911GT3

911 GT3Cup
Cup(2021–2023)
(2021)
TechnicalManual
Technical Manual
V1, 12/2020
V7,12/2022
Imprint Introduction
Dr. Ing. h.c. F. Porsche AG This technical manual is intended as a reference work that provides you with data,
Motorsport Vertrieb setting values and operating regulations relevant to the vehicle, and is also intended
Porschestraße 911 to assist you in the maintenance and repair of the vehicle.
71287 Weissach If you have any questions about vehicle information that you cannot find in this
Germany technical manual, please contact the Technical Racing Support, see 7.1 Technical
Racing Support on page 1023.
P.O. Box 1340
71287 Weissach, Germany Porsche shall not assume any guarantee for conformity with the applicable rules and
regulations. Any change to the original specifications may affect homologation
compliance.
V7,12/2022
We wish you many sporting successes with your Porsche 911 GT3 Cup.
Figures, descriptions and schematic drawings serve only as visualisation of the text.
Your customer support centre

We shall not accept liability for completeness of the content or for conformity Dr. Ing. h.c. F. Porsche AG
of the content with applicable legal regulations. Motorsport Vertrieb
Porschestraße 911
The state of the art is subject to modifications without notice. 71287 Weissach
Germany
© Copyright by Dr. Ing. h.c. F. Porsche AG.
Email: [email protected]

V7,12/2022 911 GT3 Cup (2021–2023) 2

Intended use Further information
This vehicle has been specially designed for participation in circuit races. Continuous optimisation of our products means that this technical manual is updated
For obvious reasons, the standards set for our series-production vehicles with respect at regular intervals. Please note that only the most recent version of the technical
to body design can therefore not be assumed here. manual is valid. The most recent version can be viewed and downloaded in the
"Porsche Motorsport Racecar Service Information" portal (PMRSI) at
The 911 GT3 Cup is a racecar; special skills and knowledge are required to drive https://motorsport.porsche.com.
a racecar. We therefore recommend that 911 GT3 Cup drivers first complete the
"Porsche Track Experience", the "Porsche Racing Experience" or an equivalent training
programme.

Repair, maintenance and adjustment work on a racecar requires special skills and
knowledge and an extremely high level of care and attention.
Persons who carry out work on the 911 GT3 Cup must be sensitised to the particular
requirements of motorsport.

Figures, descriptions and schematic drawings serve only as visualisation of the text.

We shall not accept liability for completeness of the content or for conformity of the
content with applicable sporting codes and legal regulations.

Porsche Motorsport does not accept any claims for repair and goodwill if control units
and/or CANs have been manipulated.

Improper use
This vehicle cannot be approved for use on public roads and does not meet
the requirements of the German Road Traffic Licensing Regulation
(German designation: StVZO).

V7,12/2022 911 GT3 Cup (2021–2023) 3

Warnings and safety notices
Warnings and safety notices are classified by signal words (Danger, Warning, Caution) These warnings and safety notices must be read and understood and strictly observed
and corresponding warning symbols. at all times to avoid personal injury as well as any impairment of the vehicle's operating
safety and roadworthiness or damage to it resulting from improperly performed work.
DANGER WARNING OF IMMINENT DEATH OR MOST SEVERE PERSONAL
INJURIES THAT WILL OCCUR IF THE NOTICE IS NOT OBSERVED.
Dr. Ing. h.c. F. Porsche AG cannot possibly and ultimately foresee and assess all
WARNING OF DEATH OR MOST SEVERE PERSONAL INJURIES hazardous situations persons executing tasks may encounter. Repair, maintenance
WARNING and service or adjustment work must only be performed by professional and trained
THAT MAY OCCUR IF THE NOTICE IS NOT OBSERVED.
mechanics. Any attempt to perform repair, maintenance and service or adjustment
CAUTION WARNING OF MINOR PERSONAL INJURY THAT MAY OCCUR IF work without proper training, tools and equipment may lead to death or injury of the
THE NOTICE IS NOT OBSERVED. person attempting such work or other persons.
In addition, damage to the vehicle or malfunctions may occur or the correct function
NOTICE WARNING OF MATERIAL DAMAGE THAT MAY OCCUR IF THE of the vehicle may be compromised.
NOTICE IS NOT OBSERVED.
It is explicitly pointed out that all applicable guidelines, regulations and stipulations
of local authorities and all such rules and regulations pertaining to health, work and
environmental safety must be observed when performing any work associated with
Information supporting actions or facilitating work procedures.
the work procedures described.

V7,12/2022 911 GT3 Cup (2021–2023) 4

Version history
Version Date Creation/change see page included in chapter
1 12/2020 Creation of original version 1-9
2 07/2021 Revised: Complete chapter Quick-Start revised 22 Quick start
Added: Service intervals: Air filter, engine oil and oil filter, spark plugs 48 1.1 Service intervals
Revised: Starting up vehicle - Step 2a) 56 1.3 Starting up the vehicle
1.4.3 Building up engine oil pressure.. Procedure I
Added: Building up engine oil pressure - Procedure I 59
(without Racecon)
Revised: Measuring the engine oil level - Scenario I and scenario II 61 1.4.4 Measuring the engine oil level
Added: Engine oil quick-fill 62 1.4.5 Engine oil quick-fill
Revised: Installing the belt - Step 4 adjusted 66 1.5.2 Installing the belt
Revised: Complete Chapter Engine and gearbox removal/installation 70–79 1.7 Engine and gearbox – removal/installation
Revised: Cleaning the air filter 82 1.8.1 Air filter... Cleaning the air filter
Revised: Resonance flaps test 84 1.8.3 Resonance flaps... Resonance flaps test
Revised: Information on building up fuel high-pressure 92 1.9 Fuel system
Revised: Information on mounting high-pressure supply lines 93 1.9.2 High-pressure fuel system
Revised: Procedure draining the coolant 102–103 1.11.5 Draining the coolant
1.11.6 Filling the cooling system... Variant 2 – filling
Added: Information on the filling device 9696 106
device 9696
Added: Noise emissions from the exhaust systems 110 1.12 Exhaust system...1.12.1 Noise emissions
Added: Shifting conditions 125 2.2.4 Shifting conditions
Added: Information on Oil-level measuring and mounting position 130–132 2 GEARBOX...2.2.8 Oil level – measuring

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Version Date Creation/change see page included in chapter
2.3.3 Clutch fluid – changing/bleeding... Clutch
Revised: Clutch system-bleeding procedure 142–143
system – bleeding
2.5.1 Subassembly of gearbox housing... Bearings –
Revised: Assembly description bearing outer race and differential bearing 192–193
installation
2.5.6 Pinion shaft – installation... Pinion shaft position
Revised: Pinion shaft measurement ([3] blue writing) 220
– adjustment
2.5.23 Differential assembly – general
Revised: Pressure plates lamellae packages - Further plate sizes added 264
overview... Stacking the plate sets
Revised: Service instruction for upright left/right front axle removed 291 3.1 Service intervals... Front axle
Added: Max. runtime wishbone top left/right front axle 291
Added: Max. runtime upright left/right rear axle 292 3.1 Service intervals... Rear axle
Revised: Service instructions Brakes adjusted 293 3.1 Service intervals... Brakes
Revised: Service interval Brake rotor cup removed
Added: Max. runtime Anti-roll bars FA & RA 293 3.1 Service intervals... Anti-roll bars
Added: Check the locking effect of the self-locking nuts 295 3.2.1 Using self-locking nuts in suspension
Added: Tolerance specification screw front axle and specification of the 298 3.4 Measuring and adjusting ride height
minimum ride height at the front axle
3.4 Measuring and adjusting ride height... Measuring
Added: Specification of the minimum ride height at the rear axle 299
and changing ride height at rear axle
Added: Information to secure the camber plates at the front axle 300 3.5 Front axle
3.5.3 Assembly of front axle... Mechanical adjustment
Added: Mechanical adjustment range of the wishbone at the front axle 313
range of the wishbone
3.5.3 Assembly of front axle... Mechanical adjustment
Added: Mechanical adjustment range of the trailing arm at front axle 314
range of the trailing arm

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Version Date Creation/change see page included in chapter
3.5.3 Assembly of front axle... Damper strut to bottom
Added: Special tools for damper assembly 318
wishbone
3.5.3 Assembly of front axle... Positioning of main
Added: Positioning of main spring and helper spring at the front axle 319
spring and helper spring
Added: Warning notice for disassembling the steering rack 328 3.6.1 Steering rack
Added: Chapter track rod 329–333 3.6.2 Track rod
Revised: Information to secure the camber plates at the rear axle 339 3.7 Rear axle
3.7 Rear axle...3.7.2 Upright... Installation of wheel
Added: Installing wheel bearing at the rear axle 340
bearing/wheel hub
Added: Alignment of the fixed bearing of the lower right wishbone at the 3.7.3 Assembly of rear axle
333
rear axle
3.7.3 Assembly of rear axle... Mechanical adjustment
Added: Mechanical adjustment range of the wishbone at the rear axle 346
range of the wishbone
3.7.3 Assembly of rear axle... Positioning of main
Added: Positioning of main spring and helper spring at the rear axle 359
spring and helper spring
Revised: Safety Notice and Information on purchasing TPMS Sensors 372 3.8.4 Tyre pressure monitoring system (TPMS)
Revised: Brake pad replacement procedure - additional information at step 386 3.9.4 Changing brake pads
5
Added: Bleeding brake system (with ABS) 392 3.9.6 Brake fluid... Bleeding brake system (with ABS)
Revised: Bedding brakes on circuit 393 3.9.7 Bedding brakes on circuit
Added: Note on position numbers for rear wing adjustment 476 4.4.21 Rear wing... Rear wing adjustment
Added: Information on deformations > 2 mm 497 4.6 Body repair
Added: Quantity and item numbers of rivets required for repair 498 4.6.1 Replacing damper strut support
Added: Chapter replacing wishbone mounting 506 4.6.2 Replacing wishbone mounting

V7,12/2022 911 GT3 Cup (2021–2023) 7

Version Date Creation/change see page included in chapter
Added: Chapter rear quarter panel repair 549 4.6.5 Rear quarter panel repair
Added: Chapter front chassis section repair 575 4.6.6 Front chassis section repair
Added: Chapter repair rear chassis section 610 4.6.8 Rear chassis section repair
Added: Chapter repair rear wing mounting 619 4.6.9 Repair rear wing mounting
4.10.1 Design and components of fuel
Revised: Description of Bowser de-fuelling couplings 661
tank... Overview of fuel tank
4.10.1 Design and components of fuel tank... Safety
Added: Information and overview safety foam (Fuel tank) 664
foam
Added: Specification of the seat pad thickness 684 5.4.2 Seat pads
Revised: Passenger seat installation/removal 5.4.4 Passenger seat... Passenger seat – installation/
689
removal
Added: Stipulations & guidelines for „Taxi“ rides 5.4.4 Passenger seat... Stipulations & guidelines for
690
“Taxi” rides
Added: Information on cranked locking pin for the safety net connection 5.5.1 Outer safety net – installation/
693
point adjustment... Attachment
Added: Base plate for additional weights 701 5.8 Additional weights
Revised: Informations on battery charger CTEK Pro 25 S 719 6.2.4 Battery charger
Added: Closing of electric contactor 720 6.2.4 Battery charger... Closing of electric contactor
6.3.2 Engine control unit (Bosch MS 6.6)... ECU error
Revised: ECU error code list 735
code list
Added: Mating connectors to separating points 755–764 6.5 Option separating points
6.5 Option separating points... Separating point 12 –
Revised: Separating point 12 renamed 759
Windscreen heater

V7,12/2022 911 GT3 Cup (2021–2023) 8

Version Date Creation/change see page included in chapter
6.6.2 Calibrating the sensors... Steering angle
Revised: Description of calibration steering angle sensor 768
sensor... Calibration
Added: Reed sensor mounting (brake light switch) 769 6.6.3 Reed sensor mounting (brake light switch)
Revised: Activation of the indicators 783 6.10.2 Function description: Buttons/switches
Revised: Status Powerbox - channel name adapted 796 6.12.1 Display pages... Vitals (Mechanic)
Added: Information on Brake bias overlay 799 6.12.2 Display messages... Brake bias
Revised: Information on Steering shunt mode 806 6.12.2 Display messages... Steering shunt mode
Added: Alarm signal Throttle 837 6.12.3 Alarm signals
Revised: Meaning of the ABS diagnostic alarm 844
Added: Information on setting the sensors 946 6.14.6 Sensors... Beacon DINs
Added: Recommendation for mounting a resistor in the radio system 975 6.15 Radio
Added: Information on mounting antenna 977 6.15.3 Mounting antenna
Added: Installation GPS and radio antennae 978 6.15.4 Installation GPS and Radio Antennae
Added: Radio Equipment Directive (RED) / Certificates - TPMS 979 6.15.5 Radio Equipment Directive (RED) - TPMS
Revised: Informations on Antilock brake system (ABS) 999 6.17.2 Antilock brake system (ABS)
Added: Property damage notice 999
Added: Antilock brake system - Function test 1000 6.17.2 Antilock brake system (ABS)... Function test
6.17.2 Antilock brake system (ABS)... ABS Repair and
Added: Informations on ABS Repair and Bleeding 1002
Bleeding
Added: Error Memory 1003 6.17.2 Antilock brake system (ABS)... Error Memory
Added: ABS Settings 1005 6.17.2 Antilock brake system (ABS).. ABS Settings

V7,12/2022 911 GT3 Cup (2021–2023) 9

Version Date Creation/change see page included in chapter
Added: Information on shoring the ABS hydraulic unit and Mounting of the 1006–1007 6.17.2 Antilock brake system (ABS)... Mounting ABS
acceleration sensor wiring loom
Added: Video system (Racelogic) 1017 6.18 Video system
Added: Contacts Technical Racing Support 1023 7.1 Technical Racing Support
Added: Contacts Motorsport and spare parts sales 1024 7.2 Motorsport and spare parts sales
Revised: Contacts 1025 7.3 Addresses (service + equipment)
Added: Company contact cirp GmbH 1025
Added: Company contact HAZET 1026
Revised: Scope of service Manthey Racing 1027
Added: Company contact Racelogic 1028
Revised: Ride height and unit specification camber 1031 8.1.1 Setup
Revised: Values for toe and camber 1033 8.2.2 Toe/camber
Added: Informations on using Brake air duct front axle 1034 8.2.3 Brake air duct front axle
Revised: Vehicle dimensions - Front vehicle overhang 1048 8.3.1 Vehicle dimensions
3 07/2021 Revised: Service intervals of master brake cylinders 293 3.1 Service intervals... Brakes
Added: Information on the replacement of wear parts on the brake master 394 3.9.8 Brake hydraulics
cylinders
Revised: Service intervals air jack system 427 4.1 Service intervals
Added: Cleaner and adhesive 498 4.6.1 Replacing damper strut support
Revised: Part number of rivets WHT.008.074 changed to WHT.009.074 506 4.6.2 Replacing wishbone mounting
Revised: Part number of rivets WHT.008.074 changed to WHT.009.074 577–593 4.6.6 Front chassis section repair
Added: Chapter front chassis section-subframe repair 594 4.6.7 Front chassis section-subframe repair

V7,12/2022 911 GT3 Cup (2021–2023) 10

Version Date Creation/change see page included in chapter
Revised: Part number of rivets WHT.008.074 changed to WHT.009.074 611–618 4.6.8 Rear chassis section repair
Added: Warning notice for bleeding lifting cylinder 631 4.7 Air jack system
Added: Information for bleeding lifting cylinder before shipment 631
5.5.1 Outer safety net – installation/
Revised: Graphic outer safety net attachment rear 693
adjustment... Attachment
Added: Service scope Krontec Maschinenbau GmbH 1027 7.3 Addresses (service + equipment)
4 07/2021 Added: Tightening torque for bleeding screw brake caliper (FA/RA) 378 & 381 3.9.1 Brakes on front axle & 3.9.2 Brakes on rear axle
5 08/2021 Revised: Validity model year 2022 1 Title
Revised: Introduction 2 Introduction
Revised: Overspeed indication 50 1.2.2 Behaviour when exceeding max. engine speed
Added: Information about handling a gearbox stuck between gears 125 2.2.4 Shifting conditions
Revised: Max. runtime side member left/right RA 292 3.1 Service intervals... Rear axle
3.7.3 Assembly of rear axle... Damper strut and drive-
Added: Loctite high strength for mounting driveshaft nut 358
shaft to upright
Added: Warning notice about the fixing screw for the brake disc 377 & 380 3.9.1 Brakes on front axle & 3.9.2 Brakes on rear axle
Revised: 4.5.9 Repair rear wing mounting 619–630 4.6.9 Repair rear wing mounting
5.3.2 Attaching the lap and crotch belt to the
Revised: Dimensions of shims and bolts for lap belt 679
bodyshell
Added: Alarm signal EPS Derating 839 6.12.3 Alarm signals
Added: Declaration of conformity (RED) / Certificates Japan 979 6.15.5 Radio Equipment Directive (RED) - TPMS
6 03/2022 Quick start... 0.1.2 Centre panel... WET TYRE – tyre
Added: Information on the WET TYRE button 24
selection
Revised: Information on the Gearbox Emergency function 25 Quick start... 0.1.2 Centre panel... GBX – gearbox

V7,12/2022 911 GT3 Cup (2021–2023) 11

Version Date Creation/change see page included in chapter
Revised: Information on pit speed 32 Quick start... 0.3.4 Pop ups... Pit speed
Revised: Information on Full Course Yellow (FCY) mode 32 Quick start... 0.3.4 Pop ups... Full Course Yellow (FCY)
Added: Information on resetting the fuel counter 34 Quick start... 0.3.4 Pop ups... Fuel Reset and Low Fuel
Revised: Engine oil quick-fill 62 1.4.5 Engine oil quick-fill
Added: Tightening torque for ground cable of the engine - Step 13 73 1.7 Engine and gearbox – removal/installation
Revised: Step 28. of Chapter 1.7 Engine and gearbox-removal/installation 77
Revised: Step 29. of Chapter 1.7 Engine and gearbox-removal/installation 77
Added: 1.8.2 Restrictor aperture 83 1.8.2 Restrictor aperture
Revised: Step 4. of resonance flaps test 84 1.8.3 Resonance flaps... Resonance flaps test
Added: Information about the single throttle butterfly system 86 1.8.4 Single throttle butterfly system
Added: Protective cover throttle butterfly system 86 1.8.5 Protective cover throttle butterfly system
Added: Removing/installing the intake manifold module 90 1.8.6 Removing/installing the intake manifold module
Revised: Information on the mixing ratio and use of anti-freeze 99 1.11.2 Fill volumes and specifications
Revised: 1.12.4 Overview of silenced exhaust system 114 1.12.4 Overview of silenced exhaust system
Added: Service interval and instructions for the electronic shift barrel 120 2.1 Service intervals
Added: Description of figure 17 for oil level measuring of the gearbox 131 2.2.8 Oil level – measuring
Added: Description of figure 18 for oil level measuring of the gearbox 132
2.3.3 Clutch fluid – changing/bleeding... Clutch
Revised: Clutch system - bleeding 142–143
system – bleeding
2.3.3 Clutch fluid – changing/bleeding... Clutch pedal
Revised: Clutch pedal - adjustment 144
– adjustment
Added: Mixing ratio for cleaning agent Bonderite C-NE 20 145 2.3.4 Clutch release bearing

V7,12/2022 911 GT3 Cup (2021–2023) 12

Version Date Creation/change see page included in chapter
Revised: Property damage notice for the alignment of joint heads 296 3.2.2 Alignment of joint heads
Revised: Information on measuring and adjusting ride height 298 3.4 Measuring and adjusting ride height
3.5.3 Assembly of front axle... Anti-roll bar to cross
Added: Information on installing the anti-roll bar 306
member
3.5.3 Assembly of front axle... Reinforcement to cross
Added: Installing reinforcement to front cross member 321
member
Added: Steering ratio and turning circle 326 3.6 Steering... Steering ratio and turning circle
Revised: Teach steering stops 327 3.6 Steering... Teach steering stops
Added: Installing track rod to axial joint 331 3.6.2 Track rod... Track rod to axial joint
Added: Installing track rod bellows to steering rack 332 3.6.2 Track rod... Track rod bellows to steering rack
Revised: Installing axial joint to steering rack 333 3.6.2 Track rod... Axial joint to steering rack
Deleted: Information on the alignment of the fixed bearing of the lower 346 3.7.3 Assembly of rear axle
right wishbone (RA)
Added: Installing fixed bearing to RA bottom wishbone 3.7.3 Assembly of rear axle... Fixed bearing to bottom
wishbone
3.7.3 Assembly of rear axle... Damper strut and drive-
Added: Information on disassembly/assembly 358
shaft to upright
Added: Colour code rims FA + RA 367 3.8.1 Wheel/tyre combination
Added: Danger notice insufficient filling of the brake fluid reservoir 374 3.9 Brake system
379 3.9.1 Brakes on front axle... Single brake disc
Added: Information and replacement of single brake discs
382 3.9.2 Brakes on rear axle... Single brake disc
Revised: 3.10.4 Installing and removing balance bar system/brake master 410–411 3.10.4 Installing and removing balance bar system/
cylinder brake master cylinder
Added: Information collision breather pipe of the clutch 415 3.12 Clutch hydraulics

V7,12/2022 911 GT3 Cup (2021–2023) 13

Version Date Creation/change see page included in chapter
Added: Colour code body exterior 428 4.2 Colour code body exterior
Added: Warning notice air ducts front lid 430 4.4.1 Front lid
Revised: Tightening torque of the door 441 4.4.5 Door
Added: Installing door window 443 4.4.6 Installing door window
Revised: 4.4.12 terminology changed from Wing to Fender 450–453 4.4.12 Fender
Revised: Bonding rear wing edge (Gurney) 478 4.4.21 Rear wing... Bonding rear wing edge (Gurney)
Added: Spare body 485 4.5.4 Spare body
Revised: Information on deformations > 2 mm 497 4.6 Body repair
Revised: Front chassis section repair - Diagnosis 575 4.6.6 Front chassis section repair... 575
4.8 Removing/installing the windscreen...
Revised: Preparation for installation 641–644
Preparation for installation
Added: Colour code body interior 677 5.2 Colour code body interior
Added: Information about non-flammable material of the seat cladding 680 5.4 Seat system
Added: Service interval and instructions fire extinguisher system 708 6.1 Service intervals
Added: Service interval and instructions emergency switches fire
extinguisher system
Added: Information on using the latest software versions 724 6.3 Control units
Added: Information on wiring loom protection
Revised: Information on the CAN IDs 751 6.3.5 CAN bus... CAN IDs
Added: Information on fastening the option separating points 753 6.5 Option separating points
Revised: 6.6.3 Reed sensor mounting (brake light switch) 769 6.6.3 Reed sensor mounting (brake light switch)
Added: Danger notice on the fire extinguisher system 770 6.7 Fire extinguisher system

V7,12/2022 911 GT3 Cup (2021–2023) 14

Version Date Creation/change see page included in chapter
Added: Information on checking the fire extinguisher emergency switch 771 6.7.1 Actuation of fire extinguisher system
outside the car
Added: Replacing main switch and ignition switch 786 6.11.2 Replacing main switch and ignition switch
6.11.3 Overview of instrument panel... WET TYRE –
Added: Information on the WET TYRE button 789
tyre selection
Revised: Information on the gear box emergency function 789 6.11.3 Overview of instrument panel... GBX – gearbox
Revised: Throttle sense 792 6.12.1 Display pages... Race 1 (Driver)
Revised: Information on pit speed 800 6.12.2 Display messages... Pit speed
6.12.2 Display messages... Setting pit speed target
Added: Setting pit speed target speeds 801
speeds
Added: Information on resetting the fuel counter 805 6.12.2 Display messages... Fuel consumption counter
Revised: Information on Full Course Yellow (FCY) mode 808 6.12.2 Display messages... Full Course Yellow (FCY)
6.12.2 Display messages... Setting FCY mode target
Added: Setting FCY mode target speeds 808
speeds
Added: Overlay and description of ABS reset 811 6.12.2 Display messages... ABS reset
Revised: Overview alarm signals category 1 814 6.12.3 Alarm signals... Overview alarm signals
Revised: Coolant temperature alarm (alarm_tmot) 819 6.12.3 Alarm signals
Revised: Engine oil temperature alarm (alarm_toil) 828
Revised: Coolant pressure alarm (alarm_pwat) 829
Added: Alarm warn hazard on (warn_hazard_on) 847
Added: Information on using the latest software version 931 6.14 Porsche Toolset
6.17.2 Antilock brake system (ABS)... Change
Revised: Information on change between wet and dry 1005
between wet & dry

V7,12/2022 911 GT3 Cup (2021–2023) 15

Version Date Creation/change see page included in chapter
Added: 6.17.4 Logging on USB storage systems 1012 6.17.4 Logging on USB storage systems
Added: Ordering numbers for safeties air jack system of Krontec 7.3 Addresses (service + equipment)
1027
Maschinenbau GmbH
Revised: Equipment advice of the manufacturer Manthey-Racing 1027
Revised: Equipment advice of the manufacturer SOBEK Motorsporttechnik 1029
7 12/2022 Added: Information on adjusting the brake balance 26 0.1.2 Centre panel
Added: Information on function settings at steering angles > 45° 28 0.2.2 Function Concept
Added: Information on limitation engine speed at race start 43 0.6.3 Race start
Added: Information on bolt of the crankcase 49 1.2 General
Added: Installing an external intake pressure sensor 91 1.8.7 Installing an external intake pressure sensor
Revised: Fuel use information 92 1.9 Fuel system
Added: Information on cable routing of the camshaft sensors 94 1.10.1 Removing/installing the ignition coils
Added: Information on upgrading to reinforced Shur-Lok systems. 122 2.2 General information
Revised: Oil capacity gearbox adjusted 3.0 -> 3.5 l 123 2.2.1 Technical data
Revised: Arrangement of tables adjusted 125 2.2.4 Shifting conditions
Added: Information on new parts in the differential from model year 2023 127 2.2.6 Differential
Revised: Distance between measuring point and oil surface 7.2 -> 6.5 cm 131 2.2.8 Oil level – measuring
Revised: Distance between measuring point and oil surface 8.0 -> 7.1 cm 132
Revised: Measurement sheet Sachs sintered clutch 138 2.3.1 Clutch – scope of inspection
Revised: Graphic assembly differential 155 2.4 Disassembly... Differential package – removal
Revised: Cross shaft – removal - Step 10. & special tools and graphic
161 2.4 Disassembly... Cross shaft – removal
adapted to model year 2023

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Version Date Creation/change see page included in chapter
Revised: Gear housing and gear set – removal - Steps 6.–12., special tools 2.4 Disassembly... Gear housing and gear set –
164
and graphic adapted to model year 2023 removal
Revised: Pinion shaft – installation - Steps 11.–13. special tools and
216 & 217 2.5.6 Pinion shaft – installation
graphic adapted to model year 2023
Revised: Gear set – installation - Overview adapted to model year 2023 221 2.5.8 Gear set – installation
Revised: Graphics adapted to model year 2023 227
Revised: Special tools, tightening instructions & graphics adapted to model
240–243 2.5.18 Pinion shaft and mainshaft – tightening
year 2023
Revised: Special tools, tightening instructions & graphics adapted to model
247–251 2.5.22 Cross shaft – installation
year 2023
Added: Information on the use of new components in the differential as of
256 2.5.23 Differential assembly – general overview
model year 2023
Added: Special tools for reinforced Shur-Lok systems and differential from
289 2.7 Special tools
model year 2023
Added: Service instructions for Systems, Lines and Connections 293 3.1 Service intervals... Brakes
Added: Information on new versions of wheel speed sensors 303 3.5.2 Upright... Installation of speed sensor
Revised: 3.6.1 Steering rack 328 3.6.1 Steering rack
Added: Information on new versions of wheel speed sensors 342 3.7.2 Upright... Installation of speed sensor
3.7.3 Assembly of rear axle... Track rod and bottom
Added: Notice on alignment of the track rod joint heads of rear axle 345
wishbone to side section
Added: Informations on optional brake pads for endurance operations 376 3.9 Brake system
3.9.1 Brakes on front axle... Installation of brake disc
Revised: Graphic - Installation of brake disc and brake caliper 378
and brake caliper
Revised: Installing instructions of the brake hose adjusted 380 3.9.1 Brakes on front axle... Installation of brake hose

