Porsche 2015 911 GT3 Cup Technical Manual Download Page 173

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Bodywork

911 GT3 Cup (991)

MY 2015

4.2

Front and side view

Front bumper

The lateral air intakes of the front bumper have been redesigned and enlarged. The

newly developed daytime running lights are integrated and include LED direction

indicators. The front bumper is made of PUR GF 18 (polyurethane).

4.2.1

Version: 16.12.2014

172

Summary of Contents for 2015 911 GT3 Cup

Page 1: ...Technical manual 911 GT3 Cup 991 MY 2015...

Page 2: ...ook up data settings und operating regulations and to facilitate maintenance or repair of the vehicle We wish you many sporting successes with your 911 GT3 Cup 991 Customer Sport Dr Ing h c F Porsche...

Page 3: ...man Road Traffic Licensing Regulations Pictures descriptions and schematic drawings are used solely for illustrating the text We assume no responsibility for the completeness and conformity of the con...

Page 4: ...Fax 49 0 711 911 82920 Technical Support Hr Maximilian M ller Tel 49 0 711 911 86183 Fax 49 0 711 911 89535 Porsche Carrera Cup Germany Ms Andrea Hagenbach Tel 49 0 711 911 84041 Assistent Mr Marco V...

Page 5: ...ooling system 19 1 4 5 Races at low temperatures 19 1 5 Intake system 20 1 5 1 Resonance flaps 20 1 5 2 Throttle 21 1 6 Work on the engine 22 1 6 1 Cylinder head installation 22 1 6 2 Flywheel tighten...

Page 6: ...mechanism 44 2 3 Sequential six speed gearbox 45 2 3 1 Overview 45 2 3 2 Technical specifications 46 2 3 3 Gear set 47 2 3 4 Drive 50 2 3 5 Oil circuit 52 2 4 Gear shift mechanism 53 2 4 1 Gear shifti...

Page 7: ...2 9 2 Gear housing pre assembly 86 2 9 3 Differential lid pre assembly 92 2 9 4 Pinion shaft bearing assembly 93 2 9 5 Pinion shaft 94 2 9 6 Pinion shaft position adjustment 96 2 9 7 Assembly of gear...

Page 8: ...2 Fixation trailing arm bracket 146 3 3 3 Rear axle transverse control arm 147 3 3 4 Rear axle wheel mount 148 3 3 5 Rear axle shock absorber 149 3 3 6 Rear axle anti roll bar 150 3 3 7 Rear axle sid...

Page 9: ...Rear view 174 4 4 Body shell 175 4 4 1 General 175 4 4 2 Weight distribution 177 4 4 3 Weight percentage of the Body in White 177 4 4 4 Body aluminum parts 178 4 4 5 Body features 179 4 4 6 Body stee...

Page 10: ...2 Defueling 199 4 14 3 Tank installation 200 4 15 Repairing the body 200 4 15 1 Repairing the front section 201 4 15 2 Replacing the front strut mount 215 4 15 3 Repairing the rear end 223 4 16 Threa...

Page 11: ...6 4 3 Carburation 260 6 4 4 Ignition system 260 6 5 Sensors 261 6 5 1 Sensor rated values 262 6 5 2 Optional sensors 263 6 6 ICD Display 264 6 6 1 General 264 6 6 2 Race page 266 6 6 3 Practice page...

Page 12: ...valve timing 296 7 1 8 Engine tightening torques 297 7 1 9 Engine runtime 297 7 2 Fuel system 298 7 2 1 Fuel 298 7 2 2 Fuel pump 298 7 2 3 Fuel extraction 298 7 3 Power transmission 300 7 3 1 Gearbox...

Page 13: ...mi or first test drive 315 7 7 2 After each session 315 7 7 3 After each weekend sprint race 316 7 7 4 After 3 4 race weekends sprint races 316 7 7 5 After 30 hours run time 316 7 7 6 After 50 hours r...

Page 14: ...ially for use in motor sports New features include the electronic accelerator and the accompanying throttle Furthermore the Bosch Motronic MS4 6 controller has been used as engine control The engine h...

Page 15: ...ement 3 797 cm3 Hole 102 7 mm Stroke 76 4 mm Compression approx 12 1 Maximum speed 8 500 rpm Intake valve diameter 41 mm Intake valve stroke 12 0 mm Intake valve lobe center line 110 after TDC Exhaust...

Page 16: ...t pressure oil supply to the engine components requiring lubrication in any driving situation The oil tank which is installed separately on the front side of the engine always contains enough oil to s...

Page 17: ...ump 3 Safety valve 4 Oil filter 5 Pressure sensor 6 Oil water heat exchanger 7 Pressure relief valve 8 Crankshaft 9 Injector 10 Chain tensioner 11 Camshaft 12 Hydraulic valve lifter 13 Suction pump ca...

Page 18: ...nd damage the engine When refilling engine oil it should be taken into account that this oil only runs slowly through the dipstick guide tube into the oil tank Therefore wait a few minutes before meas...

Page 19: ...and to keep this temperature stable The lid of the water expansion tank is equipped with a pressure regulating valve which opens at 1 4 bar Check the system if there is a coolant loss or leaks are su...

Page 20: ...t races to the Formula 1 world championship the coolant has to be substituted as described below Approx 20 liters 21 qts of water plus at least 2 liters 2 1 qts of corrosion protection spare part no 9...

Page 21: ...of the engine and thereby have a positive influence on the airflow within the intake system thus contributing to a power torque increase For functional testing the vacuum cells 1 and 2 can be tested u...

Page 22: ...There is no mechanical connection between the throttle and accelerator pedal The electrical signal from the accelerator pedal is converted by an electric servo motor in the throttle into an opening a...

Page 23: ...r cylinder head installation 1 Lightly oil the threads and contact surfaces 2 Pre tighten to 30 Nm 22 ft lb in the specified order 3 Wait for 15 minutes 1 6 1 1 4 Completely untighten the bolts in the...

Page 24: ...00 3 Tighten the bolts crosswise to 30 Nm 22 ft lb 4 Retighten the bolts to 30 Nm 22 ft lb and tighten them crosswise with a 45 rotation angle 1 6 3 Setting the valve timing Porsche Motorsport recomm...

Page 25: ...sert Porsche ET No 000 721 973 21 Crankshaft seal fitting tool Porsche ET No 000 721 216 40 Fitting tool spacer ring Porsche ET No 000 721 979 71 Crankshaft protective cap Porsche ET No 000 721 979 70...

Page 26: ...the punch marked locations using a drill 2 mm 1 6 4 2 5 Screw in the screw head of a commercially available slide hammer puller 1 alternately into the holes and carefully in an alternating way remove...

Page 27: ...7 Push and position the template on the crankshaft flange up to the sealing ring 8 Wet the drill 2mm sufficiently with heavy duty grease 9 Drill holes at the specified locations 10 Screw in the screw...

Page 28: ...ther fitting tool 1 Porsche ET No 000 721 216 40 with spacer ring 2 000 721 979 71 1 6 4 5 2 Always dry mount the crankshaft seal do not use grease 3 Push protective cap 1 Porsche ET No 000 721 979 70...

Page 29: ...flange and screw in hexagon bolt 3 wrench width SW17 6 Tighten hexagon nut 4 until spacer ring 2 fits snugly on the crankshaft flange 1 6 4 8 7 Leave the tool mounted for approx two minutes so that th...

Page 30: ...g special tools for installing or removing the crankshaft seal on the flywheel side Pressure piece Porsche ET No 000 721 912 60 Seal fitting tool Porsche ET No 000 721 971 90 The tools may be ordered...

Page 31: ...crankcase Never pry it out 4 Thoroughly remove the drilling shavings 5 Drill two more holes arrows using a 0 2 mm drill Place these holes carefully as possible in the corners metal body of the seal 6...

Page 32: ...the screw head of the slide hammer puller in the holes and uniformly pull out the seal 1 6 5 3 b Screw in two tapping screws and pull out the seal using the claw type sleeve of a slide hammer puller...

Page 33: ...urface be treated with emery cloth or brushes with metal bristles Remove corrosion on the crankshaft flange only using a special metal polishing pad Then clean the crankshaft flange thoroughly with ac...

Page 34: ...on the base plate attach the crankshaft seal on the cone and slide it carefully onto the base plate 3 Remove the magnetic cone and slide the crankshaft seal in a plane parallel position using the pres...

Page 35: ...t seal on the crankshaft flange by turning clockwise the fitting nut until the mounting bell fits snugly and completely on the crankcase contact surface 6 Leave the fitting tool in the final position...

