Porsche 2012 911 GT3 CUP, 911 GT3 Cup 2011 Technical Manual

Technical Manual

2012 Model

Preface

This technical information will give you the 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 Cup

Dr. Ing. h.c. F. Porsche

Aktiengesellschaft

Vertrieb Sonder- und Rennfahrzeuge

Race car 911 GT3 Cup Model 2012

This car is specifically designed for participation in one-make cup

competitions.

For obvious reasons, measurements referring to bodywork dimensions

of the production cars cannot be used as reference.

Porsche 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 schematic drawings serve exclusively as

presentation for the text. Porsche Motorsport accepts no liability for the

completeness and conformity of the contents of this brochure with

respect to the legality of the current regulations.

1

Contents

1. CONTACTS 4

2. GENERAL TECHNICAL DATA 5

2.1. Dimensions 5

2.2. Weight 5

3. ENGINE 6

3.1. Engine technical data 6

3.2. Engine power and torque curves 7

3.3. Engine lubrication 8

3.4. Engine cooling system 12

3.5. Induction system 18

3.6. Throttle butterfly 18

3.7. Working on the engine 23

3.8. Engine component tightening torques 36

3.9. Engine mileage 37

4. FUEL AND EXHAUST SYSTEM 38

4.1. Fuel system 38

4.2. Fuel cell 39

4.3. Exhaust system 42

5. GEARBOX 46

5.1. Technical data gearbox 46

Gearbox layout 47

5.2. 47

5.3. Modifications 2012 model 48

5.4. Gearbox lubrication 49

5.5. Ratio chart 49

5.6. Gear recognition 50

2

5.7. Changing gear 51

5.8. Differential 53

5.9. Clutch 54

5.10. Working on the gearbox 57

5.11. Tightening torques gearbox 79

5.12. Gearbox mileage 79

6. SUSPENSION 80

6.1. Front suspension 80

6.2. Rear suspension 84

6.3. Basic wheel alignment 87

6.4. Wheel alignment procedure 88

6.5. Working on the suspension 95

6.6. Tightening torques suspension 96

6.7. Sachs damper service information 106

7. WHEELS 108

8. BRAKE SYSTEM 110

8.1. Technical data brake system (steel) 110

8.2. Technical data brake system (PCCB) 110

8.3. Brake force distribution (brake balance) 111

8.4. Brake caliper 118

8.5. PCCB brake disk information 118

8.6. Tightening torques brake system 119

9. CHASSIS 120

9.1. Interior 120

9.2. Exterior 120

9.3. Rear wing 121

9.4. Fire extinguisher system 122

3

9.5. Air-jack system 124

10. ELECTRIC 126

10.1. Alternator 126

10.2. Battery 126

10.3. Steering wheel 126

10.4. Centre console 128

10.5. Shift Light Module 129

10.6. MoTeC Dash 130

10.7. Car sensors 134

10.8. Engine Control Unit (ECU) 136

10.9. Relay- and fuse assignment 137

10.10. Fuse carrier 138

11. CAR MAINTENANCE 139

11.1. After approx. 200 km and/or first test 139

11.2. After every session 139

11.3. After every race weekend (sprint) 140

11.4. After 3 - 4 race weekends (sprint) 140

11.5. After 20 respectively 30 hours running time 140

11.6. After 50 hours running time 140

11.7. Operating fluids 141

4

1. Contacts

International One Make Cups Mr Michael Dreiser 0711 911 82684

Assistant Mrs Juliane Gründl 0711 911 82683

Technical support Mr Marcus Stolzenthaler 0711 911 82498

Fax: [phone]

Porsche Mobil 1 Supercup Mr Jonas Krauss 0711 911 84042

Assistant Mrs Jennifer Biela 0711 911 84096

Technical support Mr Steffen Höllwarth 0711 911 89922

Fax: [phone]

Porsche Carrera Cup Germany Mr Helmut Greiner 0711 911 84074

Assistant Mrs Andrea Hagenbach 0711 911 84041

Technical support Mr Stefan Rometsch 0711 911 84613

Fax: [phone]

Sport parts sales Mr Friedrich Weseler 0711 911 89854

Mr Karlheinz Kienle 0711 911 82923

Mr Klaus Lenzner 0711 911 82423

Mr Christian Müller 0711 911 89175

Mr Salvatore Scozzaro 0711 911 83738

Mr Emanuel Donno 0711 911 82687

Fax: [phone]

5

2. General technical data

Engine type M 97/78

Gearbox type G 97/63

Numbers of gears sequential 6

2.1. Dimensions

Length (w/o spoiler edge) [mm] 4423

Width across front axle [mm] 1787

Width across rear axle [mm] 1859

Wheelbase [mm] 2353

2.2. Weight

Dry weight [kg] appr. 1200

With steel brakes, without front exhaust silencer

6

3. Engine

The engine is based on the power unit fitted to the road approved

911 GT3 and is specially modified for motorsport purposes.

The engine is fitted with a dry sump lubrication system; the oil tank is

mounted directly on the engine. The engine oil is cooled by an oil-water

heat-exchanger integrated in the cooling system.

