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Porsche 911 GT3 R 2012, Technical Manual

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Porsche 911 GT3 R 2012 Technical Manual Download Page 117

 
 

114 

 

AP Racing provides a repair kit for the brake master cylinder 

 

 

The repair kit includes the following parts: 

 

4 --   Main seal 
5 --   Piston shim 

7 --   Secondary seal 

10 --   Circlip 

11 --   Rubber boot 
 

Repair kit installation: 

1.

 

Remove rubber boot -11- and circlip -1 

2.

 

Carefully remove the internal components 

3.

 

Remove dirt / deposit in the cylinder  

4.

 

Coat the cylinder with brake fluid 

5.

 

Replace the following parts when rebuilding the master cylinder: 

Main seal, piston shim, secondary seal, circlip, rubber boot. While 

replacing parts make sure that all seals are coated with brake 

fluid.  

8.2.1.4.

 

Runtime master cylinder 

Due to the usage of an ABS brake system (antilock braking system) in the 
911 GT3 R, it´s recommended to replace the master cylinders after 

10.000 km. 

Summary of Contents for 911 GT3 R 2012

Page 1: ...Technical Manual Model 2013...

Page 2: ...e possibility to reference data adjustment values and working procedures and make the maintenance and repair work on the vehicle easier We wish you every success with your GT3 R Dr Ing h c F Porsche A...

Page 3: ...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 and sc...

Page 4: ...6 Induction system 19 3 7 Throttle butterfly 20 3 8 Working on the engine 21 3 9 Engine component tightening torques 34 3 10 Engine mileage 35 4 FUEL AND EXHAUST SYSTEM 36 4 1 Fuel system 36 4 2 Fuel...

Page 5: ...on 93 6 6 Sachs damper service information 104 7 WHEELS 106 7 1 Wheel nuts 106 8 BRAKE SYSTEM 108 8 1 Technical data brake system 108 8 2 Brake force distribution brake balance 108 8 3 Brake caliper 1...

Page 6: ...Control Unit ECU 136 10 9 EGas 137 10 10 ABS 141 10 11 Traction control 149 10 12 Relay and fuse assignment 154 11 CAR MAINTENANCE 158 11 1 After approx 200 km and or first test 158 11 2 After every...

Page 7: ...994 0170 911 3436 Mr Steffen H llwarth 0711 911 89922 0170 911 3989 Fax 0711 911 89535 Sport parts sales Mr Christian M ller 0711 911 89175 Mr Robert Hirrig 0711 911 82687 Mr Klaus Lenzner 0711 911 82...

Page 8: ...of gears sequential 6 2 1 Dimensions Length w o spoiler edge mm see homologation papers Width across front axle mm see homologation papers Width across rear axle mm see homologation papers Wheelbase...

Page 9: ...ssion ratio approx 14 5 Maximum revs rpm 9 400 Inlet valve diameter mm 41 Inlet valve lift mm 14 Point of maximum inlet valve lift after TDC Exhaust valve diameter mm 35 5 Exhaust valve lift mm 13 5 P...

Page 10: ...7 3 3 Engine power and torque curves...

Page 11: ...n The 911 GT3 R is equipped with a dry sump lubrication system The oil tank is mounted to the engine The engine oil is cooled by an oil water heat exchanger mounted on the engine 3 4 1 Engine oil Mobi...

Page 12: ...Piston cooling 2 Pressure pump 10 Timing chain tensioner 3 Safety valve 11 Camshaft 4 Oil filter 12 Camshaft housing scavenge pump 5 Pressure sensor 13 Crankcase scavenge pump 6 Oil water heat exchang...

Page 13: ...oil tank through the dip stick guide sleeve Therefore the oil level should only be measured again after waiting for a few minutes The engine oil level must be checked regularly and corrected when nece...

Page 14: ...this display The connector for the display is located in the area of the rear side window on right hand side of the car The values indicated in percent on the display correspond to the following infor...

Page 15: ...12 3 5 Engine cooling system The GT3 R cooling system is a standard cooling system optimised for use in a race car 3 5 1 Scheme drawing...

Page 16: ...ditions see parts catalog When competing under warmer conditions the car should be driven without the thermostat in order to reduce the temperature level of the cooling system The thermostat starts to...