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Version Date Creation/change see page included in chapter
3.9.2 Brakes on rear axle... Installation of brake disc
Revised: Graphic - Installation of brake disc and brake caliper 381
and brake caliper
Revised: Installing instructions of the brake hose adjusted 383 3.9.2 Brakes on rear axle... Installation of brake hose
Added: Notice & graphic for changing brake pads on the front axle 386 3.9.4 Changing brake pads
Added: Variant 17.8 mm of master brake cylinder RA 402 & 410 3.10 Balance bar system
Added: Information on brake balance adjustment when using 17.8 mm 403 3.10.1 Brake force distribution
master brake cylinder
Revised: Tightening torque for accelerator pedal 414 3.11.3 Installation of accelerator pedal
Revised: 4.6.4 Removing/installing the roof module 532–548 4.6.4 Removing/installing the roof module
Revised: Classification Warning “Lowering the air jack system” -> Danger 631 4.7 Air jack system
Revised: 4.8 Removing/installing the windscreen 637–647 4.8 Removing/installing the windscreen
Revised: 4.9 Removing/installing the rear window 648–656 4.9 Removing/installing the rear window
Revised: Notice “Fuels with a high alcohol content” 658 4.10 Fuel tank
Added: Information on seat adjustment 685 5.4.3 Seat adjustment
Added: Information on protective pads for safety nets and seat 692 5.5 Safety nets
Added: Information on checking the base plate for additional weights 702 5.8.2 Mounting base plate and additional weights
Added: Information on using interior particulate filter 704 5.10 Interior ventilation
Added: 5.10.1 Removing/installing Interior particulate filter 705 5.10.1 Removing/installing Interior particulate filter
Added: Information on battery state of charge 710 6.2.1 Battery
Added: Information on a new battery and new battery holder 712 6.2.1 Battery... Installing the battery
Revised: Information on battery charger CTEK PRO 25 S 719 6.2.4 Battery charger

V7,12/2022 911 GT3 Cup (2021–2023) 18

Version Date Creation/change see page included in chapter
6.7.3 Fire extinguisher bottle... Removing/installing
Added: Removing/installing the fire extinguisher bottle 774
the fire extinguisher bottle
6.10.2 Function description: Buttons/
Added: Information on function settings at steering angles > 45° 784
switches... Concept of the function switches
Added: Information on adjusting the brake balance 790 6.11.3 Overview of instrument panel
Revised: Requirements for Display ABS off warning 821 6.12.3 Alarm signals... ABS off warning
Revised: Requirements for Display Alternator alarm 833 6.12.3 Alarm signals... Alternator alarm
Added: Information on data loss on USB storage device 1012 6.17.4 Logging on USB storage systems
Revised: Arrangement of tables adjusted 1025–1029 7.3 Addresses (service + equipment)
Revised: Contact to Manthey-Racing 1027
Revised: Equipment advice of the manufacturer Manthey-Racing
Added: Variant 17.8 mm of master brake cylinder RA 1031 8.1.1 Setup
Revised: Figure vehicle dimensions 1049 8.3.1 Vehicle dimensions

V7,12/2022 911 GT3 Cup (2021–2023) 19

CONTENTS
QUICK START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
0.1 Centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.6 Overview of setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
0.2 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
0.3 Display Pages (Driver) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
0.4 Display Pages (Mechanics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
0.5 Display-LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.1 Service intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
0.6 Quick start (Driver). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 3.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
0.7 Quick start (Mechanics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 3.3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3.4 Measuring and adjusting ride height. . . . . . . . . . . . . . . . . . . . . . . . . . 298
1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3.5 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.6 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
1.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3.7 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.3 Starting up the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3.8 Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
1.4 Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3.9 Brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
1.5 Replacing the belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 3.10 Balance bar system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
1.6 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 3.11 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
1.7 Engine and gearbox – removal/installation . . . . . . . . . . . . . . . . . . . . . 70 3.12 Clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
1.8 Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 3.13 Power unit mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
1.9 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.10 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4 BODY EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426
1.11 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 4.1 Service intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
1.12 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 4.2 Colour code body exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
4.3 Vehicle views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
2 GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 4.4 Body add-on parts (bodywork) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
2.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 4.5 Body shell and add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 4.6 Body repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
2.3 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 4.7 Air jack system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
2.4 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 4.8 Removing/installing the windscreen . . . . . . . . . . . . . . . . . . . . . . . . . 637

V7,12/2022 911 GT3 Cup (2021–2023) 20

4.9 Removing/installing the rear window . . . . . . . . . . . . . . . . . . . . . . . . . 648 6.17 Options (ABS & TC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997
4.10 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657 6.18 Video system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1017

5 BODY INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .676 7 CONTACTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1022

5.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677 7.1 Technical Racing Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1023
5.2 Colour code body interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677 7.2 Motorsport and spare parts sales . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024
5.3 Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678 7.3 Addresses (service + equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1025
5.4 Seat system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
5.5 Safety nets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691 8 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030
5.6 Cage padding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 8.1 Basic values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1031
5.7 Leg protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 8.2 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1033
5.8 Additional weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701 8.3 Body exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048
5.9 Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
5.10 Interior ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704 9 SERVICE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . 1055
9.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056
6 ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .706 9.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056
6.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708 9.3 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1057
6.2 Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 9.4 Body exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1059
6.3 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724 9.5 Body interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060
6.4 Wiring looms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752 9.6 Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060
6.5 Option separating points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753
6.6 Sensory system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1063
6.7 Fire extinguisher system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770
6.8 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777 OPERATING MATERIALS. . . . . . . . . . . . . . . . . . . . 1075
6.9 Windscreen wiper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
6.10 Steering wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1079
6.11 Centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785
6.12 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791
6.13 Porsche Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 876
6.14 Porsche Toolset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931
6.15 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 975
6.16 Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 996

V7,12/2022 911 GT3 Cup (2021–2023) 21

 QUICK START
0.1 Centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
0.2 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
0.3 Display Pages (Driver) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
0.4 Display Pages (Mechanics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
0.5 Display-LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
0.6 Quick start (Driver) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
0.7 Quick start (Mechanics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

V7,12/2022 911 GT3 Cup (2021–2023) 22

 | Centre console

0.1 Centre console

All functions not directly related to driving and operating the car, and which do not influence the handing of the car and are not changed frequently during a
stint or lap are located on the centre console.

0.1.1 Switches

[1] Main power [MAIN]

[2] Ignition switch [IGNITION]
[3] Activates fire extinguisher system [FIRE]

In normal driving conditions the MAIN and IGNITION switches should be DOWN.

V7,12/2022 911 GT3 Cup (2021–2023) 23

 | Centre console

0.1.2 Centre panel

The console buttons are multi state. Consecutive presses of each button scrolls through the following modes. The colour of each button changes when the
state changes as indicated below:

[1] LIGHT – headlights

▶ Push the button once – headlights ON
▶ Push the button twice – headlights + auxiliary lights ON
This function is only available when the auxiliary lights are enabled via the parameters
in the Porsche Toolset.
[2] FAN – interior fan
▶ Push the button once – driver fan
▶ Push the button twice – driver/window fan
▶ Push the button three times – window fan
[3] OPTION 1
▶ Push the button – ON/OFF

[4] WET TYRE – tyre selection

▶ Push the button if wet-tyres are mounted.

The ABS system must be informed about the type of tyres fitted. For a detailed description
see Change between wet & dry on page 1005.

V7,12/2022 911 GT3 Cup (2021–2023) 24

 | Centre console

[5] GBX – gearbox

▶ Push the button – emergency mode ON/OFF

The gearbox emergency button allows driving to be continued in the case

of gearbox-relevant sensor malfunctions.
▶ When the Gearbox Emergency function is activated, gear changes (up and down) can
only be done using the clutch.
[6] RAIN LIGHT – rain light
▶ Push the button – rain light ON/OFF

[7] FUEL PUMP – fuel pumps

▶ Push the button to enable technician mode (manual activation of fuel pumps)

[8] OPTION 2
▶ Push the button – ON/OFF

[9] OPTION 3 or TC
OPTION 3
▶ Push the button – ON/OFF
TC

Traction control is available as an option.

Remove the sticker for OPTION 3 and stick on the TC sticker.
▶ 0 = OFF = Dry (Dry conditions)
▶ 1 = ON = (Wet conditions)

V7,12/2022 911 GT3 Cup (2021–2023) 25

 | Centre console

[10] HAZARD – hazard flashers

▶ Push the button – hazard flashers ON/OFF

[11] Brake balance adjustment

▶ Turn the adjustment wheel forward to increase the brake force of the front axle.
▶ Turn the adjustment wheel backward to increase the brake force of the rear axle.

Depending on the master brake cylinder used for the rear axle, the brake balance must be
adjusted accordingly.

V7,12/2022 911 GT3 Cup (2021–2023) 26

 | Steering Wheel

0.2 Steering Wheel

All functions directly related to driving and operating the car, and which influence the handling of the car or are changed frequently during a stint or lap, are
located on the steering wheel.

0.2.1 Steering Wheel buttons and switches

[1] High Beam [HB]
[2] Radio [RAD]
[3] Crank [CRK]
[4] Function Left
[5] Acknowledge [ACK]
[6] Reverse [RVS]
[7] Joker
[8] Pitspeed [PIT]
[9] Mark [MRK]
[10] Wiper [WIP]
[11] Function Right
[12] Full Course Yellow [FCY]
[13] Drink [DRK]
[14] Display [DISP]
[15] Indicator Right
[16] Upshift
[17] Indicator Left
[18] Downshift

For a detailed description siehe 6.11.1 Overview of buttons and switches auf Seite 785.

V7,12/2022 911 GT3 Cup (2021–2023) 27

 | Steering Wheel

0.2.2 Function Concept

The function concept is used to adjust the following values.

the current values are displayed to the right of the function abbreviation.

• ABS - ABS Stage (only displayed if activated)

• TC - TC Stage (only displayed if activated)
• DIM - Dimmer
• ATH - Throttle sensitivity
• MUL - Backup Functions

▶ Turn the left thumbwheel to select a function.

The upper function is always displayed when the thumbwheel is initially turned.
▶ Select the function with the left thumbwheel [1].
▶ Adjust the values with the right thumbwheel [2].

To prevent an unintentional change of settings during steering, function settings can only
be made up to a steering angle of 45°.
Exception: defect or malfunction of the steering angle sensor.

V7,12/2022 911 GT3 Cup (2021–2023) 28

 | Display Pages (Driver)

0.3 Display Pages (Driver)

▶ Scroll through the display pages via DIS button on steering wheel.

0.3.1 Race Page 1

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 | Display Pages (Driver)

0.3.2 Race Page 2

V7,12/2022 911 GT3 Cup (2021–2023) 30

 | Display Pages (Driver)

0.3.3 Quali Page

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 | Display Pages (Driver)

0.3.4 Pop ups

Pit speed

Activate and deactivate pit speed by pressing the PIT button on the steering wheel.
When pit speed is activated, the set target speeds are only maintained in 1st and 2nd gear.
If the speed is higher than the target pit speed the background is red.
When the pit speed limiter is activated the full course yellow (FCY) function is deactivated
automatically.
▶ When the pit speed mode is activated from the Full Course Yellow mode, the pit speed
must first be undercut in order for the pit speed limiter to maintain the set pit speed.

Full Course Yellow (FCY)

Activate and deactivate full course yellow by pressing the FCY button on the steering
wheel.
When FCY mode is active, the set target speeds are only maintained in 2nd–4th gear.
When full course yellow (FCY) function is activated the pit speed limiter is deactivated
automatically and the set target speeds are automatically maintained.

V7,12/2022 911 GT3 Cup (2021–2023) 32

 | Display Pages (Driver)

Alarms

If an alarm appears, it is displayed in one of the following three sizes (depending on the
priority). Press ACK on the steering wheel to acknowledge and cancel an alarm.

V7,12/2022 911 GT3 Cup (2021–2023) 33

 | Display Pages (Driver)

State Change

Any status change will be displayed.

For expamle: Ignition, Fan, Wiper, Light etc..

Fuel Reset and Low Fuel

Press and hold MRK on the steering wheel for 2–3 s to reset fuel counter.
▶ After each refuelling, the fuel counter should be reset by a FUEL RESET. Without a
reset, the Fuel level indicator may show incorrect values while driving and the fuel level
alarm (Low Fuel) cannot be triggered.

Brake Balance

If the brake pedal is pressed when the car is stationary (< 5 .km/h), the brake balance
overlay is displayed.

V7,12/2022 911 GT3 Cup (2021–2023) 34

 | Display Pages (Mechanics)

0.4 Display Pages (Mechanics)

These display pages are only available when the car is stationary.
If a mechnic page is selected when the car starts moving the display page changes automatically to page Race 1.

0.4.1 Warm up Page

When warm up page is active, shift lights indicate the engine RPM for easier visualization.

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 | Display Pages (Mechanics)

0.4.2 Vitals Page

V7,12/2022 911 GT3 Cup (2021–2023) 36

 | Display Pages (Mechanics)

0.4.3 Chassis

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 | Display Pages (Mechanics)

0.4.4 Trackmap

V7,12/2022 911 GT3 Cup (2021–2023) 38

 | Display-LEDs

0.5 Display-LEDs
[1] Shift Lights
[2] LED Side indicators

0.5.1 Shift Lights

• The LED shift lights are used to indicate the ideal gear shift point (upshift only).
• As the shift point approaches the lights glow on the outside before converging in the
centre.
• The colours displayed start with green, then green and yellow and then green, yellow and
red before all the lights glow blue and flash to signify the ideal shift point.

V7,12/2022 911 GT3 Cup (2021–2023) 39

 | Display-LEDs

LED Side Indicators

Alarm active
If an alarm is active, all the LEDs flash once before the lowest LEDs remains active until the
alarm is acknowledged.

Front left wheel locking

If an alarm is active, the LEDs are flashing.

Front right wheel locking

If an alarm is active, the LEDs are flashing.

Rear left wheel locking

If an alarm is active, the LEDs are flashing.

Rear right wheel locking

If an alarm is active, the LEDs are flashing.

V7,12/2022 911 GT3 Cup (2021–2023) 40

 | Display-LEDs

Traction control is active/regulating

If the TC is active, the LEDs are flashing.

High beam Light

When the high beam is activated, the LEDs light up.

Indicator Right active

If the right indicator is active, the LED is flashing.

Indicator Left active

If the left indicator is active, the LED is flashing.

V7,12/2022 911 GT3 Cup (2021–2023) 41

 | Quick start (Driver)

0.6 Quick start (Driver)

0.6.1 Starting the engine

b The main switch [MAIN] is switched on.

1. Switch on the ignition [IGN].
2. Press the clutch pedal or shift into neutral [N].
3. Press button ENGINE START on the left side or button CRK on the steering wheel
to start the engine.

0.6.2 Stopping the engine

1. Press the clutch pedal.

2. Car stationary (< 5 km/h).
3. The engine can be stopped with either of the following steps:
– Press button ENGINE START on the left side.
– If Pitspeed is active, press CRK button on the steering wheel.
– Turn off the ignition [IGN].

V7,12/2022 911 GT3 Cup (2021–2023) 42

 | Quick start (Driver)

0.6.3 Race start

To reduce clutch wear at the start of a race, the usable engine speed is limited in the start
phase. The control is not based on traction control; slip is limited via the clutch.
Speed control is only active during the start phase, when the car is stationary beforehand.
In normal driving operation, the control is automatically deactivated.
Activation Deactivation
1st gear is engaged Normal driving mode (> 80 km/h)
Car is stationary Gear > 1 engaged
Clutch is fully disengaged Clutch is fully engaged
Abb. 1: Bedingungen zur De-/Aktivierung der Drehzahlregelung

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 | Quick start (Driver)

0.6.4 Engaging reverse gear

1. Press the clutch pedal.

2. Release the brakes (if possible).
3. Press RVS button on the steering wheel to engage reverse gear.

If reverse gear has been engaged successfully, the display shows "Accepted" and "R".
▶ The clutch pedal can now be released.

If reverse gear has not been engaged, the display shows "Denied".
In this case, proceed as follows:
1. Slightly release the clutch pedal.
2. Press the clutch pedal again.
3. Try again to engage reverse gear by pressing button RVS on the steering wheel.

V7,12/2022 911 GT3 Cup (2021–2023) 44

 | Quick start (Mechanics)

0.7 Quick start (Mechanics)

0.7.1 Building up oil pressure

b The ignition [IGN] is switched off.

1. Press the clutch pedal or shift into neutral [N].
2. Press button ENGINE START on the left side.
→ Oil pressure is built up, and the starter switches off automatically after 3 s.

0.7.2 Steering shunt mode

ACTIVATING/DEACTIVATING MANUAL STEERING MODE

b Engine is off.
b Vehicle is stationary on its wheels.
▶ Hold down the joker button on the steering wheel for 3 s.
→ Manual steering mode is activated.
▶ Press the Joker button on the steering wheel again to deactivate manual steering
mode. If the button is not pressed, the steering is switched off automatically after
180 s.

If the battery is not sufficiently charged, the steering remains off, and the display shows
"BAT LOW".

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 | Quick start (Mechanics)

0.7.3 Fuel pump mode

While using the mechanic mode, the indicators flash and cannot be switched off.

ACTIVATING/DEACTIVATING MANUAL FUEL PUMP MODE

b Engine is off.
▶ Press the FUEL button on the centre console.
→ Manual fuel pump mode is activated.
▶ Press the FUEL button on the centre console again to deactivate manual fuel pump
mode. If the button is not pressed, the fuel pump is switched off automatically after
180 s.

If the battery is not sufficiently charged, the fuel pump remains off, and the display shows
"BAT LOW".

V7,12/2022 911 GT3 Cup (2021–2023) 46

1 ENGINE
1.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.2 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.3 Starting up the vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.4 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.5 Replacing the belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.6 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.7 Engine and gearbox – removal/installation . . . . . . . . . . . . . . . . 70
1.8 Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.9 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.10 Ignition system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.11 Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.12 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

V7,12/2022 911 GT3 Cup (2021–2023) 47

 ENGINE | Service intervals

1.1 Service intervals

When sent in for an overhaul, the engine should be in following condition:

• fixed in an engine transport case (see spare parts catalogue)
• with clutch
• with intake system
• without silencer
• all openings closed with suitable plugs

If the engine is supplied without exhaust headers, new exhaust headers will be installed and invoiced automatically.
If the engine is received in any other condition than described above, follow-up costs may occur that must be invoiced.

Engine
Components Overhaul interval Max. runtime Instructions
Engine 100 h 200 h • Overhaul (see 7.3 Addresses (service +
equipment) on page 1025).
Components Service intervals Max. runtime Instructions
Air filter before every race weekend 50 h • Before every race weekend, remove the air
filters, tap them carefully out and clean them
with the BMC-Cleaning kit, if necessary.
Oil and Oilfilter 50 h • Change the engine oil and oil filter.
Spark plugs 50 h • Change the spark plugs.

For further information please contact the Technical Racing Support.

See 7.1 Technical Racing Support on page 1023.

V7,12/2022 911 GT3 Cup (2021–2023) 48

 ENGINE | General

1.2 General

Remove the bolt [1] on the crankcase in case of failure. The engine can then be operated
without this bolt connection, without any restriction.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Bolt crank case

V7,12/2022 911 GT3 Cup (2021–2023) 49

 ENGINE | General

1.2.1 Technical data

Installation location Rear engine

Cubic capacity 3.996 cm³
Power output 510 HP / 375 KW
at engine speed 8.400 rpm
Torque 470 Nm
at engine speed 6.150 rpm
Max. engine speed 8.750 rpm
Ignition sequence 1-6-2-4-3-5

1.2.2 Behaviour when exceeding max. engine speed

Overspeed
8.900–9.100 rpm Overhaul after 60 h
9.100–9.500 rpm Immediate test on testbench
(more than 6 s)
> 9.500 rpm Immediate engine overhaul
(more than 2 s)
> 10.000 rpm Immediate engine overhaul
(first occurrence)

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 ENGINE | General

1.2.3 Engine supporting points

NOTICE INCORRECTLY SUPPORTED ENGINE
The engine may become damaged if supported at incorrect points (e.g. oil cooler).
▶ Support engine at the marked points only (see Fig. 2).

Fig. 2: Engine support points

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 ENGINE | General

1.2.4 Engine lead sealing

The following seals [yellow] must not be broken, otherwise any guarantee will be invalidated.

Seal oil guide module

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 ENGINE | General

Seal bank 1

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 ENGINE | General

Seal bank 2

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 ENGINE | General

1.2.5 Torque values for standard threaded connections

The torques stated in the table below apply to all threaded connections unless explicitly stated otherwise.

Grade
Thread 8.8 10.9 12.9
MA [Nm] MA [Nm] MA [Nm]
M4 2.8 4 4.8
M5 5.5 8 9.5
M6 10 13 16
M8 23 33 39
M10 46 65 80
M12 80 115 135
M12 x 1.5 85 120 145
M14 x 1.5 140 200 240
M16 x 1.5 210 300 360
M18 x 1.5 305 430 515
M20 x 1.5 430 610 740

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 ENGINE | Starting up the vehicle

1.3 Starting up the vehicle

1. Check coolant level with the engine cold.
2. Perform the Fire up procedure:
a. Check function of throttle valves (0 % and 100 %). If an error occurs see Accelerator
pedal on page 768.
b. Check the switches (ATH-STAGE, Multi, TC and ABS).
c. Reset the FUELCONS and OUTING counter.
d. Start the engine and let it warm up to tmot = 60–65 °C.
e. Check the gearbox shift function (gears 1–6 + reverse gear).
f. Give the accelerator pedal some short bursts and check parameters pwat, pwat(2)
and a_camctrl(2/out2).
g. Let the engine warm up further until the thermostat opens (tmot = approx. 85 °C)
3. Let engine warm up further until toil = 85 °C.
Check oil level at 1,600 rpm (no bursts for at least 20 s beforehand).
– MIN. level: 3.5 litres = 0 %
– MAX. level: 4.0 litres = 100 %
4. Perform visual inspection of vehicle for leakages.
5. Download data (data backup).

V7,12/2022 911 GT3 Cup (2021–2023) 56

 ENGINE | Engine oil

1.4 Engine oil

1.4.1 Technical data of engine oil
Specification Value
Specification Mobil 1 ESP X3 0W – 40
Fill volume at engine oil change drained engine oil volume + 0.25 l
(oil volume of oil filter)
Initial fill volume (total volume) 8.5 l
Runtime interval (oil + filter) 50 h

1.4.2 Engine oil change

CAUTION HOT ENGINE OIL
Risk of scalding from hot engine oil with engine at operating temperature.
▶ Avoid contact with hot engine oil.

b The engine oil has a temperature of 85–90 °C.

b Engine is off.
b Rear lid is removed. See 4.4.9 Engine cover on page 446.
b Diffuser removed. See 4.4.16 Diffuser on page 464.

1. Open the oil filler cap [1].

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 ENGINE | Engine oil

2. Remove the oil drain plug at the oil tank [1] and at the crankcase [2].
3. Catch the draining oil.
6 mm Allen key

4. Remove the oil filter [3].

5. Measure the drained oil volume after approx. 5–10 min.
6. Replace the oil drain plugs with their sealing rings at the oil tank [1] and crankcase [2].

7. Tighten the oil drain plug at the oil tank [1].

20 Nm

8. Tighten the oil drain plug at the crankcase [2].

31 Nm

9. Install a new oil filter [3].

Make sure to coat the seal of the oil filter with oil before installation.
Mobil 1 ESP X3
0W-40

20 Nm

10. Fill in fresh oil with a volume equal to the volume of the drained oil plus 0.25 l
(oil filter volume).
Mobil 1 ESP X3 11. Build up oil pressure (see Building up engine oil pressure on page 59)
0W-40 12. Start the engine and let it reach operating temperature.
13. Check the engine oil level and top up, if required
(see Measuring the engine oil level on page 61).

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 ENGINE | Engine oil

1.4.3 Building up engine oil pressure

• Initial start-up of vehicle

• After overhaul
• After oil change
• After engine oil filter change

Procedure I (without Racecon)

b Main switch [MAIN] is switched on.

b Ignition [IGN] is switched off.
1. Press the clutch pedal or engage neutral gear [N].
2. Press the ENGINE START button on the left side or the crank button [CRK] on the
steering wheel.
→ Oil pressure is built up, and the starter switches off automatically after 3 s.

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 ENGINE | Engine oil

Procedure II (with Racecon)

b Starter battery is connected.

b Gearbox in neutral.
b Main switch [MAIN] is ON.
b Ignition [IGN] is ON.
b Notebook is connected.

1. Open the RaceCon software.

2. Select the project.
3. Select Race Mode [F11].
4. In tab 01 ENGINE, deactivate ignition and injection system [INJOFF].
5. Press the brake pedal (at least 20 bar).
6. Press the start button [1] or the crank button [2] (crank engine for approx. 3 s).
7. Release the start button or crank button.
8. Repeat steps 6–7 three times.
→ The engine oil pressure is shown in "RaceCon" [poil] (at least 2.5 bar)
9. Activate ignition and injection system [INJON].
10. Press the brake pedal (at least 20 bar).
11. Start the engine using the start button or crank button.
12. Check engine oil pressure (4.5–6 bar) and engine oil level
(at 85–90 °C engine oil temperature).

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 ENGINE | Engine oil

1.4.4 Measuring the engine oil level

Max. engine oil level 4.0 l
Min. engine oil level 3.5 l

Scenario I Scenario II
RaceCon software Driver display

Scenario I
b Engine running (idling) at operating temperature (engine oil temperature: 85–90 °C).
b Car stationary and leveled, Gearbox in neutral.
b Oil refill cap closed and engine crankcase/oilsystem in vacuum state.
b Notebook is connected.

▶ In tab 01 ENGINE, read the engine oil temperature [toil] and the engine oil level
[oillevel_pt].

Scenario II
b Engine running (idling) at operating temperature (engine oil temperature: 85–90 °C).
b Car stationary and leveled, Gearbox in neutral.
b Oil refill cap closed and engine crankcase/oilsystem in vacuum state.
▶ Read the engine oil level in driver display. See Warmup (Mechanic) on page 795 and
vitals on page 796

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 ENGINE | Engine oil

1.4.5 Engine oil quick-fill

The regular oil filler cap is replaced by the oil filler cap incl. SOBEK quick-release cap.
Purchase via Porsche Motorsport parts catalogue.

• Engine switched off.

• Maximum pressure 2 bar.
• Fill the engine oil in 200 ml steps.

For quick filling, the pressure bottle "Oilstick Magnum" from the manufacturer SOBEK is
recommended.
Purchase and further information via SOBEK Motorsporttechnik (see Addresses (service +
equipment) on page 1029).

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 ENGINE | Replacing the belt

1.5 Replacing the belt

1.5.1 Removing the belt
b Diffuser removed. See 4.4.16 Diffuser on page 464.
b Silencer or exhaust pipes removed. See 1.12 Exhaust system on page 109.

1. Undo and remove the nuts [1].

2. Loosen and remove screw [2].
AF 16 If necessary slightly bend away the heat shield [3].
3. Remove the spacer sleeve [4] for the crash support.

4. Loosen the bolt [5] as far as possible.

The bolt [5] cannot be fully removed.

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 ENGINE | Replacing the belt

5. Turn the silencer bracket [1] with the heat shield to the side to gain access to the belt.
Make sure that the heat shield rear face is not damaged when turning the bracket.