3.1. Engine technical data

Engine type M97/78

Design

Six-cylinder boxer

Cylinders

6

Bore

[mm] 102.7

Stroke

[mm] 76.4

Cubic capacity

[cm³] 3797

Compression ratio

approx. 12 : 1

Maximum revs

[rpm] 8,500

Inlet valve diameter

[mm] 41

Inlet valve lift

[mm] 12.0

Point of maximum
inlet valve lift

[°] 105 after TDC

Exhaust valve
diameter

[mm] 35.5

Exhaust valve lift

[mm] 12.0

Point of maximum
exhaust valve lift

[°] 110 before TDC

Cooling media

Water cooled

Lubrication

Dry sump lubrication

Oil-water heat-exchanger

7

3.2. Engine power and torque curves

8

3.3. Engine lubrication

The 911 GT3 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.

3.3.1. Engine oil

Mobil 1 0W - 40

Mobil 1 5W - 40

9

3.3.2. Engine oil system

1 – Oil tank

9 – Piston cooling

2 – Pressure pump 10 – Timing chain tensioner

3 – Safety valve 11 – Camshaft

4 – Oil filter 12 – Hydraulic valve lifter

5 – Pressure sensor 13 – Camshaft housing scavenge pump

6 – Oil-water heat-exchanger 14 – Crankcase scavenge pump

7 – Pressure relief valve 15 – Balance shaft

8 – Crankshaft

10

3.3.3. Checking the oil level

The engine oil temperature must be over 80°C and the engine running at

idle speed (approx 2,000 rpm) to measure the oil level correctly. The oil

level must be between the two marks on the dip-stick. The distance

between the two marks corresponds to 1 litre of engine oil.

An e

xcessively high oil level can lead to oil entering the induction

tract.

If engine oil is added it should be noted that this oil only flows slowly into

the 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 necessary especially when the engine is new. Oil pressure

signal drop outs in the MoTeC data logging are a clear indication

for low oil level. Therefore the oil pressure must be carefully and

regularly monitored. (e.g. with MoTeC). The MoTeC oil pressure

alarm is active if the oil pressure falls below 2.5 bar for at least

one second at an engine speed of 2,500 rpm or greater (for a

minimum of two seconds).

3.3.4. Filling capacities

New engine: 11.0 l

With oil filter change: 8.3 l

Without oil-filter change 8.1 l

11

3.3.5. Digital oil level display

An optional oil level display is available (997.641.139.9A):

The car wiring loom is already prepared for use of this display. The

connector for the display is located in the area of the rear side-window on

right-hand side of the car.

In addition, the oil level sensor 996.606.140.00 is necessary for

displaying the oil level. The sensor is plugged in the oil tank.

Attention: Do not fill above 90 %

12

3.4. Engine cooling system

The GT3 Cup cooling system is a standard cooling system optimised for

use in a race car.

3.4.1. Scheme drawing

1 – Left-hand side cooler 4 – Gearbox heat-exchanger

2 – Centre cooler 5 – Engine heat-exchanger

3 – Right-hand side cooler 6 – Cooling water expansion tank

di – Bleed throttle

3.4.2. Thermostat

The thermostat fitted starts to open when the water temperature exceeds

60°C. The thermostat is completely open from 72°C.

13

3.4.3. Cooling fluid

The cooling system if filled with 11 litres of water and 11 litres of anti-

freeze when delivered. The coolant remains fluid to temperatures of -30°C

in delivery specification with this water/anti-freeze ratio.

For all race events Porsche Motorsport recommends that the factory filled

engine coolant is replaced by 20 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, reduces

cavitation, lubricates the water pump and increases the boiling point of

the cooling water.

For Cup races supporting Formula 1 events the coolant must be

changes as described below: Approx 20 litres water plus minimum

2 litres anti-corrosion additive part number 997.106.907.90.

3.4.3.1. Capacity

Approx 22 litre

s

14

3.4.4. Filling the cooling system

A quick-release coupling is integrated in the engine bay in the area of the

expansion tank. The water system can be filled and bled quickly and

safely via this coupling – after an engine change for example.

