2 x M8x20 4.15.1.6 Bolt suspension strut mounting to the mounting plate with 3 x M8x35 4.15.1.7 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 256 This tool kit has been assembled specially for repair work on aluminum components. The tool kit must only be used on aluminum components. Bodywork Required tools by Wieländer+Schill Description Item No. Body saw WPS 2010 230V 120020 Wieländer + Schill Siederstr.
Page 257 Consumables Item No. Bodywork Solid carbide drill ø 6.7 mm 627010 3M 2K glue DP 490 (Porsche) 99991532340 Blind rivet (long) 5.0-8.5 (Porsche) 99919023001 Blind rivet (short) 3.0-6.5 (Porsche) 99907354901 Counter sunk screw 8x16 99907354901 HAZET Designation Item No. Tool trolley...
Page 258 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 259 Removing the front section Bodywork The front section (Z front section Cup) is available as spare part. 4.15.1.8 Together with the front section are consumables such as glue and blind rivets. Mark the carrier (Picture 4.15.1.9 red dot line) this reference point is required for the 4.15.1.9 later alignment of the new part.
Page 260 Body Bodywork Heat the bonded joint (2) with the hot air gun and lever the plate apart in an upwards direction using a cutting chisel. 4.15.1.11 Support the body front section in order to avoid stresses due to bending down of the front section upon sawing.
Page 261 The figure shows the saw line on the outer right side. Bodywork Cut the support frame using the power saw (saw blade 14) along the line (1). Starting from the center of the oval cut-out, the cut must be made immediately behind the two threads shown.
Page 262 Bodywork 4.15.1.17 Cut of body front section, red dashed line, do not damage support in rear area. Remove the body front section forwards with the help of another person. Use the sliding hammer with hook if necessary. Figure 4.15.1.18 shows the separated body front section from the right-hand side. Remove any unevenness, adhesive residue or weld seam residue of the support, remove remaining piece (angle plate).
Page 263 Saw template for left side Bodywork The three threaded bores (1) are used as a fixing point. 4.15.1.22 4.15.1.21 The inner reinforcement plate (2) must not be damaged when cutting. 4.15.1.23 Clamp a plate (arrow) between the support and reinforcement plate to protect the reinforcement plate (2).
Page 264 Heat the upper section (hatched) of the two carrier sheets and open with the separating chisel. Bodywork 4.15.1.26 Carry out the inner saw cut (hatched) A = outer sheet B = inner sheet 4.15.1.27 Saw the carrier upper section (1). Remove glue residues in the hatched area.
Page 265 Drill out and remove rivet nut, Figure 4.15.1.29 Bodywork 4.15.1.29 Grind off and drill through rivet points The reinforcement plate (1) must not be damaged 4.15.1.30 Remove adhesive residue from support (blue hatched area) 4.15.1.31 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 266 Remove paint at the bonding points on body front section new part Bodywork 4.15.1.32 Body front section outer side connection to support 4.15.1.33 Filler plate in the area of the spring-strut dome/body front section Angle piece connection Bonding surface 4.15.1.34 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 267 Body front section inner side Bodywork 4.15.1.35 Figure 4.15.1.36 shows the outer right side of the new part. The new part is riveted to the old support frame. Position (1) shows where the bores for the rivets should be made. 4.15.1.36 The figure shows the right support from the inside.
Page 268 Fitting the new part The required blind rivets and fixing screws can be Bodywork Information obtained from the parts catalogue. The lower cross member and the rivet points at the upper end near the spring-strut domes are used for positioning. All surfaces that are riveted or bolted must also be bonded using two-component adhesive.
Page 269 The figure (4.15.1.40 shows the right inner body front section Bodywork 4.15.1.40  4 screws: FL-KPF-SHR M8x16 torque: 15 Nm (11 ft-lb) (arrow, Figure 4.15.1.40) The figure shows the body front section on the left side Angle piece 4.15.1.41  14 short blind rivets (3,0-6,5 mm) 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 270 The figure (4.15.1.43) shows the upward view of left inner side of body front section, underside of support Bodywork An angle attachment must be used for the riveting tool in order to set the bottom rivets (Figure 4.15.1.42) 4.15.1.42 4.15.1.43 ...
Page 271 The figure shows the rear panel of the body front section from below Bodywork 4.15.1.45 4 long blind rivets (5,0-8,5 mm)  Sealing measures: Coat unpainted surfaces with primer, apply sealing compound along the plate ends. Body front section inner pan (Figure 4.15.1.46) 4.15.1.46 Front side (Figure 4.15.1.47) 4.15.1.47...
Page 272 Body front section rear side (Figure 4.15.1.48 and 4.15.1.49) Bodywork 4.15.1.48 4.15.1.49 Side view (Figure 4.15.1.50) 4.15.1.50 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 273: 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 Airborne foreign bodies during grinding, drilling and WARNING milling Risk of eye injuries...
Page 274 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 275 Consumables Item No. Bodywork Solid carbide drill ø 6.7 mm 627010 3M 2K glue DP 490 (Porsche) Blind rivet (long) 5.0-8.5 (Porsche) HAZET Designation Item No. Tool trolley 179-6-RAL 4000896148851 Door RAL 9006 179-21 4000896146246 Can holder 179-35 4000896141074 Attachable box...
Page 276 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 277 Drill the marked rivets using a solid carbide drill (Ø 6.7 mm (0.26 inches)) from behind (if accessible) until they can be knocked out using a drift punch (Ø 6.0 mm Bodywork (0.24 inches)).  Saw the defective dome using an air saw (2) ...
Page 278 Do not remove the beads on the carrier inside; they are part of the body! Debur the bore holes on both sides of the body. Bodywork Creating a drilling template Only a drilling template ensures exact positioning of the holes. Make a drilling template from the defective strut mount.
Page 279 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 280: Repairing The Rear End Protective Measures
4.15.3 Repairing the rear end Protective measures Bodywork 4.15.3.1 The protective equipment listed must always be worn to prevent injuries caused by heat or flying parts. Safety glasses   Safety shoes Protective gloves   Ear protectors Airborne foreign bodies during grinding, drilling, and WARNING milling Risk of eye injuries...
Page 281 Hot components Caution Bodywork Danger of burns Let hot components cool down. • Wear personal protective equipment. • Hot components Caution Danger of burns Let hot components cool down. • Wear personal protective equipment. • Damage evaluation: If a rear damage is repairable must be evaluated by a consultant or expert of chassis technology.
Page 282 Consumable supplies Bodywork Rear carrier 3M 2C adhesive DP 490 (1 per side) Mixing nozzle (1 per side) Blind rivet 3.0-8.5 mm (0.12-0.33 inches) (55 pieces, instead of screws) M5 Torx screw (55 pieces) Preparation for removing the rear section Remove bumpers Remove drive unit Removing the rear section...
Page 283 Installing the new part Bodywork Apply evenly two-component glue on the old bonded joints. The curing time of two- component glue is 2-3 hours at 60 °C (140 °F) The illustration shows the rivets (1) from the outside on the left. Place the new part, fit the rivets and rivet them.
Page 284: Reinforcement Plates Cast Carrier
4.15.4 Reinforcement plates cast carrier Bodywork The reinforcement plates (shown in red, Figure 4.15.4.1) of the cast carrier can be replaced in the event of damage caused as a result of the rim colliding with something. When removing the reinforcement plates, the area of the cast carrier behind the plates must be checked for damage.
Page 285: Side Panel Repair - Flange Edge Wheel Arch
