Porsche 911 GT3 Cup 2018 User manual

Technical manual
911 GT3 Cup (991 II) MY 2018

Version: 4/20/2018
911 GT3 Cup (991 II)
MY 2018
1
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 II).
Customer Sport
Dr. Ing. h.c. F. Porsche
Inc.
Motorsport Sales

Version: 4/20/2018
911 GT3 Cup (991 II)
MY 2018
2
Preface
Competition Vehicle 911 GT3 Cup (991 II) Model 2018
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: 4/20/2018
911 GT3 Cup (991 II)
MY 2018
3
Preface
Contact
Technical Support
Mr. Christoph Werner
Tel. [phone]
Mr. Dominik Quosdorf
Tel. [phone]
Mr. Maximilian Müller
Tel. [phone]
Fax. [phone]
Sports Divisions Sales
Part order
[email protected]
Consulting & sale
Mr. Christian Müller
Tel. [phone]
Mr. Mario Heinzel
Tel. [phone]
Mr. Karlheinz Kienle
Tel. [phone]
Mr. Jens Lange
Tel. [phone]
Mr. Klaus Lenzner
Tel. [phone]
Mr. Christian Pelters
Tel. [phone]
Mr. Salvatore Scozzaro
Tel. [phone]
Fax. [phone]
International One-make Cup Series
Assistent
Mrs. Nicole Nagel
Tel. [phone]
Mr. Tobias Hütter
Tel. [phone]
Mr. Christoph Hewer
Tel. [phone]
Fax. [phone]
Porsche Mobil 1 Supercup
Mr. Oliver Schwab
Tel. [phone]
Assistent
Mrs. Tamara Falkenstein
Tel. [phone]
Fax. [phone]
Porsche Carrera Cup Germany
Mr. Oliver Köppen
Tel. [phone]
Assistent
Mrs. Lena Strycek
Tel. [phone]
Fax. [phone]

Version: 4/20/2018
911 GT3 Cup (991 II)
MY 2018
4
Preface
Warnings and safety instructions
The warning notes and safety instructions are classified by the
respective signal word (Danger, Warning, Caution) beside the warning
symbol.
Warns against death or very serious injury which will certainly occur
if the instructions are ignored.
Warns against death or very serious injury which may occur if the
instructions are ignored.
Warns against minor injury if the instructions are ignored.
Warns against damage to property if the instructions are ignored.
Contains advisory information which makes the work procedure
easier.
WARNING
DANGER
Caution
NOTE
Information

Version: 4/20/2018
911 GT3 Cup (991 II)
MY 2018
5
Preface
To prevent injury and adversely affecting the operational and road safety of the vehicle,
or damage to the vehicle as a result of improper work, read these warnings and safety
instructions carefully and observe them fully.
It is not possible for Dr. Ing. h.c. F. Porsche AG to give a detailed evaluation of all
danger situations for the persons carrying out the work. It is therefore imperative that
all persons carrying out repair and maintenance work on Porsche vehicles use their
specialist knowledge to ensure that their own safety is not put at risk and that the
procedure chosen will not have any negative effects on the vehicle - especially with
regard to safety.
It is therefore expressly specified that all work involved in the work procedures
described should be carried out only in accordance with the valid guidelines and
regulations of the local authorities responsible with respect to health, accident
prevention and environmental protection, and in compliance with the respective legal
provisions in force.

Version: 4/20/2018
911 GT3 Cup (991 II)
MY 2018
6
Preface
Contents
Preface 1
1Engine 15
1.1 General information 15
1.2 Technical data 16
1.3 Engine lubrication 17
1.3.1 Oil level measurement 17
1.3.2 Filling capacities 17
1.3.3 Engine oil 17
1.3.4 Engine oil circuit 18
1.3.5 Central oil supply 19
1.3.6 Oil mist separator 19
1.4 Engine cooling system 20
1.4.1 Schematic diagram 20
1.4.2 Thermostat 20
1.4.3 Coolant 21
1.4.4 Filling the cooling system 21
1.4.5 Racing at low temperatures 21
1.5 Intake system 22
1.5.1 Throttle valve 23
1.6 Working on the engine 24
1.6.1 Tightening specification for the flywheel 24
1.6.2 Valve timing 24
1.6.3 Removing and installing the crankshaft sealing ring (flywheel side) 25
1.6.4 Changing the poly-V-belt 30
1.6.5 Fuel high-pressure line 31
1.7 Tightening torques for engine 32
1.8 Exhaust system 34
1.9 Mounting front muffler 36
1.10 Mounting wheel arch 54
1.11 Sensors 58