6. Remove the bolt [1] and the sleeve [2].

E10

Fig. 3: Console of central oil feed

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 ENGINE | Replacing the belt

7. Release the belt tension.

AF30

8. Remove the belt from all pulleys and unthread over the point where the central oil feed
sleeve was removed (see Fig. 3).

Fig. 4: Release the belt tension.

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 ENGINE | Replacing the belt

1.5.2 Installing the belt

The belt routing is embossed in the silencer bracket.

1. Place the belt on the pulleys in the following order:

a. Crankshaft
b. Tensioner pulley
c. Coolant pump
d. Alternator
e. Idler pulley (replacing the A/C compressor fitted to series production vehicles)
2. Release the belt tension (see Fig. 4) and then place the belt on the idler pulley [f].
3. Return the tool to its initial position.
→ The belt is tensioned.
4. Verify that the belt is correctly seated on all pulleys.
Let the engine spin (see 0.7.1 Building up oil pressure on page 45).

5. Install the sleeve [2] and the bolt [1] and tighten it.

E10,
13 Nm

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 ENGINE | Replacing the belt

6. Turn the silencer bracket [1] with the heat shield back into its original position.
7. Install the spacer sleeve [2] for the crash support and push in the bracket
with the heat shield.
8. Start the bolt [3].
9. Start the bolt [4] and the nuts [5].

10. Tighten the bolts [3+4] and nuts [5] evenly in a crosswise pattern.

AF16,
50 Nm

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 ENGINE | Replacing the belt

11. Bend the upper heat shield [1] back into its original position.

12. Install silencer and exhaust pipes. See 1.12 Exhaust system on page 109.

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 ENGINE | Flywheel

1.6 Flywheel
1.6.1 Assembly instructions

The flywheel bolts are micro-encapsulated and must only be used once!

[1] Flywheel
[2] Bolts M10 x 1 x 22.3
60 Nm + 90° ▶ Tighten bolts evenly in a crosswise pattern.
▶ The bolts [2] are micro-encapsulated and must be renewed whenever they are
loosened.
Make sure to always clean the internal threads with compressed air before installing
the new bolts.
[3] Stud M12 x 1.5 x 43
projection to flange: 38 mm
[4] Stud M12 x 1.5 x 43
projection to flange: 43 mm

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 ENGINE | Engine and gearbox – removal/installation

1.7 Engine and gearbox – removal/installation

CAUTION HOT FLUIDS
Risk of scalding due to hot engine oil and/or coolant when engine at operating
temperature.
▶ Avoid contact with hot enginge oil coolant.
▶ Allow engine to cool before starting engine related work.

CAUTION HOT COMPONENTS

Risk of scalding due contact with hot components.
▶ Allow components to cool.
▶ Wear personal protective equipment.

CAUTION HEAVY COMPONENTS

A greater risk of injury exists when handling heavy components.
▶ Carry out each working step with an assistent.

NOTICE INCORRECTLY SUPPORTED ENGINE

The engine can be dammaged when supported incorrectly (e.g on the oil cooler).
▶ Only support the engine at the points marked (see 1.2.3 Engine supporting points
on page 51).

b Battery disconnected.
b Rear wheels removed.
b Rear underbody panel removed. See Removing/installing rear underbody panel
on page 456.
b Diffuser removed. See 4.4.16 Diffuser on page 464.
b Rear apron removed. See 4.4.17 Rear apron on page 466.

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 ENGINE | Engine and gearbox – removal/installation

1. Drain coolant:
a. Open the coolant reservoir cap.
6 mm Allen key b. Remove the drain plug [1] and collect the coolant in a suitable drain tray.
25 Nm c. Pump the coolant out of the system by squeezing the rubber hoses [2] uniformly and
collect the coolant in suitable drain tray.
d. After draining the coolant, fit a new seal to the drain plug [1] before tightening the
Klüberplus Gel plug to the specified torque.
e. Release and remove the spring clamps.
f. remove the coolant hoses [2] and allow the coolant to drain into a suitable drain tray.
g. Check the O-rings in the quick release couplings and replace if necessary.

If an O-ring needs replacing, coat the O-ring with the specified lubricant.
h. Close and lock the spring clamps.
i. Clean the quick release couplings and coolant hoses before refitting. Fig. 5: Drain coolant
j. When fitting the coolant hoses [2] ensure that the spring clamps click audibly into
position.
k. Check the coolant hoses [2] are seated correctly.

2. Remove the diagonal braces and the reinforcement panel. See Diagonal strut and
stiffening plate to body on page 364.
3. Remove the rear-axle cross member. See Side section to cross member on page 343.

4. Remove the air duct [1] on the right-hand side.

5. Remove the air duct [2] on both sides.
Torx 30 See Air duct to bottom wishbone on page 344.

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 ENGINE | Engine and gearbox – removal/installation

6. Disconnect the anti-roll bar on both sides from the coupling rods.
See Coupling rod to anti-roll bar on page 354.
7. Remove the anti-roll bar. See Trailing arm and anti-roll bar to mount on page 348.
8. Remove the brake caliper cooling duct on the right-hand side.
See Installation of brake cooling on page 343.
9. Remove the driveshafts on both sides of the gearbox.
See Driveshaft to gearbox on page 362.
10. Disconnect the right wheel speed sensor.
11. Disconnect the right brake caliper and secure it to the side using a tie wrap.
See Installation of brake disc and brake caliper on page 381.

12. Remove the right-hand side member including upright, control arms and console in
order to avoid damaging the oil tank on the engine:
AF 16 + 18
a. Remove the bolt [1] to disconnect the damper from the upright.

125 Nm

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 ENGINE | Engine and gearbox – removal/installation

b. Remove the bolt [1].

115 Nm
c. Remove the bolt [2].
d. Remove the nut [3].
65 Nm e. Remove the bolts [4].

f. Remove the nut [1].

135 Nm
g. Remove the bolt [2].

65 Nm

h. Remove the side member including upright, control arms, console and driveshaft.

If the stud bolts come loose, they (incl. nuts) must be replaced when reassembling.

13. Remove the bolt [3] to disconnect the ground cable from the engine.

Torx 12
20 Nm

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 ENGINE | Engine and gearbox – removal/installation

14. Disconnect the gearbox wiring loom [1] from the bodyshell separating point.
15. Disconnect the coolant hose [2] from the gearbox.
16. Disconnect the hydraulic line [3].

17. Disconnect the B+ line [4] and remove the cable guide from the bodyshell.

B+: AF 13,
cable guide:
AF 8

18. Remove the screws [1] from the gearbox longitudinal support.
The nuts [2] are removed at a later point.
AF 16,
30 Nm + 90°

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 ENGINE | Engine and gearbox – removal/installation

19. Disconnect the fuel line [1].

20. Unclip the oil service tray [2].
21. Disconnect the compact connector motor wiring harness [3] from the body shell
separating points and unclip it from the cable holder.
22. Pull the vacuum line [4] from the rubber hose.
23. Release the hose clamps [5] and remove the rubber hose [6] from the throttle body and
the air filter housing.

24. Disconnect the left coolant hose [1] from the engine.
25. Disconnect the vent line [2] on the left from the coolant expansion tank and on the right
from the coolant pipe.
26. Disconnect the right coolant hose [3] from the coolant pipe.

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 ENGINE | Engine and gearbox – removal/installation

27. Remove the cooling water hose [1] from the bottom of the cooling water expansion
tank.

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 ENGINE | Engine and gearbox – removal/installation

28. Position the engine carrier with the lifting table under the drivetrain. See 1.2.3 Engine
supporting points on page 51.

29. Remove the nuts [2] from the gearbox longitudinal support.

AF 16,
30 Nm + 90°

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 ENGINE | Engine and gearbox – removal/installation

30. Remove the bolts [1] of the engine mount on both sides.

AF 18
30 Nm + 90°

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 ENGINE | Engine and gearbox – removal/installation

31. Lower the drivetrain slowly.

CAUTION! Risk of collision of the vacuum line [1] at the left side member and at the oil tank
on the right-hand side of the body.
▶ Lower the drivetrain carefully, guiding the vacuum line past the side member and
making sure that the oil tank does not collide with the body on the right-hand side.

32. Installation is performed in reverse order.

Follow the instructions for correct installation of the engine mounts.
See Assembly sequence engine mount on page 423.
33. Filling and venting the cooling system (see 1.11.6 Filling the cooling system
on page 104).
34. Wheel alignment (see 3.3 Wheel alignment on page 297).

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 ENGINE | Intake system

1.8 Intake system

1.8.1 Air filter
Air filter – removal/installation
b Rear lid removed. See 4.4.9 Engine cover on page 446.
b Rear apron removed. See 4.4.17 Rear apron on page 466.

1. Remove the bolts [1] and the two air filter housing covers.

Fig. 6: Air filter mounting position

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2. Remove both air filters [1].

3. Clean or replace the air filters [1].

▶ Installation is performed in reverse order.

Ensure that the air filters are installed in their defined positions (see yellow tabs).
2.5 Nm ▶ Remove air filter before each race weekend and clean with BMC-Cleaning kit, if
necessary (see Cleaning the air filter on page 82).
▶ Torque the bolts of the air filter housing covers to specification.
BMC-Cleaning kit
Nr. WA 250-500

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 ENGINE | Intake system

Cleaning the air filter

NOTICE IMPROPER CLEANING
Risk of damage to the filter element.
▶ Do not clean the air filter using compressed air.
▶ Avoid high water pressure when cleaning.
▶ Avoid high temperatures caused by direct sunlight or hot air guns.

1. Remove the air filter. See Air filter – removal/installation on page 80.
2. Carefully tap the air filter on a firm surface to remove coarse dirt.

3. Place the air filter in a suitable container and sprinkle approx. ½ a bottle of BMC
cleaning agent evenly over the entire filter element.
BMC
cleaning agent

4. Allow the cleaning agent to take effect for approx. 20–30 min.
5. Rinse the air filter with cold water.
6. Allow the air filter to dry on a clean lint-free cloth.

7. Cut a V-shaped opening in the dispensing tip of the BMC regeneration fluid bottle.
Fig. 7: Air filter
BMC
regeneration fluid

8. Position the V-shaped opening of the dispensing tip onto the first pleat and apply the
fluid onto all the air filter pleats by lightly squeezing the bottle.
9. Repeat the procedure to apply a second coating.
10. Allow the fluid to take effect for approx. 30 min.
11. Remove excess fluid from the air filter frame using a soft lint-free cloth.
12. Check that the filter element is an even red colour.
13. Apply a further coating if necessary.
14. Fit the air filter. See Air filter – removal/installation on page 80.

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1.8.2 Restrictor aperture

Depending on the regulations, the use of restrictor apertures in the car may be mandatory.
Restrictor apertures are available in different sizes and can be fitted subject on the
"Balance of Performance" classification assigned to the car.
Purchase via Manthey-Racing.
See 7.3 Addresses (service + equipment) on page 1028.

Removing/installing restrictor aperture

b Engine cover removed. See 4.4.9 Engine cover on page 446.

1. Loosen the hose clamp [1].

2. Pull off the intake scoop [2] from the throttle body [3].

3. Insert restrictor aperture [4] into the intake scoop [2].

▶ The phase of the restrictor aperture points towards the throttle body, the part number
of the restrictor aperture is positioned towards the intake scoop (see figure).

▶ To install follow the above-mentioned sequence in reverse.

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 ENGINE | Intake system

1.8.3 Resonance flaps

Resonance flaps test

b Vehicle is at standstill.
b Engine is running.

1. Connect the vehicle to the Bosch RaceCon software (ECU = green).

2. Select tab CAR.
3. Activate RESO_TESTMODE by pressing the desired RESO1_TEST or RESO2_TEST
button.
→ B_reso1 and B_reso2 show the control state (1 = actuated = closed)
4. When finished, all three parameters return to FALSE automatically after 5 s.

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[1] Large reso flap (flap control in the direction of travel at the front see Fig. 8)
[2] Small reso flap (flap control under the suction system see Fig. 8)
[3] Valve for reso flap [1] (see Fig. 9)
[4] Valve for reso flap [2] (see Fig. 9)

Fig. 8: Resonance flaps

Fig. 9: Vacuum control resonance flaps

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 ENGINE | Intake system

1.8.4 Single throttle butterfly system

The single throttle valve system (EDK) is a sensitive component in which the smallest
changes to the basic setting can lead to malfunction and render the component useless.
No changes of any kind must be made to the EDK, screw connections loosened or
components replaced, with the exception of replacing the throttle valve actuator.
The installation of components from other derivatives has an influence on the engine
control and will probably lead to malfunctions, even if the components appear identical on
the outside.

1.8.5 Protective cover throttle butterfly system

Porsche Motorsport provides a protective cover to shroud the throttle butterfly system to
prevent the intrusion of foreign bodies and avert system malfunctions to the engine.

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 ENGINE | Intake system

Installation protective cover

b Engine removed. See 1.7 Engine and gearbox – removal/installation on page 70.
b Low pressure fuel line removed.
b Breather hose cooling water expansion reservoir removed.
b Oil tank breather vacuum hose removed.
b Intake manifold removed.
b Connectors in area of modification removed.

INSTALLATION INNER PROTECTIVE COVER

1. Loosen bolt [1], move knock sensor slightly to one side.
2. Insert the protective cover [2].
▶ Apply gentle pressure to the protective cover to ease it past the injection valve [3].
3. Fit the M6 x 12 (WHT.008.124) bolts [4] and tighten.

E10,
10 Nm
4x bolts
M6 x 12
(WHT.008.124)

4. Fit the knock sensor to the correct position and tighten [1].

E12,
23 Nm

5. Reconnect and click (audible) connectors together.

6. Refit intake manifold.

▶ Before refitting the intake manifold check that the intake manifold seals are correctly
seated.
▶ Only fit and tighten the intake manifold retaining bolts after the outer protective cover
is fitted!

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 ENGINE | Intake system

INSTALLATION LEFT-HAND CYLINDER BANK OUTER PROTECTIVE COVER

1. Fit protective cover [1] in position.

▶ Do not damage the engine seal [2] when installing the protective cover!
2. Insert the bolts [3] and screw them in by hand to fix the protective cover.
▶ Tighten according to sequence and to specified torque only after all outer guards have
E10, been fitted.
13 Nm → For tightening sequence see 1.8.6 Removing/installing the intake manifold module
on page 90.

INSTALLATION RIGHT-HAND CYLINDER BANK OUTER PROTECTIVE COVER

1. Fit protective cover [1] in position.

Owing to its design, the protective cover clamps between the intake manifold and the side
contour of the high-pressure fuel pump [2]. To fit correctly, increased manual force must
be used to press the protective cover past the bulge [3] into the correct position.
▶ Do not use excessive force or a hammer!
▶ Do not damage the engine seal [4] when installing the protective cover!
2. Insert the bolts [5] and screw them in by hand to fix the protective cover.
▶ Tighten according to sequence and to specified torque only after all outer guards have
E10, been fitted.
13 Nm → For tightening sequence see 1.8.6 Removing/installing the intake manifold module
on page 90.

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Subsequent operations
1. Fit the breather pipe cooling water expansion reservoir.
2. Fit the low-pressure fuel pipe.
3. Fit the oil tank breather vacuum hose.
4. Fit the intake manifold.
5. Fit, reconnect and click (audible) all connectors into position on the intake manifold.
6. Fit engine. See 1.7 Engine and gearbox – removal/installation on page 70.

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1.8.6 Removing/installing the intake manifold module

b Engine removed.
b All connectors and air pipes removed from the intake manifold.
b Outer protective covers of the throttle butterfly system removed.

1. Remove M6 x 20 bolts [1].

2. Remove M6 x 35 bolts [2].
10 Nm

3. Unlatch quick release coupling [3] on the oil tank and remove the pipe.
4. Remove the oil deaertor with the pipe [4] [arrow A].

5. Remove M8 x 30 [A] bolt on the oil tank.

23 Nm

6. Remove M6 x 45 [1]–[5] bolts on the left and right of the intake manifold.
7. Remove the intake manifold module.
13 Nm

8. To install follow the above-mentioned sequence in reverse.

▶ Tighten the bolts in the specified sequence (see figure).

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1.8.7 Installing an external intake pressure sensor

The intake pressure must only be measured via an external sensor in place of the blanking
plug on the right-hand side of the intake system above the electronic throttle control actor.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Connector for external airbox pressure sensor

1. Remove the blanking plug [1].

2. Install the adapter [2] in place of the blanking plug.
Note: The adapter must fully engage with the connection socket of the vacuum line.

3. Tighten the adapter to the intake manifold module with a clamp [3] and the upper
M6 x 12 bolt [4] of the bracket [5].
13 Nm

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 ENGINE | Fuel system

1.9 Fuel system

DANGER RISK OF FIRE AND EXPLOSION FROM LEAKING FUEL SYSTEM
The components of the fuel system are difficult to remove and installed with the engine in place
because space is confined.
▶ Work on the fuel system must be performed by qualified personnel only.
▶ Perform a leakage test.

After work has been performed on the fuel system, it is difficult to build up fuel high-pressure because of the air trapped in the system.
▶ Start the engine several times and run it above 3000 rpm for 30 s.

1.9.1 Low-pressure fuel supply

The performance and fuel consumption of the engine is optimized for unleaded and metal-
free Super plus fuel according to EN 228 with RON 98/MON 88 (E5).
▶ In case of deviations or when using other fuels, please contact the Technical Racing
Support. See 7.1 Technical Racing Support on page 1023.

Returnless fuel system

The 4.0-litre engine is fitted with a returnless fuel system (RF – Returnless Fuel).

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 ENGINE | Fuel system

1.9.2 High-pressure fuel system

[1] High-pressure fuel pump (single-piston pump, triple pump cam)

[2] High-pressure supply lines
Note: Replace the high-pressure supply lines after each loosening!
[3] High-pressure rail
[4] Multi-point injectors (with soft clip)
[5] High-pressure fuel sensor
High-pressure fuel control
The electric in-tank pump supplies the fuel with a pressure of approx. 5 bar to the high-
pressure pump [1].
The volume control valve controls the fuel high-pressure via the filling of this 1-piston
high-pressure pump.
When the engine is running, the high-pressure fuel pump driven by the camshaft feeds the
high-pressure fuel via the high-pressure supply line [2] to the fuel rails [3] of the left or
right cylinder bank up to the injectors [4].
The high-pressure fuel sensor [5] is located on the fuel rail.

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 ENGINE | Ignition system

1.10 Ignition system

1.10.1 Removing/installing the ignition coils

To avoid chafing on the camshaft sensor cables, the cables must be routed as illustrated
CYLINDER BANK 1
1. Remove the camshaft sensor outlet from the front under the cable to the ignition coil
1 + 2 and than route the cable above (Fig. 10).
→ Chafing protection on each cable lies on one another.
CYLINDER BANK 2
1. Route the cable as illustrated (Fig. 11).
2. Position the edge clip [1] to the recess in the heat shield [2].
Fig. 10: Cable routing cylinder bank 1

Fig. 11: Cable routing and edge clip cylinder bank 2

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The ignition coils are integrated into a module.

The ignition coils cannot be replaced individually.

[A] Bank 1
[B] Bank 2
1. Unlock the connector [1] at the intake module and remove it from its bracket.
2. Open the mounting clamp [2].
3. Remove the oxygen sensor cable from the sheet metal clip at the heat shield.
4. Remove the heat shield.

5. Remove the bolt [3] of the ground cable.

6. Fully loosen the bolts [4] of the ignition coils.

The bolts are captive in the ignition coils and cannot be removed or lost.

7. Remove the ignition coils.

▶ Installation is performed in reverse order.

▶ Tighten the screws [4] of the ignition coils to the specified torque.
10 Nm

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 ENGINE | Ignition system

1.10.2 Removing/installing the spark plugs

NOTICE IMPROPER REMOVAL AND INSTALLATION
The spark plug recess is angled, which may lead to the electrodes colliding with the edge
in the cylinder head during removal and installation, resulting in damage to the electrodes.
▶ Take care not to damage the electrodes during removal and installation.
▶ Using a socket and extension, carefully start and screw in the spark plugs by hand.

Sparks must not be screwed in more than twice.

b Remove the ignition coils. See 1.10.1 Removing/installing the ignition coils
on page 94.

▶ Remove the spark plug [1] using a spark plug socket [2] and an extension [3].

Spark plug socket,

Extension 3/8“

▶ Installation is performed in reverse order.

New spark plug:

23 Nm ±3 Nm

Re-used spark
plug:
21 Nm ±3 Nm

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 ENGINE | Cooling system

1.11 Cooling system

WARNING HIGH COOLANT PRESSURE
Risk of injury/scalding.
▶ Let the engine cool down before performing any work on the system.

NOTICE EXCESSIVE COOLANT TEMPERATURE

An excessive coolant temperature (warning at: 110 °C) may cause damage to the engine.
▶ Check the temperature (tmot).
▶ Allow the engine to cool down.

NOTICE EXCESSIVE TORQUE OF THE HOSE CLAMPS

An excessive torque of the hose clamps (e.g. when installing/removing the engine)
may damage the coolant hoses.
▶ When tightening the coolant hose clamps, do not exceed a torque of 3.5 Nm.

NOTICE SOILED OR DEFECTIVE RADIATORS

Soiled or defective radiators may lead to increased engine temperatures. This may cause
engine damage.
▶ Clean the radiators regularly.
▶ Perform a visual inspection for damage.
▶ Check the anti-freeze concentration regularly.

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1.11.1 General information

The marked dent in the coolant pipe is not a manufacturing fault!

The coolant pipe has been adopted from the series production vehicle (992), and the dent
shown is intended to provide space for the petrol particulate filter (OPF) bracket.

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1.11.2 Fill volumes and specifications

Total volume including engine 24 l

Total volume of vehicle without engine 17 l
Anti-freeze (supplied condition) Mixing ratio
water: anti-freeze = 50: 50
Specification: Glysantin G40

If the race organiser prohibits Glysantin G40 anti-freeze (e.g. the event of Formula 1 or IMSA events), it must be replaced with 2 litres of corrosion inhibitor
and 22 litres of distilled water.
The corrosion inhibitor protects the water-carrying parts against corrosion, reduces cavitation, lubricates the water pump and increases the boiling point
of the coolant (Corrosion inhibitor is available in the Porsche Motorsport parts catalogue).
The system must be filled with anti-freeze with the above specification for transport (sea/air transport), to prevent damage due to the outside temperature.

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1.11.3 Overview of cooling system

[1] Radiator right [2] Radiator centre [3] Radiator left [4] Ventilation separating point

[5] Coolant expansion tank [6] Thermostat [7] Gearbox oil heat exchanger [8] Engine oil heat exchanger

[9] Engine temperature sensor [10] Coolant pump [11] Coolant pressure sensor

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 ENGINE | Cooling system

1.11.4 Checking the coolant level

b The cooling system is cold and pressureless.

b Rear lid removed. See 4.4.9 Engine cover on page 446.

1. Open the coolant cap [1].

2. Check the coolant level and adjust it, if required.
→ The coolant level must be on the maximum mark (see Fig. 12).
If this is not the case, suction off coolant or top up.

Fig. 12: Fill level mark

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 ENGINE | Cooling system

1.11.5 Draining the coolant

b The cooling system is cold and pressureless.

b Rear lid removed. See 4.4.9 Engine cover on page 446.
b Rear underbody panel removed. See Removing/installing rear underbody panel
on page 456.
b Diffuser removed. See 4.4.16 Diffuser on page 464.

1. Open the coolant cap [1].

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2. Open the drain plug [1] at the coolant regulator housing and catch the coolant in
a suitable drain tray.
3. Pump out the coolant water by squeezing the coolant hoses [2] (see Fig. 14) uniformly
and collect it in a suitable drain tray.

4. After draining the coolant, screw in the drain plug [1] with a new sealing ring and
tighten it.
6 mm Allen key
25 Nm

Fig. 13: Drain plug coolant regulator housing

5. Unlock the spring clamps [1].

6. Pull off the coolant hoses [2] and catch the coolant in a suitable drain tray.

7. Check the O-rings at the plug-type couplings and replace them, if required.

Klüberplus Gel
Coat any O-ring to be replaced with the specified lubricant.
8. Lock the spring clamps [1].

9. Clean the plug-type couplings and coolant hoses before installation.

10. Install the coolant hoses [2] and make sure that the spring clamps [1] engage audibly.
11. Check coolant hoses [2] for secure seat.

Fig. 14: Coolant hoses

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 ENGINE | Cooling system

1.11.6 Filling the cooling system

▶ Use only genuine Porsche coolant Glysantin G40-91 EF.

Mixing it with other coolants is not permissible.

For further information about the filling device, contact manufacturer SOBEK.
See 7.3 Addresses (service + equipment) on page 1025.

Variant 1 – Sobek filling device

b Rear lid removed. See 4.4.9 Engine cover on page 446.

1. Fill the filling device completely with coolant (mixing ratio 50:50).
2. Disconnect the quick-release coupling [1] at the vehicle.
3. Connect the filling device to the cooling system: Connect the supply end [2]
to the coupling of the coolant hose [3]. Connect the return end [4] to the coupling
of the coolant hose [5].
4. Start the filling procedure and fill the cooling system.

Leave the filling device on for approx. 10 min to ensure optimal filling and venting.

5. With the filling device switched on, pull off the return end [4].
6. With the filling device switched on, pull off the supply end [2].
7. Switch off the filling device.

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 ENGINE | Cooling system

Prior to first engine start (tmot < 45 °C):

1. Fill the filling device completely with coolant (observe mixing ratio).
2. Connect the filling device to the cooling system: [2] supply, [4] return.
3. Start the filling procedure and fill the cooling system to the max. level of the coolant
expansion tank.
4. With the filling device switched on, pull off the return end [4] (to create pilot pressure).
5. With the filling device switched on, pull off the supply end [2].
6. Switch off the filling device.
7. Check the coolant level and repeat steps 1–7 until the max. mark is reached.
8. Start the engine and let it run until a coolant temperature of 90 °C is reached.
([tmot] = 90°C).
9. Stop the engine
10. Allow the cooling system to cool down.
11. Check the coolant level again and repeat steps 1–7 until the max. mark is reached,
if required.

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Variant 2 – filling device 9696

For further information on the filling device 9696, please contact a Porsche partner.

b Cooling system is cold (< 50 °C) and completely drained.

b The coolant volume provided is approx. 2 litres more than the fill volume actually
needed in order to avoid air being sucked into the system.
b The mixing ratio of 50:50 (coolant/water) corresponds with an anti-freeze mixture
suitable for -35 °C.

CONNECTING THE FILLING DEVICE

▶ Locate the coolant container at an elevated position.

1. Screw the single adapter [1] onto the expansion tank.
2. Attach the pressure gauge [2] to the adapter [1] of the coolant expansion tank.
3. Make sure that the stop cocks [3], [4] are closed.
4. Connect the venturi [5] to the pressure gauge [2].
5. Connect the air supply [6] to the venturi [5] (6–10 bar).
6. Immerse the filling hose [7] into the coolant and secure it against slipping off.
7. Connect the return hose [8] to the venturi [5] and place the other end in
a suitable container.
Fig. 15: Connection components of filling device 9696

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 ENGINE | Cooling system

EVACUATING THE COOLING CIRCUIT

b Compressed air is applied.
b Stop cock [4] is open, stop cock [3] at the filling hose connection is closed.
1. Apply vacuum and maintain it for two minutes.
– Squeeze all accessible hoses to facilitate vacuum creation.
→ A value of -0.85 to -0.95 bar indicates that the final vacuum is reached, meaning
that sufficient vacuum has been created in the cooling system when the needle is
in the green area of the pressure gauge dial.
2. Close stop cock [4].
3. Disconnect the air supply [6] from the venturi [5] (see Fig. 15).

Information for verification

• If the cooling system does not build up vacuum or if the vacuum drops within 30 s, the
cooling system has a leak or the connection pressure is too low.
• Deformations of the rubber hoses of the cooling circuit are normal.
• When both stop cocks are closed and if the air supply is disconnected, the vacuum
must not drop.

