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Porsche 911 GT3 Cup MR Gen. II, Technical Manual

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Porsche 911 GT3 Cup MR Gen. II Technical Manual Download Page 15

 

15

 

Version V2, 08/2020

 

 

 

 

 

 

 

  

 

  Porsche 911 GT3 Cup MR Gen.II

 

 

Home

 

 

 

 

3.1    Service Intervals

 ...................................................................... 

16

 

 

3.2    Exhaust Manifolds 

 .................................................................. 

17

 

 

3.3    Porsche Motorsports Silencers 

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18

 

 

3.4    Fuel System 

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 Refuelling

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19

 

 

3.5    Fuel system 

-

 Capacity increase 

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20

 

 

 

 

 

3 

Exhaust System & Fuel System

 

Summary of Contents for 911 GT3 Cup MR Gen. II

Page 1: ...Porsche 911 GT3 Cup MR Gen II Type 991 2 Technical Manual Version V2 08 2020...

Page 2: ......

Page 3: ...y to look up data settings and operating regula tions and also to facilitate the maintenance of the car It should be clearly pointed that this manual should only make the operation of your 911 GT3 Cup...

Page 4: ...or this technical manual Please note that only the latest version of the technical manual is valid This can always be found in the download area of the Manthey Racing GmbH homepage under https www man...

Page 5: ...t proper training tools and equipment may result in death or injury to yourself or others In addition there may be vehicle damage or malfunction of the correct vehicle function It is therefore express...

Page 6: ...Brake Lines Quick Couplings 32 4 7 Rear Axle Suspensions Struts 33 4 8 Rear Axle Side Subframes 35 4 9 Drive Shaft Spacers 36 4 10 Power Steering 37 4 11 Rims 39 5 Body Exterior 41 5 1 Service Interv...

Page 7: ...7 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home 1 1 Service Intervals 8 1 2 Engine Oil Quick Filler 9 1 3 Central Radiator 10 1 Engine...

Page 8: ...Before every session Check the filling hose in the engine com partment for firm seating and chafe marks Check the quick disconnect coup ling for cleanliness and damage Central radiator Before every se...

Page 9: ...he vehicle opera tor must confirm with the organizer whether the opening in the engine cover is permitted Under certain circumstances this can be inter preted as an irregular aerodynamic change Only f...

Page 10: ...ant antifreeze approved by Porsche AG may be used The specified mixing ratio for the 911 GT3 Cup Gen II has to be used 10 Nm 10 Nm 10 Nm 10 Nm NOTE The hose clamps for the connectors may only be used...

Page 11: ...Cup MR Gen II Home ENGINE Central Radiator Cooling System Schematic GB_WT Bank 1 Bank 2 Central radiator KMAB MO_WT Water system short cut Ventilation line GB_WT Gearbox_heat exchanger MO_WT Engine oi...

Page 12: ...12 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home 2 1 Service Intervals 13 2 2 Clutch Bleeding Line 14 2 Gearbox...

Page 13: ...up MR Gen II Home ENGINE Service Intervals 2 1 Service Intervals Part Service interval Max runtime Service advice Bleeding the clutch Before each session Bleed the clutch before each session Check the...

Page 14: ...stalled in the area of the water pipe around the ventilation line Failure to observe this may cause damage to the ventilation line A failure of the clutch system is possible NOTE The components of the...

Page 15: ...0 Porsche 911 GT3 Cup MR Gen II Home 3 1 Service Intervals 16 3 2 Exhaust Manifolds 17 3 3 Porsche Motorsports Silencers 18 3 4 Fuel System Refuelling 19 3 5 Fuel system Capacity increase 20 3 Exhaust...

Page 16: ...ervals Max runtime Service advice Exhaust manifolds Before every session 50 hours Check the exhaust manifold and heat protection for damage before each sessi on If the side silencers available from Po...

Page 17: ...to the effects of heat Risk of fire Only new exhaust manifolds can be provided with the heat protection insulation New exhaust manifolds with heat protection must be obtai ned from Manthey Racing GmbH...