Page 36: ...nts from the crankshaft flange to the steel ring flat surface arrows using a vernier caliper Measuring depth approx 5 mm 0 2 Maximum allowable tilt is 0 5 mm 0 2 9 If the comparative values exceed the...

Page 37: ...5 50 37 ft lb Water drain plug cyl 1 3 M10 x 1 10 7 4 ft lb Water drain plug cyl 4 6 M10 x 1 10 7 4 ft lb Flywheel M10 refer to 1 6 2 Cylinder head Cylinder head bolt M10 refer to 1 6 1 Camshaft housi...

Page 38: ...45 7 ft lb 2 rotation angle Expansion resulting from tightening 0 200 0 015 mm 0 008 0 0006 Auxiliary Units Pulley on generator 55 40 6 ft lb Lambda sensor M18 x 1 5 50 37 ft lb Flywheel coupling M8 x...

Page 39: ...ons the exhaust system has also been refined A version with muffler and a version without muffler are available Both versions are equipped with exhaust manifold including catalysts 100 cells System wi...

Page 40: ...Porsche Motorsport points out that the fixation of the pre silencers makes the following changes necessary Part list Pos Part number Name Item per car 1 991 111 147 9A Pre silencer left 1 2 991 111 14...

Page 41: ...ned for a maximum speed of 8 500 rpm so that an inspection interval of 50 hours is recommended If an engine speed above 8 500 rpm is recorded Porsche Motorsport will not accept any good will claims 1...

Page 42: ...eumatic actuation by means of the compressed air system In addition the gearbox is equipped with a limited slip differential an oil filter and an oil water heat exchanger for cooling Despite the compa...

Page 43: ...ng and unloading etc 2 2 1 Installation instructions Make sure that the wings of the multiple disk clutch sintered disks 1 are stacked and aligned A if possible Lightly grease the gear teeth of the hu...

Page 44: ...ommends to vent the system after each session and to change the fluid after each race weekend Venting Depress the clutch pedal 2 to 3 times and keep it depressed Shortly open the vent valve illustrati...

Page 45: ...oid any contact with transmission oil Otherwise the seal may swell which in the worst case may lead to a loss of function Only use the Sachs special tool to fit the seal Also make sure to remove oil r...

Page 46: ...x speed gearbox 2 3 1 Overview 2 3 1 1 2 1 4 5 6 3 7 1 Limited slip differential 2 Connecting shaft 3 Drive shaft 4 Gear shift drum 5 Cross shaft 6 Pinion shaft 7 Gear shift cylinder Version 16 12 201...

Page 47: ..._const i_bevel crown gear i_total 1 13 41 3 154 2 412 1 571 11 951 2 17 40 2 353 2 412 1 571 8 916 3 19 36 1 895 2 412 1 571 7 181 4 19 29 1 526 2 412 1 571 5 782 5 24 30 1 250 2 412 1 571 4 737 6 34...

Page 48: ...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 generat...

Page 49: ...rollers and angular contact ball bearings directly in front of the bevel gear This bearing arrangement directs the occuring forces into the housing in the best possible way The pinion shaft accommoda...

Page 50: ...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 t...

Page 51: ...tion of the torque speed is changed from the longitudinal to transverse direction by means of the cross shaft with constant ratio The final drive ratio transmits the torque through the limited slip di...

Page 52: ...2 The differential gears pivoted on these bolts drive the output shaft flanges by means of the lateral bevel gears Depending on the torque gradient traction thrust the cross pin bolts move the pressu...

Page 53: ...separate oil water heat exchanger 2 for heating and cooling the gear set oil The heat exchanger is fitted externally on the upper side of the gearbox The internal oil pump is driven by the idler of th...

Page 54: ...addle shift system is used by the driver to change gears and to protect the drive train against incorrect handling Shift paddles on the steering wheel pass electrical signals to the Bosch engine contr...

Page 55: ...id blocked wheels Connenction of the components Valve block 2 4 3 1 Upshift 2 Downshift Shift cylinder 2 4 4 1 Upshift 2 Downshift 2 4 1 Gear shifting Gear shifting is initiated by the paddles on the...

Page 56: ...t accelerator pedal 0 and the throttle position must be less than 20 Up shifting Down shifting R N N 1 1 6 6 1 1 N N R Paddle pushb Right Right Right Left Left Reverse button Throttle Not actuated Not...

Page 57: ...ottom position when mounted correctly 2 4 3 Emergency gearbox switch In case of failure of certain sensors that normally ensure the correct operation of the gear shift system an emergency program may...

Page 58: ...sor run time Big Service Every two years Max 20 000 km Max 20 h compressor run time Contact data MEGA Line Racing ELECTRONIC GmbH Haunersdorf Str 3 D 93342 Saal a d Donau Phone 49 9441 6866 0 Fax 49 9...

Page 59: ...ide 150 g 5 3 ounces Grease quantity for joint on gearbox side 120 g 4 2 ounces Porsche spare part No 100 g 3 5 ounce tube 000 043 110 01 2 5 1 Tightening instructions 1 Tighten all bolts to 30 Nm 22...

Page 60: ...il suction pipe 6KT MU M6 1 9 7 Nm Gearbox housing gear shift drum 6KT MU M6 2 9 7 Nm Gearbox housing thrust bearing with stop 6KT MU M8 1 25 Nm Gearbox housing thrust bearing with stop 6KT MU M6 1 9...

Page 61: ...50 Nm 60 then untighten 50 Nm 60 Gearbox housing oil spray pipe ZYL SHR M5x10 3 5 6 Nm Gearbox housing oil spray pipe ZYL SHR M5x15 3 5 6 Nm Gearbox housing oil spray pipe ZYL SHR M5x15 2 5 6 Nm Gear...

Page 62: ...ead to component damage Preliminary work Drain transmission oil 2 8 1 Dismantling of hang on parts Dismantle axle shaft flanges with panel puller 1 Figure 2 8 1 1 Remove the shaft sealing ring of the...

Page 63: ...smantling Remove the locking ring 1 of pinion shaft and rotation prevention Figure 2 8 2 1 By twisting the pinion shaft engage gear 1 and fix the drive shaft in place with tool no 19 Figure 2 8 2 2 Lo...

Page 64: ...t the shift rod toward the top ensure that the shift forks do not drop out of the sleeves Remove the shift forks Remove the reverse gear shift fork Remove the locking ring drive shaft Remove the pinio...

Page 65: ...wrench and loosen the shift drum nut with socket Porsche spare part No 997 450 306 00 Figure 2 8 4 2 2 8 5 Dismantling the locking sleeve Loosen the nut 2 and 3 and the screw 1 of the locking sleeve...

Page 66: ...se the shift module cannot be pulled out otherwise Oil pump Remove the locking ring 1 of the oil pump gearwheel Figure 2 8 6 3 Pull off the gearwheel Keep in mind the insert washers between shaft and...

Page 67: ...Remove the cross shaft lid catch Open the cross shaft lid with the assembly lever Figure 2 8 7 2 Remove adjusting disk P2 of the anti lash plate Figure 2 8 7 3 Clamp tool no 49 into the vice and inse...

Page 68: ...the cross shaft nut The bearing shell of the four point bearing is behind it Remove the bearing shell of the four point bearing Carefully tap out the shaft of the cross shaft lid with a rubber hammer...

Page 69: ...f the bearing Figure 2 8 7 7 Push the cage out of the cylinder roll bearing cross shaft with tool no 44 Figure 2 8 7 8 Heat the cross shaft lid 1 at 130 C 266 F for 30 minutes Take the outer ring of t...

Page 70: ...pinion shaft in the transmission shell Figure 2 8 8 1 Take out the pinion shaft through the assembly opening Press out the cylinder roll bearing of the pinion shaft with tool no 44 Figure 2 8 8 2 See...

Page 71: ...130 C 266 F for 30 minutes Remove the bearing 2 without applying great force Remove the differential from the gearbox housing Figure 2 8 9 3 Loosen the differential lid screws evenly using a crisscro...

Page 72: ...re 2 8 9 5 2 8 10 Central clutch operator removal Remove the central clutch operator Figure 2 8 10 1 2 8 11 Connecting shaft dismantling Drive out the connecting shaft with the panel puller Figure 2 8...

Page 73: ...e 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 f...

Page 74: ...arbox housing at 130 C 266 F for 30 minutes Remove the outer rings of the bearings in the housing The outer rings of the bearing can be dismantled without applying great force Outer ring of the drive...

Page 75: ...nnecting 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 Heat the gear housing at 130 C 266 F for 30 minutes Push out t...