Page 17: ...ine coolant is replaced by 24 3 litres of water and 2 litres of anti corrosion additive part number 997 106 907 90 which protects the water galleries and other cooling system parts from corrosion redu...

Page 18: ...ter an engine change for example Attention When the water system has reached its operating temperature the expansion tank cap should under no circumstances be opened and the pressure released Since th...

Page 19: ...the initial reaction from the heating system the valve remains open in the race car system allowing the system to be bled continuously A special filling system available from Sobek should be used to f...

Page 20: ...orrectly filled and bled Disconnect both water replenishing device connectors and reconnect the engine s quick release coupling to form a closed system again Warm up the engine 80 C and if required fi...

Page 21: ...rvoir with a coupling The reservoir is charged with a pressure of 2 5 3 0 bars The system filling procedure should be carried out as follows Disconnect the quick release fitting in the engine bay and...

Page 22: ...19 3 6 Induction system 4 stage resonance induction system Activated by vacuum actuator resonance valve 3 6 1 Under pressure routing Vacuum actuator Reso 2 su2 Vacuum actuator Reso 1 su...

Page 23: ...e butterfly setting There is no mechanical connection between the throttle butterfly and the throttle pedal The signal of the pedal is transferred to the throttle butterfly via an electro motor An adj...

Page 24: ...e bolt and fit the bolt strain gauge Tighten to the required elongation 0 160 0 005 mm With a torque wrench check to see if a minimum torque of 55 90 Nm was achieved Loosen the second bolt and follow...

Page 25: ...bolts to 20 Nm before finally tightening to 120 torque angle 3 8 3 Set valve timing 3 8 3 1 Special tools Porsche Motorsport recommends use of the following special tools to adjust and set the valve t...

Page 26: ...er and lower valve spring seats till coil bound with a spring balance before reducing the stack height slightly 0 7 1 0 mm 2 Record the spring stack height seat to upper edge of spring seat 3 Add the...

Page 27: ...aining key pulley 000 721 973 21 Press tool crankshaft seal 000 721 216 40 Spacer for press tool 000 721 979 71 Protective cap crankshaft 000 721 979 70 3 8 6 2 Removal 1 Remove the pulley from the cr...

Page 28: ...ed end of a commercially available slide hammer 1 into the drilled holes Carefully remove the seal 2 by swapping the slide hammer alternatively between the drilled holes 6 Make a drill jig according t...

Page 29: ...pointed end of a commercially available slide hammer alternatively into the two holes and pull out the seal 11 Remove swarf 12 Thoroughly clean the flange with a cleaning solvent or acetone 3 8 6 3 In...

Page 30: ...to the crankshaft flange and fit the hexagon head bolt 3 17 mm AF 6 Tighten the hexagon head nut 4 till the spacer 2 touches the crankshaft flange 7 Leave the tool fitted for approximately two minutes...

Page 31: ...fit the flywheel side crankshaft seal Pressure pad 000 721 912 60 Seal extractor jig 000 721 971 90 3 8 7 2 Removal 1 Drill two holes 2 5 mm 180 opposed from one another into the metal ring of the cra...

Page 32: ...fitted behind the crankshaft seal which should prevent the possibility of the seal being fitted inclined Aluminium swarf which may appear during drilling should be carefully removed 7 Remove the seal...

Page 33: ...y circumstances be treated with emery cloth polish compounds or wire brushes Remove corrosion on the crankshaft flange with a special metal polish wad Afterwards carefully clean the crankshaft flange...

Page 34: ...push it onto the base plate 3 Fit the seal dry 4 Remove the magnetic cone and using the pressure piece 000 721 912 60 push the crankshaft seal in a coplanar position 5 Fasten the insertion jig mountin...

Page 35: ...y tools for one or two minutes in the final position the seal and sealing lip position themselves as a result 8 Loosen the inserting nut and remove the hexagon head bolt of the inserting jig remove th...

Page 36: ...33 Measurement depth is approximately 5 mm Maximum permissible misalignment is 0 5 mm 10 If the comparable values exceed the maximum difference use the insertion jig again to press home...

Page 37: ...t crankcase M20 x 1 5 70 Water drain bolt cylinders M10 x 1 10 Flywheel M10 90 Cylinder head Cylinder head bolt M10 see 3 8 2 Camshaft housing Anti knock sensor M8 23 Spark plugs M12 x 1 25 20 Spark p...