4.15.5 Side panel repair – flange edge wheel arch Bodywork After repairing the side panel, a return must be bent on the panel edge of the wheel arch as well as being pulled outwards to generate sufficient clearance (see image 4.15.1 below).
Page 286: 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.
Page 287: Thread Repair Of Chassis Bolt Connections
4.16.1 Thread repair of chassis bolt connections Bodywork Airborne foreign bodies during grinding, drilling, and WARNING milling Risk of eye injuries Wear safety glasses. • Working with compressed air WARNING Risk of eye injuries Damage and dirtying of components Wear safety glasses with side eye protection. •...
Page 288 Threaded bushings without collar Bodywork 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  Time-Sert thread repair No.122-1 Item.1   Time-Sert thread repair No.122-1 Item.2 4.16.1.1 4.16.1.2...
Page 289 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 ...
Page 290 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 ...
Page 291 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) 4.16.1.12 Briefly heat the thread insert with a WE1119 hot air blower, Leister- ...
Page 292 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 293 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 294 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 II) Version: 4/20/2018 MY 2018...
Page 295 Type Basic value Threads 1 and 2 Dimension Y Length 33 mm Threads 1 and 2 Dimension X Length 5 mm Use repair kit 9843 with threaded bushings (Porsche). 4.16.1.19 4.16.1.20 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 296 Thread M6 Thread 1: 4.16.1.21 Explanation Type Basic value Thread 1 Dimension Y Length 20 mm Length 5 mm Thread 1 Dimension X Use repair kit 9843/3 with threaded bushing (Porsche). 4.16.1.22 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 297 Type Basic value Dimension Y Length 20 mm Thread 2 Dimension X 5 mm Length Thread 2 Use repair kit 9843/3 with threaded bushing (Porsche). 4.16.1.23 Thread 3: Explanation Type Basic value Length Thread 3 Dimension Y 9.4 mm Use repair kit No.122-1 Item 1 Time-Sert with short threaded bushing.
Page 298 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 299 Basic value Thread 1 Dimension Y Length 27 mm Thread 1 Dimension X Length 5 mm Use thread repair kit 9843 with threaded bushing (Porsche). 4.16.1.27 Thread 2/3: Explanation Type Basic value Thread 2 and 3 Dimension Y Length 25 mm...
Page 300 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 (Porsche). 4.16.1.29 Thread 5: Explanation Type Basic value Thread 5 Dimension Y Length 37 mm Length...
Page 301 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. 4.16.1.31 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 302 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: 4.16.1.32 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 303 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. 4.16.1.34 4.16.1.35 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 304: Installing Roof Assembly
4.17 Installing roof assembly Bodywork Preparation measure Toxic substances WARNING Poisoning or suffocation Burns to the eyes and skin Ventilate the work area well. • Never ingest or inhale. • Read specific information on the Hazard Sheet. • Do not smoke, eat, or drink in the work area. •...
Page 305 Installation: Bodywork Two people are needed in order to insert, position and Information 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 306: Interior
5 Interior Interior 5.1 General The interior design of the 911 GT3 Cup (991 II) 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 307: Drivers Safety
5.2 Drivers safety Interior The substantial occupant safety system of the 911 GT3 Cup (991 II) primarily includes the following components:  Certified safety cage with feed protection pads  FIA homologated racing bucket seat with longitudinal adjustment  Six-point safety belt connected to safety cage ...
Page 308 Use of seats and belts after an accident. DANGER Interior Not sufficient protection. Serious injury Check the seats and belts after an accident and • replace if necessary. Using Recaroseat without HANS System DANGER Serious injury Use Recaro seat only in conjunction with the •...
Page 309: Seat Rail Tightening Torques
5.2.2 Seat rail tightening torques Interior Incorrect handling of safety-relevant bolts WARNING Injuries Loss of torque Always use new fastening bolts and nuts following • removal. Observe specified tightening torques. • Carry out a visual inspection of all re-used parts. •...
Page 310: Bucket Seat Tightening Torques
5.2.3 Bucket seat tightening torques Interior Incorrect handling of safety-relevant bolts WARNING Injuries Loss of torque  Always use new fastening bolts and nuts following removal.  Observe specified tightening torques.  Carry out a visual inspection of all re-used parts.
Page 311: 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). For safety and homologation reasons only the yellow colored seat pads may be changed (Figure 5.2.4.2) The sections shown in yellow may be covered with a foamed seat insert, as long as all FIA and possible local requirements.
Page 312: Steering Wheel
5.3 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 313: Cockpit Ventilation
5.4 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 314: Electrical System
6 Electrical system Electrical system General The 911 GT3 Cup (991 II) 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 315: Battery Master Switch
6.2.3 Battery master switch Electrical system Operating the battery disconnect switch WARNING Electrical system disconnected from battery Electrical consumers turned off Engine stops Changed vehicle handling  Only operate the battery disconnect switch 6.2.3.1 in an emergency or when the vehicle is stationary 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.
Page 316: Electrical System Protection
Electrical system protection Electrical system 6.3.1 Electrical system control unit IPS32 In the 911 GT3 Cup (991 II), 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 317 Output C (low power) Electrical system mean Pin name Pin LED Consumer active if Channel Name current current switch brake light, diagnostic msa box, common supply 3 option CAN/sensor, c50 logger, option Ignition is on pcu_01_com_sply3 connector headlights left (cabin side), common supply 1 connector headlights right (cabin side), Ignition is on...
Page 318 Output B (high power) Electrical system Pin name Consumer active if mean current Channel Name current shifting Power shifting power 4 amps (Peaks Ignition is on (with delay 5 sec) 24 Amps pcu_23_shiftcmp source source up to 26 Amps) screen heating windshield heater 1, switch heatscreen is on 24 Amps...
Page 319: Fuse Holder Hydraulic Pump
6.3.2 Fuse holder hydraulic pump Electrical system A fuse holder is provided below the battery cover in the passenger foot well. The holder is equipped with an 80 A fuse and protects the hydraulic pump of the electrohydraulic steering system. DME engine electronics CAN network In addition to the sensors and actuators that are directly connected to the DME control...
Page 320: Dme Control Unit
Device programming is carried out exclusively at Porsche Motorsport. The online Error diagnosis functionality is only available for the engineers of Porsche AG. If an engine overhaul is to be performed at Porsche Motorsport, the corresponding engine control unit has to be sent with the engine.
Page 321: Dme Diagnosis
6.4.2 DME diagnosis Electrical system For Bosch component diagnosis, a separate connector is provided on the wiring harness, which is located on the B-pillar of the passenger side. This connection allows communication between the ECU and a computer using an interface cable MSA-Box II. A software tool called RaceCon is available for diagnosis.
Page 322: Error Codes
