Porsche 2015 911 GT3 Cup User manual

Technical manual
911 GT3 Cup (991) MY 2015

Preface
Preface
This document should give you the opportunity to look up data, settings, und
operating regulations, and to facilitate maintenance or repair of the vehicle.
We wish you many sporting successes with your 911 GT3 Cup (991).
Customer Sport
Dr. Ing. h.c. F. Porsche
Inc.
Motorsport Sales
Version: 16.12.2014
911 GT3 Cup (991)
MY 2015 1

Preface
Competition Vehicle 911 GT3 Cup (991) Model 2015
The design of this vehicle is specially configured for use in one-make cup
competitions.
For understandable reasons, it cannot therefore be assumed that the standards set
by our production vehicles are relevant for the car body design.
Porsche assumes no responsibility for compliance with regulations.
The vehicle is not approved for use on public roads and does not comply with the
German 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
contents with the prevailing sporting codes.
Due to the constant improvement of our products and the related documentation at
the time of your purchase, a new version of this technical manual could be available.
The latest Version is always accessible at the "Porsche Motorsport race car service
information" database (PMRSI), and can be downloaded on the following homepage.
https://motorsport.porsche.com
Version: 16.12.2014
911 GT3 Cup (991)
MY 2015
2

Preface
Contact
International One-make
Cup Series
Mr. Michael Dreiser Tel. [phone]
Assistent Ms. Nicole Nagel Tel. + 49 (0) 711 911 84900
Fax. + 49 (0) 711 911 88920
Technical Support Mr. Christoph Werner Tel. + 49 (0) 711 911 82690
Hr. Stefan Rometsch Tel. [phone]
Fax. + 49 (0) 711 911 89535
Porsche Mobil 1
Supercup
Mr. Jonas Krauss Tel. + 49 (0) 711 911 84042
Assistent Fr. Olivia Wegner Tel. + 49 (0) 711 911 84096
Fax. + 49 (0) 711 911 82920
Technical Support Hr. Maximilian Müller Tel. [phone]
Fax. + 49 (0) 711 911 89535
Porsche Carrera Cup
Germany
Ms. Andrea Hagenbach Tel. + 49 (0) 711 911 84041
Assistent
Mr. Marco Vierkötter
Tel. + 49 (0) 711 911 84074
Fax. + 49 (0) 711 911 82920
Technical Support Hr. Maximilian Müller Tel. [phone]
Fax. + 49 (0) 711 911 89535
Sports Divisions Sales Mr. Karlheinz Kienle Tel. + 49 (0) 711 911 82923
Mr. Klaus Lenzner Tel. + 49 (0) 711 911 82423
Mr. Christian Müller
Tel. + 49 (0) 711 911 89175
Mr. Salvatore Scozzaro
Tel. + 49 (0) 711 911 83738
Fax. + 49 (0) 711 911 82808
Version: 16.12.2014
911 GT3 Cup (991)
MY 2015 3