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MY 2018
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Preface
1.12 Running time of engine 59
1.12.1 Behavior if the maximum engine speed is exceeded 60
2Powertrain 61
2.1 General 61
2.2 Clutch 62
2.2.1 Installation instructions 62
2.2.2 Clutch wear 63
2.2.3 Fluid for clutch actuation 63
2.2.4 Central release mechanism 64
2.3 Sequential six-speed gearbox 65
2.3.1 Overview 65
2.3.2 Technical specifications 66
2.3.3 Gear set 67
2.3.4 Drive 70
2.3.5 Oil circuit 72
2.4 Gear shift mechanism 73
2.4.1 Gear shifting 74
2.4.2 Gear recognition 76
2.4.3 „Emergency gearbox“ switch 76
2.4.4 Maintenance shift system 77
2.5 Drive shafts 78
2.5.1 Tightening instructions 78
2.6 Gearbox run time 79
2.7 Gearbox tightening torques 79
2.8 Transmission dismantling 81

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MY 2018
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Preface
2.8.1 Dismantling of hang-on parts 81
2.8.2 Gear housing dismantling 82
2.8.3 Gear set removal 83
2.8.4 Dismantling the shift drum 84
2.8.5 Dismantling the locking sleeve 84
2.8.6 Oil supply 85
2.8.7 Cross shaft dismantling 86
2.8.8 Pinion shaft dismantling 89
2.8.9 Differential removal 90
2.8.10 Central clutch operator removal 91
2.8.11 Connecting shaft dismantling 91
2.8.12 Drive shaft dismantling 92
2.8.13 Bearing dismantling 93
2.9 Transmission assembly 95
2.9.1 Gearbox housing pre-assembly 95
2.9.2 Gear housing pre-assembly 106
2.9.3 Differential lid pre-assembly 112
2.9.4 Pinion shaft bearing assembly 113
2.9.5 Pinion shaft 114
2.9.6 Pinion shaft position adjustment 116
2.9.7 Assembly of gear sets 118
2.9.8 Premounting shift drum 124
2.9.9 Oil pump assembly 125
2.9.10 Reverse idler gear 126
2.9.11 Locking sleeve 127
2.9.12 Shift rod and shift forks 128
2.9.13 Suction tube assembly 129
2.9.14 Central clutch operator assembly 131
2.9.15 Cutted gear housing assembly 131
2.9.16 Determining cross shaft bearing adjusting disk Q1 133
2.9.17 Cross shaft setup 134
2.9.18 Cross shaft assembly 135
2.9.19 Differential setup 139
2.9.20 Mounting gearhousing 146
2.10 Rolex assembly 152
2.11 Overview gearbox settings 166
3Chassis 167
3.1 General 167

Version: 4/20/2018
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MY 2018
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Preface
3.1.1 Wheel bearing 168
3.1.2 Wheel hub 169
3.1.3 Wheel nut 170
3.1.4 Locking piece 171
3.2 Front axle 172
3.2.1 Front axle cross member 173
3.2.2 Front axle transverse control arm 174
3.2.3 Longitudinal control arm 176
3.2.4 Front axle wheel mount 177
3.2.5 Front axle shock absorber 179
3.2.6 Front axle anti-roll bar 181
3.3 Rear axle 184
3.3.1 Rear axle control arm and tie rod 185
3.3.2 Rear axle transverse control arm 186
3.3.3 Rear axle wheel mount 188
3.3.4 Rear axle shock absorber 190
3.3.5 Rear axle anti-roll bar 192
3.3.6 Rear axle side part 195
3.4 Wheel alignment 196
3.4.1 Preparatory measures 197
3.4.2 Vehicle ride height measuring points 198
3.5 Steering system 199
3.5.1 Bleeding the steering system 202
3.6 Rims and tire 203
3.6.1 Rim 204
3.6.2 Tires 204
3.7 Brake system 205
3.7.1 General information 205
3.7.2 Front axle brake 208
3.7.3 Rear axle brake 209
3.7.4 Master cylinders 210
3.7.5 Changing the brake fluid 211
3.8 Brake pressure distribution 212
3.8.1 Balance beam basic setting 213
3.8.2 Calculating the brake power 215
3.9 Balance bar replacement kit 216
3.9.1 Replacing the trunnion 216
3.9.2 Replacing the balance bar 217
3.10 Performance setup 218