Page 38: ...35 3 10 Engine mileage The engine in the 2012 911 GT3 R is designed to rev to a maximum of 9 400 rpm in this case the rebuild interval is 35 hours...

Page 39: ...s fuel system FT3 safety fuel cell Fuel cell volume 104 l Integrated 6 3 l catch tank 4 intank pumps Vane type main and reserve pump Engine supply Tank vent Safety valve Reserve pump Main pump Fuel fi...

Page 40: ...reserve fuel pumps are of the electrical vane type The fuel filter is located in the front luggage compartment and should be replaced after approximately every 24 hours of use There is a preliminary...

Page 41: ...system pressure can exceed the burst pressure of the fuel filter 4 2 1 Catchtank The catch tank allows customized adjustment of the reserve volume The height of the scavenge point can be changed by ad...

Page 42: ...ssure regulator The 911 GT3 R is equipped with a returnless fuel system Due to this design fluctuation in fuel pressure is possible The average fuel pressure over one complete lap should not be lower...

Page 43: ...s as follows A warning lamp in the shift light module and also a warning message in the MoTec dash indicate when the minimum fuel level is reached If this warning is ignored an engine misfire shortly...

Page 44: ...3 1 Configuration with exhaust pre silencer It is possible to change the exhaust system s configuration by fitting either an optional unit with catalytic converter or a unit with additional silencing...

Page 45: ...above mentioned exhaust system configuration the possibility exists to use a version without pre silencer With this configuration the unit with the catalytic converter must be mounted in the rear sile...

Page 46: ...manifold the correct nut tightening sequence must be observed 4 3 5 Stop Choc Elements Porsche Motorsport emphasizes that the maximum service life for the 5 Stop Choc elements 997 111 228 8A in the r...

Page 47: ...arbox technical data Gearbox type G 97 72 Design Sequential Number of gears 6 Standard gear ratios Drop Gear 25 32 1 280 Crown wheel pinion 9 26 2 889 1st gear 13 41 3 154 2nd gear 16 39 2 438 3rd gea...

Page 48: ...iges 11 662 25 29 iges 4 289 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0 50 100 150 200 250 300 V km h n Mot 1 min 5 3 Connection scheme gearbox heat exchanger vom Vorlauf Motork hlkreislauf fro...

Page 49: ...the right hand paddle Down shift pull the left hand paddle 5 4 3 System description An electrically operated compressor compresses air which is stored at a pressure of approximately 6 bar in a pressur...

Page 50: ...47 5 4 4 Component position in car The position of the individual components is illustrated in the following image...

Page 51: ...1 1 6 6 1 1 N N R Paddle trigger Right up Right up Right up Left down Left down Reverse Throttle butterfly Not activated Not activated 20 20 Not activated Not activated Clutch Activated Activated Act...

Page 52: ...y the shift light module above the MoTec display The function Warning Light is activated both outermost LEDs blink orange and one of the following three messages is shown in the display MoTec warning...

Page 53: ...t mounting and final test 6603 997 618 409 8A 378 014 011 blip cylinder 997 RSR MY B C 8482 10000 km demount and clean replace all tightness parts review of the duct wearing check of piston rod and ho...

Page 54: ...eans of plugs The fittings of the air hoses as well as the fittings at the component cases have to be covert with a safety cap For service and or maintenance of your paddle shift system please contact...

Page 55: ...tion when shifting gear 5 5 1 Gearbox potentiometer calibration The gear position sensor must be recalibrated after repairs are carried out on the gearbox or if the gear ratios are changed Turn on the...

Page 56: ...65 power overrun dynamic locking value The differential is checked by means of a friction test in which the preload and wear of the clutch disc plates are determined 5 6 1 Differential assembly 6 Clut...

Page 57: ...he use of the present Tilton clutch is still possible 5 7 1 Mounting of ZF Sachs clutch The following points should be observed when mounting the clutch The clutch housing contains a label ZF Sachs Ra...

Page 58: ...d side of the reference lug with the label ZF Sachs Race Engineering Arrow has to point towards flywheel Place intermediate and drive plates alternately in the clutch housing with raising dot marks Do...

Page 59: ...nserted after the third intermediate plate The arrow marking on the hub has to point towards the flywheel and has to align with the reference lug of the clutch housing Arrow mark on hub Dot mark on th...