6.4.3 Error codes Electrical system Errorcodes Description E_tmot Error in engine temperature sensor E_toil Error in engine oil temperature sensor E_tx not used E_tgear Error in transmission oil temperature sensor E_tfuel Error in fuel temperature sensor E_texh not used E_texh2 not used E_tint Error in intake air temperature sensor...
Page 323 Errorcodes Description E_pclutch Error in clutch pressure sensor Electrical system E_gear_can not used E_pfuel Error fuel low press. E_pfuel2 not used E_pgear Error oil press. gearbox sensor E_brev Error reverse gear switch E_shiftcylpos Error shift cylinder position switch E_camctrl Error camshaft intake control bank1 E_opc_diff not used E_opc_dc...
Page 324: Carburation
Errorcodes Description Electrical system E_injector_cyl6 Error injector control cylinder 6 E_nvram Error in NVRAM E_ssply1 Error in sensor supply 1 E_ssply2 Error in sensor supply 2 E_ssply3 Error in sensor supply 3 E_etccal Error throttle calibration E_canmsg_dyno_0 Error CAN- communication dyno_0 E_canmsg_dyno_1 Error CAN- communication dyno_1 107 E_canmsg_dyno_2...
Page 325: Transmission
Transmission Electrical system 6.5.1 Error codes The list includes the faults transmitted by the engine control unit and provides support during troubleshooting. ICD data: bit numbers from 0-7 are displayed. Information RaceCon: bit numbers from 1-8 are displayed. gc_error Designation tcmpr - sensor icmpr - sensor prsv - sensor...
Page 326: Sensors
Sensors Electrical system Upon delivery, the following sensors are used in the vehicle: Parameter Label in the Cosworth ICD Label in Bosch Display RaceCon Engine Oil temperature Oil Temp toil Water temperature Water Temp tmot Oil pressure Oil Pressure poil Water pressure Eng Coolant Pres pwat...
Page 327: Sensor Rated Values
6.6.1 Sensor rated values Electrical system Parameter Bosch label Rated value Comment RaceCon Engine idle speed nmot 2000 +/-100 At operating temperature (oil 80 °C (176 °F) Throttle angle idle 5,8 % +/- 1,0 % Throttle angle full 100 % power Lambda cyl.
Page 328: View Online Sensor Values
6.6.2 View online sensor values Electrical system The steering-angle sensor and the brake pressure sensors can be calibrated (zeroed) using Pi Toolset. Procedure: Brake system must be pressure-free. Select the tab "Live Data" in the main toolbar. If the steering-angle sensor, accelerometers or brake pressure sensor channels are not visible, a new channel must be generated using the "+"...
Page 329 Calibrating the Accelerometer sensor Electrical system  Select the group "Accelerometers"  Zero the channel by pressing the "Zero" button 6.6.3.2 Calibrating the brake pressure sensor  Select the group "Brakes"  Zero the channel by pressing the "Zero" button 6.6.3.3 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 330 Calibrating the steering-angle sensor Electrical system  Select the group "Steering"  Zero the channel by pressing the "Zero" button 6.6.3.4 Calibrating the Suspension travel sensor  Select the group "Suspension travel"  Zero the channel by pressing the "Zero" button 6.6.3.5 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 331: Display Icd
Display ICD Electrical system 6.7.1 General information Using the ICD (Intelligent Color Display) while driving WARNING Using the ICD and changing ICD settings while driving can distract your attention from the road. You may lose control over the vehicle. The ICD may only be used while driving if the traffic situation allows you to do so safely.
Page 332 The display has five main pages that are configured in accordance with requirements. Only the following two purpose-configured pages are available while driving: Electrical system  Race  Practice Three diagnostic interfaces are additionally available when driving at below 10 km/h (6 mph). The yellow button (1) on the right-hand side of the steering wheel is used to navigate through the different pages.
Page 333 6.7.2 Race page 1 Electrical system The "Race" page configured for racing is divided into five sections. 6.7.2.1 Engine speed display The engine speed is transmitted to the display by the Bosch engine control module and shown in a range from 1,500 to 9,000 rpm. The engine speed range is divided into three zones: ...
Page 334 Permanent display of engine speed, selected gear, speed Electrical system Display Description Indicates a gear shift drum position between two gears Reverse gear Neutral Unknown value from control unit 1,2,3,4,5,6 Valid gear indications Permanent display of Fuel Level/Fuel Press (while stationary)/Fuel Used ...
Page 335: Race
6.7.4 Race page 3 Electrical system 6.7.4.1 Light and TPMS displays TPMS PM: Black background: Off Yellow background: Status not OK (e.g. sensor failure), partial monitoring only "Tyre press": Parameter information can be cycled by pressing the "Display" button on the steering wheel. Tyre pressure parameterisation is also possible via the ToolSet.
Page 336: Practice Page
6.7.5 Practice page Electrical system The relevant data for training sessions especially for qualifying sessions is configured on the "Practice" page on the display. This page has a similar structure to the "Race" page, but contains different information. 6.7.5.1 Left-hand area: Lap Time and Laps After crossing of start / finish (= laptrigger by beacon activated) the lap time of the past lap will be displayed for 30 secosnds.
Page 337 Right-hand area: Time Diff Electrical system This value calculated in "Qualifying Mode" is the time difference between the lap currently being driven and a reference lap. The top image (Figure 6.7.5.3) shows a lap 0.11 seconds faster than the reference lap.
Page 338: Warmup Page
6.7.6 Warmup page Electrical system The "Warmup" page (Figure 6.7.6.1) shows the engine speed, water temperature, and oil temperature in an enlarged display. This means that the values can also be seen from outside the vehicle. 6.7.6.1 Engine speed display The engine speed range for engine warm-up is shown using a smaller scale.
Page 339: Vitals Page
6.7.7 Vitals page Electrical system The "Vitals" page (Figure 6.7.7.1) provides an overview of the vital functions of the engine and vehicle. All the important channels are shown on one page here. The views and values are fixed on this page and cannot be changed. 6.7.7.1 The "Vitals"...
Page 340 Engine speed display Electrical system  0 – 3,500 rpm Green:  4,000 – 5,000 rpm Orange: Fuel display Display Channel designation Resolution Unit Value range Tank Level dash_fuellevel_filt liters 0 to 110 (0 to 116.2 quarts) Fuel Press ecu_pfuel 0 to 10 (0 to 145 psi) Rail Press ecu_prail...
Page 341: Control Page
6.7.8 Control page Electrical system 6.7.8.1 The "Control" page (Figure 6.7.8.1) of the display shows all the important information about the pedals and steering wheel. This means that the brake pressures as well as the position/function of the gas pedal and the electronic throttle valve can be checked. Fixed overview of various vehicle systems.
Page 342 Clutch Electrical system Display Channel Resolution Unit Value range Description designation Clutch ecu_pclutch 0.01 0 to 100 (0 100 bar Pressure to 1,450 psi) (1,450 psi) sensor Throttle Display Channel Resolution Unit Value Description designation range ecu_aps 0 to 110 Gas pedal position ecu_athcan...
Page 343: Chassis Page
6.7.9 Chassis page Electrical system 6.7.9.2 6.7.9.1 Setting the setpoint pressures for the TPMS: The tyre manufacturer's specifications must be NOTE HINWEIS observed! 6.7.9.1 Preset value 1.9 bar (27.6 psi) (for front axle and Information rear axle) Select "Setups" in the ToolSet Select "Lookup Tables"...
Page 344 TPMS alarms Electrical system Flat tire alarm: The symbol in the overlay additionally shows which tire is flat. Conditions: pressure drop of 0.7 bar/min (Figure 6.7.9.5) Slow puncture alarm: The symbol in the overlay additional shows which tire has a slow puncture. 6.7.9.5 Conditions: pressure drop of 0.3 bar/min (Figure 6.7.9.6) The sensor detects at a frequency of 0.33 Hz.