Preface
Contents
Preface 1
1Engine 13
1.1 General 13
1.2 Specifications 14
1.3 Engine lubrication 15
1.3.1 Engine oil circuit 16
1.3.2 Oil level measurement 17
1.3.3 Refilling engine oil 17
1.3.4 Engine oil 17
1.4 Engine cooling system 18
1.4.1 Schematic diagram 18
1.4.2 Thermostat 18
1.4.3 Coolant 19
1.4.4 Filling the cooling 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 tightening instructions 23
1.6.3 Setting the valve timing 23
1.6.4 Removing and installing the crankshaft seal – pulley side 24
1.6.5 Removing and installing the crankshaft seal – flywheel side 29
1.7 Engine tightening torque overview 36
1.8 Exhaust system 38
1.9 Fixation pre-silencer 39
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1.10 Engine run time 40
1.10.1 Behavior when exceeding the maximum speed 40
2Powertrain 41
2.1 General 41
2.2 Clutch 42
2.2.1 Installation instructions 42
2.2.2Clutch wear 43
2.2.3 Fluid for clutch actuation 43
2.2.4 Central release 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 shifting 54
2.4.2 Gear recognition 56
2.4.3 „Emergency gearbox“ switch 56
2.4.4 Maintenance 57
2.5 Drive shafts 58
2.5.1 Tightening instructions 58
2.6 Gearbox run time 59
2.7 Gearbox tightening torques 59
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2.8 Transmission dismantling 61
2.8.1 Dismantling of hang-on parts 61
2.8.2 Gear housing dismantling 62
2.8.3 Gear set removal 63
2.8.4 Dismantling the shift drum 64
2.8.5 Dismantling the locking sleeve 64
2.8.6 Oil supply 65
2.8.7 Cross shaft dismantling 66
2.8.8 Pinion shaft dismantling 69
2.8.9 Differential removal 70
2.8.10 Central clutch operator removal 71
2.8.11 Connecting shaft dismantling 71
2.8.12 Drive shaft dismantling 72
2.8.13 Bearing dismantling 73
2.9 Transmission assembly 75
2.9.1 Gearbox housing pre-assembly 75
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 sets 98
2.9.8 Vormontage Schaltwalze 104
2.9.9 Oil pump assembly 105
2.9.10 Reverse idler gear 106
2.9.11 Locking sleeve 107
2.9.12 Shift rod and shift forks 108
2.9.13 Suction tube assembly 109
2.9.14 Central clutch operator assembly 111
2.9.15 Cutted gear housing assembly 111
2.9.16 Determining cross shaft bearing adjusting disk Q1 113
2.9.17 Cross shaft setup 114
2.9.18 Cross shaft assembly 115
2.9.19 Differential setup 119
2.9.20 Gear housing assembly 126
2.10 Overview gearbox settings 130
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MY 2015
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3Chassis 131
3.1 General 131
3.1.1 Wheel bearing 132
3.1.2 Wheel hub 133
3.1.3 Wheel nut 134
3.1.4 Locking piece 135
3.2 Front axle 136
3.2.1 Front axle cross member 137
3.2.2 Front axle transverse control arm 138
3.2.3 Longitudinal control arm 139
3.2.4 Front axle wheel mount 140
3.2.5 Front axle shock absorber 141
3.2.6 Front axle anti-roll bar 142
3.3 Rear axle 144
3.3.1 Rear axle control arm and tie rod 145
3.3.2 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 side part 152
3.4 Wheel alignment 152
3.4.1 Preparatory measures 153
3.4.2 Vehicle ride height measuring points 154
3.5 Steering system 155
3.5.1 Bleeding the steering system 157
3.6 Rims and tire 158
3.6.1 Rim 158
3.6.2 Tires 158
3.7 Brake system 159
3.7.1 General 159
3.7.2 Front axle brake 161
3.7.3 Rear axle brake 162
3.7.4 Master cylinders 163
3.7.5 Changing the brake fluid 164
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3.8 Brake pressure distribution 165
3.8.1 Balance beam basic setting 166
3.8.2 Calculating the brake power 168
3.9 Balance bar replacement kit 169
3.9.1 Replacing the trunnion 169
3.9.2 Replacing the balance bar 169
3.10 Performance setup 170
4Bodywork 171
4.1 General 171
4.2 Front and side view 172
4.3 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 steel parts 180
4.4.7 Materials overview 181
4.4.8 Roll cage 182
4.4.9 Recovery device 183
4.5 Aerodynamics 184
4.5.1 General 184
4.5.2 Rear wing 184
4.5.3 Additional aerodynamic improvements 184
4.6 Exterior mirrors 185
4.7 Roof 185
4.8 Air jack system 186
4.9 Doors 188
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4.10 Trunk and engine lid 188
4.10.1 Trunk lid 188
4.10.2 Engine lid 188
4.11 Windows 189
4.11.1 Installing and removing the windshield 189
4.11.2 Preparing the window cutout for installation 193
4.11.3 Preparing the windshield for installation 194
4.11.4 Installing the windshield 195
4.12 Fenders 197
4.13 Wheel cover 197
4.14 Fuel system 198
4.14.1 Fuel 199
4.14.2 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 Thread repair kit 227
4.16.1 Thread repair of chassis bolt connections 229
4.17 Installing roof assembly 245
5Interior 247
5.1 General 247
5.2 Drivers safety 248
5.2.1 Seat 248
5.2.2 Seat rail tightening torques 249
5.2.3 Bucket seat tightening torques 250
5.2.4 Padding system 251
5.3 Steering wheel 252
5.4 Cockpit ventilation 253
Version: 16.12.2014
911 GT3 Cup (991)
MY 2015 9