Page 76: ...g the studs the thread holes must first be cleaned thoroughly with petroleum benzine brake cleaner and afterwards with acetone The gearbox housing and the gear housing must finally be blown out with o...

Page 77: ...1 Dimensions M10x22 Porsche spare part No 999 062 014 01 Projection 24 mm 0 94 Adhesive Loctite 2701 green Thread position Screw in short thread Gear housing connection studs green Dimensions M8x50 P...

Page 78: ...hread Oil pump studs 2 Dimensions M6x28 Porsche spare part No 999 062 100 02 Projection 27 mm 1 06 Adhesive Loctite 2701 green Thread position Screw in short thread Screw in suction tube screw stud 1...

Page 79: ...91 303 498 9B must first be pressed in Dimensions M6x35 Porsche spare part No 999 062 093 01 Projection 29 mm 1 14 Adhesive Loctite 2701 green Thread position Screw in long thread Locking sleeve screw...

Page 80: ...01 Projection 19 mm 0 75 Adhesive Loctite 2701 green Thread position Screw in long thread Injection tube stud Dimensions M6x10 Porsche spare part No 999 062 001 01 Projection 10 mm 0 39 Adhesive Loct...

Page 81: ...f Heat resistant gloves must be worn for any work with hot items because of the risk of burning Drive shaft bearing Dimensions 34x62x17 Type Cylinder roll bearing Porsche spare part No 991 302 283 9A...

Page 82: ...shaft bearing Dimensions 50x90x20 Type Cylinder roll bearing Porsche spare part No 991 302 492 9A Tool No 6 Locking ring 90x2 5 Porsche spare part No 999 152 095 01 Insert locking ring at a 90 offset...

Page 83: ...ing Dimensions 59 5x90x23 Type Cylinder roll bearing Porsche spare part No 991 332 645 9A Tool No 8b With locking ring Porsche spare part No 999 152 138 01 Insert locking ring at a 90 offset to the op...

Page 84: ...307 9A Adhesive Loctite 638 Press in up to the limit Gearbox housing gear housing screw connection bushing 12x6x16 Press in fitting sleeve Porsche spare part No 991 301 643 9A Pinion shaft retaining...

Page 85: ...Dimensions M12x1 5 alu Porsche spare part No 900 219 006 30 Torque 9 Nm 6 6 ft lb Attach with sealing ring Porsche spare part No 900 123 101 30 12x18 Plug without pressure sensor Dimensions M10x1 Por...

Page 86: ...74 orange Bleeding 2 Porsche spare part No 962 355 522 00 Sealing ring Porsche spare part No 900 123 003 20 Pressure line 1 Porsche spare part No 999 105 027 30 Sealing ring Porsche spare part No 900...

Page 87: ...pressed air The studs must be cleaned thoroughly with petroleum benzine After the studs are inserted the gear housing has to set in an oven for approx 40 minutes at 130 C 266 F Heat resistant gloves m...

Page 88: ...nsions M5x20 12 9 Porsche spare part No 999 069 005 09 Projection 7 mm 0 27 Adhesive Loctite 2701 green Shift module screw connection stud 26 Dimensions M6x18 Porsche spare part No 999 062 003 01 Proj...

Page 89: ...10 9 Porsche spare part No 900 060 107 01 Projection 45 mm 1 77 Adhesive Loctite 2701 green Thread position Screw in short thread Press in fitting sleeve 1 Porsche spare part No 991 301 641 9B up to t...

Page 90: ...must be tapped with an appropriate tool after the housing has cooled off Heat resistant gloves must be worn for any work with hot items because of the risk of burning Labels of outer and inner bearing...

Page 91: ...the shift drum 1 Dimensions 50x65x7 Porsche spare part No 900 052 225 00 Tool No 31 Screw connection of baffle M5 Porsche spare part No 900 817 005 02 Torque 6 Nm 4 4 ft lb Shift module bushing 27 Di...

Page 92: ...Sealing ring Porsche spare part No 900 123 018 30 Sealing plug Dimensions M12x1 5 Porsche spare part No 900 219 006 30 Torque 9 Nm 6 6 ft lb Adhesive Loctite 574 orange Sealing ring Porsche spare par...

Page 93: ...hot items because of the risk of burning Cylinder roll bearing 2 Dimensions 54 5x85x19 Porsche spare part No 991 332 641 9A Tool No 8 8a Point the label to the top and secure with snap ring Porsche sp...

Page 94: ...ompression of 0 03 mm in the retaining frame of the pinion shaft The compression is calculated as follows Fix the probe indicator 1 in place on the retaining frame with bracket 3 no 37 Apply probe ind...

Page 95: ...unting ring no 25 reverse gear replacement The mounting ring no 25 in this case only serves as a substitute and is replaced with the reverse gear wheel spur gear during final assembly 2 9 7 Assembly o...

Page 96: ...5 Tightening instructions Use tool no 20 Figure 2 9 5 4 Pre tightening 30 Nm 22 ft lb 60 angle of rotation Loosening Final tightening 30 Nm 22 ft lb 60 angle of rotation Tighten the pinion shaft retai...

Page 97: ...ion 2 e g 75 002 measured by the manufacturer on the gearbox housing This measurement is the distance between the gearbox housing opening and the shift module axis red dotted line The measurement from...

Page 98: ...ll bearing and four point bearing see Figure 2 9 5 3 Observe the assembly of the pinion shaft in 2 9 5 The basic P1 disk used in chapter 2 9 5 is then replaced with the calculated P1 disk Subsequently...

Page 99: ...Push on thrust plate 2 Porsche spare part No 991 302 381 9C Secure with locking ring 1 30x1 5 Porsche spare part No 900 041 015 01 use the shortened snap ring pliers Figure 2 9 6 2 Moisten the pinion...

Page 100: ...earing the claws then point away from the pinion head Figure 2 9 7 5 Insert idler gear bearing needle cage 4 Figure 2 9 76 Moisten the guide sleeve running surface 5 with oil Insert the guide sleeve 5...

Page 101: ...ward Figure 2 9 7 10 Insert the 2nd gear idler gear 8 with the idler gear bearing 7 the claws point toward the selector sleeve 6 here Figure 2 9 7 11 Push the fixed gear 3rd gear B on the drive shaft...

Page 102: ...extensive oil supply Push on selector sleeve 3rd 4th gear 12 with the label facing outward Figure 2 9 7 15 Push the idler gear 4th gear 14 with idler gear bearing 13 claws in the direction of the 3rd...

Page 103: ...directly on top of each other extensive oil supply Put on the selector sleeve 18 Figure 2 9 7 18 Push the spacer sleeve E between 5th and 6th gear fixed gears Porsche spare part No 991 302 268 9B Fig...

Page 104: ...shaft Figure 2 9 7 22 Put on the inner ring of the pinion shaft 21 Put the nut 22 loosely on the pinion shaft Do not tighten the nut 22 final tightening is not done until step 2 9 20 Putting on the g...

Page 105: ...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 tighten with 60 Nm 44 3 ft lb with tool no 21 Figure 2 9 8 2 Us...

Page 106: ...crisscross pattern Check whether the shaft can be spun smoothly at that Final tightening of the oil pump with 10 Nm 7 4 ft lb Put on the oil pump gearwheel ensure that the feather key is inserted in t...

Page 107: ...th tool no 32 Heat resistant gloves must be worn for any work with hot items because of the risk of burning Secure the needle bearing sleeve 2 with the locking ring 1 Insert reverse idler gear 3 with...

Page 108: ...between housing and lever The bushing 2 must be flush with the housing 4 Tension the lever with a slot screwdriver and insert the locking sleeve in the gearbox housing Put on Simmonds nuts 3 and tigh...

Page 109: ...9A Grease two O rings 1 11x2 Porsche spare part No 999 701 948 40 with Optimol Paste MP3 and put on the shift rod 1 Lubricate the shift rod and put it in all the way to the stop Do not insert the upp...

Page 110: ...housing Put on nut 4 Porsche spare part No 900 817 001 02 and tighten with 10 Nm 7 4 ft lb Oil filter Insert the oil filter element 2 in the gear housing without a specific installation direction put...

Page 111: ...he drive shaft until it engages clearly Put guide ring connecting shaft Porsche spare part No 991 301 119 9B on the bearing Grease shaft sealing ring connecting shaft 26x41x6 Porsche spare part No 997...

Page 112: ...he gear housing is fitted only after a check and possibly a correction Push on the cutted gear housing and fix in place with four nuts Engage the 1st gear by turning the shift drum Fix drive shaft in...