Page 345 Electrical system TPMS Overlays: Display Channel designation Resolution Unit Value range Description FL Speed dash_speed_fl 0 to 500 (0 to 311 Front left wheel speed miles) FL TPMS Press TPMS_press_FL 0 to 6.3 (0 to 27.6 Front left tire pressure psi) RL Speed dash_speed_rl...
Page 346 Information overlays Electrical system Additional information of increased information during driving are shown for a short time, superimposed over the other values. Brake Bias Adjustment of the brake force WARNING Different braking behavior Loss of control over the vehicle Adjust the setting to the weather conditions Adjust the settings to the vehicle setup Exercise care when testing the new setting.
Page 347: Pit Speed
6.7.10 Pit Speed Electrical system "Pit Speed" mode is activated via an orange button (1) on the steering wheel (Figure 6.7.10.1). Activation is only possible above a vehicle speed of 10 km/h (6 mph). There are two kinds of pit speed display: The green background is shown as long as the speed of 60 km/h (37 mph) is not exceeded (Figure 6.7.10.2).
Page 348: Alarm Displays
6.7.11 Alarm displays Shiftlights Electrical system Alarmlights R Alarmlights L Overlay 6.7.11.1 Page Alarm Bar Every alarm message can be manually deleted. The Information alarm message may appear on the display again if the Error is not sporadic and remains active. Priorität Alarm name Chanal...
Page 349 Electrical system Alarm Name Kanal Bedingungen Anzeige Camshaft control Dash_alarm_cam Dash_alarm_cam_ctrl >0.0 Bar: ALARM No Cam ctrl [camshaft control not enabled] Alarmlight: L4+R4 lights up red Overlay: REFILL OIL [value] Min. oil level alarm_oillvl_low2 alarm_oillvl_low = triggered ecu_oillevel ecu_oillevel <10% Bar: WARN Oil level <min [idle speed and toil >80°C (176°F) or pit speed active and toil>80%]]...
Page 350 Electrical system Alarm Name Kanal Bedingungen Anzeige Starter dash_alarm_startbtn dash_alarm_startbtn > 0.0 Bar: ERROR Starter Alarmlight: L3 lights up yellow DME Error ecu_B_mildiag ecu_B_mildiag > 0.0 Bar: ALARM ECU mildiag [when engine is off] Alarmlight: L3 lights up yellow Ignition switched on dash_cond_ign_ch dash_cond_ign_ch >...
Page 351 Electrical system 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 352 Locking warning Electrical system This function is designed to help the driver prevent an unnecessary load and damage due to unwanted locking of the front and rear wheels. A flashing LED on the display indicates a risk of the front or rear wheels locking. If the front brake pressure is at least 10 bar (145 psi) and the speed of the left front wheel is more than 20 km/h (12 mph) below that of the left rear wheel, the top left warning lights come on (Figure 6.7.11.2).
Page 353: Trackmap Page
6.7.12 Trackmap page Electrical system 6.7.12.1 Files in bmp format with a resolution of 800x480 can be uploaded on this page, for example to show the track layout. 6.7.13 Diagnose page The Diagnose page provides a quick overview of the alarms or Error entries that occurred while driving.
Page 354 Example: Vehicle leaves the pit. An ALARM Fuel Press occurs during the outing. This Error is then Electrical system displayed on Diagnose page 1. All other Errors are grayed out on Diagnose page 1. Diagnose pages 2 to 4 are not displayed. Diagnose page 1: 6.7.13.1 Diagnose page 2:...
Page 355: Position Of Balance Bar
Diagnose page 3: Electrical system 6.7.13.3 Diagnose page 4: 6.7.13.4 6.7.14 Position of balance bar To check the position of the balance bar, the brake pedal must be pressed for more than 3 seconds (pressure > 35 bar). Conditions: Main switch on, ignition on. The overlay is displayed for 10 seconds in the display (Figure 6.7.14.1).
Page 356: Lights
Lights Electrical system The 911 GT3 Cup (991 II) 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 357: 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: 6.9.1 6.9.2 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 358 CAN ID Electrical system The following table shows the CAN ID´s, respective channel names and properties which are necessary to program any external data device. The connection of the devices is made through connector "option CAN", pin layout see chapter 6.10. All Endianness are in Intel. Name Startbit Length [Bit]...
Page 359: Wiring Harness
Wiring harness Electrical system For the 911 GT3 Cup (991 II), a wiring harness that runs along the center tunnel from the front to the back has been specially developed for racing use. The cable ends of the main wiring harness are labeled and color-coded; a white marking indicates a plug The wiring harness is separated as follows: connection that is mated as standard, a blue marking indicates an optional plug connection.
Page 360 Electrical system Plug type on the wiring Pos. Connection designation harness Corr. mating connector Pin assignment/max. current 1. +12V/0,5A 2. GND 3. nc 4. nc option 3 DTM 06-8 SA DTM 04-8 PA 5. nc 6. nc 7. CAN 4 high 8.
Page 361: Ground Connection Roof Antenna
Electrical system Plug type on the wiring Item Connection designation harness Corr. mating connector Pin assignment/max. current sig USB D- +5V USB Bosch C50 USB logger DTM 06-4 S DTM 04-4 P GND USB sid USB D+ +12V option cockpit light DTM 06-2 S DTM 04-2 P DTM 06-3 S...
Page 362: Fire Extinguisher
Fire extinguisher Electrical system Activation of the gas fire extinguishing system DANGER Risk of suffocation  Exit the vehicle without delay after the fire extinguishing system is activated. Loss of consciousness can occur in under 1 minute. Loss of consciousness in an atmosphere filled with extinguishing gas can result in death by suffocation.
Page 363: Testing The Trigger Switch
Extinguishing nozzle positions Electrical system Driver‘s footwell Interior B-pillar top Engine compartment front middle Engine compartment rear left/right 6.12.4 6.12.1 Testing the trigger switch The switch test is performed on the fire extinguishing system control unit (Figure 6.12.1.1). Always follow the steps below to prevent unintended triggering of the system.
Page 364: Battery Change
6.12.2 Battery change Electrical system The battery is located behind a cover in the control unit (1). It is a 9 V block battery. Turn off the system when changing the batter. 6.12.2.1 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 365: Driver Control Systems
Driver Control Systems Electrical system 6.13.1 Steering wheel The most important functions can be comfortably carried out with the press of a button directly from the steering wheel. 6.13.1.2 6.13.1.1 The steering wheel is attached to the steering column by means of a quick release coupling.
Page 366: Center Console
Preselection downshift (Shiftomat) Electrical system There is a function included in the ECU, which preselects up to 3 downshifts by pulling the downshift paddle (SHIFTOMAT). The preselection is only active during coast / breaking, during normal race operating conditions (no clutch actuation) and no gearbox errors are active.
Page 367: Interior Fan Switch
6.13.3 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 (Figure 6.13.3.1). The wiper motor has two stages: slow and fast. Switching logic: Press once short: one time wiping Press once longer 1.5 second: continuity wiping...
Page 368: Maintenance
7 Maintenance Maintenance 7.1 Engine 7.1.1 Oil level measurement The oil level is determined electronically by means of a level sensor in the oil tank. The oil level can be read off in two ways: 1. Via the dashboard display 2.
Page 369 Maintenance ≈ 60 sec. 7.1.1.1 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 370: Oil Level Measurement With Display (Optional)
Conditions for a correct measurement:  Filling port for oil must be closed! Maintenance  The vehicle must be on a flat, level surface (Figure 7.1.1.2)  Engine at operating temperature, oil temperature 80°C /176°F (“eco_toil” <80°C/176°F)  Oil measurement requires ~120 sec. transient adjustment (Figure 7.1.1.1) ...