When the water system has reached its operating temperature,

the expansion tank cap should under no circumstances be opened

and the pressure released. Since the operating temperature has

already been achieved the water pressure cannot be built up

again. This system pressure is necessary to increase the coolant

boiling point.

Q

uick release coupling

15

Valves in the expansion tank allow the exhaust of steam at a pressure of

1.4 bar, and the release of water at a pressure of 1.8 – 2.0 bar.

The bleed valve in the standard production car improves 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 fill the

water system. The filling system consists of an electric pump that pumps

water from a tank into the system.

Bernd Sobek – Mattern

Fliederstr. 10

D – 69517 Gorxheimertal

Tel [phone]

Fax [phone]

www.sobek-motorsporttechnik.eu

16

Filling the system should be carried out as follows:

 Disconnect the quick release fittings in the engine bay and

connect the corresponding fittings with those of the filling system

 Switch on the pump, the system will be filled
 The device must run for ten minutes to guarantee that the system

is correctly filled and bled

 Warm-up the engine (80°C) and, if required, fill the reservoir

to the maximum level with the filling device still attached

 The e

xpansion tank cap must be closed throughout the

entire procedure

3.4.4.1. Filling the cooling system with engine at

normal operating temperature:

A special filling system to fill the engine water system when the engine is

at normal operating temperature is also available from Sobek. This

appliance consists of a fluid reservoir with a coupling. The reservoir is

charged with a pressure of 2.5 – 3.0 bar.

The system filling procedure must be carried out as follows:

 Disconn

ect the quick release fitting in the engine bay and connect

the filling system coupling to the corresponding end of the quick-

release fitting.

 The system is filled via the expansion tank.

17

3.4.4.2. Filling the cooling system with pre-heated water

A special filling system to fill the engine water system when the engine is

at normal operating temperature is also available from Sobek.

18

3.5. Induction system

V

acuum actuator

Reso 1 (su)

V

acuum actuator

Reso 2 (su2)

 Four-stag

e resonance induction system

 Activated by vacuum actuator resonance valves (x2)

3.6. Throttle butterfly

1.) Adjuster screw

2.) Lock nu

t

3.) Threaded bush

4.) Potentiometer

 Mechan

ical single throttle butterfly without by-pass

 Idle speed set via adjuster screw

19

3.6.1. Throttle cable

Compensation of the throttle-cable length is made by the spring fitted in

the connecting piece. To achieve this the spring is tensioned and/or un-

tensioned by rotating the connection piece.

We point out that it is imperative to ensure the complete locking of

all 3 clips of the housing of the connecting piece.

20

3.6.1.1. Tension-free setting of the throttle cable

Be

fore calibrating the throttle-butterfly potentiometer the throttle cable

must be set “tension-free”:

1. Rotate the throttle cable in the direction “auf” on the connecting

part behind the driver seat

close

open

2. Press t

he two halves of the connecting part together

3. Rotate the throttle cable in the direction “zu”

1 3

2

The

throttle cable has play in this position. Tasks such as throttle butterfly

reset can now be carried out.

21

3.6.1.2. Play compensation

To remove throttle cable follow the procedure described below:

2

1

1. The

throttle cable is tensioned automatically by the length

compensation spring

2. To finish, rotate the connecting part in the direction “close” till the

marking lugs on both parts of the connecting part are aligned

The throttle cable is tensioned automatically by the length compensation

spring

3.6.2. Throttle butterfly potentiometer calibration

The throttle butterfly potentiometer must always be recalibrated if:

 ECU was changed or reprogrammed
 Engi

ne was changed

 Throttle butterfly potentiometer was changed
 Implausible throttle butterfly position values are displayed

The following steps must be taken to calibrate the potentiometer:

1. Adjust the throttle cable so it is tension free (see

3.6.1.1)

2. Disconn

ect the throttle cable from the cam-disc

3. Loosen the idle adjustment screw 1.)

4. The cam-disc must now rest on the threaded bush 3.),

the throttle butterfly is now completely closed.

Calibration of the throttle butterfly is made in this

position (reset the throttle butterfly angle to 0°)

5. This calibration is made via Bosch Modas a.) or the

MoTeC Dash b.)