Page 113: ...position of the gearwheel pairings Check the free movement of the shift fork The necessary consistent axial clearance of the shift forks in all gears can be achieved only with correct adjustment of th...

Page 114: ...ing ring that is also ultimately used for installation must be used Figure 2 9 16 1 Aligning the depth caliper Carry out the distance measurement Figure 2 9 16 2 from stamp end to ring disk 1 Carry ou...

Page 115: ...worn for any work with hot items because of the risk of burning Lubricate the shaft Press the heated bearing 1 quickly onto the shaft It must be possible to mount the bearing without applying great f...

Page 116: ...loves must be worn for any work with hot items because of the risk of burning Insert the cylinder roll bearing 2 in the housing with tool no 7 bearing label must face toward the top Clamp tool no 36 a...

Page 117: ...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 Loosely put on the nut Clamp tool no 49 into the vice In...

Page 118: ...ng 130x2 5 on the lid Porsche spare part No 999 701 580 40 Visually check the gearbox housing Put on the adjusting disk basic 1 4 P2 Insert the shaft with the lid rotate shaft slightly to prevent two...

Page 119: ...three more times If the clearance is too big a thinner adjusting disk P2 must be inserted If the clearance is too little use a thicker adjusting disk Block the pinion shaft in the position coast with...

Page 120: ...to be measured during reassembly and must be corrected to the specified dimension by using a variety of pressure plates in different sizes Grease the axial needle bearing 6 mount into the ring 7 and a...

Page 121: ...on mark Disk package 10 Insert inner disk 3 Insert outer disk 3 Insert inner disk 2 Insert outer disk 2 Insert inner disk 1 Insert outer disk 1 Insert pressure plate 9 disk spring 8 observe installati...

Page 122: ...erance 0 1 0 3 mm Measurement without springs 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 t...

Page 123: ...pieces Therefore the layered arrangement of the friction package has to be measured from the differential housing face the differential housing cap face to the cross pin marked red and the difference...

Page 124: ...lts with 15 Nm Sequence 1 11 6 16 Check the basic locking action Clamp tool no 52 into the vice Figure 2 9 19 10 Put on tool no 53 Check the locking action with drag torque wrench no 59 Tighten 16 bol...

Page 125: ...8 00 Dimensions 35x40x17 Put on snap ring 4 Porsche spare part No 999 332 997 9A Insert the differential in the gearbox housing Figure 2 9 19 13 Put on differential lid with greased O ring and tighten...

Page 126: ...the probe indicator Attach stop no 26 on the differential lid catch Figure 2 9 19 14 Block the cross shaft with tool no 15 Figure 2 9 19 15 Check the measured value by rotating the differential measu...

Page 127: ...d insert it in the gearbox housing Figure 2 9 20 2 The cutted gear housing can be replaced with the gear housing after all settings have been made Drive shaft and pinion shaft are already mounted in t...

Page 128: ...Figure 2 9 20 4 Put on the pinion shaft lid 23 with greased sealing ring 24 and tighten the nuts 25 with 10 Nm 7 4 ft lb Figure 2 9 20 5 Put on the cross shaft lid cover with greased O ring and fix in...

Page 129: ...shift control Calibrate the shift control potentiometer 6th gear 4 5 V Gearbox to gearbox bracket 65 Nm 48 ft ib Shift cylinder to gearbox bracket and shift control tighten with 12 Nm 8 9 ft lb The in...

Page 130: ...b Insert the oil injection tube 2 for the pinion shaft into the gearbox housing with greased sealing ring 1 and tighten the nut 4 with 10 Nm 7 4 ft lb tightening torque and Loctite 2701 Fill transmiss...

Page 131: ...stment disk P1 Cross shaft Preload 4 point bearing Set valve Pressung 0 15mm via adjustment disk Q1 Figure 2 9 20 13 Backlash pinion crownwheel drive Set valve 0 15 0 19 mm via adjustment disk P2 Figu...

Page 132: ...nt axle design is a MacPherson strut type axle with aluminum transverse control arms The rear axle is a multi link axle 3 1 1 Based on the previous model the following major development objectives wer...

Page 133: ...sing 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 i...

Page 134: ...ub 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 chec...

Page 135: ...e after approx 6 hours running time to verify and regenerate them Clean the threads judge them by visual inspection and re grease them with Optimol Paste TA Porsche spare part no 000 043 020 00 Also g...

Page 136: ...Chassis 3 1 4 Locking piece The locking pieces are used as wheel nut locking mechanism and to prevent the wheel from loosening 3 1 4 1 1 Locking Piece Version 16 12 2014 135 911 GT3 Cup 991 MY 2015...

Page 137: ...e control arm and tie rod to the wheel mount as well as a stiffer shock absorber clamp increase the wheel mount s overall stiffness The use of high performance joint bearings in all control arms minim...

Page 138: ...er Item Dimensions Tightening torque in Nm Comments 3 M12 x 1 5 x 50 120 Nm 88 5 ft lb 5 M12 x 1 5 120 Nm 88 5 ft lb 7 M12 x 1 5 x 60 120 Nm 88 5 ft lb 8 M10 65 Nm 48 ft lb 11 M6 10 Nm 7 4 ft lb 14 St...

Page 139: ...combining individual spacers 2 is 18 mm on the front axle The transverse control arm must be installed in such a way that the screw connection of the camber adjustment washer is accessible from below...

Page 140: ...h is 430 mm 3 2 2 5 3 2 3 Longitudinal control arm The longitudinal control arms are stiffness optimized forged control arms When working on the suspension care must be taken to see that the wheel mou...

Page 141: ...1 25 x 45 170 Nm 125 ft lb 7 M8 x 32 35 Nm 26 ft lb 8 M22 x 1 5 470 Nm 347 ft lb then free ca 90 then 470 Nm 347 ft lb 15 500 525 Nm 369 387 ft lb lubricate with Alupaste 17 M6 x 16 10 Nm 7 ft lb 19 M...

Page 142: ...on the shock absorber For stroke limitation and protection of the shock absorber the latter is equipped with an integrated bump stop 3 2 5 1 List of tightening torques for front axle shock absorber I...

Page 143: ...ved when the bending lever is at a 90 angle to the anti roll bar link 3 2 6 1 List of tightening torques front axle anti roll bar Item Dimensions Tightening torque in Nm Comments 2 M6 10 Nm 7 ft lb 8...

Page 144: ...een the anti roll bar and other components over the entire suspension travel On the front axle there is a risk of collision with the transverse control arm or the tie rod if the setting is incorrect A...

Page 145: ...erse control arm are screwed to the body by means of the side part The lower longitudinal control arm is connected to the body by means of a forged bracket A blade type anti roll bar that is adjustabl...

Page 146: ...Nm Comments 2 Stud 10 Nm Loctite 276 7 M12 120 Nm 88 5 ft lb 19 M6 x 20 10 Nm 7 4 ft lb 20 M12 x 75 16 Nm 11 8 ft lb 24 M10 65 Nm 48 ft lb 25 M10 x 50 65 Nm 48 ft lb 4 M10 65 Nm 48 ft il The rear scr...

Page 147: ...b frame versions Version number on the bottom of sub frame 3 red circle Part specification Sub frames with version number 009 Pos Part number Name Pcs per car 1 2 999 072 055 01 hex screw M10X80 4 3 9...

Page 148: ...543 83 8 00 mm 996 341 543 84 The maximum permissible adjustment washer width to be achieved by combining the individual washers 1 is 15 mm on the rear axle When inserting the spacers it s important...

Page 149: ...wheel mount Item Dimensions Tightening torque in Nm Comments 3 M12 x 1 25 x 45 170 Nm 125 ft lb 6 M8 x 32 35 Nm 26 ft lb 7 M22 x 1 5 470 Nm 347 ft lb then free ca 90 then 470 Nm 347 ft lb 14 500 525...

Page 150: ...ck absorber the latter is equipped with an integrated bump stop 3 3 5 1 List of tightening torques for rear axle shock absorber Item Dimensions Tightening torque in Nm Comments 12 M8 33 Nm 24 3 ft lb...

Page 151: ...ng lever is at a 90 angle to the anti roll bar link 3 3 6 1 List of tightening torques rear axle anti roll bar Item Dimensions Tightening torque in Nm Comment 2 M6 10 Nm 7 4 ft lb 8 M8 x 18 Set 0 25mm...

Page 152: ...sion with the longitudinal control arm or the rim if the setting is incorrect A distance of 12 mm 0 47 inches towards the control arm is recommended when the axle is decompressed figure 3 3 5 3 Axial...