Page 371: Changing Engine Oil
7.1.3 Changing engine oil Maintenance Hot fluid WARNING Danger of scalding  Avoid contact with hot fluid.  Wear personal protective equipment. Run the engine until the oil temperature has reached 80°C (176°F) and then switch it off 7.1.3.1 Open the cover of the filler neck ...
Page 372: Refilling Engine Oil
7.1.4 Refilling engine oil Maintenance Improper adding of engine oil NOTE Risk of damage to the engine Engine oil must not be added when the engine is • running. The engine must be stopped before adding • engine oil.  New engine: 9.5 liters (10 qts) ...
Page 373: Engine Cooling System
7.1.6 Engine cooling system Maintenance Periodically remove dirt from the radiators and carry out a visual inspection for damage. support races Formula Information Worldchampionship, the coolant is to be substituted as described below: approx. 20 liters (21.1 qt) of water plus min.
Page 374 Filling the cooling system Maintenance Hot fluid WARNING Danger of scalding  Let the fluid cool down.  Wear personal protective equipment. Corrosive fluids WARNING Danger of chemical burns • Wear personal protective equipment. • Ensure good ventilation. • Avoid contact with corrosive fluid. •...
Page 375 A special filling device should be used for filling the water system (7.1.6.2). This device is distributed by Sobek. The filling device includes an electric pump that pumps the Maintenance cooling water from a tank into the system. Never open the cover of the coolant compensating Information tank after reaching the operating temperature.
Page 376 Checking the coolant level Maintenance As far as possible, only open the cap of the expansion tank when the engine is cold (arrow in Figure 7.1.6.3). If the system is opened when the engine is at operating temperature, air can get in and impair the function. Behind the cap is a filler gauge that shows the fluid level (Figure 7.1.6.4).
Page 377: Engine Tightening Torques
7.1.7 Engine tightening torques Maintenance Screw Tightening torque [Nm (ft- Component dimension lb)] Engine Retaining bracket at central oil supply line M6x16 13 Nm (9.6 ft-lb) 20 Nm (14.8 ft-lb) +90° Pulley on crankshaft M8x1.25 crossed Pulley on alternator 55 Nm (40.6 ft-lb) Oil filter 1"-12 UNF 20 Nm (14.8 ft-lb)
Page 378: Engine Runtime
Final 33 Nm (24.4 ft-lb) 7.1.8 Engine runtime Engine speed of 8,500 rpm exceeded NOTE Serious damage to the engine Porsche warranty voided Do not exceed an engine speed of 8,500 rpm. • Component Running time Stop-choc elements of the exhaust system (see 1.9)
Page 379: Fuel System
Engine damage  The ethanol content of the fuel must not exceed 20% (E20). 7.2.1.1 Check fuel lines Porsche Motorsport recommends inspecting all fuel Information line adapter fittings (Figure 7.2.1.1.1/red circles before the next operation of the aforementioned vehicle. 7.2.1.1.1...
Page 380 If a leaking connection is identified during the inspection, then this connection must be tightened in accordance with the instruction below: Maintenance 7.2.1.1.2 Remove all foreign object debris and thoroughly clean both ends of the connectors and their threaded sections (1). 7.2.1.1.3 Apply motor oil to the threaded section of the adapter.
Page 381: Fuel Extraction
7.2.2 Fuel extraction Maintenance Highly flammable or explosive substances WARNING Fire or explosion  Before draining the tank, make sure to attach an earthed ground terminal to the body.  Avoid contact with hot parts or sources of ignition.  Use suction to remove ignitable vapors.
Page 382 Switching logic of the fuel pump switches (center console): Maintenance Switch position Defueling position/manual activation Switch position center Switch position down Normal operation Auxiliary material: Fuel extraction hose Drainage process WARNING Danger of chemical burns  Make sure that the hose fitting is securely seated.
Page 383: Power Transmission
7.3 Power transmission Maintenance 7.3.1 Gearbox The running time is 60 hours. Running time cross shaft 30 hours Transmission oil fill quantity Hot fluid WARNING Danger of scalding Let the fluid cool down.   Wear personal protective equipment. For a rebuild, the fill quantity is 3 liters (3.2 qt). Filling: 7.3.1.1 ...
Page 384 For any maintenance work, the following items should be respected: Gearbox mounted neck Maintenance 7.3.1.1.1  Light wear Neck ca be used further with regular inspections.  7.3.1.1.2  Excessive wear  Neck and the chassis side quick release couplings must be replaced 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 385 Chassis mounted quick release couplings Maintenance 7.3.1.1.3  Light contamination Quick release coupling can be used further but requires regular inspection  7.3.1.1.4 Excessive contamination   Quick release coupling should be cleaned as described below Please ensure that the car-side quick release Information coupling is always clean and free of dirt, and if necessary the coupling should be lubricated with...
Page 386: 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 387 Clutch actuation Maintenance Racing Brake Fluid-325° from Performance Friction Brakes is used as clutch fluid. Porsche recommends bleeding the system after each practice and changing the fluid after each race. Fill quantity: approx. 500 ml (17 oz)  Bleeding procedure:...
Page 388 Central release mechanism Maintenance Central clutch release lever seal NOTE Damage to the central clutch release lever Loss of clutch function  Do not allow the seal to come into contact with engine oil or transmission oil.  The seal must only be fitted using the special tool from Sachs.
Page 389: Paddle Shift
7.3.3 Paddle shift Maintenance The maintenance includes the compressor, the valve block and the shift cylinder. Small Service:  Once p.a.  Max. 10.000 km  Max. 10 h compressor run time Big Service:  Every two years  Max 20.000 km ...
Page 390 Handling Mega-Line components Maintenance Mega-Line components NOTE Failure of the circuit Oils and lubricants must not get into the  compressed air system. The system is designed for unlubricated operation.  Cover all open air lines/device adapters immediately after dismounting to protect from contamination Don`t crush air filter on valve block outlets (air flow reduction) ...
Page 391: Drive Shafts
7.3.4 Drive shafts Maintenance It is recommended breaking in drive shafts on new vehicles or newly fitted drive shafts for about 50 km (31 miles) with reduced load and at max. 200 km/h (124 mph). The load on the drive shaft should be continuously increased, this helps to prolong the lifetime of the joints.
Page 392: Chassis
WARNING Loss of wheels Loss of control over the vehicle  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 nut.
Page 393: Locking Piece
7.4.2 Locking piece Maintenance 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: Optimol Paste HAT The locking mechanism may be removed from the hub for maintenance and cleaning. Proceed as follows: Press the locking pieces into the hub (blue arrow) ...
Page 394: 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 395: Brake System
7.4.6 Brake system Maintenance Brake pad wear limit: Removing brake piston NOTE Damage of piston seal Clean the piston before they move back  The wear limit is reached when the pad has been worn down to the bottom of the slot (7.4.6.1).
Page 396 Extending the brake piston Caution Maintenance Risk of crush injuries  Do not insert fingers between the brake pistons.  Press the brake piston outwards with low air pressure  Completely pull the brake pistons out of the caliper by hand Clean all components and remove any dirt (brake dust) ...
Page 397 Brake fluid Maintenance Corrosive fluids WARNING Danger of chemical burns Wear personal protective equipment. • Ensure good ventilation. • Avoid contact with corrosive fluid. • If you do come into contact, wash off immediately • with plenty of warm water and contact a doctor if necessary.
