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

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MY 2018
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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

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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]

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MY 2018
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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

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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.

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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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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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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

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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

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4Bodywork 219
4.1 General 219
4.2 Front and side view 220
4.3 Rear view 222
4.4 Body shell 223
4.4.1 General 223
4.4.2 Weight distribution 225
4.4.3 Weight percentage of the Body -in-White 225
4.4.4 Body aluminum parts 226
4.4.5 Body features 227
4.4.6 Body steel parts 228
4.4.7 Materials overview 229
4.4.8 Roll cage 230
4.4.9 Recovery device 231
4.5 Aerodynamics 232
4.5.1 General 232
4.5.2 Rear wing 232
4.5.3 Additional aerodynamic improvements 232
4.6 Exterior mirrors 233
4.7 Roof 233
4.8 Air jack system 234
4.9 Doors 236
4.10 Trunk and engine lid 236
4.10.1 Trunk lid 236
4.10.2 Engine lid 236
4.11 Windows 237
4.11.1 Installing and removing the windshield 237
4.11.2 Preparing the window cutout for installation 241
4.11.3 Preparing the windshield for installation 242
4.11.4 Installing the windshield 243
4.12 Fenders 245
4.13 Wheel cover 245
4.14 Fuel system 246

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4.14.1 Fuel 247
4.14.2 Defueling 247
4.14.3 Tank installation 248
4.15 Repairing the body 248
4.15.1 Repairing the front section 249
4.15.2 Replacing the front strut mount 270
4.15.3 Repairing the rear end Protective measures 277
4.15.4 Reinforcement plates cast carrier 281
4.15.5 Side panel repair –flange edge wheel arch 282
4.16 Thread repair kit 283
4.16.1 Thread repair of chassis bolt connections 284
4.17 Installing roof assembly 301
5Interior 303
5.1 General 303
5.2 Drivers safety 304
5.2.1 Seat 304
5.2.2 Seat rail tightening torques 306
5.2.3 Bucket seat tightening torques 307
5.2.4 Padding system 308
5.3 Steering wheel 309
5.4 Cockpit ventilation 310
6Electrical system 311
General 311
Power supply 311
6.2.1 Battery 311
6.2.2 Generator 311
6.2.3 Battery master switch 312
Electrical system protection 313
6.3.1 Electrical system control unit IPS32 313
6.3.2 Fuse holder hydraulic pump 316
DME engine electronics 316

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6.4.1 DME control unit 317
6.4.2 DME diagnosis 318
6.4.3 Error codes 319
6.4.4 Carburation 321
6.4.5 Ignition system 321
Transmission 322
6.5.1 Error codes 322
Sensors 323
6.6.1 Sensor rated values 324
6.6.2 View online sensor values 325
6.6.3 Calibrating sensors 325
Display ICD 328
6.7.1 General information 328
6.7.2 Race page 1 330
6.7.3 Race page 2 331
6.7.4 Race page 3 332
6.7.5 Practice page 333
6.7.6 Warmup page 335
6.7.7 Vitals page 336
6.7.8 Control page 338
6.7.9 Chassis page 340
6.7.10 Pit Speed 344
6.7.11 Alarm displays 345
6.7.12 Trackmap page 350
6.7.13 Diagnose page 350
6.7.14 Position of balance bar 352
Lights 353
Data bus system 354
Wiring harness 356
Ground connection roof antenna 358
Fire extinguisher 359
6.12.1 Testing the trigger switch 360
6.12.2 Battery change 361
Driver Control Systems 362

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6.13.1 Steering wheel 362
6.13.2 Center console 363
6.13.3 Windscreen wiper 364
6.13.4 Interior fan switch 364
7Maintenance 365
7.1 Engine 365
7.1.1 Oil level measurement 365
7.1.2 Oil level measurement with display (optional) 367
7.1.3 Changing engine oil 368
7.1.4 Refilling engine oil 369
7.1.5 Oil specification 369
7.1.6 Engine cooling system 370
7.1.7 Engine tightening torques 374
7.1.8 Engine runtime 375
7.2 Fuel system 376
7.2.1 Fuel 376
7.2.2 Fuel extraction 378
7.3 Power transmission 380
7.3.1 Gearbox 380
7.3.2 Clutch 383
7.3.3 Paddle shift 386
7.3.4 Drive shafts 388
7.4 Chassis 389
7.4.1 Wheel nut 389
7.4.2 Locking piece 390
7.4.3 Wheel bearings 391
7.4.4 Wheel hub 391
7.4.5 Wheel rim 391
7.4.6 Brake system 392
7.4.7 Replacing the piston seal rings 392
7.4.8 Remodeling/Maintenance Main brake cylinder 395
7.4.9 Shock absorber/spring 401
7.4.10 Anti-roll bar 401
7.4.11 Steering system 402
7.5 Body 404
7.5.1 Airjack system 404
7.6 Electrical system 404