Page 18: ...of fire Detailed installation instructions can be downloaded from the down load area of the Manthey Racing website WARNING The components of the side silencers must be checked for damage before each...

Page 19: ...e tank cans with a hose attachment 3 5 Nm 20 Nm NOTE Fireproof clothing is strongly recommended for all work on the fuel system including refueling and defueling Failure to observe can result in serio...

Page 20: ...ing Failure to observe can lead to serious injuries Suitable fire extinguishers must be provided for all work on the fuel system The fuel system including the tank tower and its components must be che...

Page 21: ...spension Struts Shock Absorbers 24 4 3 Brake Cooling Front Axle 27 4 4 ABS M4 28 4 5 Brake Lines Rear Axle 31 4 6 Brake Lines Quick Couplings 32 4 7 Suspension Struts Rear Axle 33 4 8 Side subframes R...

Page 22: ...tight fit Check play in the joints Tie rod rear axle Before every session 90 hours Check for damage and tight fit Check play in the joints Side sections rear axle Before every session 90 hours Check t...

Page 23: ...fore each event Brake cooling ducts hoses front axle Before every session Check air ducts for free passage over the entire length Check flexible pipe parts for chafe marks Replace defective parts ABS...

Page 24: ...ing wheel clockwise direction of arrow to the desired level and count the clicks 3 Always start with step 1 for further adjustment of the rebound damping and then perform step 2 Position 0 Rebound Clo...

Page 25: ...ller bearings can be dismantled Cleaning is done using isopropanol High temperature resistant and water resistant roller bearing grease e g STALOC RED BEARING roller bearing grease is suitable for the...

Page 26: ...ve suspension variant The following suspension variants are available Suspension variant GP Track MTH034810A Spring FA 180 60 120 180 N mm with lenght l 120mm P Nr MTH411865 Spring RA 200 60 140 200 N...

Page 27: ...pec tion before each session is recommended Defective hose sections must be replaced immediately 3 Nm 10 Nm 3 Nm NOTE Do not tighten the hose clamps with a higher torque as specified NOTE Before each...

Page 28: ...cal assignment are not corrected life threatening driving conditions can arise while driving DANGER The brake master cylinders with part number 9913551708C installed in the base vehicle MUST be replac...

Page 29: ...nd the vehicle The RaceABS software at least version 1 4 0 9 from Bosch is requi red for communication diagnosis and maintenance of the ABS M4 A suitable FPS file for displaying the fault memory in pl...

Page 30: ...nce an optimal ABS setting depends not only on many vehicle and track specific factors but also not least on the driving skills of the driver In order to familiarize yourself with the control interven...

Page 31: ...must be observed If the connector is removed from the brake caliper the marked sealing ring must be re placed WARNING Check the brake lines for damage chafing abrasion and firm seating before each se...

Page 32: ...sferred to the pistons of the brake caliper whereby the driver assumes that the brake is fully functional brake pedal feedback DANGER Never attempt to connect disconnect the quick coupling while the s...

Page 33: ...for the individual linkages must be observed The length of the struts is preset and is delivered ready for installation If there is play in a linkage ball joint the link must be replaced ATTENTION ATT...

Page 34: ...t be mounted on the UPPER hole of the subframe Pos Part Description Part Number Preset Lenght mm 1 Wishbone lower MTH331053 300 mm 2 Trailing arm lower MTH331043 332 mm 3 Wishbone upper MTH331047 220...

Page 35: ...rt of the regular vehicle maintenance the side subframes must be checked for damage 120 Nm M12x1 5 65 Nm M10x1 5 120 Nm M12x1 5 120 Nm M12x1 5 Changes to the attachment point in the aluminum side subf...

Page 36: ...ocess Stage 1 30 Nm Stage 2 60 Nm Stage 3 90 Nm The standard shims with part number 7L0501357D must NOT be used anymore Failure to do so can result in damage to the body and powertrain components ATTE...

Page 37: ...N Even small amounts of air in the system significantly reduce the ser vice life of the power streeing pump and the steering rack ATTENTION NOTE The protective housing around the power steering pump m...