Page 398: Remodeling/Maintenance Main Brake Cylinder
7.4.8 Remodeling/Maintenance Main brake cylinder Maintenance Failure of the brake system WARNING Loss of control of the vehicle Particular care must be taken when working on • the brake system Ensure that the components are correctly fitted • Cleaning the brake system NOTE Damage to the piston seal and reservoir.
Page 399 Removing: Maintenance 7.4.8.1  Remove the bellows from the seat  Lightly press the pushrod and remove the circlip  Remove the pushrod and spacer (Fig. 7.4.8.1) 7.4.8.2  Remove the brake piston (Fig. 7.4.8.2) 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 400 Maintenance 7.4.8.3 Components must not be interchanged with parts Information from other brake master cylinders.  Remove brake piston, spring and guide pin (Fig. 7.4.8.3) 7.4.8.4 Perform all work on the seals using new gloves. Information  Remove the main seal and piston ring in the specified sequence (Fig. 7.4.8.4) 7.4.8.5 ...
Page 401 Assembly preparation: Maintenance As described in the manufacturer's warning Information instructions, (Fig. 7.4.8.6), all metallic repair kit components must be cleaned using soapy water or alcohol-based cleaning agent. All repair kit seals must be cleaned with brake fluid. Assembly: 7.4.8.6 7.4.8.7 Fit the seals from the end marked by the arrow with the contour opening ...
Page 402 Maintenance 7.4.8.9 Check the housing (1) for contamination and sharp edges   Position the guide pin and spring (2) centrally  Install the piston with seals (3) without folding back the seals (Fig. 7.4.8.9) 7.4.8.10 Do not close off the supply bore when assembling ...
Page 403 Maintenance 7.4.8.11  new circlip Use a Lightly press down the pushrod and fit the circlip (Fig. 7.4.8.11)  7.4.8.12  Check that the circlip is correctly seated (Fig. 7.4.8.12) The copper sealing rings for the distributor must be Information replaced before assembly.
Page 404: Shock Absorber/Spring
7.4.9 Shock absorber/spring Maintenance Clean the shock absorber/spring unit after each practice or race and carry out a visual inspection for damage and leaks. 7.4.10 Anti-roll bar Check all moving components for free movement. Check the bearings of the anti-roll bar connection and suspension for inadmissible play.
Page 405: Steering System
7.4.11 Steering system Maintenance Reservoir capacity: 0.65 liter (0.7 qt) Bleeding the steering system Hydraulic pump running dry NOTE Damage to the hydraulic pump The reservoir must always be filled. • 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.
Page 406 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. 7.4.11.1 The picture (7.4.10.2) shows the open quick release coupling (coupling ring pulled out). Clean and grease the lateral sliding surfaces.
Page 407: Body
Risk of crush injuries  The system must be depressurized before working on it 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 7.5.1.1...
Page 408: Maintenance Intervals
7.7 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 409: 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))  Clean/replace air filter Change brake fluid  Check balance beam setting ...
Page 410: Special Tools 911 Gt3 Cup
Runtime Maintenance Designation Runtime in hours Overhauling gearbox Cross shaft Overhauling engine Stop-Choc elements exhaust system Master brake cylinder Seal ring brake caliper 60 (if necessary earlier) Drive shaft 20 standing starts/30 endurance Steering gear 7.8 Special tools 911 GT3 Cup (991) Designation Company Part number...
Page 411 Designation Company Part number Maintenance Fork ring wrench ¼“ Brake nipple Hazet Polygon head socket ¼“ Brake disk Hazet chamber Unlock plier T40024 Brake pedal Matra T40024 linkage Hook wrench Shocks Sachs 00 1795 000 149 Hook wrench Shocks Sachs 00 1795 00 150 Exterior car body Air jack lock, front axle...
Page 412: Partner Contacts
7.9 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 413 Twentypence Road (Cottenham) Cambridge CB24 8PS - United Kingdom 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.
Page 414: After Sales
8. After Sales After Sales Aftersale The After Sales chapter contains information on all the accessories offered by Porsche Motorsport for the vehicle. 8.1 Engine oil rapid filling system The engine oil rapid filling system allows engine oil to be refilled with the rear lid closed.
Page 415  Remove rear lid After Sales Aftersale Aftersale  Attach template to the inside of the lid (Figure 8.1.2), making sure that the contour of the template and lid are flush You can find the templates in chapter 8.1.1 or Information contact your technical customer support.
Page 416  torque: 35 Nm (26 ft-lb)  Check system for leaks Porsche Motorsport recommends sealing the Information opening in the rear lid with helitape to prevent foreign bodies and water entering the engine compartment through the opening. This also improves aerodynamics.
Page 417: Templates
8.1.1 Templates After Sales Aftersale Aftersale Rear lid from above 8.1.1.1 Rear lid from below 8.1.1.2 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 418: Led Oil Level Display
8.2 LED oil level display After Sales Aftersale The oil level display is screwed onto the body via a holder behind the rear side window (Figure 8.2.2). The plug connection to the main wiring harness is located on the right B-pillar 8.2.1 8.2.2 Display logic of the LEDs:...
Page 419: Safety Nets
8.3 Safety Nets After Sales Aftersale Aftersale Incorrectly installed safety nets WARNING Vision impeded The driver must be positioned in the seat so  that the eye line is in the corridor – see image 8.3.1. The eye line of every driver must be marked on the head rest! When viewed from the side, the upper net ...
Page 420 Loose safety net WARNING After Sales Aftersale Head or neck injury The net must be tensioned in such a way that when a force of 50 N, which originates laterally from the driver, is applied at every point on the longitudinally running straps, the net deforms less than 50 mm.
Page 421 After completing the installation, the team is Information After Sales responsible to ensure that the installation complies Aftersale Aftersale with the FIA ‘Racing Nets Installation Specification’! Installation Safety Net (outer net / driver’s door net) Remove the cage padding to position the strap mounting (for upper strap ...
Page 422 Installation Outer Net After Sales Aftersale Unintentional release of safety net WARNING Release by foreign objects  Push button for outer net must point upwards (image 8.3.9) 8.3.9 Insert “1” into “2” until the mechanism engages Screw the nut “4” to the end stop on the outer thread Screw “2”...
Page 423 Mounting points for the three rear straps on the roll-cage After Sales Aftersale Aftersale Pay attention that the straps are correctly inserted into the adjuster brackets and the distance to the roll-cage tube! Loop length 8.3.11 Loop length upper <125mm Loop length middle <100mm Loop length lower <125mm 8.3.10...
Page 424 Adjusting the Outer Net After Sales Aftersale Adjust the net based on the angle as well as in relation to head and shoulder support on the seat. In doing so, the net must rest on the side of the seat and the net must remain tensioned or be re-tensioned.
Page 425 Installation Inner Net After Sales Aftersale Aftersale  Unclip and remove the dashboard cover (image 8.3.16), the red arrows indicate the mounting points  Mark the trim line (image 8.3.15 arrows) and remove the stay pos. 1 8.3.15  Mount the forward strap onto the chassis (image 8.3.17) 8.3.16 ...
Page 426 Loop length upper <100mm Loop length After Sales Aftersale Loop length middle <100mm Loop length lower <125mm 8.3.21 Adjusting Inner Net The car must be positioned on a level surface. The net must be secured in the positions shown in image 8.3.21. Adjust the net based on the angle as well as in relation to head and shoulder support on the seat.