Leak test
b Vacuum is applied to the cooling system for 1 min.
▶ Observe the pressure gauge.
→ If the vacuum remains constant, you may start filling the system.

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 ENGINE | Cooling system

FILLING PROCEDURE
b The coolant container (at least 25 litres) is located in an elevated position.
Glysantin G40-91 1. Open the stop cock [3], stop cock [4] remains closed.
EF → Coolant flows into the cooling circuit.
The filling procedure is completed when the needle of the pressure gauge rests
against the zero stop and coolant flow has ceased.

After the filling procedure, the vehicle should be started to also vent the secondary circuit.
The coolant level may drop and must be adjusted by manually topping up.
If the filling method feeds less volume into the system, the procedure must be repeated
(draining and subsequent filling, see 1.11.5 Draining the coolant on page 102).

CAUTION! Risk of burns from hot system components.

▶ Let the system cool down before performing any work.
2. After the system has cooled down, check the coolant level and adjust it, if required
(see Checking the coolant level on page 101).
3. Install the rear lid. See 4.4.9 Engine cover on page 446.

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 ENGINE | Exhaust system

1.12 Exhaust system

CAUTION HOT COMPONENTS
Risk of burns.
▶ Allow hot components to cool down.
▶ Wear personal protective equipment.

NOTICE IMPROPER MOUNTING

Risk of exhaust system mounts breaking.
▶ Check the exhaust system regularly for stress-free mounting.
▶ In particular after initial installation, slacken all mounting points and re-tighten them
to ensure stress-free mounting.

Make sure that the exhaust header seals [1] are correctly seated on the exhaust headers.

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 ENGINE | Exhaust system

1.12.1 Noise emissions

Summary „Drive-by-Noise“ testing

Measurement parameters Exhaust system version

Height of noise Distance to tailpipe Angle relative to Engine rpm (rpm) Quiet exhaust Standrard exhaust Loud exhaust
meter [m] [m] tailpipe [°] system system system
Noise level Noise level Noise level
[dB (A)] [dB (A)] [dB (A)]
6 7,5 90 119 131 138
5 17 90 96 108 115
Not defined
1,2 15 90 97 109 116
1,2 10 90 98 111 118

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 ENGINE | Exhaust system

Summary stationary measurement

Measurement parameters Exhaust system version

Height of noise Distance to tailpipe Angle relative to Engine rpm (rpm) Quiet exhaust Standard exhaust Loud exhaust
meter [m] [m] tailpipe [°] system system system
Noise level Noise level Noise level
[dB (A)] [dB (A)] [dB (A)]
0,50 0,50 45 3.800 96 100
0,20 0,50 45 4.500 102 105
0,50 0,50 45 4.500 100 105
0,50 0,50 45 105 115
Not available
0,50 45 107 115
75 % max rpm
1 45 101 109
Tailpipe muzzle (6.563)
2 45 95 103
3 45 91 99

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 ENGINE | Exhaust system

1.12.2 Overview of standard exhaust system

[1] Connecting pipe right
[2] Connecting pipe right
[3] Exhaust header clamps

18 Nm

micro GLEIT
LP475
[4] Nuts M8 (3 nuts per side)

23 Nm

[5] Silencer

[6] Clamps

18 Nm

[7] Tailpipe
[8] Nuts M8 (including two eccentric shims under the outer nuts and a washer 9 x 29 x 3
under the centre nut)
23 Nm

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 ENGINE | Exhaust system

1.12.3 Overview of loud exhaust system

[1] Tailpipe left and right

[2] Exhaust header clamps

18 Nm

micro GLEIT
LP475

[3] Bracket left

[4] Bracket right
[5] Bolts M6 x 12

10 Nm
[6] Tensioning straps

18 Nm

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 ENGINE | Exhaust system

1.12.4 Overview of silenced exhaust system

NOTICE INCORRECT ECU SETTING

Risk of engine damage if the ECU data are not changed to the silenced exhaust system.
▶ If the vehicle is converted to the silenced exhaust system, the ECU must be adjusted/
set accordingly.
▶ After the changed setting, the symbol shown must appear in the display.

Fig. 16: Symbol for ECU in silent mode

Setting the ECU to silent exhaust mode

1. Connect the vehicle to the Bosch RaceCon software (ECU = green).

2. Select tab CAR.
3. Set CW_SILENCE to 1.
→ B_silence_pt changes to 1
→ The shown symbol (see Fig. 16) appears in the display.
4. Press SAVE TO ECU.

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 ENGINE | Exhaust system

Assembly

[1] Silencer

[2] Exhaust header clamps

[3] Clamps
18 Nm

micro GLEIT
LP475
[4] Tailpipe
[5] Nuts M8 (including two eccentric shims under the outer nuts and a washer 9 x 29 x 3
under the centre nut)
23 Nm

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 ENGINE | Exhaust system

1.12.5 Oxygen sensors

NOTICE IMPROPER INSTALLATION OF THE OXYGEN SENSOR
If not lubricated, the threads may become damaged, making the components unfit for use.
▶ Coat the threads of the oxygen sensors with Microgleit LP 475.

Removing/installing the oxygen sensors

b Rear wheels removed.

b Diffuser removed. See 4.4.16 Diffuser on page 464.
b Rear lid removed. See 4.4.9 Engine cover on page 446.

1. Remove the plug connection [1].

2. Push the plug connection [2] from the bracket [3].

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 ENGINE | Exhaust system

3. Remove the cable of the oxygen sensor from the clamp [1] and the sheet metal
clamp [2].

4. Remove the oxygen sensor [3] from the exhaust header.

48 Nm

▶ Installation is performed in reverse order.

Before installing an oxygen sensor, make sure that the thread of the oxygen sensor
Microgleit LP 475 is coated with the specified grease.

Fig. 17: Bank 1

Fig. 18: Bank 2

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 ENGINE | Exhaust system

1.12.6 Exhaust manifold

Exhaust manifold disassembly/assembly
[1] Exhaust manifold (Cyl. 1-3)
[2] Exhaust manifold (Cyl. 4-6)
[3] Exhaust manifold gasket
[4] Nuts M8
▶ Tighten the nuts in the order given (see Fig. 19)
33 Nm
[5] Secondary air gasket
[6] Sealing cap secondary air
[7] Screws M6 x 12

13 Nm

Fig. 19: Tightening sequence

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2 GEARBOX
2.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.3 Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.6 Overview of setting values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

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 GEARBOX | Service intervals

2.1 Service intervals

Gearbox
Components Overhaul interval Max. runtime Instructions
Gearbox 60 h - • Overhaul by Porsche Motorsport.
Electronic shift barrel 60 h - • Mileage relates to the mileage counter in the
Bosch ECU (Iteng2), Service by MEGA-Line
Racing ELECTRONIC GmbH (see Addresses
(service + equipment) on page 1027).

For further information about overhaul intervals please refer to the PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com).
▶ Download the latest overhaul list.

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 GEARBOX | General information

2.2 General information

NOTICE IMPROPER ASSEMBLY
The gearbox may become damaged if assembled improperly.
▶ Only parts from the latest Porsche Motorsport parts catalogue are permissible
for installation.

The 911 GT3 Cup (992) is fitted with a sequential six-speed gearbox that has been specifically developed for motorsports.
▶ All locknuts, sealing rings and circlips must be used only once and must be renewed whenever removed!

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 GEARBOX | General information

Reinforced Shur-Lok systems are available for the Porsche 911 GT3 Cup (992).
Porsche Motorsport highly recommends upgrading to the reinforced version as part of the
next overhaul interval. New Shur-Lok systems are 3-piece, instead of the previous 2-piece,
and are mounted on the drive shaft, pinion shaft and cross shaft.
When using the reinforced version, it is imperative that the new tightening instructions are
observed. In the course of the chapter, therefore, a difference is made with insert V7 of the
manual between model year 21/22 (old version) and from model year 2023 (reinforced
version).
Upgraded gear units are marked with an "S".
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Shur-Lok shaft fastener

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 GEARBOX | General information

2.2.1 Technical data

Specification Value
Type/model number G92/70
Design features Sequential constant-mesh gearbox
Number of forward gears 6
Oil capacity of system 3.5 l
Oil specification Mobilube 1SHC 75W-90
Oil filling volume after gear set change Collect drained oil, measure oil volume and
refill gearbox with measured volume.
Weight 72 kg

2.2.2 Overview
[1] Clutch
[2] Input shaft
[3] Differential
[4] Mainshaft with fixed gears
[5] Shift barrel
[6] Electronic shift barrel
[7] Pinion shaft with idler gears
[8] Cross shaft

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 GEARBOX | General information

2.2.3 Transmission ratios

GEAR 911 GT3 Cup (992)
1 13/41
3.154
2 17/40
2.353
3 20/37
1.850
4 24/36
1.500
5 24/30
1.250
6 28/30
1.071

Bevel gear/ Final drive

crown wheel
15/23 16/39
1.533 2.438

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 GEARBOX | General information

2.2.4 Shifting conditions

If the gearbox is stuck between gears, shifting is only possible at an engine speed of less than 3.000 rpm and a throttle opening of 10 %. This is a protective
function of the gearbox.
In order to ensure a fault-free function of the shifting system, the following conditions must be met.
Upshift
R -> N N -> 1 1 -> 6
Paddle right right right
Throttle pedal - - -
Throttle butterfly < 10 % < 30 % > 30 %
Engine speed < 3.000 rpm - > 3.000 rpm
Car speed < 5 km/h - -
Fuel rail pressure - - > 5 bar
Clutch pressure > 30 bar > 30 bar -

Downshift
6 -> 1 1 -> N N -> R
Paddle/Reverse Button [RVK] left left Reverse-Button [RVK]
Throttle pedal <3% - -
Throttle butterfly Auto. Blip < 20 % < 30 %
6 -> 5: < 7.280 rpm
5 -> 4: < 7.080 rpm
Engine speed 4 -> 3: < 6.950 rpm < 3.000 rpm < 2.500 rpm
3 -> 2: < 6.750 rpm
2 -> 1: < 6.270 rpm
Car speed - < 70 km/h < 5 km/h
Fuel rail pressure > 5 bar - -
Clutch pressure - > 30 bar > 30 bar

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 GEARBOX | General information

2.2.5 Power flow

Overview

The engine torque is transferred to the gearbox via the clutch and the input shaft.
The mainshaft and the respective fixed gears transmit the torque to the idler gears and
the pinion shaft.
Power flow: fixed gear – idler gear – dog ring – dog ring hub – pinion shaft.
The crown wheel with its constant transmission ratio diverts the direction of the power
flow from longitudinal to transverse direction. The axle drive transmits the torque via
the limited-slip differential to the axle flanges and finally via the axle shafts to the
drive wheels.

Connected • Direction of rotation under traction load

• Movement of shaft (traction)

• Movement of shaft (deceleration)

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 GEARBOX | General information

2.2.6 Differential

Verbindet New bevel gears and bevel pinions as well as new joint flange plugs will be used in the
differential of the Porsche 911 GT3 Cup (992) from model year 2023.
For further information see page 255.

Function
The ramps, which are driven via the differential housing, in combination with the internal cross pin as
well as the differential and bevel gears transfer the torque from the drivetrain to the axles. Depending
on the transmitted wheel torque, the ramps are pushed outwards by the cross pin. This changes the
pressure applied to the plate set according to the load, permitting a greater torque difference at the
wheels.
The installed spring washers ensure that a defined basic preload is present in the differential in the
unloaded condition. This preload causes connection of the friction plates and thus connection of the
drive wheels. The basic locking torque is retained under load.

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 GEARBOX | General information

Ramps and friction surfaces

As standard, the limited-slip differential is fitted with a ramp with a 52° traction side / 35° thrust side and
12 friction surfaces. The basic locking torque, which is measured using a torque wrench, may vary depending
on wear condition.
▶ Inspect the differential plates at regular intervals and replace if required.

Standard differential design (example):

6 clutch discs and 6 pressure plates = 12 friction surfaces

▶ For further designs, see Possible arrangements of pressure plates and clutch discs
on page 264.

Connected

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 GEARBOX | General information

2.2.7 Electronic shift barrel

An electric shift barrel from MEGA-Line is used for executing the requested shift
operations. It replaces the pneumatic and external mechanical shift components of
the 911 GT3 Cup (991) (predecessor model). The advantages of the compact
high-performance actuator motor are, for example, the increased control and positional
accuracy as well as the low weight of 850 g. Communication with the engine control
system is realised via CAN.

SERVICE WORK IS CARRIED OUT BY MEGA-LINE:

Connected
MEGA-Line Racing ELECTRONIC GmbH
93342 Saal a.d. Donau, Germany
Haunersdorfer Strasse 3
Tel.: +49 9441 6866-0
Fax: +49 9441 6866-11
E-mail: [email protected]

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 GEARBOX | General information

2.2.8 Oil level – measuring

Whether installed or removed, the measurement must always be taken at right angles to the filler opening.

90°
Connected

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 GEARBOX | General information

z
4.5°
1
Connected
2 x

Fig. 20: Gearbox is installed, car is on a level surface

[1] Measuring point

[2] Oil surface

Distance between measuring point and oil surface: 6.5 cm

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 GEARBOX | General information

x
1

Connected 2

Fig. 21: Gearbox is removed and aligned on a workbench

[1] Measuring point

[2] Oil surface

Distance between measuring point and oil surface: 7.1 cm

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 GEARBOX | Clutch

2.3 Clutch
The clutch (dry clutch) is subject to wear during operation.
▶ Measure the clutch at regular intervals and replace if required.

Basic requirements for fault-free operation:

• The vehicle's clutch system as well as the clutch release bearing on the gearbox are OK.
• Improper use of the clutch during vehicle operation is ruled out.

ZF Sachs – 5 1/2" sintered clutch

Connected

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 GEARBOX | Clutch

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 GEARBOX | Clutch

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 GEARBOX | Clutch

2.3.1 Clutch – scope of inspection

Maximum permissible wear of friction package: 1.50 mm

Maximum permissible wear of clutch disc sinter pads: 0.40 mm

▶ For measurement, use the data sheet on page 138.

1. Remove the clutch and mark the installation position of the clutch discs.
2. Measure the 1st clutch disc at positions 1–6.
Outside 3. Measure the 1st intermediate disc.
micrometre 4. Enter the measured values in the data sheet and calculate the average value.
5. Repeat step 1 and 2 for all clutch discs and intermediate plates.
6. Check clutch basket, hubs and sinter discs for cracks.
7. Check the spring fingers for wear.
8. Check the housing legs for wear.

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 GEARBOX | Clutch

Spring finger wear – determination

▶ Check the wear of the spring fingers.

Note: The wear must not exceed a maximum depth of 0.5 mm.

V7,12/2022 911 GT3 Cup (2021–2023) 137

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GEARBOX | Clutch
 GEARBOX | Clutch

2.3.2 Clutch – assembly

Important information on assembly:

▶ Align the pads of the sinter discs with each other.
▶ During assembly, do not allow any grease to come into contact with the hub or shaft profile.
→ The grease is pushed outwards by the centrifugal force and spreads over the friction surfaces,
causing clutch slippage.
▶ Assemble the components dry and without grease.

1. Place the clutch assembly ring into the housing.

2. Position the clutch basket with the open side facing upwards.
3. Install the pressure plate.
4. Install the clutch discs and intermediate plates:
clutch disc – intermediate plate – clutch disc – intermediate plate – clutch disc.
Make sure that the hub is installed the right way round and in the correct position!

5. Install the clutch alignment tool.

6. Attach the clutch with alignment tool to the flywheel.
Special tool The alignment tool must be fully inserted in the flywheel bearing!
9F1.012.277.AH

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 GEARBOX | Clutch

7. Tighten the bolts [1] with washers [2] in a crosswise sequence.

8. Remove the clutch alignment tool.
Initial tightening 9. Remove the clutch assembly ring [3].
12 Nm
Final tightening
33 Nm

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 GEARBOX | Clutch

2.3.3 Clutch fluid – changing/bleeding

WARNING CORROSIVE FLUIDS
Corrosive fluids can cause irritation if they come into contact with skin and eyes.
▶ In the event of eye contact, rinse immediately with water.
▶ In the event of skin contact, wash with soap and water.
▶ If inadvertently swallowed, seek medical advice immediately.

NOTICE CONTAMINATED CLUTCH FLUID

Contaminated clutch fluid can cause the clutch system to malfunction.
▶ Use only clutch fluid from clean and sealed containers.
▶ Do NOT mix clutch fluid with other fluids.
▶ Always keep the reservoir sealed.

NOTICE CLUTCH FLUID

Clutch fluid can cause damage to painted and electrical components.
▶ Avoid contact with painted surfaces and electrical components.
▶ In the event of contact with painted surfaces, rinse immediately with water.
▶ In the event of contact with electrical components, clean immediately with a clean
and dry cloth.

Clutch fluid causes corrosion.

Polyglycol-based fluids (clutch fluid) are hygroscopic (i.e. they absorb water).

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 GEARBOX | Clutch

Clutch system – bleeding

▶ To bleed the clutch system properly, make sure that there is always clutch fluid in the reservoir.
b The clutch system is assembled to specification.
b The reservoir is filled with fluid.
b The cap has been removed.

1. Measure and note the length of the clutch pedal stop.

Note: Basic setting of the clutch pedal stop: 30 mm
2. Extend the clutch stop bolt to 50 mm.

Fig. 22: Basic setting of the clutch pedal stop

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 GEARBOX | Clutch

3. Connect a suitable container to the clutch bleeding line [1] and open the bleeding valve
[2].
4. Bleed the system using the clutch pedal either until the fluid shows no more air or until
the used fluid has been pumped from the system.
5. Close the bleeding valve.
6. Depress the clutch pedal repeatedly.
7. Depress and hold down the clutch pedal.
8. Open the bleeding valve, allow the fluid to escape and then close the nipple again.
9. Release the clutch pedal.
10. Repeat this procedure at least twice to bleed the remaining air from the system.

11. Tighten the bleeding valve [2] to torque.

15 Nm

12. Check the clutch system for leak tightness.

13. Check the fill level of the reservoir and top up fluid if required.
14. Screw on the reservoir cap hand-tight.
15. Immediately remove any clutch fluid that may have escaped. <

16. Set the measured value (see step 1) of the clutch stop again.

SCENARIO: SYSTEM LEAKING

1. Locate and repair the leak.
2. Repeat the bleeding process.

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 GEARBOX | Clutch

Clutch pedal – adjustment

NOTICE CLUTCH PEDAL INCORRECTLY ADJUSTED
Incorrect adjustment of the clutch pedal can damage components.
▶ Do not exceed the actuating travel of the clutch pedal.

1. Lift the vehicle or the rear axle.

2. Mount at least one wheel on the rear axle.
3. Engage 1st gear.
4. Turn the wheel by hand against the closed clutch.
5. Depress the clutch pedal (screw in the clutch stop bolt in increments of 5 mm) until
the clutch disengages.
→ The wheel begins to turn.
6. Adjust the clutch pedal between 10 mm and 30 mm to increase pedal travel.
7. Release the clutch pedal.
8. Depress the clutch pedal and verify that the clutch disengages.
→ The wheel must turn freely.
9. Torque the lock nut of the clutch stop bolt to 23 Nm.
10. Shift the gearbox into neutral.
Fig. 23: Basic setting of the clutch pedal stop

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 GEARBOX | Clutch

2.3.4 Clutch release bearing

NOTICE IMPROPER CLEANING OF THE CLUTCH RELEASE BEARING
The use of any cleaning agent may remove the internal grease, leading
to bearing damage.
▶ Clean the bearing with a rag only.

Cleaning

The components of the clutch release mechanism (except bearing) should be cleaned in an ultrasonic bath only.
Non-approved cleaning agents (petroleum, brake cleaner, etc.) may affect the friction properties of the surface, thereby also affecting the function.
The following procedure must be strictly observed:

1. Fill the ultrasonic bath with 24 litres of water and 0.4 litres of Bonderite C-NE 20.
Mixing ratio 60:1.
Bonderite C-NE 20 2. Let the fluid degas at a temperature of 50 °C–60 °C for approx. 30 min.
3. Disassemble the clutch release bearing into its individual parts.
4. Wash the parts according to their degree of soiling.
5. Rinse the parts with water, blow water off with oil-free air and let parts dry.

Optipit If the bearing does not turn freely, it must be replaced.

Coat the new sealing rings with grease before installation.

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 GEARBOX | Disassembly

2.4 Disassembly
CAUTION HOT GEARBOX OIL
Risk of burns from contact with hot gearbox oil.
▶ Avoid contact with hot gearbox oil.
▶ Allow the gearbox to cool down before disassembly.

CAUTION HOT COMPONENTS

Risk of burns from contact with hot components.
▶ Personal protective equipment (e.g. gloves) must be worn wherever components have
become hot.

NOTICE NON-OBSERVANCE OF THE DESCRIBED SEQUENCE

Components can be damaged if the described sequence is not observed.
▶ Observe the described sequence of gearbox disassembly steps.

▶ After disassembly, clean the individual components thoroughly and check them for damage in accordance with the overhaul list.
The gearbox is disassembled in the reverse order of assembly. A number of specific procedures and operations are described in greater detail below.

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 GEARBOX | Disassembly

REMOVING/ATTACHING THE GEARBOX

1. Unclip the B+-cable [1] from its retainer.

2. Disconnect the coolant hose [1] from the gearbox.

3. Release the coolant hose [1] from its retainer [2].
AF 14 4. Remove the nuts [3].
5. Carefully and evenly disconnect the gearbox from the engine in arrow direction.

▶ The attachment is performed in reverse order.

Ensure that the input shaft of the gearbox is coated with grease before assembly.
Copper paste

▶ Install new nuts [3] uniformly in a crosswise sequence and torque to specification.

80 Nm

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 GEARBOX | Disassembly

GEARBOX OIL – DRAINING

1. Remove the oil drain plug [1] with aluminium sealing ring.
2. Drain the gearbox oil into a clean receptacle.

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 GEARBOX | Disassembly

OIL FILTER – REMOVAL

1. Remove the circlip [1].

2. Pull off the cap [2] with sealing ring [3].

Slide hammer

3. Remove the oil filter element [4] from the gearbox housing.

WIRING LOOM – REMOVAL

1. Disconnect all wiring connectors.

2. Remove the gearbox wiring loom with all brackets.

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 GEARBOX | Disassembly

ELECTRIC SHIFT BARREL – REMOVAL

1. Undo and remove the nuts [1].

2. Remove the electric shift barrel [2] with adapter ring [3].

HYDRAULIC LINES – REMOVAL

▶ Remove the bleed line [1] and pressure line [2] of the clutch.

When the hydraulic lines are removed, some of the clutch fluid is discharged.
▶ Collect the fluid and dispose of properly.

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 GEARBOX | Disassembly

HEAT EXCHANGER – REMOVAL

1. Drain the coolant via the connections [1] using the quick-release coupling.

2. Undo and remove the nuts [1].

3. Lift off the heat exchanger [2].

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 GEARBOX | Disassembly

CLUTCH RELEASE BEARING – REMOVAL

1. Remove the piston [1] of the clutch release bearing.

2. Undo and remove the nuts [2].
3. Remove the clutch release bearing.

When the clutch release bearing is removed, some of the clutch fluid is discharged.
▶ Collect the fluid and dispose of properly.

GEARBOX HOUSING CAP – REMOVAL

1. Remove the circlip [1].

2. Remove the cap [2].
Slide hammer

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 GEARBOX | Disassembly

DRIVESHAFT OUTPUT FLANGES – REMOVAL

1. Engage 1st gear using the adjustment tool.

2. Lock the input shaft using the special tool [1].
Special tool
9F1.012.277.Q,
Special tool
9F1.012.279.AK

3. Undo and remove the bolts of the driveshaft output flange axial lock [1].
4. Remove the driveshaft output flanges [2].
NOTE Be sure not to damage the shaft sealing rings.
5. Shift the gearbox into neutral and remove the tools.

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 GEARBOX | Disassembly

DIFFERENTIAL – REMOVAL

1. Undo the nuts [1] uniformly in a crosswise sequence and remove.

2. Carefully release the gearbox cover [2] using one or two pry bars and remove.
NOTE Be sure not to damage the gearbox cover and gearbox housing.
Pry bar

3. Remove the differential [3] from the gearbox housing.

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 GEARBOX | Disassembly

DIFFERENTIAL PACKAGE – REMOVAL

1. Clamp the special tool in a vice.

2. Place the differential in the special tool.
Special tool 3. Preload the differential using the special tool as shown.
9F1.012.278.D Note: Preload the differential slowly and only far enough that the circlip can
be removed.

4. Release the circlip [1] in an upward direction and remove together with the differential
cover.
Special tool 5. Carefully remove all components from the differential.
9F1.012.278.D

Fig. 24: Illustration shows model year 2023

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 GEARBOX | Disassembly

REMOVING THE DIFFERENTIAL BALL BEARING

1. Place special tool on differential housing.

2. Remove the differential ball bearing using the puller.
Special tool
9F1.012.279.AG,
external puller

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 GEARBOX | Disassembly

OIL SPRAY PIPE – REMOVAL

1. Undo and remove the nut [1].

2. Remove the spray pipe [2].
Slide hammer

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 GEARBOX | Disassembly

SPEED SENSOR – REMOVAL

1. Undo and remove the nut [1].

2. Remove the speed sensor [2].

REMOVING THE TEMPERATURE SENSOR

1. Undo and remove the temperature sensor [1].

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 GEARBOX | Disassembly

CROSS SHAFT – REMOVAL

1. Remove the circlip of the cap.

2. Remove the cap using a slide hammer.

Slide hammer

3. Undo the nuts [1] of the cross shaft cover uniformly and remove.

4. Carefully remove the cross shaft cover [1] using one or two pry bars.
NOTE Be sure not to damage the cross shaft cover and gearbox housing.
Pry bar

5. Carefully remove the cross shaft.

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 GEARBOX | Disassembly

6. Remove adjustment shim P2 [1].

7. Clamp the special tool [1] in a vice.

8. Place the cross shaft [2] into the tool.
Special tool
9F1.012.278.C

9. Secure the cross shaft in the tool using the centring sleeve.

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 GEARBOX | Disassembly

10. Remove the Shur-Lok locking ring [2] (step required for version from model year 2023)
11. Remove the Shur-Lok locking element [1].
Model year 21/22: 12. Release and remove the Shur-Lok threaded sleeve.
Special tool 13. Pull the cross shaft out of the cover.
9F1.012.277.AE,
Special tool
9F1.012.277.S
From MY 2023:
Special tool
9F1.012.277.AR,
Special tool
9F1.012.277.AQ

14. Remove the crown wheel [1] from the cross shaft using a hydraulic press.
Note: Place an aluminium sleeve between the hydraulic press and the crown
Hydraulic press, of the cross shaft.
Aluminium sleeve 15. Remove the sleeve from the cross shaft.

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16. Place the two half shells [1] of the special tool under the cylindrical roller bearing [2]
of the cross shaft [3] and place it into the tool cup.
Special tool
9F1.012.278.A

17. Remove the cylindrical roller bearing [1] as shown using a hydraulic press.
Note: Place an aluminium sleeve between the hydraulic press and the crown of the
Special tool cross shaft.
9F1.012.278.A

Hydraulic press

Aluminium sleeve

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GEAR HOUSING AND GEAR SET – REMOVAL

1. Move the gearbox to a horizontal position.

2. Using the tool, turn the shift barrel to engage 1st gear.
Special tool 3. Lock the input shaft using the tool.
9F1.012.277.Q,
Special tool
9F1.012.277.T

4. Undo the nuts of the gear housing uniformly and remove.

5. Remove the gear housing.

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6. Attach the cut-away housing and secure it with four, evenly spaced nuts [1].