Page 60: ...tance before the clutch reaches its maximum wear No greasy or oily substances should contaminate the clutch plates The splined section of the gearbox input shaft must mesh over the entire length of th...

Page 61: ...d when mounting the clutch Place pressure plate on first intermediate plate Place pressure plate and first carbon disc in the cage The mark on the intermediate plate arrow must lie on the left hand si...

Page 62: ...S Flywheel Side mark on the drive plates must point towards the engine Furthermore the FS mark of each drive plate should lie on top of each other FS mark After the third intermediate plate the hub is...

Page 63: ...60 Then insert drive plate 3 and intermediate plate 4 Attention The clutch plates should be refitted in the original sequence and orientation Please observe the markings on the edges...

Page 64: ...number 000 043 004 00 before assembly 5 7 3 Clutch wear It is possible to service the carbon carbon clutch to achieve a longer service life To compensate for the carbon disc wear compensation pressure...

Page 65: ...1 Special tools 997 450 116 9A Assembling tool clutch Wire bow for preload while assembling deliverable 997 450 372 9A Assembling tool Tool fitting release spearing deliverable 997 450 379 9A Assembli...

Page 66: ...Add Mobilube SHC through the oil fill opening till the oil overflows from the above mentioned tube approx 3 litres for a newly build gearbox Close the oil overflow pipe and add 1 0 litre of oil Porsc...

Page 67: ...from the M32 x 1 25 nut Remove anti rotational safety Loosen M32 x 1 25 nut Completely remove gear ratio housing Extract shift rod Remove shift forks Remove circlip from input shaft Remove M 32x1 25 n...

Page 68: ...shaft fixed gears face to the outside 5 8 4 Release bearing Under no circumstances whatsoever must gearbox come into contact with the clutch release bearing seal otherwise the seal can swell which in...

Page 69: ...gns of wear and pitting Check the oil for signs of metallic debris The following work should be carried out after a total running time of approximately 30 hours Check the crown wheel and pinion for pi...

Page 70: ...67 5 8 6 Starter motor maintenance The starter motor maintenance includes the following work After each race Shell Stamina Grease HDS ET Nr 997 605 920 9A 400 g...

Page 71: ...s Component Bolt dimensions Tightening torque Nm Clutch on Flywheel M8 33 Gearbox closure plate M6 9 7 Gear ratio housing M8 25 Pinion shaft nut M32 x 1 25 1 Tighten with 250 Nm 2 Losen the nut 3 Tigh...

Page 72: ...ile 6 1 Front suspension McPherson strut suspension Adjustable main spring Adjustable anti roll bar Two way adjustable dampers 6 1 1 Front springs The front coil spring has a three step adjustment ran...

Page 73: ...and rebound compression droop is fitted to the front axle The bump and rebound damping forces are adjustable in the high speed piston range Both softer and harder are adjusted on the valve block 6 1...

Page 74: ...curves F2T1 1 2 4 6 8 10 16 1 2 4 6 8 10 16 12 14 12 14 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0 500 1000 1500 2000 2500 3000 3500 4000 0 0 131 0 262 0 393 0 524 piston speed m s bump dampin...

Page 75: ...anti roll bar link The minimum stiffness is achieved when the blade is aligned at 90 Pos1 1 to the anti roll bar link Always use suitable tools to rotate the blade as incorrect tools can cause damage...

Page 76: ...n implementing the test this level of system pressure should be held for an absolute maximum of ten seconds If it is necessary to repeat this procedure a pause of at least 10 seconds should be made be...

Page 77: ...he engine is running Fill the reservoir before starting the engine to bleed the system Recheck the reservoir level immediately after the engine has started Rotate the steering wheel quickly and repeat...

Page 78: ...listed in the table below Colour Part number Stiffness Range N mm green 997 333 531 9A 220 280 braun 997 333 531 9C 250 320 anthracite 997 333 531 9D 275 325 The spring is twisted into or out of the...

Page 79: ...for one step in spring rate change For example when the spring rate is softened by one step the ride height must be lowered four turns to compensate If the spring rate is stiffened the ride height mus...

Page 80: ...speed adjustment range has 16 positions 1 less damping forces 16 higher damping forces 6 2 2 2 Bump The bump is adjustable in the high speed range The high speed adjustment range has 16 positions 1 le...