Page 38: ...nt Damaged lines must be re placed 16 Nm 16 Nm 20 Nm NOTE NOTE The power steering pump s ventilation line must not be kinked Check the condition of this line regularly NOTE The connections 12Volt BATT...

Page 39: ...er of Molub Optimol Paste TA lubricant to the rim cone and the wheel nut cone face Before use thread new wheels several times with the specified tighte ning torque tighten loosen 3 times until a unifo...

Page 40: ...wo years Do not block the openings of the pressure sensor with the tire mounting paste This can impair the function of the pressure sensor NOTE Only original valves with part number 9F2601361 may be u...

Page 41: ...Home 5 1 Service Intervals 42 5 2 Air Jack System 44 5 3 Front Bumper 47 5 4 Front Impact Bar 48 5 5 Polycarbonate Windscreen 49 5 6 Fender 50 5 7 Trunk Lid 51 5 8 Underbody 52 5 9 Rear Covering 57 5...

Page 42: ...by the manufac turer Check the jacks for damage every time the vehicle is serviced and maintain with silicone spray Lock pins Before every session Check for tightness and damage Replace if necessary...

Page 43: ...Before every session Check the underbody and skid pads for wear and damage Replace components if necessary Rear wing wing supports Before every session Check the rear wing and wing supports for firm s...

Page 44: ...raining in hand ling the air jack system WARNING Never work under the raised vehicle without securing it against unin tentional lowering It must always be secured with the standard air jacks supports...

Page 45: ...n sure that the air jacks are retracted completely and to prevent the jacks from being inadvertently removed when the system heats up NOTE NOTE If the optionally available Autostart function is ordere...

Page 46: ...ing the air jack system A second level for the air jack supports is available to make working under the vehicle easier Always park the bottle trolley securely and secure it against falling over ATTENT...

Page 47: ...o the left and right of the central air inlet for the front brake cooling The front bumper is attached using four fastening screws in the lower area The front bumper must clip into the corresponding b...

Page 48: ...MR Gen II The position and length of the towing eye mount must be adjusted The attachment points of the bumper on the body remain unchanged The corresponding tightening torque can be found in the ill...

Page 49: ...ower susceptibility to stone chips and the resulting cracks 5 5 Polycarbonate windscreen NOTE The use of a multi layer tear off film MTH541916 is strongly recom mended to protect against scratches Det...

Page 50: ...aced separately The exhaust vents in the fenders Louvre ensure continuous ventilation of the wheel house This counteracts lifting caused by excess pressure turbulence in the wheel house which is notic...

Page 51: ...t be replaced The bolts must be checked for damage and firm seating as part of the vehicle preparation An improperly closed trunk lid can open tear off and hit the wind screen while driving WARNING Pu...

Page 52: ...ont Splitter Underbody Centre Sill Cover LH Sill Cover RH Underbody Centre Rear Underbody Rear Diffuser The marked areas represent skid pads The skid plates can be replaced individually and are arrang...

Page 53: ...found in the detailed assembly instructions This is available for download from the Manthey Racing website The brackets on the front underbody to hold the cables and the atta chment points on the bod...

Page 54: ...tal alignment of the two strips is required The corresponding tightening torques can be found in the detailed assembly instructions This is available for download from the Manthey Racing website The s...

Page 55: ...0 Nm 8 Nm The standard air ducts for the drive shaft joint cooling of the 911 GT3 Cup Gen II are installed in the positions shown NOTE The two service flaps on the left and right on the underbody can...

Page 56: ...insulation Damage to the heat protection must be repaired immediately Failure to observe may lead to thermal overloading of the fiber composite material and cause a fire NOTE 35 Nm 8 Nm 8 Nm ATTENTIO...

Page 57: ...terial Failure to observe this can result in heat damage to the rear bumper The weight optimized rear bumper is made of carbon fiber composite and is designed for fastening the rear diffuser ATTENTIO...

Page 58: ...d onto the two tabs on the wing supports and then fixed to the front hol ding peg using two lock pins Care must be taken that the two pins in the wing supports engage in the recesses in the engine cov...

Page 59: ...ng support are ex tended by three additional attachment points This results in a wider adjustment range for the rear wing The Gurney contributes significantly to the overall downforce and is therefore...