Page 427 Trimming the Roll-Cage Padding After Sales By fitting the bracket for the upper strap of the inner net, the roll-cage padding must Aftersale Aftersale be trimmed at this position. Refer to the dimensions in image 8.3.23. Two cable ties are also required. 27 mm 8.3.24 18 mm...
Page 428: Endurance Tank
8.4 Endurance tank After Sales Aftersale Since there is different vehicle build statuses, the required parts must be ordered individually on the basis of a list. Flammable or explosive materials WARNING Fire or explosion Avoid contact with hot parts or sources ...
Page 429 Preliminary work: After Sales Aftersale Aftersale System must be de-energized • Flammable or explosive materials WARNING Fire or explosion  When filling and emptying the tank, establish equipotential bonding between the vehicle and fuel installation  Carry out vehicle-side equipotential bonding via hood pin (arrow, Figure 8.4.1) Drain tank 8.4.1...
Page 430 Installing in-tank pumps After Sales Aftersale  Fix in-tank pumps and filter with cable ties  Connect fuel lines Connect wiring harness to in-tank pumps  RR carry-over Direction of travel 8.4.2 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 431 Pre-assembly of pump module, 8 bar (116 psi) After Sales Aftersale Aftersale  Mount suction line with filter (pay attention to installation position!) and angle piece on pump unit Filter Angle piece Suction line 8.4.3  Mount retaining plate on pump module with black screws + washers (arrows, Figure 8.4.4) ...
Page 432 Pre-assembly of catch tank After Sales Aftersale  Mount 4 check valves on 7 l catch tank using supplied sealing ring Direction of travel 8.4.5 Mount level sensor with seal and screws M5 x 16  Mounting return line union ...
Page 433  Mount valve plate with supplied screws After Sales Aftersale Aftersale  Screw sealing cap into thread (arrow) 8.4.7 Assembly/tank foam part  Foam part set, complete  Insert foam block no. 1 on right 8.4.8 Direction of travel 8.4.9 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 434  Insert foam block no. 2 on right After Sales Aftersale Direction of travel 8.4.11 8.4.10  Insert foam block no. 3 on right 8.4.12 Direction of travel 8.4.13 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 435  Insert foam block no. 4 on right After Sales Aftersale Aftersale 8.4.14 Direction of travel 8.4.15 Insert foam block no. 5 on right  8.4.16 Direction of travel 8.4.17 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 436  Insert foam block no. 6 on right After Sales Aftersale Direction of travel 8.4.19 8.4.18  Put pre-assembled catch tank into position and fix at 4 tabs Plug fuel return line onto union (arrow)  Direction of travel 8.4.20 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 437 Connect the fuel lines (green) of the in-tank pumps to the catch tank as  After Sales shown in the graphic Aftersale Aftersale 8.4.21 8.4.22 Connection of main pumps  Put pump unit into position and secure at the three mounting points ...
Page 438  Insert foam block no. 7 on right After Sales Aftersale 8.4.24 Direction of travel 8.4.25  Insert foam block no. 8 on right 8.4.26 Direction of travel 8.4.27 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 439  Insert foam block no. 9 on right After Sales Aftersale Aftersale 8.4.28 Direction of travel 8.4.29 Insert foam block no. 10 on right  8.4.30 Direction of travel 8.4.31 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 440  Insert foam block no. 11 on right After Sales Aftersale 8.4.32 Direction of travel 8.4.33  Insert foam block no. 12 on right 8.4.34 Direction of travel 8.4.35 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 441  Insert foam block no. 13 on right After Sales Aftersale Aftersale 8.4.36 8.4.37 Direction of travel Tank plate assembly  Mount roll-over valve (carry-over part) on tank plate 991.201.317.9B with O-ring 13x2 (999.707.146.40); the O-ring is not a carry-over part! ...
Page 442 Mount retaining plate 991.201.573.8B for fuel pressure regulator, screws  M5 x 12 After Sales Aftersale Union D06 M12x1.5 • O-ring 9x2 • O-ring 7x2 • Drain coupling • Direction of travel 8.4.39  Assembly kit includes: Hexagon socket screw M6x16 O-ring 120x2 ...
Page 443 Connect the fuel return and flow lines to the tank plate After Sales  Connect wiring harness to tank plate Aftersale Aftersale  Screw tank plate together with seal, screws are carry-over parts M5x16 (26 ea.) Direction of travel 8.4.41 Pre-assembly of fuel pressure regulator ...
Page 444  Insert circlip in housing (arrow) After Sales Aftersale  The vacuum connection on the pressure regulator must face in the direction of the cut-off valve; no vacuum hose is connected! 8.4.43 Tank plate connection layout ROV valve Return line Wiring harness connection Cut off valve Supply line to rail...
Page 445: Tank Opening In Front Lid
8.4.1 8.4.1 Tank opening in front lid After Sales Aftersale Aftersale Flying foreign bodies during grinding, drilling, and milling WARNING Risk of eye injuries  Wear safety glasses. Pointed or sharp objects Caution Risk of lacerations, puncture injuries or cuts ...
Page 446  Remove cathodic dip coating on the outer skin from inside at the bonding surface (Figure 8.4.1.2) After Sales Aftersale  Roughen/grind bonding surface at carbon ring with air grinder Apply adhesive bead to carbon ring (Figure 8.4.1.3), adhesive: DP 490 ...
Page 447: Fuel Draining System
8.4.2 Fuel draining system After Sales Aftersale Porsche Motorsport offers a gas-tight fuel draining and filling system for the FT3 tank. Aftersale It consists of two quick-action couplings which are mounted on the tank plate and of corresponding in-tank tubes.
Page 448 Preliminary work After Sales Aftersale Flammable or explosive substances WARNING Fire or explosion Avoid contact with hot parts or sources of • ignition. Collect flammable fumes. • Place the warning sign in a clearly visible position. • Corrosive liquids WARNING Acid burns Wear protective equipment.
Page 449 Removing tank plate After Sales Aftersale Aftersale Rotating foreign bodies during grinding, drilling and WARNING milling Eye injuries Wear safety glasses. • Sharp or sharp-edged objects Caution Crack-, stitch- or cuts injury Wear protective equipment. •  2 Drill the passages for the couplings, Ø 19.2 mm (arrows Figure 8.4.2.2) Use the drilling template! ...
Page 450 Assembly of couplings / hose After Sales Aftersale  The assembly is carried out as shown in the following diagram:  Pos. 2 Sealing ring, pos. 3 Washer  Torque Pos. 1 (5): 34 Nm 8.4.2.4 Torque table (Figure 8.4.2.5) 8.4.2.5 Component/Position Dimension...
Page 451 Installation from the hose After Sales Aftersale Aftersale  Screw the hose with the clamp to the Catchtank, torque: 9 Nm To insert the hose into the tank, some foam blocks Information must be removed from the tank. The installation of the removed components takes place in the reverse order. Leaking fuel-carrying pipes WARNING Leaking fuel...
Page 452: Taxi Seat
8.5 Taxi seat After Sales Aftersale 8.5.1 8.5.1 Chassis preparation for console fixation Risk of damage to the threads. NOTE Make sure the self-tapping drill screws are  proper centered and aligned! 8.5.1.1 It´s necessary to install threads into the four console fixation points on the ...
Page 453 After Sales Aftersale Aftersale 8.5.1.2 Leave some gap between the screw head and the mounting surface.  High torques Caution Risk of injury from flying metal spurs Use safety glasses and gloves to prevent injuries. 8.5.1.3  Insert the self-tapping drill screw into the console fixation holes in the chassis. The screw will align itself due to the tip guiding „pin“.
Page 454: Fixation Six-Point Safety Belt