Page 81: ...2 4 6 8 14 16 1 2 4 6 8 14 16 10 12 10 12 6500 6000 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 0 0 131 0 262 0 393 0 524 piston speed...

Page 82: ...ti roll bar link The minimum stiffness is achieved when the blade is aligned at 90 Pos 1 1 to the anti roll bar link Always use suitable tools to rotate the blade as incorrect tools can cause damage N...

Page 83: ...el alignment In the event of an accident or any other damage occurring to the suspension every component including those not directly affected should be measured checked for cracks and where necessary...

Page 84: ...the wheel alignment including camber toe in ride height and corner weights with the fuel cell half full and the appropriate driver ballast placed in the driver s seat Put the car on the corner weight...

Page 85: ...rface set up platform to check the ride height The front and rear suspension should be loaded and unloaded compressed several times to allow the suspension to settle The ride height is adjusted by rot...

Page 86: ...the clamping screw Porsche Motorsport provides a special tool to remove the trunnion pin 997 450 349 9B The steering gear is shimmed on the two mounting points by a 3 mm shim It is not allowed to remo...

Page 87: ...mm adjustment in length equates to a camber change of approximately 13 Trailing arm mounting hole The mounting position of the trailing arm should not be changed wheel clearance Porsche Motorsport pro...

Page 88: ...85 6 3 1 4 Trailing arm 6 3 1 5 Upper mount The upper mount position can be adjusted by using the slots in the car body 28 mm Buchse 8 mm Buchse...

Page 89: ...ced on a level surface set up platform to check the ride height The front and rear suspension should be loaded and unloaded compressed several times to allow the suspension to settle Ride height adjus...

Page 90: ...87 6 3 2 2 Toe The length of the toe rod can be adjusted using the clamp bolt Spacers Bearing journal Clamp bolt 1x 6 mm Scheibe 2 mm Scheibe...

Page 91: ...s a 1 mm adjustment in length equates to a camber change of approximately 10 Trailing arm mounting hole The mounting position of the trailing arm should not be changed wheel clearance Porsche Motorspo...

Page 92: ...89 6 3 2 4 Trailing arm 16 mm spacer 16 mm spacer...

Page 93: ...43 91 1 996 341 543 90 1 996 341 543 90 0 8 996 341 543 98 0 8 996 341 543 98 0 6 996 341 543 97 0 6 996 341 543 97 0 3 996 341 543 96 0 3 996 341 543 96 trunnion pin mm 76 997 341 413 9H 80 997 341 4...

Page 94: ...g Bump 12 13 Rebound 9 9 Anti roll bar 1 1 5 5 1 soft 7 stiff Length trailing arm 363 mm 380 mm Length upper wishbone front 293 mm rear 272 mm Due to transportation purposes the delivery setup of the...

Page 95: ...out of the upright Put the wheel bearing in by hand It should be noted that the wheel bearing sits correctly on the wheel bearing seat in the upright after being pushed in Tighten the wheel bearing co...

Page 96: ...sition Dimension Tightening Torque Nm 2 M14 x 1 5 x50 160 3 M12 x 1 5 x30 100 5 M12 x 1 5 100 10 M10 x 1 5 65 20 M8 25 22 M8 45 with Loctite 243 23 M12 x 1 5 75 replace after dismounting 29 M14 x 1 5...

Page 97: ...nt side 4 5 M6 x 16 8 8 10 10 M8 x 35 10 9 37 11 Grease hub with longtime grease 13 M8 31 replace after dismounting 14 470 retighten after 100 km when reassembled Copper paste on contact surface 15 50...

Page 98: ...95 6 5 3 Anti roll bar front Position Dimension Tightening Torque Nm 2 M6 10 11 M10 50 12 M8 LH 23 14 M8 23 16 M6 10...

Page 99: ...96 6 5 4 Suspension stut front Position Dimension Tightening Torque Nm 9 M6 x 12 10 12 M8 75 13 M14 40 16 M8 35...

Page 100: ...5 Steering gear Position Dimension Tightening Torque Nm 2 M10 x 45 10 9 70 8 M18 x15 90 track rod on steering gear 9 M14 x 1 5 50 11 M6 x 20 10 15 M14 x 1 5 75 16 M12 x 1 5 10 9 75 replace after dismo...

