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Porsche 911 GT3 Cup 2008, Technical Handbook

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Porsche 911 GT3 Cup 2008 Technical Handbook Download Page 24

 

 

19

 

 

 

 

 

 

 

 

Remove the gear housing nuts and take off the housing. 

Remove roller bearing. 
Remove the 1

st

 gear ratio wheel. 

Remove the 1

st

 / 2

nd

 gear dog-ring hub. 

Remove the selector rod including the 1

st

 / 2

nd

 gear selector fork. 

 
 

 

 

 
 

 

Remove the 5

th

 / 6

th

 gear selector rod and reverse gear. 

 
 

 

 

 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Remove all gear ratios, hubs etc from the pinion gear shaft.  

 

 

 
 

 

 

 
 

 

Loosen the oil scavenge pipe and twist to the side. 

 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 
 
 

Summary of Contents for 911 GT3 Cup 2008

Page 1: ...911 GT3 Cup Technical Handbook 2008 Model...

Page 2: ...ossibility to reference data adjustment values and working procedures and make the maintenance and repair work on the vehicle easier We wish you every success with your 911 GT3 Cup Dr Ing h c F Porsch...

Page 3: ...Porsche accepts no guarantee that the vehicle conforms to the regulations The car can not be registered for road use and does not comply with German road traffic regulations Illustrations descriptions...

Page 4: ...2683 Technical assistance Mr Rolf Huber 0711 911 82690 Fax 0711 911 82022 Manager Porsche Carrera Cup Mr Helmut Greiner 0711 911 84074 Assistant Mrs Andrea Hagenbach 0711 911 84041 Fax 0711 911 82920...

Page 5: ...Steering 36 Chassis tightening torques 39 Cooling system 42 Brake system 44 PCCB Brake system 47 Bodywork 50 Dashboard and electronic 51 Modas 58 Fire extinguisher 74 Safety instructions Important sa...

Page 6: ...model 997 830 Engine model M 97 75 Gearbox model G 97 60 Number of gears 6 Weight Dry weight approx 1170 kg Dry weight Supercup PCCB approx 1130 kg Dimensions Overall length mm 4450 Maximum width mm 1...

Page 7: ...water cooled Number of cylinders 6 Cylinder bore mm 99 98 Stroke mm 76 4 Actual cubic capacity 3598 cm Compression ratio 12 0 0 4 1 Maximum power 309 kW 420 PS Maximum power at 7500 r p m Maximum tor...

Page 8: ...fts Inlet valve camshaft Engine M 97 75 race component Exhaust valve camshaft 911 GT3 RS Camshaft housing Engine M 97 75 modified 911 GT3 RS production component Piston cylinder Piston clearance 0 02...

Page 9: ...mating faces must be lubricated with engine oil Initial torque 30 Nm 10 mating torque Final torque 1 x 60 2 torque angle Piston The light alloy pistons are 99 95 mm in diameter The position of the inl...

Page 10: ...r is mounted to the engine production GT3 RS 1 Oil tank 9 Piston cooling 2 Pressure pumps 10 Timing chain tensioner 3 Safety valve 11 Camshafts 4 Oil filter 12 Hydraulic valve lifter 5 Oil pressure ga...

Page 11: ...and threads must be lightly oiled when tightening 1 Initial tightening to 30 Nm in accordance with tightening sequence given below Wait fifteen minutes before step 2 2 Completely loosen all the nuts i...

Page 12: ...inlet and exhaust valves with the special tool 000 721 966 10 with inlet special tool 996 450 and exhaust special tool 000 721 Mount the chain tensioning tool 00072194010 Tighten camshaft wheels to ap...

Page 13: ...ve overlap TDC Fit the special tool and if necessary correct the camshaft position After tighten the timing chain sprockets as instructed 30 Nm 90 torque angle Attention Remove camshaft block before t...

Page 14: ...ction specification Exhaust system Exhaust system with cat manifold integrated catalytic converte and silencer Noise emissions are subject to country specific regulations Delivery version without pres...

Page 15: ...ir filter in boot lid Attention The rubber sleeve in the connecting part must be removed when racing in the rain Air filter element Attention Do not clean the air filter element with high pressure Car...

Page 16: ...a spring The adjustment of the connection part is carried out as described in step 1 The throttle cable adjustment is made in 3 steps Tension free setting of throttle cable Unscrew the quick adjustme...