8.5.2 8.5.2 Fixation six-point safety belt After Sales Severe injuries or death may occur Aftersale WARNING Risk of injury due to failure of the screws Always tighten bolts with the proper torque. • Improperly tightened bolts may loosen during harness belt use and may become separated during a crash.
Page 455 After Sales Aftersale Aftersale 8.5.2.2 Mount the side straps with screws and associated sleeves. The straps need  to remain moveable on the sleeve. Torque: 50 Nm 8.5.2.3  The crotch straps have to be mounted as shown in the picture below. Torque: 50 Nm 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 456: Assembling The Footwell Cover
Severe injuries or death may occur WARNING Verletzungsgefahr durch falsche Montage After Sales Aftersale Incorrect wrapping or 3-bar slides wrapped  too far away from the roll cage bar or from any bracket may allow webbing to slide during an accident 8.5.2.4 Mount the shoulder straps in the same way as the shoulder straps of the ...
Page 457: Repositioning Vehicle Electrical System Control Unit (Ips)
8.5.4 8.5.4 Repositioning vehicle electrical system control unit (IPS) After Sales Aftersale Aftersale Parts will be used again after removal of  Information passenger seat 8.5.4.1  Remove the four fixation „K-nuts M4“ from the IPS.  Remove the damping elements and store the dismantled parts. 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 458 Risk of damage to the wiring harness. NOTE After Sales Aftersale Be careful when cutting / removing the  cable tie and bracket. Don´t cut the cable loom.  Damage of the loom can cause malfunction  of the whole car electronics! 8.5.4.2 Remove the cable tie on the wiring harness behind the battery cover.
Page 459: Position The Seat Bracket At The Rear Position
Risk of damage to the IPS. NOTE After Sales Aftersale Aftersale A proper IPS fixation has to be ensured to  prevent damage during car operation. A loose ECU may cause malfunction of the  whole car electronics! 8.5.4.3  Mount the harness to the top fixation point of the battery cover using the rubberized clamp and TORX screw.
Page 460: Installing The Seat Shell
After Sales Aftersale 8.5.5.2 Screw the seat bracket to the body with the TORX screws, 50 Nm (37 ft-lb).  Remove the transport strut after screwing the seat bracket into position, Item  8.5.6 8.5.6 Installing the seat shell 8.5.6.1 ...
Page 461 After Sales Aftersale Aftersale 8.5.6.2  Guide the safety harness through the designated holes in the seat while positioning the seat on the console.  Slightly tighten the four rear screws M8X25 of the seat fixation by hand.  Remove the rear installation aid pins. 911 GT3 Cup (991 II) Version: 4/20/2018 MY 2018...
Page 462 After Sales Aftersale 8.5.6.3  Slightly tighten the four front screws M10X20 of the seat fixation by hand.  All screws must be tighten to their designated tightening torque values. Note list beside!  Seat screw front: 23 ± 2 Nm ...
Page 463 After Sales Aftersale Aftersale Roll Cage 8.5.6.4 Feed in the crotch belt and lap belts through the seat openings  Feed in the upper belts through the upper seat openings  Attach belts to cage by means of D-ring as in the instructions ...
Page 464: Using The Passenger Seat
8.5.7 8.5.7 Using the passenger seat After Sales Aftersale Use of the Recaro seat without HANS system DANGER Serious injury  Use the Recaro seat only in combination with the HANS system. Route shoulder belts behind the seat diagonally to the front. ...
Page 465: Fitting The Base Plate And Additional Weights
8.6 Fitting the base plate and additional weights After Sales Aftersale Aftersale 8.6.1 Preparation of the bodyshell for the base plate and additional weights Risk of damage to the threads NOTE Make sure the self-tapping drill screws are  proper centered and aligned! The following work must only be performed if no taxi Information seat was previously installed...
Page 466 Risk of damage to the threads NOTE After Sales Aftersale The impact wrench should only be used for  the thread creation. As soon as the self-tapping drill screw  created the thread, the screw should remove again from the bush. 8.6.1.2 Leave some gap between the screw head and the mounting surface.
Page 467: Fitting The Base Plate And Weights
8.6.2 Fitting the base plate and weights After Sales Aftersale The base plate and additional weights are Aftersale  Information made of steel. Maximum permissible load increase 108  8.6.2.1 5x retaining nuts 6KT-MU M12x1.5. Torque: 85 Nm (Do not grease) 5x retaining nuts 6KT-MU M12x1.5.
Page 468: Heated Windshield
8.7 Heated windshield After Sales Aftersale Secure ribbon cable at the A-pillar using helitape. The plug connection to the main wiring harness is located in the right footwell under the heater box (arrow, Figure 8.7.1), label: windshield heater 1 Reference to window assembly/wiring harness labeling 8.7.1 8.7.2 ...
Page 469: Power Box
Aftersale Power box Porsche offers a power box (Figure 8.8.1) in order to permit operation of additional consumers in the vehicle. The power box is connected to the free voltage supply XX Option Powervia a DT04-2P connector. A maximum of two power boxes can be connected per vehicle.
Page 470: Cockpit Light
8.9 Cockpit light After Sales Aftersale The switch labeling in the center console is fluorescent. This means that the labeling lights up in darkness when illuminated by the cockpit light. The cockpit light is switched with the low beam headlamps. The roof bonding surface must be grease-free.
Page 471: Race Number Lighting
8.10 Race number lighting After Sales Aftersale Aftersale The race number lighting is realized by fluorescent films which are secured on the doors. The system includes a control unit per film which is located in the respective door. The control units are connected both with each other and with the main wiring harness.
Page 472  Draw the contour of the hinge on the door to ensure precise positioning for assembly After Sales Aftersale  Remove top hinge/door side Attach template (on hinge side for plug connector Deutsch) (Figure 8.10.4).  The contour of the template must be aligned with the contour of the door ...
Page 473  Fit switch on center console and connect with wiring harness 8.10.9 To hold the luminous film in position more securely, Information Porsche Motorsport recommends covering the film with a transparent film. 8.10.10 911 GT3 Cup (991 II) Version: 4/20/2018...
Page 474 8.11 Battery charging cable After Sales Aftersale 8.11.2 8.11.1 The plug connector of the battery charging cable is screwed on to the right side sill close to the additional weight plate using a holder. The holder is riveted to the body in the area of the side sill on the passenger’s side.
Page 475 8.12 Suspension travel sensor After Sales Aftersale Aftersale The suspension travel sensors are installed in the wheel housing on the body side and are connected to the transverse link via a coupling rod. 8.12.1 The description of the installation is independent of Information wheel and axle.
Page 476 Hot components Caution After Sales Aftersale Risk of burns Allow hot components to cool • down. Wear protective clothing. • Sensor holder front axle  Screw the sensor to the car body holder (pos. 2 Figure 8.12.5). Spacers (pos. 5 Figure 8.12.3) ...
Page 477 After Sales Aftersale Aftersale Sensor holder rear axle Torque screw M6x16 pos. 8 (Figure 8.12.4): 10 Nm Torque screw M5x12 pos. 6 (Figure 8.12.4): 8 Nm 8.12.4 Screw the coupling rod to the holder. (coupling rod/wishbone) (pos. 9 Figure  8.12.4).

Porsche 911 GT3 Cup 2018 Techical Manual

Preface

1 Engine

2 Powertrain

Chassis

4 Bodywork

5 Interior

6 Electrical System

Transmission

Sensors

Display ICD

Lights

Data Bus System

Wiring Harness

Ground Connection Roof Antenna

Fire Extinguisher

Driver Control Systems

7 Maintenance

8 After Sales

Quick Links

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Questions and answers

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Summary of Contents for Porsche 911 GT3 Cup 2018