Page 101: ...98 6 5 6 Steering column Position Dimension Tightening Torque Nm 3 M8 x 35 10 9 37 5 M10 46 11 M5 8 15 M5 x 35 5 18 M16 x 1 5 50 5...

Page 102: ...99 6 5 7 Side part rear Position Dimension Tightening Torque Nm 2 M12 x 97 75 with Loctite 270 3 M12 x 1 5 10 9 110 5 M12 x 80 110 6 M12 x 1 5 110...

Page 103: ...Nm 6 M12 100 7 M8 25 12 M5 8 14 M8 45 with Loctite 243 15 M12 x 1 5 75 replace after dismounting 17 M14 x 1 5 160 23 M14 x 1 5 160 25 M12 75 32 M12x1 5 110 33 M12 x 70 110 34 M12 x 1 5 110 37 M6 x 20...

Page 104: ...35 37 5 max 40 hrs 7 M8 31 replace after dismounting 5 Grease hub with longtime grease 8 470 retighten after 100 km when reassembled Copper paste on contact surface 9 200 10 500 25 17 M6 x 16 10 18 M6...

Page 105: ...102 6 5 10 Anti roll bar rear Position Dimension Tightening Torque Nm 2 M6 10 9 M4 x 10 2 12 M8 LH 25 14 M12 46 15 M6 10 20 M8 25 22 M8 x 25 25 23 M6 x 12 10...

Page 106: ...103 6 5 11 Suspension strut rear Position Dimension Tightening Torque Nm 3 upper M12 x 1 35 3 lower M12 x 1 40 15 M10 46...

Page 107: ...logiezentrum am N rburgring Rudolf Diesel Stra e 11 13 53520 Meuspath Phone 49 2691 9338 54 Fax 49 2691 9338 50 Service partner for the UK BG Motorsports Ltd 47 48 Silverstone Circuit Silverstone Nort...

Page 108: ...2 John Anderson Highway 32136 Flagler Beach FL Phone 1 386 6731936 Fax 1 386 6731184 Service partner for Asia Enable Inc Technical center 1 36 Ootsuzaki Ogakie cho Kariya shi Aichi ken 448 0813 Japan...

Page 109: ...ould be paid to the mileage of the wheels Use the collected data to ensure that wheels are used in rotation therefore ensuring a balanced and even usage and helping to identify early the need for spar...

Page 110: ...ure that the required tightening torque is also achieved also different wheel guns supplied by a different manufacturer and specification Two different wheel guns are necessary for both vehicle sides...

Page 111: ...sk thickness mm 32 32 Brake pad Pagid RS 19 gelb Pagid RS 19 gelb Pad thickness mm 22 22 Brake caliper 6 piston 4 piston Brake caliper piston diameter mm 38 30 28 35 28 Brake fluid Endless RF 650 Raci...

Page 112: ...109 8 2 1 Brake balance system If the brake balance potentiometer is rotated the lever ratio dimension x on the balance bar is adjusted directly by a adjuster cable Balance bar rod Spacer Balance bar...

Page 113: ...lforce front brakeforce l x pedalforce rear brakeforce _ _ _ 8 2 1 1 Basic setting balance bar The following dimensions must be set in the basic setting 0 Brake force HA Brake force VA Pedal force l x...

Page 114: ...rk ends This play is absolutely necessary to prevent a twisted system The lever ratios are not affected by this play Furthermore it is possible that the play changes when the balance bar system is mou...

Page 115: ...the front brake master cylinder pushrod clevis to prevent the clevis colliding with the lock nut Under all circumstances avoid the system being fitted with preload The pushrods of the two master cylin...

Page 116: ...n before mounting the adjustment shaft Afterward set the potentiometer in the MoTeC display to 0 Do not rotate more than 7 and 7 on the display the potentiometer does not have a rotation limit and wou...

Page 117: ...ernal components 3 Remove dirt deposit in the cylinder 4 Coat the cylinder with brake fluid 5 Replace the following parts when rebuilding the master cylinder Main seal piston shim secondary seal circl...

Page 118: ...calipers which includes new pistons and seals There are two bleed nipples on each brake caliper If a pressure manometer is connected to the caliper it should be noted that the system including manome...