Model year 21/22:

Special tool
9F1.012.277.H
From MY 2023:
Special tool
9F1.012.277.AM

7. Remove the Shur-Lok locking ring on the mainshaft [1] (version from MY 2023).
8. Remove the Shur-Lok locking element on the mainshaft [2].
Model year 21/22: 9. Remove the Shur-Lok locking ring on the pinion shaft [3] (version from MY 2023).
Special tool 10. Remove the Shur-Lok locking element on the pinion shaft [4].
9F1.012.277.R, 11. Release and remove the Shur-Lok threaded sleeve on the mainshaft [5].
Special tool 12. Release and remove the Shur-Lok threaded sleeve on the pinion shaft [6].
9F1.012.277.S, NOTE Do not allow the pinion shaft to fall through the assembly opening.
Special tool
9F1.012.277.AE,
Special tool
9F1.012.277.AF
From MY 2023:
Special tool
9F1.012.277.AF
Special tool
9F1.012.277.AP
Special tool
9F1.012.277.AQ
Special tool
9F1.012.277.AR

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13. Remove the cut-away housing.

14. Remove the cylindrical roller bearing [1] and thrust ring [2] from the mainshaft and
pinion shaft.

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15. Remove the O-ring from the selector rod [1].

16. Remove the selector rod [1].
Note: Do not allow the selector forks to fall out of the dog rings.

17. Remove the selector forks.

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18. Remove the idler gears, fixed gears, needle roller bearings, dog ring hubs and dog rings
one after the other.
Note: When removing the components, mark their installation position and direction
of rotation.

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PINION SHAFT – REMOVAL

1. Remove the pinion shaft through the assembly opening in the gearbox housing.
2. Place the half shells [1] of the special tool under the cylindrical roller bearing and place
Special tool it into the tool cup.
9F1.012.278.A 3. Remove the cylindrical roller bearing.
Note: Place an aluminium sleeve between the hydraulic press and the pinion shaft.

Hydraulic press

Aluminium sleeve

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INPUT SHAFT – REMOVAL

▶ Remove the input shaft.

Slide hammer

MAINSHAFT – REMOVAL

1. Remove the circlip [1] and spacer ring [2].

2. Remove the mainshaft in the direction of the gear housing.
Offset circlip pliers

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OIL SUCTION PIPE – REMOVAL

1. Undo the nut [1].

2. Remove the oil suction pipe [2].

OIL PUMP – REMOVAL

1. Remove the circlip [1].

2. Remove the oil pump gear [2].
Note: Do not allow the feather key to get lost between the shaft and gear.

3. Undo and remove the nuts [3].

4. Remove the oil pump [4].

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REMOVING COUNTER BEARING AND SHIFT BARREL

1. Undo and remove the bolt [1].

2. Undo and remove the nuts [2].
3. Remove the counterbearing [3].
4. Remove the shift barrel [4].

REVERSE IDLER GEAR – REMOVAL

1. Remove the reverse idler gear [1] from the bearing axle [2].
2. Remove the circlip [3].
3. Remove the needle roller bearing [4].

The needle roller bearing is part of the reverse idler gear.

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SHIFT BARREL – REMOVAL

1. Secure the shift barrel [6] at the hexagon to prevent it from turning.

Open-ended
wrench
AF 30

2. Undo and remove the fastening nut [1].

Special tool
9F1.012.279.J

3. Remove the sleeve [2] and remove the bearings [3] with shim disc [4] and
adjustment shim [5].

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SHAFT SEALING RING – REMOVAL

▶ Remove the shaft sealing ring.

NOTE Be sure not to damage the gearbox housing.
Pry bar

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BEARING HOUSING – REMOVAL

WARNING HOT COMPONENTS

To remove the bearings, all housing components are heated for 30 min at 140 °C. Risk of
burns when contacting hot housing components.
▶ Wear personal protective equipment.

NOTICE REMOVAL OF BEARINGS/BEARING OUTER RACES

Removing the bearings/bearing outer races may cause damage to the gearbox housing.
▶ Be sure not to damage the gearbox housing during removal of the bearings/bearing
outer races.

▶ To remove the bearings, heat all housing components for 30 min at 140 °C.

1. Remove the nuts and bolt from the retaining cage.

2. Remove the retaining cage [1], angular contact ball bearing [2] and adjustment
shims [3].

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3. Remove the circlip [1] from the cross shaft needle roller bearing.
4. Remove the cross shaft needle roller bearing [2].
Special tool 5. Remove the circlip [3] from the bearing outer race [4].
9F1.012.277.E, 6. Remove the bearing outer race [4] of the cylindrical roller bearing of the cross shaft.
Special tool
9F1.012.279.AC

Slide hammer

7. Remove the bearing outer race [1] of the cylindrical roller bearing of the pinion shaft.

Special tool
9F1.012.279.AN

Slide hammer

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8. Remove the cylindrical roller bearing [1] of the mainshaft.

Special tool
9F1.012.278.B

Slide hammer

9. Remove the circlip [1] and remove the needle roller bearing [2] of the right-hand
driveshaft output flange.
Internal puller,
circlip pliers

Slide hammer

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10. Remove the circlip [1].

11. Remove the cylindrical roller bearing [2] of the differential.
Internal puller

Slide hammer

12. Remove the needle sleeve [1] of the input shaft in the direction of the arrow.

Special tool
9F1.012.279.AA

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BEARING OF CROSS SHAFT COVER – REMOVAL

1. Remove the circlip [1].

2. Remove the adjustment shim [2].
3. Remove the angular contact ball bearing [3].
4. Remove the cylindrical roller bearing [4].

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 GEARBOX | Disassembly

BEARING OF GEARBOX COVER – REMOVAL

▶ Remove the needle roller bearing [1].

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BEARINGS OF GEAR HOUSING – REMOVAL

1. Undo the nuts [1].

2. Remove the retaining plate [2].

3. Remove the bearing outer races [3].

Use either the special tool or an internal puller for removal (3 recesses per bearing).
Special tool
9F1.012.277.F,
Special tool
9F1.012.277.P,
Internal puller

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4. Remove the circlip [4] from the shift barrel bearing [5].
5. Remove the shift barrel bearing [5].

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 GEARBOX | Assembly

2.5 Assembly

WARNING HOT COMPONENTS

Risk of burns from contact with hot components.
▶ Wear personal protective equipment.

2.5.1 Subassembly of gearbox housing

b Clean and degrease all components before assembly.

1. Check the components in accordance with the overhaul list.
2. Clean all threads with petroleum ether and then degrease with acetone.
3. Blow out the threads with oil-free compressed air.
4. After the studs have been installed, heat the gearbox housing for 30 min to 140 °C.
→ The Loctite bonds are cured during this step.

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Studs – installation

▶ Secure all studs with Loctite 276.

▶ Apply Loctite to the threads of the studs and to the threads in the tapped bores.
D

The type of Loctite specified already reaches 50% of its bonding strength after 30 min at
room temperature.
▶ Apply tension to all studs directly after assembly as shown.
The final bonding strength is reached after 24 h.

1. Screw in and tighten the studs [1] for the cross shaft cover.
▶ Install the short thread.
M8 x 30
Projection: 30 mm

Loctite 276

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2. Screw in the studs for the differential cover.

▶ Install the short thread.
M8 x 30
Projection:
[1]: 30 mm,
[2]: 32 mm

Loctite 276

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3. Screw in and tighten the studs [1] connecting the gear housing.
▶ Install the short thread.
M8 x 50
Projection: 50 mm

Loctite 276

4. Screw in and tighten the studs [2] for the retaining cage of the pinion shaft.
▶ Install the long thread.
M8 x 26
Projection: 13 mm

Loctite 276

5. Screw in and tighten the studs [3] for the oil pump.
▶ Install the short thread.
M6 x 28
Projection: 27 mm

Loctite 276

6. Screw in and tighten the stud [4] for the suction pipe.
▶ Install the long thread.
M6 x 10
Projection: 9 mm

Loctite 276

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7. Screw in and tighten the stud [1] for the counterbearing.

▶ Install the long thread.
M8 x 30
Projection: 28.5 mm

Loctite 276

8. Screw in and tighten the stud [2] for the shift barrel.
▶ Install the long thread.
M6 x 35
Projection: 29 mm
▶ Install the associated sleeve before screwing in the stud. See Sleeves and cylinder pins
– installation on page 194.
Loctite 276

9. Screw in and tighten the stud [3] for the shift barrel.
▶ Install the long thread.
M6 x 10
Projection: 11 mm

Loctite 276

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10. Screw in and tighten the studs [1] for the clutch release bearing.
▶ Install the long thread.
M6 x 18
Projection: 19 mm

Loctite 276

11. Screw in and tighten the stud [1] for the spray pipe.
▶ Install the long thread.
M6 x 10
Projection: 10 mm

Stud assembly tool

Loctite 276

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12. Screw in and tighten the stud [1] for the speed sensor.
▶ Install the long thread.
M6 x 12
Projection: 14 mm
stud assembly tool

Loctite 276

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Bearings – installation
▶ Heat the gearbox housing to 140 °C for 30 min.

After the studs have been cured in the oven, use the existing heat to install the bearings
and sleeves.
▶ Ensure that all bearings are seated correctly by tapping them home with the specified
tool after the gear housing has cooled.

1. Install the mainshaft bearing [1].

34 x 62 x 17
Cylindrical roller
bearing

Special tool
9F1.012.279

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2. Install the bearing outer race [1] of the pinion shaft bearing.

40 x 90 x 23
Cylindrical roller
bearing

Special tool
9F1.012.279.A

3. Install the input shaft bearing [1].

30 x 37 x 16
Needle roller
bearing

Special tool
9F1.012.279.H

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 GEARBOX | Assembly

4. Install the cross shaft bearing [1].

28 x 37 x 30
Needle roller
bearing

Special tool
9F1.012.277.D

5. Install the new circlip [2] with the opening facing downwards (anti-rotation lock).

55 x 1.5

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6. Install the bearing outer race [1] of the cross shaft bearing.
7. Install the new circlip [2] offset by 90° relative to the opening in the gearbox housing
50 x 90 x 20 (see circle).
Cylindrical roller
bearing

Special tool
9F1.012.279.B

Fig. 25: Bearing outer race

8. Install the driveshaft output flange bearing [1].

9. Install the new circlip [2].
40 x 55 x 22
Needle roller
bearing

Special tool
9F1.012.279.E

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10. Install the differential bearing [1].

11. Install the new circlip [2] offset by 90° relative to the opening in the gearbox housing
59.5 x 90 x 23 (see circle).
Cylindrical roller
bearing

Special tool
9F1.012.279.D

Fig. 26: Differential bearing

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Sleeves and cylinder pins – installation

1. Install the oil filter sleeve [1] up to the end stop.

Aluminium
mandrel

Loctite 638

2. Install the gear housing sleeves [1] up to the end stop.

Aluminium
mandrel

Loctite 638

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 GEARBOX | Assembly

3. Install the fixing pins [1] up to the end stop.

Aluminium
mandrel

Loctite 638

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 GEARBOX | Assembly

Threaded plugs, connections and sensors – installation

1. Install the blanking plug [1] with a new sealing ring.

– Plug dimensions: M12 x 1.5
Loctite 574 – Sealing ring dimensions: 12 x 17
2. Install the blanking plug [2] with a new sealing ring.
– Plug dimensions: M12 x 1.5
9 Nm – Sealing ring dimensions: 12 x 17
3. Install the blanking plug [3] with a new sealing ring.
– Plug dimensions: M12 x 1.5
– Sealing ring dimensions: 12 x 17
4. Install the blanking plug [4] with a new sealing ring.
– Plug dimensions: M10 x 1
– Sealing ring dimensions: 10 x 14 x 1
5. Install the blanking plug [5] with a new sealing ring.
– Plug dimensions: M10 x 1
– Sealing ring dimensions: 10 x 14 x 1

6. Install the temperature sensor [6] with a new sealing ring.

– Sensor dimensions: M12 x 1.5
Loctite 574 – Sealing ring dimensions: 12 x 17

15 Nm

7. Install the cap head bolt [7] with a new sealing ring.
– Dimensions: M6 x 10
Loctite 574 – Sealing ring dimensions: A6 x 10

6 Nm

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8. Install the clutch hydraulic connections.

– Connection [1] for the bleed line incl. a new sealing ring
Loctite 574 – Connection [2] for the pressure line incl. a new sealing ring

12 Nm

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Shaft sealing ring – installation

Ensure that the gearbox is cool when installing the shaft sealing ring!

▶ Coat the outer side of the new shaft sealing ring [1] with grease and the inner side with
gearbox oil. Install it flush with the surface using the special tool and a soft-faced
Special tool hammer.
9F1.012.279.F,
Soft-faced
hammer

Optimol paste,
Mobilube 75W90

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2.5.2 Subassembly of gear housing

b Clean and degrease all components before assembly.

1. Check the individual components in accordance with the overhaul list.
2. Clean all threads with petroleum ether and then degrease with acetone.
3. Blow out the threads with oil-free compressed air.
4. After the studs have been installed, heat the gearbox housing for 30 min to 140 °C.
→ The Loctite bonds are cured during this step.

Studs – installation

▶ Secure all studs with Loctite 276.

▶ Apply Loctite to the threads of the studs and to the threads in the tapped bore.

The type of Loctite specified already reaches 50 % of its bonding strength after 30 min at
room temperature.
▶ Apply tension to all studs directly after assembly as shown.
The final bonding strength is reached after 24 h.

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1. Screw in and tighten the studs [1] for the heat exchanger.
▶ Install the long thread.
M6 x 15
Projection: 15 mm

Loctite 276

2. Screw in and tighten the studs [1] for the bearing retaining plate.
▶ Install the long thread.
M5 x 10
Projection: 8 mm

Loctite 276

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 GEARBOX | Assembly

3. Screw in and tighten the studs [1] for the baffle plate.
▶ Install the long thread.
M5 x 10
Projection: 8 mm

Loctite 276

4. Screw in and tighten the studs [1] for the electric shift barrel.
▶ Install the long thread.
M6 x 22
Projection: 21 mm

Loctite 276

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 GEARBOX | Assembly

5. Screw in and tighten the stud [1] for the ground point.
▶ Install the long thread.
M6 x 10
Projection: 9 mm

Loctite 276

6. Screw in and tighten the studs [1] securing the wiring loom.
▶ Install the long thread.
M6 x 10
Projection: 11 mm

Loctite 276

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 GEARBOX | Assembly

Bearings and sleeves – installation

▶ Heat the gearbox housing to 140 °C for 30 min.

After the studs have been cured in the oven, use the existing heat to install the bearings
and sleeves.
▶ Ensure that all bearings are seated correctly by tapping them home with the specified
tool after the gear housing has cooled.

1. Install the gearbox bleed sleeve [1] up to the end stop.

Special tool
9F1.012.279.AB

Loctite 638

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 GEARBOX | Assembly

2. Install the shift barrel bearing [1].

3. Place the new circlip [2] into the groove as shown with the opening facing sideways
50 x 65 x 7 (anti-rotation lock).
Deep groove ball
bearing

Special tool
9F1.012.279.Q

4. Install the mainshaft bearing outer race [3].

30 x 62 x 16
Cylindrical roller
bearing

Special tool
9F1.012.277.A

5. Install the pinion shaft bearing outer race [4].

35 x 72 x 17
Cylindrical roller
bearing

Special tool
9F1.012.277.B

6. Install the retaining plate [5] and secure with the new nuts [6].

6 Nm

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 GEARBOX | Assembly

Threaded plugs – installation

1. Install the threaded plugs [1] with a new sealing ring.
– Plug dimensions: M22 x 1.5
Aluminium paste – Sealing ring dimensions: 22 x 27

40 Nm
2. Install the threaded plug [2] with a new sealing ring.
– Plug dimensions: M16 x 1.5
Loctite 574 – Sealing ring dimensions: 16 x 20

20 Nm
3. Install the threaded plugs [3] with a new sealing ring.
– Plug dimensions: M12 x 1.5
Loctite 574 – Sealing ring dimensions: 12 x 17

9 Nm

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 GEARBOX | Assembly

4. Install the coolant connections [1] with a new sealing ring.

– Sealing ring dimensions: 22 x 27
Special tool
9F1.012.279.AL

20 Nm

Loctite 574

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 GEARBOX | Assembly

Shaft sealing ring – installation

Make sure that the gearbox is cool when installing the shaft sealing rings!

▶ Coat the outer side of the new shaft sealing ring [1] with grease and the inner side
with gearbox oil. Install it flush with the surface using the special tool and a soft-faced
Special tool hammer.
9F1.012.279.AE,
Soft-faced
hammer

Optimol paste,
Mobilube 75W90

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 GEARBOX | Assembly

Baffle plate – installation

1. Install the baffle plate [1].

2. Tighten the new nuts [2].
6 Nm

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 GEARBOX | Assembly

2.5.3 Differential bearing – installation

1. Heat the differential bearing [1] to 140 °C and install on the differential housing using
the special tool.
140 x 110 x 16 Note: Ensure that there is no gap between the bearing and the housing.
Deep-groove ball
bearing

Special tool
9F1.012.279.AF

Feeler gauge

2. Install bearing [1] and secure it with the snap ring [2].

35 x 40 x 17
Needle roller
bearing

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 GEARBOX | Assembly

2.5.4 Subassembly of differential cover

l

1. Install the threaded plug [1] with a new sealing ring [2].

Loctite 574

6 Nm, threaded
plug: M6 x 10
Sealing ring: 6 x 10

2. Heat the differential cover in the oven for 30 min at 140 °C.

3. Install the needle roller bearing [3] from the inner side using the special tool.
Note: The bearing must be flush with the inner surface.
37 x 47 x 20,
Special tool
9F1.012.279.AH

Loctite 638

4. Allow the differential cover to cool down.

5. Coat the outer side of the new shaft sealing ring [4] with grease and the inner side
with gearbox oil. Install it flush with the surface using the special tool and a soft-faced
Special tool hammer.
9F1.012.279.AJ,
Soft-faced
hammer

Optimol paste,
Mobilube 75W90

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 GEARBOX | Assembly

2.5.5 Bearing of pinion shaft – installation

NOTICE INCORRECT INSTALLATION OF SHIM DISC
The gearbox can be damaged by lack of lubrication if the shim disc is installed incorrectly.
▶ It is essential to ensure that the bearing and the shim discs are installed in the
correct position.

1. Place shim disc H1 [1] (2 mm) on the gearbox housing.

Note: Align the disc so that the oil guide grooves face the ball bearing [2].
2. Position the ball bearing [2] with the inscription facing the retaining cage [4].
3. Secure the retaining cage [4] finger-tight with four new nuts offset by 90°.

Do not yet install the shim disc H2 [3] because its thickness must be determined
in the next step beforehand.

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 GEARBOX | Assembly

Thickness of adjustment shim H2 – determination

▶ To determine the adjustment shim thickness, move the gearbox to an upright position.
Note: The retaining cage must point upwards.
To preload the four-point bearing by 0.03–0.05 mm, proceed as follows:

1. Secure the dial gauge with its holder [1] on the retaining cage [2].
2. Guide the dial gauge needle through the bore in the retaining cage and position it
Dial gauge and with a preload on the four-point bearing [3].
dial gauge holder

3. Check and note down the play between the retaining cage [2] and the four-point
bearing [3].
To do so, move the bearing uniformly from the lower stop to the upper stop
(retaining cage).
Repeat the measurement at 4 points. Turn the four-point bearing between
measurements.

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 GEARBOX | Assembly

4. To achieve the specified preload, add

0.03–0.05 mm to the measured value.
5. Remove the retaining cage and place the adjustment shim H2 [1] determined between
the four-point bearing [2] and the retaining cage [3].

The base shim H2 has a thickness of 2.00 mm.

6. Position the retaining cage [1], and apply a thin coat of Loctite to the new nuts [2]
and the bolt [3] .
Loctite 243, Ensure that the parts are lightly coated with gearbox oil before assembly.
Mobilube 75W90

7. Tighten the four new nuts in a crosswise sequence.

Do not yet tighten the remaining nuts and the bolt.
33 Nm

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 GEARBOX | Assembly

2.5.6 Pinion shaft – installation

1. Heat the cylindrical roller bearing to 140 °C and install up to the end stop.
Let them cool down after assembly.

2. Install the base adjustment shim P1 [1] (2.00 mm).

3. Position the lower bearing inner race of the four-point bearing.

4. Guide the pinion shaft through the assembly opening and into the gearbox housing and
the four-point bearing.
5. Position the upper bearing inner race of the four-point bearing.

6. Position the sleeve (substitutes the reverse-gear spur gear).

Special tool
9F1.012.279.L The sleeve is used only as a temporary substitute and will be replaced by the spur gear
during final assembly.

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 GEARBOX | Assembly

7. Install the dog ring hubs [1] on the pinion shaft.

8. Place the special tool on the outer dog ring hub [1].

Special tool
9F1.012.279.N

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 GEARBOX | Assembly

9. Oil the pinion shaft bearing [1] and the thrust ring [2] and install them.

Mobilube 75W-90

10. Install the Shur-Lok nut and tighten it finger-tight.

Mobilube 75W-90

11. Attach the cut-away housing and secure it with four evenly spaced new nuts.

Model year 21/22:

Special tool
9F1.012.277.H
From MY 2023:
Special tool
9F1.012.277.AM

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12. Attach the graduated disc to the cut-away housing.

13. Tighten the new Shur-Lok nut:
Model year 21/22:
MODEL YEAR 21/22
Special tool
a. Position the special tool on the cut-away housing to lock the pinion shaft.
9F1.012.277.S
b. Pre-tightening: 30 Nm + 60° rotation angle
From MY 2023:
c. Undo the pinion shaft nut.
Special tool
9F1.012.277.AQ d. Final tightening: 30 Nm + 60° rotation angle

Graduated disc, The final torque must be greater than 220 Nm.
Electronic torque It is recommended to use an electronic torque wrench.
wrench
FROM MODEL YEAR 2023 Fig. 27: Illustration shows model year 2023
a. Pre-tightening: 50 Nm + 80° rotation angle
b. Undo the pinion shaft nut.
c. Final tightening: 50 Nm + 80° rotation angle

The final torque must be greater than 250 Nm.

It is recommended to use an electronic torque wrench.

14. Turn the pinion shaft and check that it moves freely.

15. Tighten the remaining new nuts and the bolt of the retaining cage.
Note: Loctite has already been applied.
33 Nm

16. Check the axial play of the pinion shaft (nominal: 0.02–0.05 mm).
→ The four-point bearing is centred.
Dial gauge and
dial gauge holder

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Pinion shaft position – adjustment

To ensure that the measurement result is not compromised, the pinion shaft and the housing surfaces must be free from any contamination.

The manufacturer has stamped the measured manufacturing dimension [1] into the
gearbox housing (example: 75.002 mm). This dimension is used for positioning the pinion
shaft relative to the cross shaft and is required to calculate the size of adjustment shim P1.

1. Move the transmission to an upright position with the shaft assembly opening facing
upwards.

2. Place the magnetic plate [1] on the pinion shaft [2] as shown.

Special tool
9F1.012.279.P

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3. Place the measuring plate [1] on the gearbox housing as shown.

4. Guide the depth gauge [2] into the measuring plate [1] until it makes contact.
Special tool
9F1.012.279.K

Depth gauge

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[1] Measured value

[2] Manufacturing dimension of gearbox housing
[3] Dimension from front face of bevel gear to axis of symmetry of cross shaft:
If not explicitly labelled on the part: 41.5 mm
The measurement is on the pinion shaft.
5. Determine the distance between the measuring plate (20 mm) and the
magnetic disc (5 mm) [1].
Example calculation:
• Manufacturing dimension of gearbox housing: 75.002 mm
• Dimension from front face of bevel gear to axis of symmetry of cross shaft: 41.5 mm
• Measuring plate (20 mm) – Magnetic disc (5 mm): 15 mm
→ 75.002 mm + 41.50 mm + 15.00 mm = 131.502 mm
▶ Compare the calculated dimension (131.502 mm) with the measured dimension:
Tolerance = 0.00 to +0.03 mm
▶ If the dimension is outside the tolerance, change adjustment shim P1.
CHANGING ADJUSTMENT SHIM P1:
1. Undo the pinion shaft nut.
2. Remove the cut-away housing. Fig. 28: Pinion shaft measurement
3. Remove the dog ring hubs.
4. Remove the pinion shaft.
5. Change the adjustment shim.
6. Install the pinion shaft.
7. Repeat the measurement procedure.

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2.5.7 Mainshaft – installation

1. Apply a thick coating of oil to the bearing running surfaces.

Mobilube 75W-90

2. Install the mainshaft [1] into the gearbox housing.

3. Slide the thrust plate [2] onto the mainshaft [1].

4. Install the new circlip [3].

Note: The sharp edge of the inner diameter must face outwards.

2.5.8 Gear set – installation

Overview of gear set (top: pinion shaft; bottom: mainshaft).
→ Illustration shows model year 2023.

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1. Move the gearbox to a horizontal position so that the gear set can be installed from
the side.

2. Apply a thin film of oil to the pinion shaft, mainshaft as well as all bearing points
and bearings.
Mobilube 75W-90

3. Install the reverse-gear spur gear [1] on the pinion shaft.

Note: The conically chamfered side must face the gearbox housing.

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4. Install the 1st gear idler gear [1] with idler gear bearing [2] (needle roller and
cage assembly 50 x 55 x 20) on the pinion shaft.
Mobilube 75W-90 Note: The claws must point away from the gearbox housing [arrow].

5. Install the dog ring hub [1] on the pinion shaft and apply a thin coat of oil to the
running surface.
Mobilube 75W-90 Note: Make sure that the oil bores of the pinion shaft and dog ring hub are offset from
one another.

If reused, keep the same direction of rotation.

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6. Install the dog ring [1] on the dog ring hub.

Mobilube 75W-90
If reused, keep the same direction of rotation.

7. Install the 2nd gear idler gear [1] with idler gear bearing (needle roller and
cage assembly 50 x 55 x 20) on the dog ring hub.
Mobilube 75W-90 Note: The claws must point towards 1st gear.

8. Install the fixed gear of the 3rd gear [2] on the mainshaft as shown.

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9. Slide the 3rd gear idler gear [1] with idler gear bearing (needle roller and cage assembly
50 x 55 x 20) onto the dog ring hub [2] and install the two parts on the pinion shaft
Mobilube 75W-90 as shown.
Note: The claws must point towards the 4th gear and the oil bores of the pinion shaft
and the dog ring hub must be offset from one another.

If reused, keep the same direction of rotation.

10. Install the dog ring for 3rd and 4th gear on the dog ring hub [2].

If reused, keep the same direction of rotation.

11. Slide the 4th gear idler gear [1] with idler gear bearing (needle roller and cage assembly
50 x 55 x 20) on the dog ring hub.
Mobilube 75W-90 Note: The claws must point towards the 3rd gear.

12. Install the fixed gear of the 4th gear [2] on the mainshaft.
Note: The markings on the fixed gear [2] and idler gear [1] must be on the same side.

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13. Install the dog ring hub [1] with the idler gear of the 5th gear [2] with idler gear bearing
(needle roller and cage assembly 50 x 55 x 20) on the pinion shaft.
Mobilube 75W-90 Note: The claws must point towards the 6th gear and the oil bores of the pinion shaft
and the dog ring hub [1] must be offset from one another.

14. Install the fixed-gear combination of the 5th and 6th gear [3] on the mainshaft.

If reused, keep the same direction of rotation.

15. Install the idler gear of the 6th gear [1] with idler gear bearing (needle roller and
cage assembly 50 x 55 x 20) on the dog ring hub.
Mobilube 75W-90 Note: The claws must point towards the 5th gear.

16. Apply a thin coat of oil to the bearing point of the driveshaft and pinion shaft.

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17. Install the thrust ring [1] with the large contact surface facing the fixed gear
on the mainshaft.
18. Install the roller bearing [2] on the mainshaft.
19. Loosely screw on the Shur-Lok nut [3]. Do NOT tighten.