Page 60: ...unt hole front Support mount hole front Wing mount hole rear Support mount hole rear 4 D 9 I 10 3 C 8 I 10 2 B 7 I 10 1 D 6 I 10 0 C 5 I 10 1 B 4 I 10 6 H 5 J 10 7 G 4 J 10 9 H 2 J 10 10 G 1 J 10 If t...

Page 61: ...n V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home 6 1 Service Intervals 62 6 2 Endurance Wiring Loom 63 6 3 Xenon Headlights 75 6 4 ICD Configuration 76 6 5 Traction Control TC 111 6 6 24H Lights 112 6...

Page 62: ...rrect Check the function of all connected systems Xenon headlights Before each event Check the function of the xenon head lights Check function of LED rings daytime running lights flashing func tion e...

Page 63: ...r conditi 6 2 Endurance Wiring Loom NOTE 10 Nm 5 Nm Before each event all wiring harnesses must be checked for chafing and the connectors for correct fitting NOTE If the optionally available rear wiri...

Page 64: ...64 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home ELECTRICS Endurance wiring loom Overview Main Wiring Loom Cockpit...

Page 65: ...65 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home Overview Main Wiring Loom Connectors Cockpit...

Page 66: ...66 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home Overview Main Wiring Loom Connectors Cockpit Cont...

Page 67: ...67 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home Overview Main Wiring Loom Connectors Cockpit Cont...

Page 68: ...910110 SICMA 211 PL249S0005 Front option DTM06 6S Option lights right DT06 4S Terminal front DTM04 2P RGB_right DTM06 4S RGB_left DTM06 4S Option lights DT04 2P Sensor_press_airjack Bosch 1 928403968...

Page 69: ...S Connector Front IO Connector to the front IO gate way RGB_left Connector for the left indicator ring RGB_right Connector for the right indicator ring Optionlight right Connector DT06 4S Optionlight...

Page 70: ...n Connector DT06 6S Terminal Front Connector to the relevant connector on the wiring loom Cockpit labelled Terminal Front Front option Connector to the optionally available 24h light bar Sensor press...

Page 71: ..._lenses Connector DTM04 4P headlight Connector DT06 8S Power_XENON Power supply for the Xenon Headlight control unit LED_controller Connector for the LED control LED_lenses Connector to the relevant c...

Page 72: ...72 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home ELEKTRIK Endurance Kabelstrang Overview Rear Wiring Loom MTH971300 Rubber Grommet...

Page 73: ...tor to the the suitable connector on the Cockpit wiring loom AC compressor Connector to the AC compressor Sensor pres airbox Connector to an additional pres sure sensor Spare1 Connector DTM06 2S Spare...

Page 74: ...n AC Engine Connector DT06 4S Option RADAR Connector 1 1534229 1 Trenn2 Connector to the junction at the cockpit loom Option AC Engine Connector for AC use Option RADAR Connector to an additional rada...

Page 75: ...ddition to the daytime running light function the four LEDs also perform the following functions Indicator Alarm display for error memory entries configurable in the ICD configuration NOTE The standar...

Page 76: ...sis Not availaible while driving Adjusting and operating the ICD while driving can distract from the surrounding environment Control of the vehicle can be lost Only operate the ICD while driving if th...

Page 77: ...gaged gear and vehicle speed are shown in km h in the centre of the main page In the left area of the RACE main page the driver is shown the most important vehicle vital signs Compared to the RACE and...

Page 78: ...s triggered via the IR beacon the lap time just completed is frozen in the Lap Time display for 30 seconds The display then returns to the rolling lap time On the right side of the display the driver...

Page 79: ...scale Below optimal temperature range Temperatures from 80 C to 85 C Green Bar scale Target temperature reached Temperatures from 86 C to 100 C Yellow Bar scale Above optimal temperature range Risk of...

Page 80: ...mechanics Variable Channel Name Resolution Unit Value Range Oil Press ecu_poil 0 1 bar 0 to 10 Oil Temp ecu_toil 1 C 100 to 200 Oil Level ecu_oillevel 1 30 to 130 Display Section Engine Oil Variable C...