Page 119: ...t as well as the bolt head have to be free from grease 2 Tighten both fixation bolts 900 075 010 030 with 5 Nm no Loctite 3 Fill the cylindrical countersink till 1 mm underneath the bolt head with sil...

Page 120: ...weld additional brackets or drill holes in the tubes If in doubt please contact Porsche Motorsport All unnecessary panels and sound proofing materials have been removed to reduce weight 9 1 Interior...

Page 121: ...118 9 2 Exterior 9 2 1 Front bumper...

Page 122: ...119 9 3 Rear wing engine cover Gurney 10mm P1 P12...

Page 123: ...ylinder must be protected from frost remove from vehicle The operating pressure of system is 14 bars and should be checked regularly using the manometer mounted to the extinguisher bottle The extingui...

Page 124: ...box cover and change the battery Ensure that the battery poles are connected correctly Only Alkaline batteries should be used Checking the firing button Attention The toggle switch on the trigger box...

Page 125: ...unted to the rear right air jack Max pressure Operating pressure approximately 35 38 bar The rear right airjack contains an over pressure valve Never use mineral oil based cleaning agents Never open t...

Page 126: ...Assembly instructions 1 Evenly coat the threads of all ventilation screws and Crimp Collar connections with copper paste Porsche No 000 043 004 00 2 Screw together the ring connector and ventilation s...

Page 127: ...124 9 5 1 Car lift system Never use a third party product as this can lead to damage to the air jack cover or piston tube KRONTEC Maschinenbau GmbH Pommernstra e 33 D 93073 Neutraubling www krontec de...

Page 128: ...1 Starter button The electrical connector of the starter button shall be checked on damage and proper electrical connection regularly Furthermore it has to be ensured that there is no tension on the t...

Page 129: ...12 V 80 Ah 10 4 Steering wheel Quick release race steering wheel The two parts of the release coupling are balanced together and therefore have to be used in only one combination numbers on steering w...

Page 130: ...adlight flash if the button is pressed for about 1 second the headlights stay on till the next time the button is pressed WIPER Wiper DISPLAY Change MoTeC display pages ALARM Reset MoTeC Alarm MAP Cha...

Page 131: ...FIRE Fire extuingisher LIGHT Head light ABS ABS on off WINDSCREEN Pulled 100 windscreen Pushed floor air vents driver ventilation FUEL PUMPS Fuel pump Bosch Pump runs when engine runs Middle position...

Page 132: ...ontrol mode MOTEC MODE Switch through the different MoTeC display setups practice warmup race HAZARD Hazard lights FOG REAR Fog lights 10 6 Shift Light Module The Shift Light Module SLM is located abo...

Page 133: ...red please contact Br ckle Motorsport directly Br ckle Motorsport Consulting GmbH Werner Br ckle Zennerstr 29 D 81379 M nchen Tel 49 89 72308198 Fax 49 89 72308199 Email werner brueckle t online de 10...

Page 134: ...t Speed Brake balance Centre Gear Top Traction control setting Throttle valve angle Right Actual lap time Previous lap time Bottom Engine temperature ET Oil temperature OT Oil pressure OP Fuel pressur...

Page 135: ...nt temp AT Battery voltage on dash VOLTS Distance covered TRIP_D Fuel consumption per lap FU Total fuel consumption FU Data logging LOG_RUN 10 7 1 3 Warm up mode Left Engine temperature Centre Gear To...

Page 136: ...133 Vertical acceleration G Vert Lateral acceleration G Longitudinal acceleration G Odometer ODO Trip distance TRIP_D Steering angle STANG_W Steering wheel angle SW_ANG Gearbox potentiometer GEARSEN...

Page 137: ...ction with this version Delivered with the car is a CD with the programme and the configuration used Under NO circumstances should the USB connection cable PC MoTeC Dash be removed or the power supply...

Page 138: ...s pcrank_rel 300 mbar Camshaft sensor camshpos 20 30 KW Speedsensor crankshaft RPM nmot_w Water level switch Water Level Gearbox Gear lever sensor Gear Lever Force Volt 2 ugs_w 2 5 V Gearbox poti Gear...

Page 139: ...displayed in the MoTeC dash when electric errors sensors occur at a specific frequency or are always active The message also indicates MS 4 0 system errors A special software Bosch Modas which can be...