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7.6.1 Checks after wet races 404
7.7 Maintenance intervals 405
7.7.1 After 200 km (124 mi) or first test drive 405
7.7.2 After each session 405
7.7.3 After each weekend (sprint race) 406
7.7.4 After 3 –4 race weekends (sprint races) 406
7.8 Special tools 911 GT3 Cup (991) 407
7.9 Partner contacts 409
8. After Sales 411
8.1 Engine oil rapid filling system 411
8.1.1 Templates 414
8.2 LED oil level display 415
8.3 Safety Nets 416
8.4 Endurance tank 425
8.4.1 8.4.1 Tank opening in front lid 442
8.4.2 8.4.2 Fuel draining system 444
8.5 Taxi seat 449
8.5.1 8.5.1 Chassis preparation for console fixation 449
8.5.2 8.5.2 Fixation six-point safety belt 451
8.5.3 8.5.3 Assembling the footwell cover 453
8.5.4 8.5.4 Repositioning vehicle electrical system control unit (IPS) 454
8.5.5 8.5.5 Position the seat bracket at the rear position. 456
8.5.6 8.5.6 Installing the seat shell 457
8.5.7 8.5.7 Using the passenger seat 461
8.6 Fitting the base plate and additional weights 462
8.6.1 Preparation of the bodyshell for the base plate and additional weights
462
8.6.2 Fitting the base plate and weights 464
8.7 Heated windshield 465
8.8 Power box 466
8.9 Cockpit light 467
8.10 Race number lighting 468

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8.11 Battery charging cable 471
8.12 Suspension travel sensor 472

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Engine
911 GT3 Cup (991 II)
MY 2018
Engine
1Engine
1.1 General information
The engine of the new 911 GT3 Cup (991 II) is an enhancement of the unit in the road-
approved 911 GT3 RS with displacement of 3,996 cc. New features compared with
the previous Cup engine are the direct fuel injection, camshaft control for the intake
and exhaust valves, and rigidly mounted valve levers for valve actuation. The oil supply
for the connecting-rod bearings is ensured by the central oil supply to the crankshaft.
Also new is the demand-controlled oil pump with integrated centrifuge for oil
defoaming. The engine features dry-sump lubrication with an oil tank mounted on the
engine side. The oil is cooled by an oil/water heat exchanger integrated into the cooling
system.
The Bosch Motronic MS 4.6 NG control unit is used for engine control.
1.1.1

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Engine
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911 GT3 Cup (991 II)
MY 2018
Engine
1.2 Technical data
Full load curves
1.2.1
Technical engine specifications
Number of cylinders 6
Type Flat-six engine
Valves per cylinder 4
Displacement 3,996 cc
Bore 102.0 mm (4 inches)
Stroke 81.5 mm (3.2 inches)
Compression Approx. 13.3 : 1
Max. engine speed 8,500 rpm
Cooling Water-cooled
Lubrication Dry-sump lubrication (demand-controlled oil pump)
Oil/water heat exchanger
%

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Engine
911 GT3 Cup (991 II)
MY 2018
Engine
1.3 Engine lubrication
The 911 GT3 Cup (991 II) features dry-sump lubrication with a demand-controlled oil
pump. This type of lubrication system design ensures a reliable pressure oil supply to
the engine components that require lubrication in all driving situations. The oil tank
mounted separately on the front of the engine always contains enough oil to supply the
oil pump. The crankshaft has a central oil supply to provide the connecting-rod bearings
with sufficient lubrication at high engine speeds.
An oil/water heat exchanger has been integrated into the engine's oil/water system for
controlling the engine temperature.
1.3.1 Oil level measurement
On the 911 GT3 Cup (991), the oil level is measured electronically by means of a level
sensor in the oil tank. There is no dipstick. To ensure a correct measurement, the engine
must be at operating temperature (coolant temperature 80°C (176°F)).
See Section 7.1
1.3.2 Filling capacities
Improper adding of engine oil
Risk of damage to the engine
•Engine oil must not be added when the engine is
running.
•The engine must be stopped before adding
engine oil.
Engine rebuild: 9.5 liters (10 qts)
Oil change with change of oil filter: 6.6 liters (7 qts)
Oil change without change of oil filter: 6.0 liters (6.3 qts)
1.3.3 Engine oil
The engine oil is always changed when the engine is overhauled at Porsche AG. The
following oil specification is used for this:
Mobil 1 FS 0W-40
Mobil 1 New Life 0W-40
NOTE