Page 81: ...o 500 Display Section Fuel System Display Value Black Background Shift paddle not actuated Yellow Background Shift paddle actuated Display Section Shift Paddles Variable Channel Name Resolution Unit V...

Page 82: ...Warning Symbol History pcu_error_alarm_latched Active Warning Symbol Over Current pcu_output_current_alarm Active Warning Symbol Over Temp pcu_temp_alarm Active Warning Symbol Display System Power Sys...

Page 83: ..._brk_balance 0 1 Math calculation of the brake balance Brake Bias dash_brkbias 1 Brake Bias Adjuster Position Brake Bias dash_brkbias Graphical representation of the brake force distribution between t...

Page 84: ...meter Trip 1 km 0 to 999999 Engine Lifetime dash_enginelifetime 0 5 h 0 to 99999 0 Display Section Odometer Variable Channel Name Resolution Unit Value Range Steering Voltage Input 5 Voltage 0 01 Volt...

Page 85: ...h 0 to 500 Front Circ Abs_circ_f 1 mm 0 to 5000 TPMS Press TPMS_press_FL 0 1 bar 0 to 6 3 Display Section Front Left Wheel Variable Channel Name Resolution Unit Value Range Speed dash_speed_fl 1 Km h...

Page 86: ...splay Section Rear Left Wheel Variable Channel Name Resolution Unit Value Range Speed dash_speed_rr 1 Km h 0 to 500 TPMS Press TPMS_press_RR 0 1 bar 0 to 6 3 Display Section Rear Right Wheel The value...

Page 87: ...ure is used to set a track map graphic Connect your PC to the vehicle Switch on MAIN Establish a connection between the PC and ICD On the menu ribbon select the Actions tab On the left side menu selec...

Page 88: ...for the duration Warning Channel Name Resolution Unit Condition ALARM Water Temp ecu_tmot 1 C tmot 110 C ALARM Oil Press If the oil pressure drops while driving rpm 1800 min 1 below a value of 1 0 ba...

Page 89: ...hird alarm LED on the left will alight solid yellow for the duration of this status Warning Channel Name Resolution Unit Condition WARN Gbox EMSW ecu_B_emsw 1 Gearbox Emergency switch activated ALARM...

Page 90: ...or exceeded while the engine is running the alarm message opposite will be displayed with the value of the pres sure Additionally the third alarm LED on the left will alight solid yellow for the dura...

Page 91: ...low These information overlay are display in yellow blue and grey Circ Check Toggle Ignition This message is displayed on the ICD when the vehicle is started This highlights the importance that the co...

Page 92: ...nformed in the ICD PWR Steering Parking Mode If the Mark button on the steering wheel is pressed briefly 0 75 seconds with the ignition swit ched off the power steering pump is activated for 30 second...

Page 93: ...viour Adjust the setting to the present weather conditions Brake balance setting must be adapted to the vehicle setup New setting should be tested carefully To check the braking force distribution whe...

Page 94: ...CodeXX function is only available from second gear Activation is The upper area of the ICD show the driver their compliance with the CodeXX speed stored in the system Further information on the setup...

Page 95: ...rma Display of the fuel quantity consumed Fuel Cons in this stint or since the display was last reset If the CodeXX speed set using the PI Toolset is exceeded the background colour of the entire scree...

Page 96: ...ally located speed display the current gear selection left and the accelerator pedal position right are also displayed If the preset speed is exceeded the background colour of the display page changes...

Page 97: ...cription Upper Right LED Solid Green 60 m Slow 10 km h Right The system detects an approaching vehicle on the right side of the vehicle at far distance with a low approach speed Upper Left LED Solid G...

Page 98: ...Left LEDs Slow Flashing Red 20 m Moderate 10 km h Left The system detects an approaching vehicle on the left side of the vehicle at short distance with a moderate approach speed Upper Right LED Fast F...

Page 99: ...LEDs Low Fuel Pressure ecu_pfuel ecu_pfuel 2 5 bar at rpm 1800 min 1 ALARM Fuel Press Oil Temperature ecu_toil ecu_toil 120 C ALARM Oil Temp Camshaft Control dash_alarm_cam dash_alarm_cam_ctrl 0 0 Cam...