Page 140: ...butterfly actuator must be approved by Bosch for a production application or must demonstrate the same quality and safety features Structural modifications to the actuator must only be implemented af...

Page 141: ...it must be used The use of an incompatible EGas software version any changes to the software or use of a software version not developed explicitly by Bosch Engineering GmbH for the project is prohibit...

Page 142: ...n 10 10 11 Driving the car A car equipped with a Bosch Engineering GmbH EGas system must be driven exclusively by racing drivers must have an international DMSB license or an international license of...

Page 143: ...t characteristics 1 less aggressive 3 aggressive This is carried out via the parameter CWDVEKF in Modas Engine Dashboard 10 10 14 2 Engine start No throttle application by the driver is necessary when...

Page 144: ...ty and break performance Driveability is of big importance on a street car The ABS is supposed to allow the driver to control the car under each circumstances For motorsport purposes this compromise h...

Page 145: ...ulates the corresponding wheel accelerations These values are compared with the expected optimum wheel accelerations In case the measured values differ from the calculated optimum values the ABS becom...

Page 146: ...nt manufacturer are used To change the tire circumference the following steps are necessary Open the MoTeC dash manager and load the GT3 R configuration Go to Menu Inputs Constants Remote Control A wi...

Page 147: ...ine Porsche Motorsport ABS brakes antilock braking system it is recommended to replace the brake master cylinder after 10 000 km Pos Part number Description Amount Car 1 996 355 017 9C Brake master cy...

Page 148: ...ic control unit 1 Hydraulic control unit with integrated ECU 2 Connecting cable 3 Rear brake circuit 4 Front brake circuit 5 Front left brake line 6 Rear right brake line 7 Front right brake line 8 Re...

Page 149: ...off the system Therefore the switch in centre console must be flipped When ABS is turned off an alarm appears in the MoTeC display and the outer LEDs start to flash By pushing the alarm button on the...

Page 150: ...ground speed of 20 kmph is achieved To communicate with the ABS ECU a special cable is necessary see parts catalog Zur Kommunikation mit dem ABS Steuerger t ist ein zus tzliches Kabel notwendig siehe...

Page 151: ...the error memory Mark 00_clear_error_s left display side Click on Conn 2 write Rightclick on 00_clear_error_s execute Check the error memory one more time to ensure that the previous detected errors a...

Page 152: ...eters of the following categories offer the possibility to adapt the traction control slip dependant parameters parameters of the PID controller driver influence track influence 10 12 1 Adapt the trac...

Page 153: ...ering FTCSLSMIN 1 0 is the basic calibration decrease this value if the support from the TC during cornering is insufficient increase this value if the support from the TC during cornering is more tha...

Page 154: ...component of the TC controller The I component integral component of the PID controller determines the control action during the entire duration of the regulation If the vehicle decelerates excessivel...

Page 155: ...uses a longer TC intervention less driver influence Increase of KLMIFAASR causes a shorter TC intervention more driver influence Typical values are 50 up to 90 10 12 1 7 Track KLTCDSWASR is a track de...

Page 156: ...ge steps in calibration A D component multiplied by two will lead to instability of the controller and strong oscillations in the drivetrain Calibration of a PID controller needs a lot expertise in co...

Page 157: ...154 10 13 Relay and fuse assignment 10 13 1 Fuse holder...

Page 158: ...hydraulic control unit is situated in the front trunk on the left side The fuse has to be secured by a tie wrap 10 13 3 Power steering pump The fuse 80 A for the power steering pump is situated in th...

Page 159: ...156 10 13 4 MS4 sensor system...

Page 160: ...shift system is protected by a separate fuse block in the passenger side footwell Control of the fan for cooling the compressor control unit is made via a relay This is located on the right in the re...

Page 161: ...ession Visual inspection of all systems hoses and cables etc for leakage damage or chafing Check the specified torque setting of every safety relevant fastener Check dampers for leakage Drain the fuel...

Page 162: ...alance system Change brake fluid Check clutch wear Check wheel bearing play Check air jacks for leakage and seated correctly Check seat and safety harness Check fire extinguisher Check flywheel and pu...

Page 163: ...hristoph Werner 02 2013 Illustrations descriptions and schematic drawings serve exclusively as presentation for the text We undertake no liability for the completeness and conformity of the contents w...

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