22

a.) In Modas on the ‘Throttle’ page (in Engine F1) activate

the button ‘Set Throttle’



throttle angle wdkba_w shows 0°

b.) Switch to Warmup mode, press and hold the ‘Display’ and

‘Alarm’ buttons for approx. 3 seconds till the ‘Reset’ appears

in the display and THR_BO goes to 0°

HIGH
BEAM

FLASHER

WIPER

DISPLAY

SPEED

ALARM

6. Screw t

he idle adjustment screw 1.) into the threaded

bush 3.) till a throttle value of appr. 6.5° (THR_BO in

Dash, wdkba_w in Modas) is displayed

7. The throttle value must NOT exceed 9° at idle (THR_BO

in Dash, wdkba_w in Modas)

8. Lock adjus

tment screw 1.)

9. Reconnect throttle cable to cam-disc

10. Tension the throttle cable (see 3.6.1.23.6.1)

3.6.3. Full throttle adjustment

Adjust the throttle pedal stop-screw so that full throttle equals 80° +/- 2°

(THR_BO in Dash, wdkba_w in Modas)

Attention: Only the adjustment screw under the throttle pedal

should be used to set full throttle. It is essential at full throttle, i.e.

when the throttle pedal is touching the stop, that there is sufficient

play in the throttle cable on the engine and that the throttle cable

movement is limited by the adjuster screw and NOT by the cable.

If the full throttle value is too high it is possible that mechanical

damage or a sticking throttle can occur.

23

3.7. Working on the engine

3.7.1. Connecting-rod bolt mounting instructions

1. Thoroughly clean the mating faces, bolt threads and the tapped

bores

2. Smear the threads and bolt head mounting faces with engine oil

3. Initial tightening torque: 30 +/- 3 Nm

4. Final tightening torque: 62 +/- 2° torque angle

5. Resulting elongation: 0.200 +/- 0.015 mm

Attention: Always renew the connecting rod bolts after

disassembly.

The joint surface must NOT be damaged.

As the connecting rods have a coated surface care must be taken that no

visible damage occurs to the connecting rod surface when dismantling

and assembling the engine. The connecting rods must NOT be polished.

24

3.7.2. Mounting the cylinder head

The following procedure should be adhered to when mounting the cylinder

head:

1. Lightly oil the threads and mating faces

2. Tighten the bolts initially to 30 Nm in the following sequence,

and then wait 15 minutes

3. Completely loosen the bolts in the reverse sequence

4. Initially tighten the bolts to 20 Nm, before finally tightening to

120° torque angle

3.7.3. Flywheel tightening procedure

3.7.3.1. With used flywheel:

1. Loosen and remove the bolts

2. Replace with new bolts part number 930.102.206.00

3. Tighten the new bolts to 30 Nm (tighten sequence diagonally

opposed)

4. Retighten bolts to 30 Nm and an additional 45° torque angle

(tighten sequence diagonally opposed).

3.7.3.2. With new flywheel:

1. Bec

ause a new flywheel ‘settles’ it should be mounted initially

using used bolts as described above.

2. Replace with new bolts part number 930.102.206.00

3. Tighten the new bolts to 30 Nm (tighten sequence diagonally

opposed)

4. Retighten bolts to 30 Nm and an additional 45° torque angle

(tighten sequence diagonally opposed).

25

3.7.4. Set valve timing

3.7.4.1. Valve timing

Point o

f max inlet valve lift (EM) 105° after TDC

Point of max exhaust valve lift (AM) 110° before TDC

3.7.4.2. Special tools

Porsche Moto

rsport recommends use of the following special tools to

adjust and set the valve timing of the 911 GT3 Cup

Base plate cylinder 1: 996.721.549.90

Base plate cylinder 2: 996.721.550.90

Guide element EM/AM 110/110: 996.721.551.9A

Guide element EM/AM 105/115: 996.721.551.93

Degree wheel crankshaft: 996.450.131.00

Chain tensioner: 000.721.940.10

Setting jig TDC: 996.721.511.91

Retaining key timing chain sprocket: 996.721.513.90

26

3.7.5. Removing and fitting the crankshaft seal – pulley-side

3.7.5.1. Special tools

Porsche Moto

rsport recommends use of the following special tools to

remove and fit the pulley-side crankshaft seal:

Retaining key pulley: 000.721.973.20

Adapter retaining 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

3.7.5.2. Removal

1. Remov

e the pulley from the crankshaft using the special tool

000.721.973.20 with the retaining key extension 000.721.873.20

2. Check the locating dowel on the pulley for damage and replace if

necessary

3. Centre-punch the steel ring in two points offset from one another by

180°

27

4. Drill two holes (Ø 2 mm) at the centre punched points

5. Screw the threaded-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 to the following sketch (paper our thick

card). All dimensions in millimetre