Page 17: ...between the cam disc and the idle adjustment screw throttle completely closed select warm up mode in Motec display press both menu button for 3 sec the Display show you RESET and 0 0 Open throttle 6 5...

Page 18: ...valve M18 x 1 5 40 Crankcase oil drain screw M20 x 1 5 50 Cylinder head and valve train The exact procedure for tightening the cylinder head bolts is described in the section Cylinder head Camshaft h...

Page 19: ...Smear the splines lightly with grease and slide the clutch plates along the splined input shaft till the hub moves easily on the shaft Remove excess grease Make sure no grease is smeared on the clutc...

Page 20: ...3 0 litres of oil should be added The use of Mobil Mobilube SHC gearbox oil is recommended Production gear ratio set Crown wheel and pinion 8 32 1st gear 12 38 997 302 961 6E 2nd gear 15 32 997 302 9...

Page 21: ...pe 997 model 2008 29 27 23 26 20 28 18 31 15 32 12 38 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 V km h n Mot 1 min Standard GT3 Cup Model...

Page 22: ...tch when down shifting Gearbox maintenance The following work should be carried out after a total running time of approximately 2000 km Check gear ratio pairs gear teeth and dog teeth Check the dog ri...

Page 23: ...il pipe Engage 1st gear Drive out the 5th 6th gear selector fork roll pins with a suitable drift Attention When removing the roll pins make sure the selector fork rod is properly supported Remove the...

Page 24: ...e 1st gear ratio wheel Remove the 1st 2nd gear dog ring hub Remove the selector rod including the 1st 2nd gear selector fork Remove the 5th 6th gear selector rod and reverse gear Remove all gear ratio...

Page 25: ...ull the pinion gear shaft out of the mounting plate After the removing the mounting plate remove the selector rod with the 3rd 4th gear selector fork Remove the circlip and sliding sleeve from the inp...

Page 26: ...lways replace the complete clutch pack Change individual plate s is not permitted When reassembling the differential smear all the friction faces pressure plates and the axles with gearbox oil To chec...

Page 27: ...plit input shaft and fit the sliding sleeve and circlip Fit the selector rod with the 3rd 4th selector fork and push the cam follower into selector barrel track Push the pinion gear shaft into the mou...

Page 28: ...Attention The gearbox must be positioned vertically before fitting the mounting plate Rotate the selector barrel to the 1st gear position Slide the oil pump drive spacer 3rd gear bearing hub needle r...

Page 29: ...ear dog ring hub Push the 1st gear idler wheel onto the shaft Fit the 5th 6th gear selector rod with cam follower Fit the roller bearing Fit the axial needle roller bearing and spacer ring to the sele...

Page 30: ...e pinion gear shaft Fit the splined 5th gear wheel to the input shaft Fit the reverse gear and afterwards the selector fork Tighten the collared input shaft nut to 220 Nm torque Tighten the collared p...

Page 31: ...pecial reverse gear tool 996 450 311 9A Engage reverse gear by rotating the selector barrel Slide the selector fork and dog ring till reverse gear is fully engaged Attention There must be play on both...

Page 32: ...ghten the gearbox cover M8 spring washers and nuts Fit the drive shaft and gear recognition potentiometer as marked during removal Attention The potentiometer MUST be adjusted after the gearbox has be...

Page 33: ...ing the selector barrel the position of the barrel track must be fitted in exactly same position Place the old selector barrel with spacer washers on the special base plate The barrel must sit correct...

Page 34: ...eutral latch replacement When replacing the locking pawl neutral latch bolt it must be secured with Loctite 243 Adjustment of the gear recognition potentiometer Connect the laptop to the vehicle switc...

Page 35: ...lease lever must me moved to change from 1st gear to neutral Sequence 1st gear neutral reverse gear Gear shift push pull cable The gear shift cable should be changed after 25 hours running A regular v...

Page 36: ...arbox casing nut M8 25 Input shaft nut M22 x 1 5 220 Input shaft nut M30 x 1 5 220 Pinion shaft nut M30 x 1 25 330 Selector fork screw M8 10 9 35 Drive flange bolts M10 45 Crown wheel to diff carrier...

Page 37: ...32 Special tools Gear ratio housing tool Part number 996 450 310 9A Reverse gear tool Part number 996 450 311 9A Inner shift rod tool Part number 996 450 315 9A Shift grip Part number 996 450 313 9A...