Fig. 29: Illustrations shows model year 2023

20. Install the thrust ring [1] with the large contact surface facing the idler gear
on the pinion shaft.
21. Install the roller bearing [2] on the pinion shaft.
22. Loosely screw on the Shur-Lok nut [3]. Do NOT tighten.

Fig. 30: Illustrations shows model year 2023

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2.5.9 Subassembly of shift barrel

1. Install the adjustment shim [1] (base 1.4 mm) on the shift barrel.
2. Place the deep-groove ball bearings [2] with the shim disc [3] into the sleeve [4].
3. Place the sleeve [4] on the shift barrel (installation position as shown).

4. Install and tighten the new nut [5].

Note: When tightening the new nut, always hold the hexagon of the shift barrel using
Special tool an open-jaw spanner.
9F1.012.279.J

Open-jaw spanner
AF30
60 Nm

Loctite 243

5. Apply a thin coat of oil to the sleeve [4].

Mobilube 75W90

6. Install the shift barrel into the gearbox housing.

The following section describes how to secure the shift barrel.

See 2.5.11 Counterbearing – installation on page 230.

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2.5.10 Reverse idler gear – installation

1. Heat the reverse idler gear [1] to 140 °C.

2. Install the needle roller bearing [2] in the reverse idler gear [1].
Special tool
9F1.012.279.R

3. Install the new circlip [3].

4. Apply a thin coat of oil to the needle roller bearing [2].

Mobilube 75W90

5. Install the reverse idler gear [1] on the bearing axle [4] with selector fork [5].

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2.5.11 Counterbearing – installation

1. Install the sleeve in the counterbearing [1].

Note: The sleeve must be flush with the counterbearing [1].
2. Place the counterbearing [1] in the gearbox housing.

3. Tighten the new M6 [2] nuts.

This nut also secures the shift barrel.
10 Nm

4. Tighten the new M8 nut [3].

25 Nm

5. Tighten the M8 x 75 bolt [4].

25 Nm

Bolt [4]:
Loctite 243

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2.5.12 Oil pump – installation

NOTICE IMPROPER ASSEMBLY

The gearbox may become damaged if the oil pump is installed incorrect.
▶ The oil pump gear must be installed as shown. The lettering must face the oil pump
so that it is not visible when installed.

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1. Grease the new O-rings and install them in the oil pump housing.

Optipit

2. If the oil pump gear is installed, remove the circlip and discard it.
3. Remove the oil pump drive gear from the oil pump.
4. Install the oil pump [1].

5. Screw on the new nuts [2] and pretighten in a crosswise sequence.

Note: The shaft must rotate freely.
4 Nm

6. Tighten the new nuts [2] to their final tightening torque.

10 Nm

7. Install the gear [3] on the oil pump [1].

Note: Make sure the feather key is fitted to the shaft.

Ensure a backlash of 0.11–0.23 mm between the idler gear of the 1st gear and the oil
pump gear.
8. Install a new circlip [4].
Note: The sharp-edged inner side of the circlip must face outwards.

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2.5.13 Selector rod and selector forks – installation

1. Insert the selector forks [1] into the dog rings [2] and shift barrel [3] as shown.

2. Grease the O-rings (11 x 2) [1] and install on the selector rod [2].

Optipit

3. Oil the selector rod [1] and install up to the end stop.
Note: The upper O-ring is not used until final assembly.
Mobilube 75W90

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2.5.14 Oil suction pipe – installation

1. Grease the O-ring (15 x 2.5) [1].

2. Install the oil suction pipe [2] with the O-ring [1] in the gearbox housing.
Optipit

3. Screw on and tighten the new nut [3].

10 Nm

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2.5.15 Oil filter – installation

1. Install the oil filter element [1].

Note: Install the oil filter as shown.
NOTE If this is not observed, the oil filter may become damaged.

2. Grease the O-ring [2].

Optipit

3. Install the cap [3] incl. O-ring.

4. Install the new circlip [4].
Note: The sharp outer edge must face outwards.

It must be possible to install cap and new circlip without applying any force.

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2.5.16 Input shaft – installation

1. Install the snap ring [1] on the input shaft [2].

2. Centre the snap ring [1] with grease.
Optipit 3. Install the input shaft [2] in the mainshaft.
Note: The input shaft [2] must engage audibly.

4. Install the guide ring [1] on the bearing.

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5. Grease the new shaft sealing ring (26 x 41 x 6) and slide it up to the housing using
the protective cap [A].
Optimol Paste 6. Install the new shaft sealing ring up to the end stop using the press mandrel [B].

Special tool
9F1.012.279.G

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2.5.17 Clutch release bearing – installation

1. Grease and install the O-rings [1].

Optipit

2. Coat scraper ring [1] and piston seal [2] with grease and install them.

Optipit

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3. Place the clutch release bearing [1] on the gearbox housing.

4. Screw on and tighten the new nuts [2].

5. Install piston with bearing.
10 Nm

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2.5.18 Pinion shaft and mainshaft – tightening

.

1. Attach the cut-away housing and secure it with four evenly spaced new nuts.

Model year 21/22:

Special tool
9F1.012.277.H
From MY 2023:
Special tool
9F1.012.277.AM

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2. Use the adjustment tool to put shift barrel [1] in the position of the 1st gear and lock
it with the spring loaded detent [2].
Special tool
9F1.012.279.AD,
Special tool
9F1.012.279.AK

3. Lock the mainshaft using the special tool [1].

Special tool
9F1.012.277.Q

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4. Attach the graduated disc to the cut-away housing.

5. Tighten the new pinion shaft nut:
Model year 21/22:
MODEL YEAR 21/22
Special tool
a. Pre-tightening: 30 Nm + 60° rotation angle
9F1.012.277.S
b. Undo the pinion shaft nut.
From MY 2023:
c. Final tightening: 30 Nm + 60° rotation angle
Special tool
9F1.012.AQ

The final torque must be greater than 220 Nm.

Graduated disc, It is recommended to use an electronic torque wrench.
Electronic torque
FROM MODEL YEAR 2023
wrench
a. Pre-tightening: 50 Nm + 80° rotation angle Fig. 31: Illustration shows model year 2023
b. Undo the pinion shaft nut.
c. Final tightening: 50 Nm + 80° rotation angle

The final torque must be greater than 250 Nm.

It is recommended to use an electronic torque wrench.

6. Tighten the mainshaft nut:

a. Pre-tightening: 30 Nm + 50° rotation angle
Model year 21/22: b. Undo the mainshaft nut.
Special tool c. Final tightening: 30 Nm + 50° rotation angle
9F1.012.277.R
From MY 2023:
Special tool
9F1.012.AP The final torque must be greater than 190 Nm.
It is recommended to use an electronic torque wrench.

Graduated disc,
Electronic torque
wrench Fig. 32: Illustration shows model year 2023

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7. Install the Shur-Lok anti-rotation lock [1] on the Shur-Lok nuts of the pinion shaft
and mainshaft using the special tool:
Model year 21/22: MODEL YEAR 21/22
Special tool
a. Install Shur-Lok anti-rotation locks [2] onto the Shur-Lok nuts [1] of the pinion shaft
9F1.012.277.T,
and mainshaft using the special tool.
Special tool
Note: The locks must be flush with the nuts and must be fitted as shown (see Fig. 33).
9F1.012.277.AA,
Special tool
9F1.012.277.AB, Fig. 33: Rotation locking parts model year 21/22
Special tool
9F1.012.277.AC
FROM MODEL YEAR 2023
From MY 2023:
Special tool a. Install the Shur-Lok locking parts [2] onto the Shur-Lok nuts of the pinion shaft and
9F1.012.277.AF, mainshaft using the special tool.
Special tool Note: The locking parts must fit flush against the Shur-Lok nuts (up against the stop)
9F1.012.277.AR and must not be tilted.
b. Place Shur-Lok locking rings [3] under the teeth of the Shur-Lok nuts [1].
Therefore, start at one tooth and follow the radius of the nut.
Note: The Shur-Lok locking rings must be fully engaged under the teeth of the Shur-
Lok nuts (see Fig. 34)

Fig. 34: Rotation locking parts from model year 2023

All model years:

▶ Use a soft-faced hammer to install.
▶ Shur-Lok locking parts must be renewed whenever they are removed!
▶ Shur-Lok locking parts may produce chips during installation. These must be carefully
removed.

Fig. 35: Illustration shows model year 2023

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2.5.19 Shift play – check

.

1. Move the gearbox to a horizontal position.

2. Shift the gearbox into neutral and secure it with the spring-loaded detent.
Special tool Check the backlash between idler gears and fixed gears.
9F1.012.279.AD, – Check that the clearance between selector forks and dog rings is uniform.
Special tool → 1st gear: 0.15–0.25 mm
9F1.012.279.AK → 2nd–6th gear: 0.06–0.16 mm
3. Engage 1st to 6th gear in sequence, securing each gear using the spring-loaded
detent.
Feeler gauge – Check that the dog ring is fully engaged in the idler gear.
4. Check the shift setting:
a. Shift the gearbox into neutral and secure it with the spring-loaded detent.
b. Pull the dog ring of 1st/2nd gear toward idler gear of 1st gear.
c. Using the feeler gauge, check the dimension between the claw at the idler gear
and the dog ring (see figure).
Perform this procedure for 1st to 6th gear.
Note: Always apply the same amount of force when pulling the dog ring towards
the idler gear.
The dimension determined must be identical for all gears, with a tolerance
of ±0.1 mm. If dimensions vary, this can be adjusted using the adjustment shim
of the shift barrel. See 2.5.9 Subassembly of shift barrel on page 228.

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2.5.20 Cross shaft bearing adjustment shim Q1 – determination

Measurement procedure

1. Install the measuring device [1] in the cross shaft cover.

Note: The contact surface must be free from any contamination.
Special tool 2. Install the new circlip [2].
9F1.012.279.T

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3. Measure the overall dimension of the bearings (example: 39.95 mm):

– [1] Cylindrical roller bearing 35 x 72 x 23
Depth gauge – [2] Angular contact ball bearing 35 x 72 x 17

4. Measure the distance between the plunger end and the disc [1] (example: 43.10 mm).
5. Measure the overall dimension of the measuring device [2] (85.00 mm).

Example calculation for dimension Q1:

• Overall dimension of measuring device: 85.00 mm
• Overall dimension of bearings: 39.95 mm
• Distance: 43.10 mm
• Pressing: 0.15 mm

85.00 – 39.95 – 43.10 + 0.15 = 2.1 mm (adjustment shim Q1)

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2.5.21 Cross shaft – assembly

1. Heat the cylindrical roller bearing [1] and the bearing inner race [4] to 140 °C.

2. Oil the cross shaft [5] at the bearing points.

Mobilube 75W90

3. Install the heated cylindrical roller bearing [1] on the cross shaft [5].
Note: The bearing [1] must slide onto the shaft without requiring much force.
Feeler gauge 4. Install the sleeve [2] on the cross shaft [5].
5. Install the crown wheel [3].
6. Install the bearing inner race [4].
Note: Ensure that there are no gaps between the components.

2.5.22 Cross shaft – installation

1. Heat the gearbox plate [1] to 140 °C for 30 min.

2. Install the cylindrical roller bearing [2] up to the end stop.

Note: The marking must face outwards.

3. Clamp the makeshift shaft in the vice.

4. Mount the gearbox plate [1] on the special tool.
Special tool
9F1.012.279.C

5. Install the lower inner race of the four-point bearing [3] into the cover plate.
6. Install the four-point bearing [3].
Special tool Note: The marking must face outwards.
9F1.012.278 7. Install the upper inner race of the four-point bearing [3] into the cover plate [1].

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8. Position the Shur-Lok threaded sleeve [1] and tighten until finger-tight.

Mobilube 75W-90

9. Tighten the Shur-Lok threaded sleeve [1], turn the cover and check that it can
move freely.
50 Nm → Cylindrical roller bearing and four-point bearing are centred.

Model year 21/22:

Special tool
9F1.012.277.S
From MY 2023:
Special tool
9F1.012.277.AQ
Fig. 36: Illustration shows model year 2023

10. Install the adjustment shim determined Q1 [1].

11. Install the new circlip [2].
Note: The new circlip must be aligned as shown to ensure that the oil bore in the
housing cover is not obstructed.

▶ Make sure that the new circlip is seated correctly; tap home with an aluminium mandrel
if necessary.

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12. Undo the Shur-Lok threaded sleeve and remove the special tool.
13. Blow out the cross shaft cover with compressed air.
Model year 21/22: 14. Coat the bearings with oil and ensure that the bearing inner races are seated correctly.
Special tool
9F1.012.277.S
From MY 2023:
Special tool
9F1.012.277.AQ

Mobilube 75W-90

15. Place the cover plate on the cross shaft.

16. Install the Shur-Lok threaded sleeve and tighten until finger-tight.
Fig. 37: Illustration shows model year 2023

17. Clamp the special tool [1] in a vice.

18. Place the cross shaft with cover [2] into the tool.
Special tool 19. Secure the cross shaft in the tool using the centring sleeve.
9F1.012.278.C

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20. Install the graduated disc.

21. Tighten the Shur-Lok threaded sleeve [1] (MY 21/22 & from MY 2023):
Model year 21/22: a. Pre-tightening: 50 Nm + 60° rotation angle
Special tool b. Loosen the threaded sleeve [1].
9F1.012.277.S c. Final tightening: 50 Nm + 60° rotation angle
From MY 2023:
Special tool
9F1.012.277.AQ
The final torque must be greater than 240 Nm.
It is recommended to use an electronic torque wrench.
Graduated disc,
Electronic torque
wrench
Fig. 38: Illustration shows model year 2023

22. Turn the cross shaft cover again and check that the bearings move freely.

23. Install the Shur-Lok anti-rotation lock onto the cross shaft:
MODEL YEAR 21/22
Model year 21/22:
a. Place the Shur-Lok locking element [1] into the special tool and install it onto the
Special tool
cross shaft.
9F1.012.277.S,
Note: The Shur-Lok locking element must be flush and installed as shown.
Special tool
9F1.012.277.AA,
Special tool
9F1.012.277.AD,

Fig. 39: Locking element model year 21/22

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FROM MODEL YEAR 2023

a. Install the Shur-Lok locking part [2] onto the Shur-Lok nut of the cross shaft using
From MY 2023: the special tool.
Special tool Note: The locking part must fit flush against the Shur-Lok nut (up against the stop) and
9F1.012.277.AR must not be tilted.
b. Place Shur-Lok locking ring [3] under the teeth of the Shur-Lok nut [1].
Therefore, start at one tooth and follow the radius of the nut.
Note: The Shur-Lok locking ring must be fully engaged under the teeth of the Shur-Lok
nuts (see Fig. 40)

All model years:

▶ Use a soft-faced hammer to install.
▶ Shur-Lok locking parts must be renewed whenever they are removed!
▶ Shur-Lok locking parts may produce chips during installation. These must be carefully
removed.

Fig. 40: Illustrations show model year 2023

24. Grease the O-ring (130 x 2.5) and install on the cross shaft cover.

Optipit

25. Remove the cross shaft from the special tool.

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Angle drive backlash – check

1. Put gearbox to a horizontal position and turn it with the cross shaft opening pointing
upward.

2. Install adjustment shim P2 [1] (base 1.6 mm).

3. The needles of the cross shaft needle roller bearing must be centred outward using
grease.
Optipit

4. Install the cross shaft with cover.

When installing, turn the cross shaft slightly in order to prevent direct contact
of two teeth of the crown wheel and bevel gear.
5. Install the cross shaft cover.
NOTE It must be possible to install the cross shaft without applying any force.

6. Tighten every second new nut in a crosswise sequence.

22 Nm

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7. Push the measuring device [1] into the cross shaft and clamp it.

Special tool
9F1.012.277.L

8. Attach the deck bridge [2] to one of the studs of the cross shaft cover.

Special tool
9F1.012.279.M

9. Install the dial gauge [3].

10. Place the measuring tip [4] with preload on the deck bridge [2].
Dial gauge

11. Install and secure the special tool [1] on the cut-away housing.

Special tool
9F1.012.277.N

12. Carefully push the pinion shaft in arrow direction using a plastic pry bar
at the 1st gear idler gear.
Plastic pry bar 13. Clamp the pinion shaft in this position.

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▶ Push the measuring device against the measuring stop without applying any force.
Applying counterforce will falsify measurement results.

14. Using the measuring device, push the cross shaft from the thrust flank to the traction
flank and measure the traction flank play.
15. Release all tools and turn the cross shaft by 90°.
16. Preform the measurement procedure four times.
17. Compare the average value from the measurement results with the target setting value
of 0.22–0.26 mm.

18. To determine thrust flank play, release the pinion shaft and, using a plastic pry bar at the
6th gear idler gear, push it carefully towards the gearbox housing.
Plastic pry bar 19. Clamp the pinion shaft in this position.

20. Using the measuring device, push the cross shaft from the thrust flank to the traction
flank and measure the thrust flank clearance.
21. Release all tools and turn the cross shaft by 90°.
22. Preform the measurement procedure four times.
23. Compare the average value from the measurement results with the target setting value
of 0.19–0.23 mm.

If the backlash is excessive, install a thinner adjustment shim P2.

If the backlash is too small, install a thicker adjustment shim P2.
▶ Repeat the measurement procedure.

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2.5.23 Differential assembly – general overview

New bevel gears and bevel pinions as well as new joint flange plugs will be used in the
differential of the Porsche 911 GT3 Cup (992) from model year 2023.
NOTE Cross-mounting of the new components with the old set is not possible due to
differences in geometry.

Overview of changes from model year 2023

Part No.
Name Quantity
Model year 21/22 (old) From model year 2023
Bevel gear 9F1.341.347 9F1.341.347.B 2
Bevel pinion 9F1.341.317 9F1.341.317.B 4
Plug Joint flange 9F1.321.795 9F1.321.795.A 2

The figures in chapter 2.5.23 Differential assembly show the version for model year 21/22.

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The differential can also be replaced while the gearbox is filled with oil.
▶ Be sure to always check the oil level on completion of work on the gearbox.
▶ Before assembly, apply sufficient gearbox oil to all components.
▶ Pay attention to the directions of rotation and the markings.

[1] Circlip [6] Stop ring [11] Cross pin incl. bevel pinions [15] Plate set [19] Thrust ring
[2] Differential cover [7] Plate set [12] Spacer [16] Stop ring [20] Differential housing
[3] Spring washer [8] Ramp [13] Bevel gear [17] Axial needle roller and [21] Needle roller bearing
[4] Thrust ring [9] Bevel gear [14] Ramp cage assembly [22] Circlip
[5] Axial needle roller [10] Spacer [18] Spring washer

▶ In the first step, the deep groove ball bearing must be installed on the differential
housing. See 2.5.4 Subassembly of differential cover on page 210.

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Differential – measurement procedure

All measurements must be performed on a measuring plate.

1. Height of magnetic disc VI

2. Differential housing dimensions I/ II
3. Height of ramps incl. cross pin III
4. Height of thrust ring IVa
5. Height of thrust ring IVb
6. Height of plate set Va and Vb

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MAGNETIC DISC VI

▶ Determine the height [VI] of the magnetic disc.

Vernier caliper
Special tool
9F1.012.279.P

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DIFFERENTIAL HOUSING I+II

1. Place the differential cover [1] with the magnetic disc attached into the differential
housing [2].
Special tool 2. Install the new circlip [3].
9F1.012.279.P

3. Turn over the differential housing and place it into the special tool.
4. Tap the differential cover towards the circlip using a plastic mandrel.
Special tool Note: The differential cover and the new circlip must settle at their final position.
9F1.012.279.AM

Soft-faced
hammer,
Plastic mandrel

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5. Determine dimension [I] as shown.

Repeat the measurement procedure 3 or 4 times and use the average value.
Depth gauge

6. Place the magnetic disc [1] on the housing bottom and then turn over the differential
(the differential cover is not installed).
Special tool
9F1.012.279.P,
Special tool
9F1.012.279.AM

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7. Determine dimension [II] as shown.

Repeat the measurement procedure 3 or 4 times and use the average value.
Depth gauge

RAMPS INCLUDING CROSS PIN III

▶ Place the cross pin [1] into the ramps [2] and determine dimension [III] as shown.
Repeat the measurement procedure 3 or 4 times and use the average value.
Depth gauge

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THRUST RING IVa

▶ Determine dimension [IVa] of the thrust ring as shown.

Repeat the measurement procedure 3–4 times and use the maximum value.
Vernier caliper

THRUST RING IVb

▶ Determine dimension [IV b] of the thrust ring as shown.

Repeat the measurement procedure 3–4 times and use the maximum value.
Vernier caliper

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CALCULATING THE PLATE SET Va + Vb

Differential housing dimension [I] 117.55 mm

+ Magnetic disc [VI] 5.00 mm
- Differential housing dimension [II] 31.50 mm
- Ramps incl. cross pin [III] 64.20 mm
- Left thrust ring [IVa] 3.84 mm
- Right thrust ring [IVb] 3.84 mm
- Desired play 0.07 mm
(Specification = 0.05–0.10 mm)
= [Va] + [Vb] 19.10 mm
= [Va] [Va] = 9.55 mm
= [Vb] [Vb] = 9.55 mm

The result indicates the height of the plate sets to be installed.

[Va] = Height of left-hand plate set
[Vb] = Height of right-hand plate set

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STACKING THE PLATE SETS

The plate sets each consist of three clutch discs and three pressure plates.
▶ Stack the discs and plates as shown to set up the differential with 12 friction surfaces.
To achieve the calculated dimension [Va] and [Vb], pressure plates are available with graduations of 0.05 mm.

▶ Stack the pressure plates and clutch discs.

[Va] = [Vb] = 3x clutch discs + 3x pressure plates

To ensure that the cross pin is seated centrally, the markings (dot or letter) of the
pressure plates must be aligned over each other and both plate sets must be stacked
to the same height.

Pressure plates (mm)

1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95

POSSIBLE ARRANGEMENTS OF PRESSURE PLATES AND CLUTCH DISCS

The differential is fitted with 12 friction surfaces (12FF) as standard. The arrangement
of the parts is shown in detail in the image:
PP = Pressure plates
CD = Clutch discs
FF = Friction surfaces

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PLATE SETS Va + Vb

1. Zero the depth gauge to the control dimension.

Depth gauge

Special tool
9F1.012.279.AP

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2. Determine the actual height of the two plate sets using the test weight.

Depth gauge
The plate sets must be installed exactly as they were measured. Measurement must be
repeated if the plate sets are re-stacked.
Special tool
9F1.012.279.AP

3. The plate set height determined using the test weight must be identical to the
calculated height. Otherwise the plate set must be re-stacked and measured again.

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ASSEMBLY

▶ Before assembly, coat all components with a sufficient amount of gearbox oil (Mobilube 75W90).
1. Install the axial needle roller bearing [1] and the stop ring [2] into the
differential housing.
Note: The rounded side of the inner diameter of the axial bearing must face outwards.
The marking on the stop ring must face away from the axial needle roller bearing.
2. Install the spring washer [3] and thrust ring [4] (IVb).
Note: Install the components as shown.

3. Install the plate set [1] (Vb) as shown.

Note: Align the clutch discs with the bevel gear. The splines of the pressure plate must
line up with the marking on the differential housing as shown.

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4. Install the ramp [1] with the markings (two crosses on the outer splining) pointing
to the left and right of the marking on the differential housing (dot on the front face
of the inner splining).

5. When installing the ramps, make sure that the direction of rotation is correct
(see the figure).

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6. Install the bevel gear [1].

7. Place the O-ring [1] on the spacer [2] and install it in the bevel gear.
NOTE Make sure that the ramp is seated correctly.
Optipit

8. Install the cross pin and the bevel pinion.

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9. Install the new O-ring on the spacer and place it into the bevel gear.
To install the bevel gear in the differential, use the M10 x 1 bolt as shown.
Optipit

The bevel gears and bevel pinions must be positioned correctly.

▶ Remove the bolt afterwards.

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10. Install the ramp [1] with the markings (two crosses on the outer splining of the ramps)
pointing to the left and right of the marking on the housing.

11. Install the plate set [1] (Va). The centre of the pressure plate splining should be in
alignment with the marking on the housing, as is already the case on the (Vb) side.

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12. Install the spring washer [1] and the thrust ring [2].
Note: Install the components as shown.

13. Install the stop ring [1], axial needle roller bearing [2] and differential cover [3].
Note: The rounded side of the inner diameter of the axial bearing must face outwards.
The marking on the axial bearing must face away from the axial needle roller bearing.

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14. Install the new circlip in the differential and push it against the cover at the bottom.
15. Clamp the special tool in a vice.
Special tool 16. Slowly guide the differential [1] into the special tool [2].
9F1.012.278.D 17. Mount the gearbox cover [3] and guide the short driveshaft output flange [4]
into the differential.
→ This procedure centres the bevel gear.
18. Remove the driveshaft output flange and the gearbox cover.

19. Preload the differential using the special tool as shown.

▶ Preload the differential slowly and only far enough to allow the new circlip to snap into
place.

20. Install the new circlip [1].

21. Release the preload.

▶ The new circlip [1] must fully engage.

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Basic locking torque – check

1. Clamp the special tool in a vice.

2. Place the differential [1] in the special tool [2] and install the gearbox cover [3].
Special tool 3. Guide the left-hand driveshaft output flange [4] into the differential and mount
9F1.012.278.D the special tool [5].
4. Remove the lateral tooth of the special tool.

5. Turn the driveshaft output flange four times by 180° in order to smooth the roughness
peaks
Torque wrench (2 x clockwise, 2 x anti-clockwise).
6. Measure the basic locking torque.

When measuring, pull the torque wrench smoothly and without jerking.

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Differential – installation

1. Install the differential [1] in the gearbox housing.

2. Coat the new O-ring [2] with grease and install it on the gearbox cover [3].
3. Coat the new O-ring [4] with grease and install it into the gearbox housing.
Optipit

4. Install the gearbox cover [3].

5. Install the bracket for the coolant return [5].
6. Install the bracket for the wiring loom [6].

7. Install and tighten the new fastening nuts [7] in a crosswise sequence.

22 Nm

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2.5.24 Gear housing – installation

1. Grease the O-ring [1] and install it into the groove of the selector rod.

Optipit

2. Grease the new O-rings [1] and [2] and install them in the gearbox housing.

Optipit

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3. Put the gearbox in vertical position and install the gear housing.

4. Tighten the new nuts uniformly in a crosswise pattern.

Note: It must be possible to install the gear housing without applying any force.
22 Nm ▶ Carefully guide the bearing into the housing.

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2.5.25 Cross shaft cover cap – installation

1. Install the cap [1] with greased O-ring [2].

2. Install the new circlip [3].
Optipit

2.5.26 Assembly opening cap – installation

1. Install the cap [1] with greased O-ring [2].

2. Install the new circlip [3].
Optipit

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2.5.27 Driveshaft output flanges – installation

1. Engage 1st gear using the special tool.

2. Lock the input shaft using the special tool [1].
Special tool
9F1.012.277.Q,
Special tool
9F1.012.279.AK

3. The needles of the needle roller bearings of the driveshaft output flange must be
centred outward using grease.
60 Nm 4. Install the driveshaft output flanges [1].
5. Coat the bolt head with grease.
NOTE Ensure that the thread remains free of any grease.
Special tool 6. Install and tighten the bolts [2].
9F1.012.277.G 7. Shift gearbox into neutral and remove the special tools.

Castrol Optipit

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2.5.28 Electric shift barrel – installation

1. Coat the O-ring [1] with grease and place it on the electric shift barrel with the plastic
bushings [2].
Optipit

2. Install the electric shift barrel as shown.

3. Tighten the new nuts [1].
6 Nm

▶ The position of the rotor shaft outer gearing [2] must be in alignment with the inner
splining of the shift barrel.

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2.5.29 Hydraulic lines of clutch release bearing – installation

▶ Install the bleed line [1] and pressure line [2].