Page 153: ...4 M12 120 Nm 88 5 ft lb 7 M12 x 1 5 120 Nm 88 5 ft lb 11 M12 x 45 120 Nm 88 5 ft lb 12 M12 x 45 120 Nm 88 5 ft lb 14 M8 x 25 23 Nm 17 ft lb 15 M6 x 16 10 Nm 7 4 ft lb 17 4 8 x 13 3 2 Nm 2 3 ft lb Ite...

Page 154: ...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 i...

Page 155: ...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 3 4 2 2 Measuring point rear axle The vehicl...

Page 156: ...90 4 M8 23 Nm 17 ft lb 6 M8 23 Nm 17 ft lb 7 M10 x 65 70 Nm 51 6 ft lb 8 M14 x 1 5 50 Nm 37 ft lb hold tie rod 9 M6 x 20 16 Nm 11 8 ft lb 10 12 x 1 5 120 Nm 88 5 ft lb When adjusting the tie rod on th...

Page 157: ...heel quick release are shown in the illustration below List of tightening torques Item Dimensions Tightening torque in Nm Comments 2 M5 x 16 6 Nm 4 4 ft lb 5 M5 x 35 6 Nm 4 4 ft lb 7 M18 x 26 50 5 Nm...

Page 158: ...engine Turn the steering wheel quickly from one stop to the other allowing the air in the cylinders to escape Do not turn the steering wheel with increased force against the end stop to prevent unnece...

Page 159: ...livered 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 Tire dimensions T...

Page 160: ...internally vented disks and pad which is suitable for long distance driving and was developed by Porsche Motorsport Six piston fixed calipers are provided on the front axle four piston fixed calipers...

Page 161: ...ake pistons of the caliper have to be checked immediately to find out the cause Repair instructions A repair kit with seals and pistons is available as well as a repair kit containing only seals Pisto...

Page 162: ...ues for front axle brake Item Dimensions Tightening torque in Nm Comments 2 20 Nm 14 75 ft lb 3 20 Nm 14 75 ft lb 4 5 Nm 3 7 ft lb 14 16 Nm 11 8 ft lb 9 M10 65 Nm 48 ft lb 11 M6X12 10 Nm 7 4ft lb Loct...

Page 163: ...s for rear axle brake Item Dimensions Tightening torque in Nm Comments 4 20 Nm 14 75 ft lb 2 20 Nm 14 75 ft lb 3 5 Nm 3 7 ft lb 14 16 Nm 11 8 ft lb 9 M10 65 Nm 48 ft lb 11 M6 x 12 10 Nm 7 4 ft lb Loct...

Page 164: ...e part No 991 355 170 8C 3 7 4 1 List of tightening torques for master cylinders Item Dimensions Tightening torque in Nm Comments 4 M8 x 30 23 Nm 17 ft lb 9 Insert the bolt from the right 10 M8 23 Nm...

Page 165: ...dal 2 Open the front axle and rear axle brake bleeder valves simultaneously and close them again 3 Only release the brake pedal when the bleeder valves have been closed Build up new pressure with the...

Page 166: ...g the brake power adjustment dial in the R direction increases the rear axle brake pressure in relation to the front axle In the F direction the situation is correspondingly reversed Brake Pressure Di...

Page 167: ...rpendicular to the push rod at a pedal load of 40 bar 580 psi If the adjusting wheel potentiometer is in zero position a voltage of 2 5 V can be measured When setting the balance beam a calibration sh...

Page 168: ...rod at the connection of the balance beam to the front axle master cylinder This ensures that the balance beam is perpendicular to the push rod under load The thread length to the lock nut can be betw...

Page 169: ...rear axle brake can be calculated as follows 3 8 2 1 HA Bremskraft Pedalkraft VA Bremskraft l x Pedalkraft HA Bremskraft _ _ _ 3 8 2 2 3 8 2 3 Front Axle Rear Axle y y Key Pedalkraft pedal force Brems...

Page 170: ...ng the balance bar Remove the R clips spacers circlips and clevises from the balance bar Remove the balance bar The retaining ring and circlip should be replaced after each dismantling Screw the new b...

Page 171: ...t 4 Rear axle right 4 Toe Front axle left 5 Front axle right 5 Rear axle left 17 Rear axle right 17 Brake balance Cyl front axle 17 8 mm Cyl Rear axle 17 8 mm Balance beam Display 50 55 Spring Front a...

Page 172: ...pical 911 design As its predecessor to reduce weight the 911 GT3 Cup 991 is provided with a reduced sealing and sound insulation package The fundamental changes compared to the 997 based racecar are L...

Page 173: ...t bumper The lateral air intakes of the front bumper have been redesigned and enlarged The newly developed daytime running lights are integrated and include LED direction indicators The front bumper i...

Page 174: ...me the typical compact exterior dimensions of a sports car were retained The increase in length is only 56 mm 2 2 To achieve this the overhangs were shortened by 32 mm 1 26 at the front and by 12 mm 0...

Page 175: ...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 re...

Page 176: ...e art joining technologies Aluminum steel hybrid construction 4 4 1 1 The new 911 GT3 Cup 991 has a completely newly developed body in aluminum steel hybrid construction The idea behind this concept o...

Page 177: ...bly 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 High strength A B pillars Reinfor...

Page 178: ...dy 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...

Page 179: ...nsive 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 4 4 4 2 Sheet a...

Page 180: ...mance 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 t...

Page 181: ...ts is the force transmission over the entire surface increasing the strength of the joint Further developments in steel processing allow using ultra high strength and extremely thin walled steels that...

Page 182: ...Bodywork 911 GT3 Cup 991 MY 2015 4 4 7 Materials overview 4 4 7 1 4 4 7 2 Plastic parts Aluminum parts CFRP Modified series parts New parts Carry over parts Version 16 12 2014 181...

Page 183: ...elded into the body Any modifications to the roll cage will result in non certification or disqualification of the vehicle In the event of an accident an inspection of the rollcage and an approval by...

Page 184: ...re provided on the top of the rollcage The vehicle may then be lifted using a special frame recovery bar The recovery eyebolts are clipped into the connections by pushing the red button on top Four lo...

Page 185: ...kets are directly attached to the body 4 5 3 Additional aerodynamic improvements Further aerodynamic improvements were made by implementing the following measures Improved cooling air circulation by o...

Page 186: ...and mirror heating are not installed 4 7 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 i...

Page 187: ...ange The compressed air supply valve is installed in the area of the passenger s B pillar rear side window The maximum working pressure is about 35 38 bar 508 551 psi Important notes Never work below...

Page 188: ...Krontec after two years or 2 000 lifts Check the tightening torque of the grooved nut air jack tightness during normal vehicle checks Tightening torque grooved nut rear 45 5 Nm 33 3 7 ft lb Tightenin...

Page 189: ...k and engine lids 4 10 1 Trunk lid The trunk lid is made of aluminum sheet and optimized for the special motorsport requirements It is provided with NACA intakes on the left and right providing air su...

Page 190: ...in ASE 481 202 00 000 Suction lifter Stahlwille ASE 481 161 00 000 Double cartridge gun VAS 5237 ASE 416 161 00 000 Cut system for glued panes VAS 6452 ASE 481 261 01 000 The tools can be ordered at y...

Page 191: ...y cause cuts and eye injuries Wear your personal protective equipment Only change cutting blades when the power supply is disconnected Wetting the suction cup increases the fixing force 3 Install the...

Page 192: ...n the entire circumference Clamp the free end of the cutting wire to the wiper mechanics Introduce the cutting wire 6 Pull the cutting wire through to the inside Cut adhesive bead from the inside to t...

Page 193: ...operating lever To avoid damage insert the protective film 2 supplied with the cutting system between windshield and vehicle ID number 1 When cutting lead the cutting wire 3 over the protective film R...

Page 194: ...ue serves as primer for the new glue material Keep cut surfaces clean and free of grease and do not clean with cleaning solution 2 Clean and prime paint damages resp newly built up paint surfaces in t...

Page 195: ...gluing surface Clean the window with cleaning solution Apply primer on the window flange around the marking A flash off time of at least 10 minutes should be observed between cleaning the window and a...

Page 196: ...ng time Curing time two hours Temperature at least 10 C 50 F Fixing time about one hour The glue material has an open time of 15 minutes This means that the glue should be applied and the part be join...

Page 197: ...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 Two persons are required to insert position and fix the windsh...

Page 198: ...n the respective vision areas with cleaning solution 6 Mount the interior rear view mirror 4 12 Fenders The fenders are made of aluminum sheet and screwed on with bolted connections to the body The wh...