Page 100: ...M Battery Water Level dash_sw09_watlev dash_sw09_watlev Button released ALARM Water Level Generator dash_cond_alt_stopped dash_cond_alt_stopped 1 0 ALARM Check Belt Starter dash_alarm_startbtn dash_al...

Page 101: ...quired Open the Setups tab If the corresponding ICD setup is already saved in the setup list it can be opened by double clicking If the ICD setup is not yet listed in the setup list it can either be l...

Page 102: ...l place and decimal point separators in Row 1 The default value for the front and rear axles is 1 9 bar NOTE The system will not accept value entered using a comma as the deci mal separator NOTE If th...

Page 103: ...will be lost when the changed setup is transferred Carry out a data backup beforehand NOTE Procedure for setting the Color ID display of the Error Monitor when crossing the timing signal for the LEDs...

Page 104: ...w 0 the Value 2 if the Error Monitor should be displayed after crossing beacon signal Procedure for setting the Color ID when the Pit Speed Limiter is active Enter in Row 1 the Value 1 if the Color ID...

Page 105: ...g signal Enter in Row 1 the necessary value for the desired colour flash frequency of the Color ID when activating the Pit Speed Limiter All possible settings for the colour flash frequency are listed...

Page 106: ...ium flashing and fast flashing Procedure for setting the colour of the Color ID when crossing of the timing signal and the Color ID upon activation of the Pit Speed Limiter Enter in Row 0 the necessar...

Page 107: ...n the Code_XX_Enable tab In the input area change the Value 0 function deactivated to Value 1 CodeXX active Open the tab Code_XX_Target_Speed Only whole numbers without decimal places are accepted by...

Page 108: ...e tab some values for tyres from various manufacturers are stored as comments These values do not claim to be accurate or correct NOTE Contact the tyre manufacturer for sizes or obtain by measuring us...

Page 109: ...tab some values for tyres from various manufacturers are stored as comments These values do not claim to be accurate or correct NOTE Contact the tyre manufacturer for sizes or obtain by measuring usin...

Page 110: ...field A default value 2 Radar OFF is entered in the input field Activation is only required for a system that has been retrofitted NOTE If the preset values are changed the setup with the new values...

Page 111: ...mbH The en gine control unit must be sent in for programming NOTE If the control level of the traction control is adjusted via the rotary selector switch this change is displayed to the driver in the...

Page 112: ...lights Either the existing front bumper must be sent in for modificati on or a new modified bumper must be obtained from Manthey Racing GmbH NOTE The 24 hour lighting is operated via a toggle switch i...

Page 113: ...V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home SETUP RIDE HEIGHT MEASUREMENT 7 Setup Ride Height Measurement 7 1 Delivery Setup GP track 79 7 2 Delivery Setup Nordschleife 80 7 3 Ride Height Reference...

Page 114: ...114 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home 7 1 SETUP RIDE HEIGHT MEASUREMENT...

Page 115: ...115 Version V2 08 2020 Porsche 911 GT3 Cup MR Gen II Home 7 2 SETUP RIDE HEIGHT MEASUREMENT...

Page 116: ...EIGHT MEASUREMENT The specified measuring points are used for the vehicle allignement to set the driving height A minimum ride height is not specified If this is necessary for the corresponding racing...

Page 117: ...2 08 2020 Porsche 911 GT3 Cup MR Gen II Home Region Europe Manthey Racing GmbH 49 2691 9338 807 Rudolf Diesel Stra e 11 13 techsupport manthey racing de 53520 Meuspath Germany Technical support CONTAC...

Page 118: ...a user application You can request this via the email address raceparts porsche de Motorsport parts can alternatively be ordered from the following email addresses Sport and Spare Parts Sales racepar...

Page 119: ...o recaro automotive com Website www recaro automotive com KRONTEC Maschinenbau GmbH Walhallastra e 19 93083 Neutraubling Germany Tel 49 0 9401 5253 0 Fax 49 0 9401 5252 10 E Mail info krontec de Webse...

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