Note: Route the bleed line downwards as shown.
Aluminium paste

10 Nm

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2.5.30 Heat exchanger – installation

1. Install the heat exchanger [1] with greased O-rings.

2. Screw on and tighten the new nuts [2].
Optipit

10 Nm

2.5.31 Oil spray pipe – installation

1. Install the oil spray pipe [1] with greased O-rings [2].

Optipit

2. Tighten the new nut [3].

10 Nm

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2.5.32 Speed sensor – installation

1. Install the sensor [1].

2. Tighten the new nut [2].
6 Nm

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2.5.33 Wiring loom – installation

1. Install the mounting clamp [1] with the new M6 nut, securing the connector for the
electric shift barrel in the mounting clamp.
All nuts: 2. Connect the electric shift barrel to the wiring loom.
10 Nm 3. Install the mounting clamp [2] with the new M6 nut, securing the wiring loom in the
mounting clamp.
4. Secure the ground connection with the new M6 nut [3].
5. Route the wiring loom as shown.

6. Place the wiring loom with its plastic holder [1] on the stud.
7. Connect the temperature sensor [2] to the wiring loom.
8. Attach the wiring loom to the coolant return line bracket [3].
9. Attach the wiring loom to the holder [4].
10. Connect the speed sensor [5] to the wiring loom.
11. Route the wiring loom as shown.

12. Install the bracket [1] for the B+ cable.

22 Nm

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 GEARBOX | Overview of setting values

2.6 Overview of setting values

PINION SHAFT

• Preload of four-point bearing:

Nominal value: 0.03–0.05 mm via adjustment shim H2.
• Axial play of four-point bearing:
Nominal value: 0.02–0.05 mm
• Position of pinion shaft:
Offset: 0.00–0.03 mm via adjustment shim P1.

CROSS SHAFT

• Preload of four-point bearing:

Nominal value: 0.15 mm via adjustment shim Q1.
• Backlash of angle drive (traction side):
Nominal value: 0.22–0.26 mm via adjustment shim P2.
• Backlash of angle drive (thrust side):
Nominal value: 0.19–0.23 mm via adjustment shim P2.

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 GEARBOX | Special tools

2.7 Special tools

Part number Tool number
Designation
911 GT3 Cup (992) MY 2021 911 GT3 Cup (991 II) MY 2017–2019
9F1.012.277.A - Assembly of mainshaft bearing outer race
9F1.012.277.B - Assembly of pinion shaft bearing outer race
9F1.012.277.D - Assembly of cross shaft needle roller bearing
9F1.012.277.E - Disassembly of cross shaft needle roller bearing
9F1.012.277.F - Disassembly of mainshaft bearing ring
9F1.012.277.G - Assembly of driveshaft output flange axial circlip
9F1.012.277.H - Assembly of cutaway gear ratio housing
9F1.012.277.L - Measurement of bevel gear backlash
9F1.012.277.N - Measurement of bevel gear clamping sleeve backlash
9F1.012.277.P - Disassembly of pinion shaft bearing ring
9F1.012.277.Q - Assembly of Shur Lok retaining tool for input shaft
9F1.012.277.R - Assembly of Shur Lok mainshaft threaded sleeve
9F1.012.277.S - Assembly of Shur Lok pinion shaft and cross shaft
threaded sleeve
9F1.012.277.T - Assembly of Shur Lok locking element for mainshaft
9F1.012.277.AA - Assembly of Shur Lok pinion shaft
and cross shaft locking element
9F1.012.277.AB - Assembly of Shur Lok pilot tool for mainshaft
9F1.012.277.AC - Assembly of Shur Lok pilot tool for pinion shaft
9F1.012.277.AD - Assembly of Shur Lok pilot tool for cross shaft
9F1.012.277.AE - Disassembly of Shur Lok for pinion shaft and cross shaft
9F1.012.277.AF - Disassembly of Shur Lok for mainshaft

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 GEARBOX | Special tools

Part number Tool number

Designation
911 GT3 Cup (992) MY 2021 911 GT3 Cup (991 II) MY 2017–2019
9F1.012.277.AH - Assembly of clutch pilot tool
9F1.012.278 - Assembly of cross shaft cover
9F1.012.278.A - Disassembly of pinion-shaft and cross-shaft
roller bearings
9F1.012.278.B - Disassembly of mainshaft roller bearings
9F1.012.278.C - Assembly of cross shaft cover and cross shaft
9F1.012.278.D - Assembly of differential
9F1.012.279 1 Assembly of mainshaft roller bearings
9F1.012.279.A 3 Assembly of pinion shaft bearing ring
9F1.012.279.B 6 Assembly of cross shaft bearing ring
9F1.012.279.C 7 Assembly of roller bearing of cross shaft cover
9F1.012.279.D 8B Assembly of differential roller bearings
9F1.012.279.E 9 Assembly of needle roller bearing of long driveshaft
output flange
9F1.012.279.F 10 Assembly of shaft sealing ring of long driveshaft
output flange
9F1.012.279.G 13 Assembly of shaft sealing ring of input shaft
9F1.012.279.H 14 Assembly of input shaft needle roller bearing
9F1.012.279.J 21 Assembly of shift barrel nut
9F1.012.279.K 23 Measurement of pinion shaft measuring plate adjustment
9F1.012.279.L 25 Measurement of pinion shaft replacement gear
adjustment
9F1.012.279.M 26 Measurement of measuring stop for bevel gear backlash
9F1.012.279.N 27 Assembly of pinion shaft lock sleeve

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 GEARBOX | Special tools

Part number Tool number

Designation
911 GT3 Cup (992) MY 2021 911 GT3 Cup (991 II) MY 2017–2019
9F1.012.279.P 28 Measurement of pinion shaft magnetic disc adjustment
9F1.012.279.Q 31 Assembly of shift barrel ball bearing
9F1.012.279.R 32 Assembly of reverse idler gear needle roller bearing
9F1.012.279.T 56 Measurement of cross shaft cover adjustment
9F1.012.279.AA 46 Disassembly of input shaft needle roller bearing
9F1.012.279.AB 50 Assembly of gearbox ventilation sleeve
9F1.012.279.AC - Disassembly of cross shaft bearing ring
9F1.012.279.AD 90 Measurement of shift play of shift barrel gear position
9F1.012.279.AE 95 Assembly of shift barrel shaft sealing ring
9F1.012.279.AF 99 Assembly of differential ball bearing
9F1.012.279.AG 100 Disassembly of differential ball bearing
9F1.012.279.AH 101 Assembly of differential cover needle roller bearing
9F1.012.279.AJ 102 Assembly of shaft sealing ring of short driveshaft
output flange
9F1.012.279.AK 104 Measurement of shift play of shift manual adjuster
of shift barrel
9F1.012.279.AL 105 Assembly of water tap flange
9F1.012.279.AM 109 Measurement of differential inner dimension
9F1.012.279.AN 47 Disassembly of pinion shaft bearing ring
9F1.012.279.AP 91 Measurement of plate set for testing weight
for differential

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 GEARBOX | Special tools

Special tools for reinforced Shur-Lok systems and differential from model year 2023
Part number Tool number
Designation
911 GT3 Cup (992) MY 2021 911 GT3 Cup (991 II) MY 2017–2019
9F1.012.277.AF - Disassembly/assembly of mainshaft Shur-Lok locking element
9F1.012.277.AL - Measurement of bevel gear clamping sleeve backlash
9F1.012.277.AM - Assembly of cutaway gear ratio housing
9F1.012.277.AP - Assembly of mainshaft Shur-Lok threaded sleeve
9F1.012.277.AQ - Assembly of cross shaft Shur-Lok threaded sleeve
9F1.012.277.AR - Disassembly/assembly of pinion shaft & cross shaft Shur-Lok
locking element

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3 SUSPENSION
3.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3.2 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
3.3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3.4 Measuring and adjusting ride height . . . . . . . . . . . . . . . . . . . . . 298
3.5 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3.6 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.7 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
3.8 Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3.9 Brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3.10 Balance bar system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3.11 Pedals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
3.12 Clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
3.13 Power unit mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

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 SUSPENSION | Service intervals

3.1 Service intervals

Front axle
Components Service intervals Max. runtime Instructions
Upright left/right 90 h
Lock for wheel nut left/right (complete 90 h • Check free movement of pawls after each race
with pawls and springs) or test.
Wheel hub left/right 90 h • Check thread after each race or test.
Wheel bearing left/right 90 h • Check bearing play after each race.
Upright bracket left/right 90 h
Cross member 90 h
Damper strut left/right 90 h • Check bearing play after each race.
Wishbone bracket top 90 h
Wishbone top left/right 90 h • Check bearing play after each race.
Wishbone bottom left/right 90 h

Trailing arm bottom left/right 90 h

Ball joints 90 h • Check bearing play after each race.

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 SUSPENSION | Service intervals

Rear axle
Components Service intervals Max. runtime Instructions
Upright left/right 90 h
Lock for wheel nut left/right (complete 90 h • Check free movement of pawls after each race
with pawls and springs) or test.
Wheel hub left/right 90 h • Check thread after each race or test.
Wheel bearing left/right 90 h • Check bearing play after each race.
Damper strut left/right 90 h • Check bearing play after each race.
Side member left/right 90 h
Cross member 90 h
Damper mount left/right 90 h
Trailing arm mount left/right 90 h
Driveshaft left/right 35 h • Check driveshaft after each race for leaking
grease and damaged bellows.
Track rod left/right 90 h • Check bearing play after each rave.
Wishbone top left/right 90 h
Wishbone bottom left/right 90 h
Trailing arm top left/right 90 h
Trailing arm bottom left/right 90 h

Steering
Components Service intervals Max. runtime Instructions
Steering rack 90 h
Track rod FA left/right 90 h
Steering column 90 h

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 SUSPENSION | Service intervals

Brakes
Components Service intervals Max. runtime Instructions
Fixed caliper FA left/right 30 h 120 h • Check for leakage and damage after each race.
• Replace pistons and sealing rings at every
service.
Fixed caliper RA left/right 30 h 90 h • Check for leakage and damage after each race.
• Replace pistons and sealing rings at every
service.
Master brake cylinder FA 2.500 km 90 h After each race:
• Check for leakage.
Master brake cylinder RA 2.500 km 90 h
• Check for damage.
After 2.500 km latest:
• Replace worn parts.
Systems, Lines and Connections before each use of the car • Check for tightness, leakage, damage, chafing
marks and wear.
• Replace worn parts.
• Tighten loose parts according to instructions.

Pedals
Components Service intervals Max. runtime Instructions
Pedals • Check pedal plates for secure seat after each
race.

Anti-roll bars
Components Service intervals Max. runtime Instructions
Anti-roll bar FA 90 h
Anti-roll bar RA 90 h

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 SUSPENSION | Service intervals

Coupling rods
Components Service intervals Max. runtime Instructions
Coupling rods FA 90 h • Check bearing play.
Coupling rods RA 90 h

Wheels
Components Service intervals Max. runtime Instructions
Wheels FA • Perform visual inspection
after each race.
Wheels RA
Wheel nut left/right 6h 90 h • Check thread and thread grooves after each
race or test.

Clutch actuator

Components Service intervals Max. runtime Instructions

Actuator and hoses 90 h • Check for leakage after each race.

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 SUSPENSION | General

3.2 General
3.2.1 Using self-locking nuts in suspension
NOTICE LOSS OF LOCKING EFFECT OF SELF-LOCKING NUTS
Fastening/undoing the nuts several times and applying excessive tightening torques will
reduce the locking effect, resulting in a safety risk.
▶ Observe the specified torque.
Tightening to 30 % above the nominal torque can already cause irreparable damage
to the locking mechanism.
▶ Before installing, check that the locking effect of the self-locking nuts is sufficient.
In isolated cases, even new nuts are unable to provide the required locking effect.

CHECK THE CLAMPING EFFECT

Note: The check for sufficient clamping effect must be carried out at the respective instal-
Copper paste lation site.
b Screw and nut threads are free of impurities.
b Screw threads are greased with copper paste.
1. Screw the nut until just before the stop.
2. Continue turning the nut by hand (with the fingers).
→ If twisting by hand is possible, the clamping effect is insufficient and the nut must
be replaced.
-or-
→ If twisting by hand is not possible, the clamping effect is sufficient and the nut can
be used.

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 SUSPENSION | General

3.2.2 Alignment of joint heads

NOTICE INCORRECT INSTALLATION
Risk of damage and premature wear due to incorrect installation.
▶ Do not press joints into the end stop during installation and, in particular, when
tightening the counter nuts.
▶ Do not install the joint heads twisted.
Otherwise the maximum tilt angle of the joint heads will be exceeded due to the
movement of the suspension.
▶ With the suspension in its rebound state, turn the joint heads of all suspension struts
relative to each other so that the control arm / track rod has maximum freedom
of movement in both directions.
▶ When tightening and locking, do not press the joint head to the end stop, but instead
counterhold using a tool.
▶ When removing the dampers, do not allow the axle to hang down unsecured under its
own weight. Without dampers and secure attachment, the maximum rebound travel
and therefore the maximum tilt angle of the joint heads are exceeded.
If the outer ring and the bearing shell of the joint heads are damaged, dirt can enter and
cause increased wear and friction.
▶ When disassembling/assembling dampers and drive shafts, do not press the joints
beyond their end position. Temporarily loosen and remove the bolted connections.

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 SUSPENSION | Wheel alignment

3.3 Wheel alignment

NOTICE INCORRECTLY ADJUSTED COUPLING RODS/COLLISION OF COMPONENTS
Incorrectly adjusted coupling rods can cause the anti-roll bar and other components
to collide and to be damaged as a result.
▶ When adjusting the coupling rods, pay attention to potential points of collision
between the anti-roll bar and other components over the entire suspension travel.
▶ Have the described adjustment work carried out by qualified and appropriately trained
personnel only.

ALIGNING COMPLETE VEHICLE

b Driver substitute weight (75 kg) placed on the driver's seat.
b Steering wheel fixed at the 0° position (indicator in the display).
b Air pressure set in accordance with the technical scrutineering specifications.
b Fuel tank filled with 50 % of the fuel quantity required for racing/training.
1. Detach the anti-roll bars.
2. Preset the ride height.
3. Rear axle: First adjust the camber and then the toe.
4. Front axle: First adjust the camber and then the toe.
5. Adjust the ride height and wheel loads.
– Adjust the wheel loads by changing the ride height.
– Aim for as low a wheel load deviation as possible at each axle (left relative to right).
6. Attach the anti-roll bars free of tension.

▶ If the rear axle has a large base camber, check the axial play of the mainshaft with
the wheels in the rebound state (longitudinal play min. 5 mm).

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 SUSPENSION | Measuring and adjusting ride height

3.4 Measuring and adjusting ride height

The possibility of adjusting the height allows differing wheel loads to be corrected.

New ride height measuring bolts and reinforcement sleeves are available for the Porsche
911 GT3 Cup.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Reinforcement sleeve subframe FA

b Vehicle stands with measuring wheels on level ground (and optionally on a wheel load
scale (levelled)).
b Repeated compression and rebound of the front axle and rear axle.

MEASURING AND CHANGING RIDE HEIGHT AT FRONT AXLE

The ride height at the front axle can be measured at the following positions:
– at the bolt heads of the front axle cross member [marked in yellow] (see Fig. 41).
The vertical distance from the bolt head to the level floor surface is measured.
▶ Adjust the ride height at the damper struts.
Guide value: 1 turn = approx. 1.9 mm change in ride height measured
at the wheel centre.

Minimum ride height: 72 mm

Fig. 41: Measuring point on front axle

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 SUSPENSION | Measuring and adjusting ride height

MEASURING AND CHANGING RIDE HEIGHT AT REAR AXLE

The ride height at the rear axle is measured at the side section [marked in yellow]
(see Fig. 42).
The vertical distance from the side section to the floor surface is measured.
▶ Adjust the ride height at the damper struts.
Guide value: 1 turn = approx. 1.8 mm change in ride height measured at the
wheel centre.

Minimum ride height: 106 mm

Fig. 42: Measuring point at rear axle

Notes on adjusting height/changing wheel load:

• Changing the height on one side causes the wheel load to change.
• Changing the wheel load at one wheel also causes the wheel loads of the other wheels
to change.
• Increasing the installation spring preload on one side (raise vehicle) increases
the wheel load.
• Decreasing the installation spring preload on one side (lower vehicle) decreases
the wheel load.
• A change in wheel load is always transferred diagonally to the other axle side.
– If the wheel load at a wheel is reduced or increased, the same happens at the
diagonally opposite wheel.
Example:
b Spring preload at rear left increased.
→ Wheel load increases at the rear left and front right.
→ Wheel load decreases at the rear right and front left.

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 SUSPENSION | Front axle

3.5 Front axle

NOTICE RISK OF DAMAGE TO CONTROL ARMS
Improper installation/transport can result in damage to the control arms.
▶ Use suitable devices or attach information labels to make sure that the ball joints of the
control arms are not pressed against the end stop during transport or assembly.

If necessary, the camber plates can be secured with wire or aluminium tape.

3.5.1 Axle design

Double wishbone axle (max. rigidity with low weight).

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 SUSPENSION | Front axle

3.5.2 Upright

Make sure that all function surfaces are free of grease and dirt during assembly.

Installation of wheel bearing/wheel hub

Wheel bearing to wheel hub

[1] Wheel hub

[2] Wheel bearing
[3] Axle spindle
[4] Drivers
[5] Nut M22 x 1.5
[6] Bolts M8 x 35
The bolts are microencapsulated and must be replaced with new ones each time they
31 Nm are loosened.

INSTALLING WHEEL BEARING

1. Position the wheel hub [1] on the wheel bearing [2] and press it in according to the
press-in window.
▶ Support the bearing at the inner ring when pressing in the wheel hub.
▶ The press-in process must be performed with all components at room temperature.
2. Install the axle spindle [3].
▶ Grease the splines and join the axle spindle in accordance with the press-in diagram.
Molub Alloy Paste
TA

3. Position the nut [5] and tighten as follows:

After disassambly, always replace with a new nut.
4. 470 Nm
5. Undo by 360°
6. 470 Nm Fig. 43: Press-in window

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 SUSPENSION | Front axle

Wheel bearing incl. wheel hub to upright

[1] Upright
[2] Wheel hub
[3] Bolts M12 x 1.25 x 45

80 Nm + 120°

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 SUSPENSION | Front axle

Installation of speed sensor

New versions wheel speed sensors are available. The use of the ABS system with the old
version of the wheel speed sensors is not permitted. For cars without or with deactivated
ABS system, the choice of version is free, but it is recommended to use one of the new
versions.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Wheel speed sensors

▶ Always seal the openings after disassembly and while cleaning.

[1] Wheel speed sensor

[2] Shield
[3] Cap head bolt M6 x 16
[4] Combination bolt M6 x 16
9.7 Nm

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 SUSPENSION | Front axle

Installation of cap

[1] Cap
[2] Bracket
[3] Bolt M6 x 16

10 Nm

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 SUSPENSION | Front axle

3.5.3 Assembly of front axle

Anti-roll bar to cross member

NOTICE DRIVING WITH DETACHED ANTI-ROLL BARS

Risk of collision between the anti-roll bar and surrounding components.
▶ Do not drive the vehicle with the anti-roll bars detached.

The anti-roll bar should be smooth-running.

▶ Adjust the axial play using the tolerance compensation shims (1 mm plastic) to < 1 mm.
Available for purchase via the Porsche Motorsport parts catalogue.

Pay attention to the installation direction of the anti-roll bar (see TOP marking).

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 SUSPENSION | Front axle

Position the anti-roll bar as far to the rear as possible during installation to obtain the
maximum possible distance from the engine cooling pipes [1].

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 SUSPENSION | Front axle

[1] Cross member

[2] Anti-roll bar
[3] Mounting clamp
Make sure that the arrow on the top clamp is pointing in the direction of travel.
[4] Anti-roll bar bearing
[5] Nut M10
[6] Bolts M10 x 65
65 Nm

[7] Coupling rod

[8] Spacer bush
Make sure that the large contact surface of the spacer bush rests against the nut [9].
[9] Nut M8

20 Nm

[10] Tolerance compensation shim (1 mm)

▶ Select quantity as required.
If more than one shim is used, the shims should be distributed as symmetrically
as possible on the left and right on the anti-roll bar.

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 SUSPENSION | Front axle

Basic setting of front-axle coupling rod

Measured from eye to eye: 195 mm

Reference dimension: 139 mm
▶ Tighten the two collar nuts M8 with 20 Nm.

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 SUSPENSION | Front axle

Spring leaf

The individual components of the spring leaf can be reused after disassembly.

[1] Nut M6

8 Nm

[2] Washer
[3] Spring washer
[4] Cap
[5] Cap head bolt M4 x 10

3 Nm

[6] Threaded pin M8 x 18

[7] Threaded bolt

▶ Allow the Loctite to cure under preload.
Loctite 243
[8] Spring leaf

Autol TOP 2000

→ Installation direction.

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 SUSPENSION | Front axle

Arrangement of spring washers [yellow].

Make sure that the spring washers are installed as shown in the figure.
3 + 3 + 3 + 3 + 4 = 16 spring washers

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 SUSPENSION | Front axle

During assembly, screw in the threaded pin [6] as shown in the graphic below.
The individual components can be reused after disassembly.

Gap between the threaded pin [6] and spring leaf [8].
→ 0.15–0.55 mm

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 SUSPENSION | Front axle

Adjustment

NOTICE INCORRECT ADJUSTMENT

Risk of damage to the spring leaf.
▶ When adjusting the spring leaf, use only tools with a soft surface.
▶ Do not cause any indentations or other damage.

[1] Seven notches indicate the settings.

▶ Adjust the rigidity by turning.
See 8.2.6 Dampers on page 1040.

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 SUSPENSION | Front axle

Wishbone/trailing arm
[1] Trailing arm
[2] Air duct
▶ Secure the air duct to the trailing arm using a cable tie [yellow].
[3] Bolt M12 x 1.5 x 65
[4] Nut M12 x 1.5
100 Nm
[5] Wishbone
[6] Nut M10
65 Nm

Mechanical adjustment range of the wishbone

Only lintel plates up to a thickness to 24 mm may be installed..

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 SUSPENSION | Front axle

Mechanical adjustment range of the trailing arm

The trailing arms of the front axle must be adjusted to a hole spacing of 325 mm +/- 2 mm.

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 SUSPENSION | Front axle

Upright and control arm to cross member

[1] Control arm unit (trailing arm and wishbone)
Maximum tilt angle of the bearing inside: ± 8.5° (wishbone)
Maximum tilting angle of the bearing outside: ± 13° (wishbone)
Maximum tilt angle of the bearing inside: ± 15.5° (trailing arm)
▶ The maximum tipping angles must not be exceeded.
[2] Bolt M12 x 1.5 x 90
[3] Nut M12 x 1.5
120 Nm

[4] Upright
[5] Bolt M12 x 1.5 x 90
[6] Nut M12 x 1.5
120 Nm
[7] Bolt M12 x 1.5 x 105

90 Nm + 90°

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 SUSPENSION | Front axle

Top wishbone to body

[1] Studs M8 x 40
The half dog point of the studs must point outwards.
15 Nm

[2] Top wishbone

Maximum tilting angle of the bearings inside: ± 8.5°
Maximum tilt angle of the bearing outside: ± 19°
▶ The maximum tipping angles must not be exceeded.
[3] Mounting bracket front
[4] Bolt M12 x 1.5 x 85
[5] Bolt M12 x 1.5 x 75
100 Nm [6] Nut M12 x 1.5

[7] Mounting bracket

[8] Nuts M8

50 Nm

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 SUSPENSION | Front axle

Upright to top wishbone

[1] Eccentric bolt M12 x 1.5 x 85
[2] Nut M12 x 1.5
100 Nm

[3] Eccentric washer 38 x 5

Coupling rod to top wishbone

[1] Coupling rod
[2] Nut M10
55 Nm

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 SUSPENSION | Front axle

Damper strut to bottom wishbone

[1] Damper strut
[2] Bolt M12 x 1.5 x 85
135 Nm

[3] Screw connection counter ring

Nut M10 x 1,5
38 Nm

HAZET
special tools:

Nut socket:
4910-16
Piston rod socket:
4910-68
Ratchet ring
spanner
4910-1

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 SUSPENSION | Front axle

Positioning of main spring and helper spring

▶ Position the spring ends of the main spring and helper spring opposite each other on
the intermediate plate. This puts the least stress on the intermediate plate.

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 SUSPENSION | Front axle

Engine cooling to cross member

[1] Engine cooling
[2] Clips
Make sure that the clips engage fully on both sides when installing.
[3] Bolts M6 x 16

10 Nm

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 SUSPENSION | Front axle

Reinforcement to cross member

[1] Cross member
[2] Reinforcement
[3] Roll Pins 13 x 14
[4] Bolts M10 x 35

50 Nm + 90°

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 SUSPENSION | Front axle

Front cross member to body

After removal and re-installation of the cross member, it is essential to use new studs, bolts and nuts.
[1] Cap
[2] Stud M12 x 1.5 x 75

25 Nm
[3] Nut M12 x 1.5

170 Nm
[4] Bolt M12 x 1.5 x 105

140 Nm
[5] Bolt M12 x 1.5 x 50

160 Nm

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 SUSPENSION | Front axle

Rear cross member to body

After removal and re-installation of the cross member, it is essential to use new studs, bolts and nuts.
[1] Strut
[2] Bolts M12 x 1.5 x 75

100 Nm
[3] Screw M10 x 25

40 Nm

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 SUSPENSION | Front axle

Support bearing to body

[1] Support bearing

[2] Nuts M8

33 Nm

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 SUSPENSION | Front axle

Air scoop to wheel arch

[1] Air scoop

Press the air scoop holder flat against the sleeve.
[2] Bracket
[3] Bolts 4.8 x 16

3.2 Nm
[4] Bolt 6 x 12
[5] Nut M6
8 Nm
[6] Nut C6

2 Nm

[7] Spacer
[8] Cable holder
[9] Blind rivet 5 x 10

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 SUSPENSION | Steering

3.6 Steering
NOTICE INCORRECT STEERING WHEEL POSITION
If the steering wheel is not fixed in the 0° position when working on the steering system,
the clock spring in the steering column switch may be damaged.
▶ When working on the steering system, fix the steering wheel in the 0° position. (Check
in the display).

Steering ratio and turning circle

Centre position Edge area Turning circle
15.6 14.3 20.6 m

Shunting mode

ACTIVATE/DEACTIVATE SHUNTING MODE

b Engine is switched off.
b Vehicle is stationary on its wheels.
▶ Hold down the joker button on the steering wheel for 3 s.
→ Shunting mode is activated.
▶ Press the joker button on the steering wheel again to deactivate the shunting mode.
If the button is not pressed, the steering switches off automatically after 180 s.

If the battery is not sufficiently charged, the steering remains switched off and the display
shows "BAT LOW".

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 SUSPENSION | Steering

Teach steering stops

Relearn the steering stops in the following cases:
• The steering gear is new or has been replaced.
• After removal/re-installation of the steering wheel hub.

b Steering angle sensor is calibrated (see Steering angle sensor on page 767).
b Car is stationary.
b Engine is running.
1. Slowly turn the steering wheel first to the right and then to the left as far as it will go
and hold it for 5 s with a force > 7.5 Nm in each stop.
2. Check the teach-in process:
▶ Turn the steering wheel back to the 0 position.
→ Error message Warn Steering goes out.
3. Procedure in the event of an unsuccessful teach-in procedure for the steering stops:
a. Calibrate steering angle sensor (see Steering angle sensor on page 767).
b. Carry out power cycle (switch main switch [MAIN] off and on again).
c. Then relearn the steering stops (see step 1).

For further information please contact technical race support.

See 7.1 Technical Racing Support on page 1023.