Page 199: ...ling system 4 14 1 can be obtained at the company Sobek Contact address see chapter 7 9 The following components are installed 1 Level indicator 2 Roll over valve 3 Defueling coupling 4 Fuel pressure...

Page 200: ...not sufficient to completely drain the fuel tank the switch has to be set again from the center position fuel pump off to Service Keep the fuel only in suitable containers The switch Intank Pump Servi...

Page 201: ...design it is absolutely essential to check the body in case of an accident The body of the new 911 GT3 Cup 991 is an aluminum steel hybrid construction This design allows extensive repair work within...

Page 202: ...9 1 Separating chisel incl handle body 512001 1 Anvil dolly half round 511113 1 File with grip medium cut 1 521201 1 Manual deburrer 541030 1 Spare blade for manual deburrer 547030 1 Teroson spatula 5...

Page 203: ...10 3M 2K glue DP 490 Porsche 999 915 323 40 Blind rivet long 5 0 8 5 Porsche 999 190 230 Blind rivet short 3 0 6 5 Porsche 999 190 227 01 Wiel nder Schill Siederstr 50 78054 Villingen Schwenningen Pho...

Page 204: ...3D 4000896048878 1 Anti slip mat 180 38 400089120819 6 Flat scraper 824 4000896033881 1 Heat gun 1990 2 6 4000896141586 1 Wire brush 2130 1 4000896012527 2 Ball peen hammer 2140 5 4000896012695 1 Magn...

Page 205: ...e steps are described separately The estimated time for the described repair is approximately five hours Remove the following parts Fender left right Headlights left right Wheel arch liners left right...

Page 206: ...sche spare part number 991 501 991 8A 4 15 1 1 Together with the front section are consumables such as glue and blind rivets Where possible drill out the self pierce rivets 1 from the rivets head To d...

Page 207: ...um extruded sections are in the carrier frame The aluminum profile is behind the saw line 2 This cut allows removing the front section a more precise cut will follow in a later step Do not bore throug...

Page 208: ...ut the separation cut directly behind the two threads Heat glued joints along the pierced rivets using a heat gun The illustration shows the left side with the arrow pointing in the direction of trave...

Page 209: ...part Carry out grinding operations using a stainless steel wire brush Always use special grinding wheels for grinding aluminum Use grinding wheels with grain size P80 to P200 Observe corrosion protec...

Page 210: ...end onto the carrier from the top to the bottom and align centrally to the rivet hole The saw cut is described for the right carrier frame The distance from the rear end to the saw line is 511 mm 20...

Page 211: ...carrier sheets and open with the separating chisel Carry out the inner saw cut hatched A outer sheet B inner sheet Saw the carrier upper section 1 Remove glue residues in the hatched area Remove the...

Page 212: ...ets have to be provided The illustration shows the right carrier from the inside Transfer the three holes onto the old carrier stub 1 Diameter 6 7 mm 0 26 The illustration shows the right side Saw the...

Page 213: ...are riveted have also to be bonded with two component glue Place and rivet the blind rivets connecting the new part to the body Make sure that two different rivet lengths are available Rivet connecti...

Page 214: ...15 The illustration shows the new front section and the old carrier stub 4 15 1 19 The illustration shows the front section on the left side 4 15 1 20 The illustration shows left inside of the front s...

Page 215: ...11 GT3 Cup 991 MY 2015 4 15 1 21 The illustration shows the front section from the top near the strut dome 4 15 1 22 The illustration shows the front section s left rear panel from below Version 16 12...

Page 216: ...2 Replacing the front strut mount Safety measures Always wear the indicated protective equipment to prevent injuries caused by heat or flying debris Goggles Safety shoes Protective gloves Hearing prot...

Page 217: ...with grip medium cut 1 521201 1 Manual deburrer 541030 1 Spare blade for manual deburrer 547030 1 Teroson spatula 541010 1 Circular brush stainless steel 75 mm knotted 541202 2 Wire brush V shape INOX...

Page 218: ...10 3M 2K glue DP 490 Porsche 999 915 323 40 Blind rivet long 5 0 8 5 Porsche 999 190 230 Blind rivet short 3 0 6 5 Porsche 999 190 227 01 Wiel nder Schill Siederstr 50 78054 Villingen Schwenningen Pho...

Page 219: ...3D 4000896048878 1 Anti slip mat 180 38 400089120819 6 Flat scraper 824 4000896033881 1 Heat gun 1990 2 6 4000896141586 1 Wire brush 2130 1 4000896012527 2 Ball peen hammer 2140 5 4000896012695 1 Magn...

Page 220: ...heel arch liners left Underbody front Chassis left Front bumper Fuel tank Brake lines left Draining the coolant front Water cooler and cooling hoses left Steering gear Air jack front and cross member...

Page 221: ...ween dome and body using a hot air blower Remove the damaged dome Preparation for the installation Carry out grinding operations using a stainless steel wire brush Always use special grinding wheels f...

Page 222: ...is suitable for sawing Align the drilling template exactly and drill the 7 marked rivet holes Then deburr the holes Aligning the new part Grind the gluing surfaces on the new part and on the body down...

Page 223: ...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 6 7 mm On the bottom part of...

Page 224: ...f pierce rivets Item No 628006 Taurus 4 blind riveting tool pneumatic Item No 571110 Cut off grinder angle grinder pneumatic cartridge gun 3M Item No 831101 Manual deburrer Item No 541030 4 parallel c...

Page 225: ...mbly and knock it loose from the body Carry out grinding operations using a stainless steel wire brush Always use special grinding wheels for grinding aluminum Use grinding wheels with grain size P80...

Page 226: ...onded joints The illustration shows the rivets 1 from the outside on the left Place the new part fit the rivets and rivet them The illustration shows the rivets 1 from the inside on the right The illu...

Page 227: ...ork 911 GT3 Cup 991 MY 2015 The illustration shows the rivets 1 on the rear engine mount bumper on the left The curing time of two component glue is 2 3 hours at 60 C 140 F 4 15 3 5 Version 16 12 2014...

Page 228: ...d replace the thread insert and fit a new Time Sert thread insert Defective Helicoil threads of the bolted connections of chassis and assembly carrier have to be replaced by Time Sert thread inserts I...

Page 229: ...three piece use a cutting agent 4 Insert the new thread insert with a special inserter Thread repair kits can be ordered at the following companies Wilhelm B llhoff GmbH Co KG Archimedesstr 1 4 33649...

Page 230: ...ings without collar Tools Hot air blower V A G 1416 WE1119 Thread repair kit 9843 Thread repair kit 9843 1 Thread repair kit 9843 2 Thread repair kit 9843 3 Time Sert thread repair No 122 1 Item 1 Tim...

Page 231: ...thread inserts Helicoil before drilling Release the wire thread insert Helicoil 1 with a suitable screwdriver Pull out the wire thread insert Helicoil 1 Drill out the old thread completely using a sp...

Page 232: ...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 Unscrew the in...

Page 233: ...the inserter 2 Briefly heat the thread insert with a WE1119 hot air blower Leister Electron V A G 1416 Time 2 minutes temperature 80 C 176 F Alternatively do not screw the repaired thread for approx 3...

Page 234: ...d thread completely using the drill included in the kit B The repair bushing has to be fitted more deeply Use the tool included in the tool kit for milling the appropriate recess Mill the recess with...

Page 235: ...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 Press fitting is completed...

Page 236: ...2015 Repair positions overview A Trunk cross member B Strut mount left C Strut mount right D Rear beam left E Rear beam right F Engine mount left right G Bumper mount impact absorber left right 4 16...

Page 237: ...l M12x1 5x30 Thread 2 axle support mounting Helicoil M12x1 5x30 Threads 1 2 Use Explanation Type Basic value Threads 1 and 2 Dimension Y Length 33 mm Threads 1 and 2 Dimension X Length 5 mm Use repair...

Page 238: ...alarm horn mounting only on the left strut mount Helicoil M8x16 Thread 3 sensor mounting Thread M6 Thread 1 Use Explanation Type Basic value Thread 1 Dimension Y Length 20 mm Thread 1 Dimension X Leng...

Page 239: ...Length 20 mm Thread 2 Dimension X Length 5 mm Use repair kit 9843 3 with threaded bushing 999 504 262 01 Thread 3 Use Explanation Type Basic value Thread 3 Dimension Y Length 9 4 mm Use repair kit No...

Page 240: ...hread 3 Helicoil M10x20 4x Thread 4 gearbox mounting Helicoil M10x20 1x Thread 5 M10 1x Right beam Thread 1 chassis mounting Helicoil M12x1 5x24 3x Thread 2 chassis mounting Helicoil M10x20 3x Thread...