Page 38: ...ooling fluid and approximately 18 litres of water are used when refilling the cooling system Recommended products Engine oil Mobil 1 0W 40 Engine cooling fluid Porsche cooling fluid part number 999 91...

Page 39: ...ulti link axle with spherical bearings Centre lock wheels Multi adjustable anti roll bar Non adjustable dampers Main spring 130 60 260 Helper spring 60 60 50 Wheels 3 piece BBS race wheel Front 9J x 1...

Page 40: ...ly on each side When rotating the lever arm do not damage the material with unsuitable tools Grooves or notches or any other type of damage can lead to the lever arm braking Changing the wheel bearing...

Page 41: ...s recommended that new driveshafts are run in for 100 kilometres at a maximum speed of 200 km h and at low torque Driveshafts that have already been fitted and run in a particularly direction must not...

Page 42: ...should be repeated until the fluid level in the reservoir remains constant The fluid level in the hydraulic steering oil reservoir must never drop below the min mark to prevent damage occurring to th...

Page 43: ...rst and then the toe Adjust the front axle camber first and then the toe Re adjust ride height and set corner weights It is not possible to adjust the castor The corner weights are adjusted by changin...

Page 44: ...r work under the car with the air jacks extended without proper axle stands To prevent damage occurring to the internal cylinder end stops never pressurise the system without the car being on the grou...

Page 45: ...5 x 25 100 Wishbone to subframe M12 x 1 5 x 95 120 Wishbone on upright M12 x 1 5 75 Side member to chassis M14 x1 5 x 110 160 Side member to wishbone M14 x 1 5 x 75 160 Drop link on anti roll bar M10...

Page 46: ...ontrol arm 3 on side part M12 x 1 5 x 100 110 Control arm 3 on upright M12 x 1 5 x 80 110 Control arm 4 on side part M12 x 1 5 x 100 110 Control arm 4 on upright M12 x 1 5 x 80 110 Sub frame on side p...

Page 47: ...ier frame lateral support M8 23 Oil line on steering rack M10 x 20 20 Pedal assembly Brake balance adjuster on chassis M8 23 Brake balance adjuster on chassis Aluminium spacer M8 x 154 x 80 23 Pedal s...

Page 48: ...n pipe 997 106 502 00 have different quick release Henn Couplings at each end These Henn Couplings have safety clips Engine side safety clip 996 106 802 10 Chassis side safety clip 996 106 802 11 Thes...

Page 49: ...he filling system connected and allow the cooling fluid to circulate through the system to ensure that the cooling system is pre bled sufficiently Afterwards disconnect the filling system and warm the...

Page 50: ...Pad thickness 13mm without backing plate 18mm with backing plate Brake caliper 6 piston aluminium monobloc Caliper pistons with Zirkonoxide inserts Rear brakes Brake discs Ventilated Steel D 350 mm B...

Page 51: ...green marking The front to rear brake balance can be adjusted by turning the adjuster shaft When the car is delivered the brake balance is set to 40 bar on the front and 38 bar on the rear axle Rotati...

Page 52: ...dle position before fitting the potentiometer The display values must not exceed 7 or 7 when rotating the balance bar the potentiometer will be severely damaged if rotated beyond these values Potentio...

Page 53: ...r when cleaning the cooling holes with a drill bit Brake discs with mechanical damage must be replaced The PCCB brake disc wear can ONLY be determined by the weight reduction and not by the reduction...

Page 54: ...Super Fluid brake fluid should be used Brake master cylinders and balance bar The two brake master cylinders supplying each brake circuit have different bore diameters Front axle 20 6 mm orange marki...

Page 55: ...iddle position before fitting the potentiometer The display values must not exceed 7 or 7 when rotating the balance bar the potentiometer will be severely damaged if rotated beyond these values Potent...

Page 56: ...door windows rear and front screens Fuel tank Production 90 litre tank Seat OMP racing bucket seat driver s side only optimised for HANS Safety system Safety harness Schroth 3 six point harness witho...

Page 57: ...data recording Optional 4 Mb memory Driver cooling windscreen ventilation The fan has three possible settings Pushed in position 100 foot well ventilation ducts and driver cooling Pulled out position...

Page 58: ...tor Practice Engine revs bar graph Engine revs digital Vehicle speed Brake balance Lap time Water temperature Oil temperature Oil pressure Fuel pressure Gear indicator Reverse gear indicator Battery v...