Page 241: ...imension X Length 5 mm Use thread repair kit 9843 with threaded bushing 999 504 263 01 Thread 2 3 Use Explanation Type Basic value Thread 2 and 3 Dimension Y Length 25 mm Thread 2 and 3 Dimension X Le...

Page 242: ...X Length 5 mm Use repair kit 9843 1 with THREADED BUSHING 999 504 268 01 Thread 5 Use Explanation Type Basic value Thread 5 Dimension Y Length 37 mm Thread 5 Dimension X Length 10 mm Use repair kit 98...

Page 243: ...ength 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 Cross beam rear engine mount Thread 1 in cast part Thread M8 2x...

Page 244: ...Dimension Y Length 16 2 mm Use repair kit No 122 1 Item 2 Time Sert with long threaded bushing Thread 2 Use Explanation Type Basic value Thread 2 Dimension Y Length 9 4 mm Use repair kit No 122 1 Item...

Page 245: ...dinal beam rear impact absorber mount Thread M8 in cast part Use 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...

Page 246: ...time 2 hours Temperature at least 10 C 50 F Fixing time approx 1 hour A drying time of at least 10 minutes must be observed between cleaning the frame and applying primer No cleaning solution residue...

Page 247: ...triangular bead of adhesive measuring X approx 15 mm 4 17 3 6 Position roof assembly Gap from front roof pillar to roof Gap dimension 5 5 mm 1 mm Offset from front roof pillar to roof Gap dimension 0...

Page 248: ...prove accessibility of the control elements Appearance improvements feature colored controls and a Cosworth data logger with colored display Noise insulation is omitted for weight reduction reasons Th...

Page 249: ...ety and individual comfort to the driver Compared to standard safety seats this combination of seat and seat console provides considerable adjustment options The height and longitudinal adjustment all...

Page 250: ...rior 5 2 2 Seat rail tightening torques Tighten all bolts to a tightening torque 28 Nm 2 Nm Use medium strength thread locker 5 2 2 1 1 M10x16 2 7 16 UNFx16 Version 16 12 2014 911 GT3 Cup 991 MJ 2015...

Page 251: ...ior 5 2 3 Bucket seat tightening torques Tighten all bolts to a tightening torque 23 Nm 2 Nm Use medium strength thread locker 5 2 3 1 1 M10x16 2 7 16 UNFx16 Version 16 12 2014 911 GT3 Cup 991 MJ 2015...

Page 252: ...s equipped with standard padding in medium size M Seat pad thickness S 30 mm 1 2 M 20 mm 0 8 L 10 mm 0 4 Contact address RECARO Automotive GmbH Co KG Stuttgarter Stra e 73 D 73230 Kirchheim unter Teck...

Page 253: ...wheel 5 3 1 The flattened bottom part of the steering wheel rim provides ample legroom during driving and when getting into and out of the car In order to provide additional space for getting in and o...

Page 254: ...vides fresh air through a flexible aluminum hose directly onto the driver yellow arrow The right intake leads the air into the blower unit below the dashboard A switch in the center console allows cha...

Page 255: ...Interior Version 16 12 2014 911 GT3 Cup 991 MJ 2015 254...

Page 256: ...plates binding the entire battery acid In demanding situations higher amounts of energy can be delivered by the fast reaction between the acid and the plate material The battery is maintenance free an...

Page 257: ...ch can be operated in two different ways Inside operation The Main switch 1 which is located in the center console is used as the inside actuator Outside operation Another release mechanism for the ba...

Page 258: ...o respond to the individual needs of the consumers Therefor a channel selective separately secured control is carried out A diagnosis of the module is possible using the appropriate software The diagn...

Page 259: ...ID Lights Frontlight Generator 3 Option AC Unit Low beam left 19 4 LED daytime driving light Low beam right 20 5 Flasher left front rear Starter 21 6 Brakelight right left Intakepumps 3 4 22 7 Option...

Page 260: ...nock control Electronic throttle system and blipper function Error codes Explanation 1 E_tmot Error engine temperature sensor 2 E_toil Error engine oil temperature sensor 4 E_tgear Error gearbox oil t...

Page 261: ...tch Error clutch pressure sensor 51 E_pfuel Error fuel pressure sensor 53 E_pgear Error gearbox pressure sensor 54 E_brev Error reverse gear switch 61 E_psdia_fpump Error fuel pump 62 E_psdia_mil Erro...

Page 262: ...Speed Vwheel_xx Battery voltage Battery Voltage at Dash ub Acceleration sensor x y z G Lat G Long G Force Vert accy accx Brake bias potentiometer Brake Bias Setting Brake light switch Brake Status 104...

Page 263: ...r ath 80 2 Bosch value corresponds to 100 at PI Dash Lambda cyl 1 3 4 6 Lambda 2 0 9 0 1 Throttle 10 Lambda control factor Frc 2 1 0 0 2 Battery voltage ub 13 1 V Water pressure pwat 0 2 bar 2 9 psi F...

Page 264: ...nsors Porsche Motorsport optionally offers a steering angle sensor and brake pressure sensors In addition a memory extension is recommended when fitting optional sensors See chapter 6 6 1 Version 16 1...

Page 265: ...ranged on either side are used as alarm indicators The data saved in the internal memory 32MB can be downloaded using an interface cable via the diagnostic connector on the passenger side The display...

Page 266: ...at Cosworth Cosworth part number 01D 032953 P CUP The kit includes the following extensions Storage extension from 32 MB to 128 MB The logging rate is increased from 50 to 200 Hz Extension of five ana...

Page 267: ...Bosch ECU to the display and is displayed from 1500 to 10 000 rpm The speed area is divided into three sections Green from 1 500 to 7 000 rpm Yellow from 7 000 to 8 500 rpm Red from 8 500 to 10 000 r...

Page 268: ...Left panel The left panel 6 6 2 4 displays a rotating pair of parameters Order Display name Channel Description PI Toolbox channel name 1 Water T Oil T Water temperature Oil temperature MS4 tmot MS4 t...

Page 269: ...olbox Channel Description Fuel Pressure MS4 pfuel Shown for 3 seconds after the engine has started to turn over MS4 tmot 0 Fuel Level Fuel Level The fuel sensor in the fuel tank has to be calibrated t...

Page 270: ...formation Left panel Two different times can be displayed on the left panel 6 6 3 2 The time is always shown in the following format m SS ss Display Description Lap Time The lap time from the lap just...

Page 271: ...The upper image 6 6 3 3 shows a negative value indicating that the driver is currently 0 11 seconds faster than the reference lap The green bar also shows the same value The range of the bar graph is...

Page 272: ...information 3 Alarm information The engine warmup speed range is shown in a smaller scale on the bargraph The following rpm range is sufficient for warming up the engine RPM from 0 to 5 000 rpm are in...

Page 273: ...The displays and values on this page are fixed and cannot be changed 1 Channel information 2 Alarm information Left panel Oil display 6 6 5 2 Label PI Toolbox channel Resolution Unit Scale Oil Press...

Page 274: ...oolbox channel Resolution Unit Scale Description Fuel Level Fuel Level 0 1 Liter 0 110 0 0 29 gal Calibrated sensor so min and max could change Bargraph Fuel Level 1 Non linear display Fuel Press MS4...

Page 275: ...e ICD Power system 6 6 5 9 Display PI Toolbox channel Unit Description Trip IPS Error Alarm Bit Will show active if there is a faulty current on any of the 32 IPS channels Over current IPS Output Curr...

Page 276: ...raphical interpration of front and rear brake pressures and of the balance and the brake bias is displayed 6 6 6 2 Display PI Toolbox channel Resolution Unit Scale Description BP F Brake Press Front 1...

Page 277: ...ation of balance Brake Bias Brake Bias 1 10 to 10 Mechanical bias position ATH MS4 ATH 0 1 0 127 4 Engine throttle sensor APS MS4 APS 0 1 0 127 4 Pedal sensor Right panel Graphical representation of t...

Page 278: ...verlay all other displays for a limited period Brake bias While adjusting the mechanical brake bias values in steps of 0 25 will be displayed The display will keep this setting change one second and r...

Page 279: ...ssible above 10 kph 6 2 mph There are two types of pit speed display The green background is displayed as long as the target speed of 60 kph 37 mph is not exceeded 6 6 7 3 The red background is displa...

Page 280: ...ill always be displayed in the foreground Any alarm can be cancelled manually but if the error is not sporadic and remains active the alarm re appears on the display Priority Alarm Channel Conditions...

Page 281: ...ed more than 2000 rpm 4 Oil temperature MS4 toil 140 C 284 F for 5 sec 5 Water pressure MS4 pwat 0 35 bar 5 psi for 10 sec Engine speed more than 5000 rpm Water temperature at least 68 C 154 F Vehicle...

Page 282: ...1 sec Gearbox emergency switch for manual shift without querying relevant parameters no autom double de clutching no rev matching 10 Low fuel Fuel Level 7 liters 1 8 gal for 12 seconds Engine speed mo...

Page 283: ...ph the top right warning light comes on 6 6 7 11 Other indicator lights on the display Left indicator the green LED 1 flashes Right indicator the green LED 3 flashes Warning lights the green LED s 1 a...

Page 284: ...ng the xenon lens The rear lights are also designed in LED technology The fog lamps are also without function Caution when working on xenon lights The system is under high voltage The system has to be...

Page 285: ...display 1Mbit s CAN 2 highspeed Communication between electrical system control unit and display 1 Mbit s CAN 3 lowspeed Communication between engine ECU and Paddleshift CAN 4 highspeed Acceleration...

Page 286: ...carrier Porsche Spare part number 991 612 948 8A Front section Porsche Spare part number 991 612 301 8A Fuel tank Porsche Spare part number 991 201 697 8A Starter cable B Porsche Spare part number 991...

Page 287: ...shing agent passes through three nozzles into the cockpit and through another three nozzles into the engine compartment The system can be activated from the outside 6 11 2 and from the center console...

Page 288: ...er not there or has already fired then the LED will not light Testing the trigger switch Set the switch on the control unit to the upper position The green LED lights up 1 sec battery is OK The system...

Page 289: ...ached to the steering column by means of a quick release coupling Pushbutton functions on the steering wheel Wiper Push button for the wipers 2 stage High Beam High beam flash Radio Radio system Mark...

Page 290: ...pump switch Ignition Ignition Light Low beam light with daytime running light Rear Fog Light Middle rear light Flasher Flasher left right Fan Fan Screen Driver Fan position windshield driver Emergenc...

Page 291: ...nce longer 1 5 second continuity wiping Press once short off 6 12 4 Interior fan switch The On Off switch is located in the center console The fan speed is not adjustable Another switch in the center...

Page 292: ...iller neck cap 7 1 1 1 The dipstick 7 1 1 2 is located behind the cap in the filler neck Pull the dipstick out of the filler neck and wipe the oil off the dipstick using a clean cloth Introduce the di...

Page 293: ...ine oil Warm up the engine to an oil temperature of 80 C 176 F and then turn off the engine When changing the oil filter Open the oil filler neck cover release and pull out the oil filter housing slig...

Page 294: ...oil filter change 8 1 l 8 6 qt Consumables Porsche spare part number 996 107 225 53 Oil filter element Porsche spare part number 900 123 010 20 Oil tank seal ring Porsche spare part number 900 123 118...

Page 295: ...qt of corrosion protection spare part no 997 106 907 90 Filling quantity 22 liters 23 2 qts Draining the coolant system Open the coolant compensating tank cover Remove the drain plugs item 1 in pictu...

Page 296: ...er of the coolant compensating tank after reaching the operating temperature The system pressure would escape and will not be built up again as the operating temperature has already been reached This...

Page 297: ...hind the cap When the engine is cold the fluid level should be between min and max Place the vehicle on a flat surface to ensure proper measurement Caution when opening the system when the engine is h...

Page 298: ...in plug M20 x 1 5 50 37 lb ft Water drain plug cyl 1 3 M10 x 1 10 7 4 lb ft Water drain plug cyl 4 6 M10 x 1 10 7 4 lb ft Flywheel M10 Refer to 1 8 Cylinder head Cylinder head bolt M10 Refer to 1 7 Ca...

Page 299: ...oupling for defueling Connect the quick disconnect coupling to the nipple of the tank filler neck in the front section To start the process the fuel pump switches located on the center console have to...

Page 300: ...ch position down Normal operation Auxiliary material Porsche spare part number 997 110 355 91 Fuel extraction hose The fuel pump should not run dry as this may cause damage to the pump Ensure that the...

Page 301: ...nsmission oil fill quantity For a rebuild the fill quantity is 3 liters 3 2 qt Filling Place the gearbox on a flat and even surface Slowly fill transmission oil in the inclined filler neck Oil specifi...

Page 302: ...40 mm 0 13 Replace at 3 00 mm 0 12 Installation Make sure that the star shapes of the multiple disk clutch sintered disks are aligned if possible Lightly grease the gear teeth and move the clutch disk...

Page 303: ...procedure Depress the clutch pedal 2 to 3 times and keep it depressed Shortly open the vent valve the clutch pedal has to be depressed and should not be released Close the vent valve again Repeat thi...

Page 304: ...ur hands and the working environment before handling the seal this also applies to engine oil and other oils According to the manufacturer the seal is compatible with hydraulic fluids with DOT4 and DO...

Page 305: ...e drive shaft If the drive shaft moves tight it might degrees the joint temperature and the shaft is to replace Only use HT 1 LF grease for lubrication when overhauling the drive shafts Do not interch...

Page 306: ...enerating includes cleaning of the threads visual inspection for damage and re greasing with aluminum paste Also grease the nut rim contact surface Proceed as follows to prevent the wheel nuts from se...

Page 307: ...Proceed as follows Press the locking pieces into the hub blue arrow Press the locking pins into the hub using a thin object yellow arrow Pull the mechanism approx 5 mm 0 2 out of the hub Before comple...

Page 308: ...l tolerance Proceed in the same way to check the dome bearing and the suspension arm Check the dome bearing by means of vertical movements 7 4 3 1 7 4 4 Wheel hub The wheel hub is a reinforced racing...

Page 309: ...he piston seal rings Dismounting Remove the caliper from the wheel carrier Place a piece of wood in the caliper to prevent the piston from falling out Press the brake piston outwards with low air pres...

Page 310: ...e seals are properly seated Mount the caliper again on the wheel carrier Vent the brake system Brake system cooling channels Carry out a visual inspection for damage and remove any impurities and fore...

Page 311: ...lves have been closed Build up new pressure with the brake pedal 6 Repeat the process and make sure that there is enough brake fluid in the reservoir 7 Perform flushing operation on both valves of a c...

Page 312: ...ing tank must be filled before starting the engine to vent the system Check the fluid level in the tank immediately after starting the engine Turn the steering wheel quickly from one stop to the other...

Page 313: ...nts of the quick release coupling The picture 7 4 10 1 shows the locking pins of the quick release coupling 7 4 10 1 The picture 7 4 10 2 shows the open quick release coupling coupling ring pulled out...

Page 314: ...d function 7 5 1 Airjack system Porsche Motorsport recommends overhauling after two years or 2 000 strokes Only clean air jack piston with silicone grease or spray Regularly check the air jacks for me...

Page 315: ...stem Regularly check connectors for tight fit and corrosion 7 6 1 Checks after wet races Remove moisture from the interior Check electrical connectors for moisture remove if required Version 16 12 201...

Page 316: ...mage or chafing Check the specified tightening torque of all safety critical bolts Check the shock absorbers for leaks Fuel extraction and determination of fuel consumption Check all wheel suspension...

Page 317: ...ange clutch fluid Check clutch wear Check wheel bearing clearance Check air jacks for tightness and leaks Check seats and seat belt Check fire extinguishing system Check Simmerring seal for leaks on f...

Page 318: ...checking Hazet 4800 12A Power transmission Chassis Axle shaft pressing off tool 9454 PAG 000 721 947 00 Axle shaft nut wrench socket 9471 PAG 000 721 947 10 Fork ring wrench Brake nipple Hazet Polygon...

Page 319: ...ngs M5 M6 Threaded nuts threaded pins F rch Rivet tongs 9399 1 threaded bolt rough PAG 000 721 939 91 Mouthpiece threaded mandrel 9399 2 PAG 000 721 939 92 Rep Tool for threaded bushes M12 x 1 25 PAG...

Page 320: ...technik GmbH Co KG Industriestra e 8 68542 Heddesheim Phone 49 0 62 03 40 43 90 0 Fax 49 0 62 03 40 43 91 8 E Mail info sobek motorsporttechnik de MATRA Werke GmbH Dieselstra e 6 63512 Hainburg Phone...

Page 321: ...rookfield Technology Centre Twentypence Road Cottenham Cambridge CB24 8PS United Kingdom Telefon Porsche UK Support Mobil Team 44 1604 598814 Porsche UK Support Non Business Hours 44 1604 598809 Porsc...

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Porsche 2015 911 GT3 Cup, Technical Manual

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