Page 59: ...nsors fitted in car 4 x wheel speed sensors Clutch system pressure sensor Acceleration sensor Fuel level Lap Trigger Fuel pressure sensor Oil pressure sensor Engine speed sensor Water pressure sensor...

Page 60: ...ump only runs when the engine is running Data logging Motec Display with 1 Mb data logging memory Option Steering angle sensor in connection with 2 Mb memory Interface CAN When using the CAN interface...

Page 61: ...to reset the alarm display in the Motec display Pit lane speed limiter is programmed to 50 km h but can be re programmed with the Bosch Modas system Battery main relay Only operate the master switch a...

Page 62: ...57 Relay and fuse layout...

Page 63: ...58 Location of main fuse for steering hydraulic Boot front right 80 Amp...

Page 64: ...32 MB Ram LPT1 interface KIC2 interface with Modas release The connection between the PC and ECU is made through a KIC2 interface MODAS release licence is made via the KIC2 interface Files ASAP and CF...

Page 65: ...e saved values can be transferred to the ECU Changing the adjustable values is possible without a direct connection to the ECU The functions are activated in the Parameter File Manager in the Menu too...

Page 66: ...nd the description file given in the MODAS configuration drive the user is requested to load the description file belonging to the programme version in the control unit from the disk drive If the desc...

Page 67: ...played behind the actual value Supplementary information full description of variable about the measured or adjustable variables is super imposed when the mouse pointer hovers over a field The adjusta...

Page 68: ...ns One page can contain up to 10 displays with their display choice buttons The display choice buttons remain the same only when the choice of displays is changed Display choice buttons are white page...

Page 69: ...64 Bosch Modas Start page Bosch Modas Porsche GT3 Cup Mj 2008...

Page 70: ...r temperature Engine oil temperature Gearbox oil temperature Intake air temperature Relative air mass Engine oil tank level Crankcase pressure Battery voltage Lambda cylinder 4 6 Regulation factor 4 6...

Page 71: ...ase with throttle angle wdkba w is zero 0 when throttle reset wdk_w and wdklm are equal after reset Check Reso 1 Function reset throttle 1 Check Reso 2 Function reset throttle 2 Error throttle poti Ra...

Page 72: ...inMax to reset minimum and maximum values Run time ECU Vehicle mileage Vehicle mileage Run time engine Over rev 1 Over rev 2 Max revs Fuel consumption ECU number Template for lifetime and mileage ltee...

Page 73: ...e oil temperature B oellamp Display TRUE if oil pressure warning lamp is activated phase test When cylinder 1 identified display 1 0 1 0 1 0 phspos_w if display 25 at idle speed and or 27 30 at full t...

Page 74: ...our Real time minute Real time second Flag memory Flag flashcard detect Flag new init Flashc Flag recording active Set real time year Set real time month Set real time day Set real time hour Set real...

Page 75: ...68 Error flag speed Vehicle speed Vehicle speed Number of pulses FR Wheel circumference FR ERROR wheel speed error speed detection display TRUE E vradxx error...

Page 76: ...0 V cut off starts at 2 9 V E GSH error gearshift sensor display TRUE BUTTON SYNCHRO code for synchronised gearbox must be flashed to reference page by using Action Flashing Workingpage to reference P...

Page 77: ...must be flashed to reference page by using Action Flashing Working Page to Reference Page ugang_w Voltage gear poti set to 3 85 V in 6 Gear CAL GEAR calibrates gear potentiometer to 3 85 V must be fl...

Page 78: ...71 Lap counter Flag Lap trigger f ECU Flag Lap trigger Track length Factor min tr length Factor max tr length Min speed...

Page 79: ...speed CWVMAX code for pitspeed Limit 0 for km h or Button Pitlane km h 1 for mph or Button Pitlane mph must be flashed to reference page by using Action Flashing Working Page to Reference Page Error w...

Page 80: ...73 Loading data files hex files 1 Action 2 Datapart 3 Download to ECU 4 Open in corresponding file window...

Page 81: ...ng the manometer mounted to the extinguisher bottle Attention The extinguishing agent extinguisher cylinder and flexible pipes should be replaced after a maximum of 2 years from the date of manufactur...

Page 82: ...correctly Only Alkaline batteries should be used Checking the firing button Attention The toggle switch on the trigger box must be set in the System Inactive position Press the button in the windscre...

Page 83: ...Version 1 2008 Illustrations descriptions and schematic drawings serve exclusively as presentation for the text We undertake no liability for the completeness and conformity of the contents with resp...

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