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 SUSPENSION | Steering

3.6.1 Steering rack

DANGER STEERING RACK FAILURE
Disassembling the steering rack may cause the steering to malfunction or fail. The car
thus becomes uncontrollable.
Do not loosen any bolts on the steering rack apart from the connecting bolts to the cross
member and the axial joints.

Steering rack to wishbone

[1] Steering rack
[2] Roll pin
[3] Sleeve steering gear
[4] Cross member
[5] Bolt M10 x 60
Note: The bolt head and the mating surface must be free of any dirt.
30 Nm + 90° ▶ Coat the thread of the bolt with Loctite 243.
▶ Loctite 243

After tightening, it is recommended to mark the position of the bolt head on the cross
member.
▶ Check the bolts for tightness before each new track activity.

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 SUSPENSION | Steering

3.6.2 Track rod

NOTICE INCORRECT INSTALLATION OF THE TRACK ROD BELLOWS

In the event of a collision of the track rod bellows with components of the front axle, the track rod bellows may be damaged. This can result in soiling and
therefore impairment of the steering function.
▶ Fit the track rod bellows with a distance of 52.6 mm between the mounting position and the lock nut..

Track rod to Upright

[1] Track rod
Maximum tipping angle of the rod end: ± 15°
▶ The maximum tipping angle must be not exceeded.
[2] Upright
[3] Bolt M12 x 90
[4] Nut
120 Nm

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 SUSPENSION | Steering

Track rod end to track rod

[1] Track rod end

[2] Track rod
[3] Bolt
[4] Threaded sleeve
8 Nm

The position of the threaded sleeve to the rod end may be twisted.
Grease Klüberplex Coat the bolt [3] with Klüberplex BEM 34-132 grease.
BEM 34-132
[5] Lock nut

50 Nm

The screw-in depth of the track rod end must be at least 32 mm

The test dimension of 17 mm is practical for checking (see Fig. 44).

Fig. 44: Screw-in depth of the track rod end

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 SUSPENSION | Steering

Track rod to axial joint

[1] Track rod
[2] Lock nut
120 Nm [3] Axial joint

[4] Steering rack

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 SUSPENSION | Steering

Track rod bellows to steering rack

[1] Clamp ring D=14
[2] Clamp ring D=64
[3] Track rod bellows
[4] Axial joint
[5] Steering rack

Push the track rod bellows [3] onto the steering rack as far as it will go and position it as
shown in Fig. 26.

Fig. 45: Position track rod bellows

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 SUSPENSION | Steering

Axial joint to steering rack

[1] Axial joint
[2] Steering rack
120 Nm

V.A.G. 1923 - For assembly work on the axial joint, the special tool V.A.G 1923 - Open-ended spanner
Open-ended AF 38 is recommended.
spanner AF 38 ▶ Use the special tool on the octagon [1] of the axial joint [2] to loosen or fasten the axial
joint from the steering rack.

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 SUSPENSION | Steering

3.6.3 Assembly of steering system

Clamping ring on steering column

1. Slide the holder [1] incl. hose clamp [2] and clamping ring [3] incl. hose clamp onto the
steering column.
2. Fasten the clamping ring [3] with the hose clamp.

The hose clamp [2] is not tightened until the electronics unit is installed.

Electronics unit on steering column

1. Slide the electronics unit [1] onto the steering column.

2. Fasten the electronic unit to the clamping ring with the screws [2].

1.3 Nm

3. Push the holder against the electronics unit and tighten the hose clamp [3].

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 SUSPENSION | Steering

Steering angle sensor on steering column

[1] Adapter
[2] Steering angle sensor
[3] Clamping ring incl. hose clamp

Steering angle sensor bracket

[1] Bracket
▶ Secure the bracket to the steering column and to the adapter of the steering angle
sensor.
[2] Bolts M5 x 10

1.3 Nm
[3] Bolt M5GF x 10

4.5 Nm

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 SUSPENSION | Steering

Steering column assembly

25 Nm ▶ When assembling the steering column, make sure that the nuts [1–4] are tightened in
the order shown.

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 SUSPENSION | Steering

Intermediate steering shaft to steering column

[1] Intermediate steering shaft

[2] Bolt M8 x 30

20 Nm + 90°

Intermediate steering shaft to steering rack

[1] Steering column incl. intermediate steering shaft

[2] Sealing cuff
When installing, make sure that the markings [yellow] on the bulkhead and
on the sealing cuff line up with each other.
[3] Steering rack
[4] Bolt M8 x 30
After unscrewing, always replace with a new bolt.
20 Nm + 90°

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 SUSPENSION | Steering

Steering wheel to steering column

Before installing the hub, make sure that the steering rack (EPS) is in centred position.
Both markings [yellow] must line up with each other.

Fig. 46: Straight-ahead position

[1] Hub
[2] Bolt M18 x 1.5 x 18
50 Nm
[3] Steering wheel hub
[4] Bolts M5GF x 16
5.6 Nm

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 SUSPENSION | Rear axle

3.7 Rear axle

NOTICE RISK OF DAMAGE TO CONTROL ARMS
Improper installation/transport can result in damage to the control arms.
▶ Use suitable devices or attach information labels to make sure that the ball joints of the
control arms are not pressed against the end stop during transport or assembly.

If necessary, the camber plates can be secured with wire or with aluminium tape.

3.7.1 Axle design

Multi-link axle (rigidity-optimised).

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 SUSPENSION | Rear axle

3.7.2 Upright

Make sure that all function surfaces are free of grease and dirt during assembly.

Installation of wheel bearing/wheel hub

Wheel bearing to wheel hub
[1] Wheel hub incl. wheel bearing
[2] Drivers
[3] Bolts M8 x 32
The bolts are microencapsulated and must be replaced with new ones each time they
31 Nm are loosened.
INSTALLING WHEEL BEARING
1. Position the wheel hub on the wheel bearing and press it in according to the press-in
window (see Fig. 47).
▶ Support the bearing at the inner ring when pressing in the wheel hub.

Fig. 47: Press-in window

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 SUSPENSION | Rear axle

Wheel bearing incl. wheel hub to upright

[1] Upright
[2] Wheel hub incl. wheel bearing
[3] Shield
[4] Bolts M6 x 16

10 Nm
[5] Bolts M12 x 1.25 x 45

80 Nm + 120°

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 SUSPENSION | Rear axle

Installation of speed sensor

New versions wheel speed sensors are available. The use of the ABS system with the old
version of the wheel speed sensors is not permitted. For cars without or with deactivated
ABS system, the choice of version is free, but it is recommended to use one of the new
versions.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Wheel speed sensors

▶ Always seal the openings after disassembly and while cleaning.

[1] Wheel speed sensor

[2] Bolt M6 x 16

9.7 Nm

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 SUSPENSION | Rear axle

Installation of brake cooling

[1] Brake cooling
[2] Bolts

8 Nm

3.7.3 Assembly of rear axle

Side section to cross member

[1] Cross member

[2] Side section
[3] Bolt M12 x 1.5 x 80
[4] Nut M12 x 1.5
120 Nm [5] Bolt M12 x 1.5 x 60

[6] Bracket

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 SUSPENSION | Rear axle

Air duct to bottom wishbone

[1] Brake air duct, large
[2] Brake air duct, small
Make sure that the hook fully engages in the bracket.
[3] Brake air duct bracket
[4] Bolt M6 x 40
[5] Nut M6
10 Nm [6] Bolt M6 x 52
[7] Bolts M6 x 16

V7,12/2022 911 GT3 Cup (2021–2023) 344

 SUSPENSION | Rear axle

Track rod and bottom wishbone to side section

[1] Track rod
Maximum tilt angle of bearings: ± 15°
[2] Wishbone
Maximum tilt angle of inner bearing: ± 6°
Maximum tilt angle of outer bearing: ± 10.5°

NOTICE ▶ The maximum tilt angles must not be exceeded.

Align the joint heads correctly (see Alignment of joint heads on page 296) and ensure
that there is no strain on the track rod over the entire suspension travel.
[3] Bolt M12 x 1.5 x 80
[4] Bolt M12 x 1.5 x 95
100 Nm [5] Nuts M12 x 1.5

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 SUSPENSION | Rear axle

Fixed bearing to bottom wishbone

[1] Fixed bearing
[2] Camber shims

▶ Insert the camber shims from above.

[3] Washers 10.5 x 18 x 1.6
[4] Nuts M10
65 Nm

[5] Wishbone

Mechanical adjustment range of the wishbone

Only lintel plates up to a thickness to 24 mm may be installed.

V7,12/2022 911 GT3 Cup (2021–2023) 346

 SUSPENSION | Rear axle

Wishbone and top trailing arm to side section

[1] Trailing arm

Make sure that the studs [yellow] are pointing upwards.
Maximum tilt angle of bearings: ± 7°
[2] Wishbone
Maximum tilt angle of bearings: ± 7°
▶ The maximum tipping angles must not be exceeded.
[3] Bolt M12 x 1.5 x 80
[4] Bolt M12 x 1.5 x 95
100 Nm [5] Nuts M12 x 1.5

V7,12/2022 911 GT3 Cup (2021–2023) 347

 SUSPENSION | Rear axle

Trailing arm and anti-roll bar to mount

NOTICE DRIVING WITH DETACHED ANTI-ROLL BARS
Risk of collision between the anti-roll bar and surrounding components.
▶ Do not drive the vehicle with the anti-roll bars detached.

NOTICE INCORRECT ADJUSTMENT

Incorrect adjustment of the anti-roll bar can result in collision with the trailing arm and
damage to the anti-roll bar.
▶ With maximum rigidity of the spring leaf and at maximum compression, there should be
a minimum gap of 12 mm between the spring leaf (in position 6) and the lower trailing
arm.

The anti-roll bar should be smooth-running.

▶ Adjust the axial play using the tolerance compensation shims (1 mm plastic) to < 1 mm.
Available for purchase via the Porsche Motorsport parts catalogue.

Pay attention to the installation direction of the anti-roll bar (see TOP marking).

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 SUSPENSION | Rear axle

[1] Mount
[2] Trailing arm
Maximum tilt angle of bearings: ± 10°
▶ The maximum tipping angles must not be exceeded.
[3] Anti-roll bar
[4] Bolt M12 x 1.5 x 80
[5] Nut M12 x 1.5
125 Nm

[6] Plain bearing

[7] Upper clamp part
[8] Lower clamp part
[9] Nuts M8

25 Nm

[10] Tolerance compensation shim (1 mm)

▶ Select quantity as required.
If more than one shim is used, the shims should be distributed as symmetrically
as possible on the left and right on the anti-roll bar.

V7,12/2022 911 GT3 Cup (2021–2023) 349

 SUSPENSION | Rear axle

Spring leaf

The individual components of the spring leaf can be reused after disassembly.

[1] Nut M6

8 Nm

[2] Washer
[3] Spring washer
[4] Cap
[5] Cap head bolt M4 x 10

3 Nm

[6] Threaded pin M8 x 18

[7] Threaded bolt

▶ Allow the Loctite to cure under preload.
13 Nm,
Loctite 243
[8] Spring leaf

Autol TOP 2000

→ Installation direction.

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 SUSPENSION | Rear axle

Arrangement of spring washers [yellow].

Make sure that the spring washers are installed as shown in the figure.
1 + 1 + 1 + 1 + 1 + 1 + 1 + 1 + 1 + 1 + 1 = 11 spring washers

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 SUSPENSION | Rear axle

During assembly, screw in the threaded pin [6] as shown in the graphic below.
The individual components can be reused after disassembly.

Gap between the threaded pin [6] and spring leaf [8].
→ 0.15–0.55 mm

V7,12/2022 911 GT3 Cup (2021–2023) 352

 SUSPENSION | Rear axle

Adjustment

NOTICE INCORRECT ADJUSTMENT

Risk of damage to the spring leaf.
▶ When adjusting the spring leaf, use only tools with a soft surface.
▶ Do not cause any indentations or other damage.

[1] Seven notches indicate the settings.

▶ Adjust the rigidity by turning.
See 8.2.6 Dampers on page 1040.

V7,12/2022 911 GT3 Cup (2021–2023) 353

 SUSPENSION | Rear axle

Coupling rod to anti-roll bar

[1] Coupling rod

[2] Spacer bush
[3] Nut M8

20 Nm

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 SUSPENSION | Rear axle

Basic setting of rear-axle coupling rod

Measured from eye to eye: 292 mm

Reference dimension: 256 mm
▶ Make sure that the joint heads are aligned correctly and that the coupling rod is not
subject to strain over the entire suspension travel.
→ See page 296 for alignment of the joint heads.
▶ When adjusting, make sure that there is no collision between the anti-roll bar and
surrounding components over the entire suspension travel.
▶ Tighten the two collar nuts with 10 Nm.

V7,12/2022 911 GT3 Cup (2021–2023) 355

 SUSPENSION | Rear axle

Upright to control arm

[1] Upright
[2] Nut M12 x 1,5

100 Nm
[3] Bolt M12 x 80
[4] Nut M12 x 1,5
120 Nm
[5] Bolt M12 x 80

130 Nm
[6] Bolt M12 x 75
[7] Nut M12 x 1,5
120 Nm
[8] Bolt M12 x 75
[9] Nut M12 x 1,5
115 Nm

Fig. 48: View of inside

V7,12/2022 911 GT3 Cup (2021–2023) 356

 SUSPENSION | Rear axle

Coupling rod to upright

[1] Coupling rod

[2] Spacer sleeve
[3] Bolt M8 x 45 x 80
[4] Nut M8
31 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 357

 SUSPENSION | Rear axle

Damper strut and driveshaft to upright

During disassembly/assembly, the spherical bearings of the rear axle suspension arms can
be pushed beyond their end position and therefore can be damaged. To prevent damages,
it is necessary to temporarily loosen and remove the bolt connection [yellow] between the
spherical bearing of the lower wishbone and the rear upright before starting disassembly/
assembly.
[1] Bolt M12 x 80
[2] Nut M12 x 1,5
120 Nm

[1] Damper strut

[2] Bolt M12 x 1.5 x 80
[3] Nut M12 x 1.5
125 Nm
[4] Driveshaft
▶ Fully grease the driveshaft splines.
Molub Alloy Make sure that the thread remains free of grease.
Paste TA
[5] Nut M22 x 1.5-S
After disassembly, always replace with a new nut.
470 Nm INITIAL TIGHTENING
Undo by 360° b Thread is free of grease.
470 Nm
1. Tighten to 470 Nm.
2. Undo by 360°.
3. Tighten to 470 Nm.
Loctite high
strength

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 SUSPENSION | Rear axle

Positioning of main spring and helper spring

▶ Position the spring ends of the main spring and helper spring opposite each other on
the intermediate plate. This puts the least stress on the intermediate plate.

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 SUSPENSION | Rear axle

Rear axle to body

[1] Stud

30 Nm
[2] Nut M12 x 1.5

135 Nm
[3] Bolt M12 x 1.5 x 95

65 Nm
[4] Bolts M12 x 1.5 x 95

115 Nm
[5] Brake line (upright end)
Make sure that the brake line is installed without twisting.
16 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 360

 SUSPENSION | Rear axle

Trailing arm mount to body

[1] Stud

30 Nm
[2] Nut M10
[3] Bolts M10
65 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 361

 SUSPENSION | Rear axle

Driveshaft to gearbox

[1] Shim plates

[2] Bolts M10 x 1 x 60
After unscrewing, always replace with new bolts.
85 Nm ▶ Tighten the screws one after the other.
Undo by 90° 1. Tighten to 85 Nm.
85 Nm 2. Undo by 90°.
3. Tighten to 85 Nm.

V7,12/2022 911 GT3 Cup (2021–2023) 362

 SUSPENSION | Rear axle

Air duct to stiffening plate

[1] Air duct (NACA)

[2] Snap nuts ST4.8
[3] Self-tapping screws ST4.8 x 16-R

3.2 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 363

 SUSPENSION | Rear axle

Diagonal strut and stiffening plate to body

[1] Diagonal strut

[2] Stiffening plate
[3] Bolt M12 x 1.5 x 45

135 Nm
[4] Bolt M10 x 45

55 Nm
[5] Bolts M8 x 22

30 Nm
[6] Bolt M12 x 1.5 x 45

155 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 364

 SUSPENSION | Rear axle

Support bearing to body

[1] Nuts M8

33 Nm

Air hose for brake cooling

[1] Air hose
[2] Hose clamps

V7,12/2022 911 GT3 Cup (2021–2023) 365

 SUSPENSION | Wheels and tyres

3.8 Wheels and tyres

WARNING IMPERMISSIBLE TYRE CONDITION
Tyre pressures below the specified minimum pressure as well as embedded foreign
objects, punctures, cracks and bulges in the side wall caused by ruptured plies lead to
a change in vehicle handling and therefore increase the risk of accident and severe injury.
▶ Observe the minimum air pressure specified by the tyre manufacturer.
▶ Inspect the tyres for cracks, punctures and bulges on the side wall and/or embedded
foreign objects.

WARNING USE OF TRANSPORT TYRES

The 911 GT3 Cup (992) is fitted with Michelin transport tyres for delivery. Using
transport tyres when testing or racing can cause you to lose control of the vehicle, thereby
compromising your own safety.
▶ Do not use the transport tyres fitted to the vehicle on delivery when testing and racing.
Information regarding the use restrictions of the tyres is issued on delivery of the
vehicle.

NOTICE INSUFFICIENT GREASING

Risk of damage to the rim cone and loosening of the wheel nut.
▶ Before mounting the wheels, always apply a closed layer of grease to the rim cone.

▶ Mount new wheels several times before use (loosen/tighten 3 times) to create
a uniform contact pattern in the cone. Grease the cone again after this procedure.

V7,12/2022 911 GT3 Cup (2021–2023) 366

 SUSPENSION | Wheels and tyres

3.8.1 Wheel/tyre combination

The vehicle was developed and tested with Michelin tyres of the dimensions listed below.

Tyre size Rim diameter Nominal width

Front axle Michelin Slick 12J"x18" (one piece) ET 23.5 mm
Cup N3 Competition • Colour code:
30/65-18 Platinum semi-matt
Michelin Rain (0B5)
P2L 30/65-18
Rear axle Michelin Slick 13J"x18" (one piece) ET 44.5 mm
Cup N3R Competition • Colour code:
31/71-18 Platinum semi-matt
Michelin Rain (0B5)
P2L 31/71-18

These tyre dimensions represent the approval state. The use of tyres from other
manufacturers, of other dimensions and of other types is the responsibility of the vehicle
operator.

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 SUSPENSION | Wheels and tyres

3.8.2 Wheel nut

WARNING LOSS OF WHEEL
Severe injury caused by losing control of the vehicle.
▶ Make sure that the correct tightening torque is applied to the wheel nut (550 Nm).
▶ In addition, if a pneumatic impact screwdriver is used, make sure that the pressure
gauge on the pressure cylinder is calibrated to the correct value. To do so, refer to
the operating instructions from the manufacturer for information on adjusting the
pressure gauge.

Handling and maintenance

l

Right side of vehicle: Wheel nut with left-hand thread (blue).

Left side of vehicle: Wheel nut with right-hand thread (red).

USING NEW WHEEL NUTS FOR FIRST TIME

1. Mount the wheel.

2. Loosen/tighten the new wheel nut 3 or 4 times.

550 Nm,
Molub Alloy Paste
TA

3. Loosen the wheel nut again.

4. Remove and clean the wheel nut, and lubricate the thread and clamping surface.

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 SUSPENSION | Wheels and tyres

MAINTAINING WHEEL NUT

1. Clean the thread using brake cleaner and additionally rinse off with acetone.
Brake cleaner, 2. Use compressed air to dry and to remove any shavings.
Molub Alloy Paste 3. Clean the outside thread of the wheel hub in the same way.
TA 4. Grease the thread [1] and clamping surface [2] with Molub-Alloy Paste TA.

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 SUSPENSION | Wheels and tyres

Wheel lock
NOTICE JAMMED LOCKING PINS
Risk of damage to the locking mechanism and/or wheel caused by jammed locking pins.
▶ To ensure that the pawls [4] can move in the holder without excessive resistance,
regular cleaning is necessary (e.g. using brake cleaner).
▶ Make sure that the locking mechanism is dry before installing.

[1] Locking pins

[2] Coil springs
[3] Wheel lock plug
[4] Pawls
[5] Locking pin springs

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 SUSPENSION | Wheels and tyres

If the wheel nut opens when driving, the pawls can become canted and must then be
released manually.
Always have a hammer and drift punch at hand.

1. Release the pawl [1] using a hammer and drift punch.

Hammer, drift
punch

2. The wheel nut [2] can be opened.

3.8.3 Transport nut

The transport nuts are approved for transport only and not for operation of the vehicle.
▶ Tighten the transport nuts to 120 Nm.
The special tool required to tighten and loosen the transport nuts can be purchased via the Porsche Motorsport parts catalogue.

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 SUSPENSION | Wheels and tyres

3.8.4 Tyre pressure monitoring system (TPMS)

CAUTION INCORRECT TYRE PRESSURE
Incorrect tyre pressure influences vehicle handling.
▶ If a red tyre pressure warning is displayed, drive back to the pits carefully and at an
appropriate speed.
▶ If the vehicle has defective tyres, continue to drive only as far as the pits.

Despite the tyre pressure monitoring system (TPMS), it is still essential to check the tyre
pressure manually at regular intervals!

A set (4 pcs.) of TPMS sensors are included with the vehicle on delivery.
Additional sensors for purchase are available via the Porsche Motorsport catalogue.
▶ When fitting the tyres, make sure that the openings for the pressure sensor are not
clogged with tyre fitting paste.
The tyre pressure monitoring system (TPMS) consists of the following components:
• 4 TPMS sensors screwed into the rims.
• 4 receivers inside the wheel arches.
• An antenna (control unit) attached in the tunnel between two aluminium struts.

New TPMS sensors configure themselves autonomously.

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 SUSPENSION | Wheels and tyres

Assembly of TPMS sensor/valve

INSTALLING WHEEL ELECTRONICS

1. Insert the wheel valve [1] into the rim and tighten the union nut [2] incl. washer [3].
4 Nm When doing so, counterhold the valve with a suitable retaining mandrel!
NOTE Excessive tightening torque/excessive tightening will damage the seal.
▶ Always observe the specified tightening torque.
▶ Once the tightening torque is reached, do NOT tighten further.
2. Screw the wheel electronics [4] to the valve [1] using the bolt [5] and tighten.
When doing so, push the wheel electronics against the rim bed.
4 Nm 3. Screw the dust cap [6] onto the valve by hand.

Fig. 49: TPMS sensor/valve on rim

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 SUSPENSION | Brake system

3.9 Brake system

DANGER INSUFFICIENT FILLING OF THE BRAKE FLUID RESERVOIR
Failure of the brake system due to air entering the hydraulic system if the level of the
reservoirs is too low.
▶ Before every use of the car, a sufficiently high level of brake fluid in the reservoirs must
be ensured.
a. The level must be within 10 mm of the rear upper edge of the reservoir (see Fig. 50).
b. Level determination with unscrewed reservoir cap and car in horizontal position.
c. For level determination, the brake pistons are applied to the brake pad back plate and
the brake system is completely bled.
▶ In case of endurance races, also ensure a sufficiently high filling level during pit stops.

Fig. 50: Brake fluid level

WARNING INCORRECT HANDLING OF BRAKE FLUID

Contact with brake fluid can cause skin irritation and eye damage.
▶ Wear personal protective equipment.
▶ Ensure good ventilation.
▶ Avoid contact with brake fluid.
▶ In the event of contact with skin, wash thoroughly with soap and water. In the event
of contact with eyes, rinse thoroughly for at least 15 min under flowing water with
eyelids held open; contact a doctor if necessary.

CAUTION HOT COMPONENTS

The brake system can become extremely hot during vehicle operation.
▶ Allow the brake system to cool down before starting work.
▶ Wear personal protective equipment.

V7,12/2022 911 GT3 Cup (2021–2023) 374

 SUSPENSION | Brake system

CAUTION COLD BRAKE SYSTEM

If the brake system has not reached operating temperature, the vehicle will handle
differently and the braking distance will be longer.
▶ Always warm up the brake system to prevent damage to the brake discs.

NOTICE CARELESS REMOVAL/MOUNTING OF WHEELS

Careless and incorrect removal/mounting of the wheels can result in damage to the brake
system.
▶ Guide the wheel onto the wheel hub carefully to prevent hard impacts against the brake
disc and brake calipers.

NOTICE INSTALLATION OF INCORRECT BRAKE PADS

The use of brake pads that are not approved by PAG can result in changed characteristics
with respect to performance, wear and ABS functionality.
▶ Use only the brake pads specified for the vehicle model. Available for purchase via the
Porsche Motorsport parts catalogue.
▶ When the wear limits are reached, replace all brake pads on the axle concerned.
▶ Make sure that the brake pads are installed correctly (see 3.9.4 Changing brake pads
on page 386).

NOTICE UNSUITABLE CLEANING AGENTS

Unsuitable cleaning agents (e.g. brake cleaners) can damage the brake piston seals,
the brake master cylinder seals and the reservoir.
▶ Use only isopropanol and ethanol for cleaning.
▶ Before pushing back the brake pistons, clean them with isopropanol or ethanol
to prevent damage to the seals.
▶ To clean the entire brake system, do not use commercially available brake cleaner,
petroleum ether, cold cleaners or lubricant sprays such as WD-40.

NOTICE INCORRECT DISASSEMBLY/ASSEMBLY

Incorrect disassembly/assembly of the brake pistons and piston sealing rings can cause
the piston seal to become distorted, which increases the risk of brake system leaks and
impairs the braking behaviour.
▶ Moisten the brake pistons and piston seals sufficiently with brake fluid.
See 3.9.5 Replacing brake pistons/piston seal on page 387.

V7,12/2022 911 GT3 Cup (2021–2023) 375

 SUSPENSION | Brake system

▶ After changing the brake hoses or brake calipers, bleed the brake system completely
because most air bubbles form around the seals.
▶ Bleed the brake system again if required.

Optional products are recommended for endurance operations.

Not available from Porsche Motorsport, please contact the manufacturer directly.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Endurance brake pads

V7,12/2022 911 GT3 Cup (2021–2023) 376

 SUSPENSION | Brake system

3.9.1 Brakes on front axle

WARNING OVERSIZED SCREW HEAD

An oversized screw head of the brake disc fixing screws can prevent a flush contact
between the rim and the brake disc bell. This can result in the wheel seating incorrectly.
▶ Only use screws [2] approved by Porsche to fix brake discs [1]. Purchase via Porsche
Motorsport parts catalogue.

A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service

Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Screw connection disc bell

V7,12/2022 911 GT3 Cup (2021–2023) 377

 SUSPENSION | Brake system

Installation of brake disc and brake caliper

[1] Brake disc
Dimensions: 380 x 32 mm
[2] Bolts M6 x 12

10 Nm

Loctite 243
[3] Studs

21 Nm

[4] Brake pad

[5] Brake caliper
[6] Nuts M10

65 Nm

[7] Bleeder valves with dust cap

14 Nm ± 2 Nm
(cold) When installing for the first time:
9 Nm ± 1 Nm ▶ Wet the bleeder valves with brake fluid before assembly.
(caliper After every bleeding:
temperature ▶ Tighten the bleeder valves with the specified torque.
> 100 °C)

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 SUSPENSION | Brake system

Single brake disc

The disc bell can be reused once with a new brake disc, providing the disc bell was not
previously used with ABS. The mounting bolts must also be replaced when the brake disc
is exchanged. If the brake bell’s disc has already been replaced, the entire brake disc must
be disposed with the next time the wear limit is reached.
▶ Reference is expressly made to the fact that the single brake discs are only seen as a
supplement to the existing product range.
Replacing single brake disc

b Brake disc removed. See Installation of brake disc and brake caliper on page 378.

1. Remove the M5 bolts [4].

2. Remove the bell fastening ring [3].
3. Remove the single brake disc [1] from the disc bell [2].

4. Clean disc bell and bell fastening ring.

NOTE Check the components for damage, deformation, distortion and wear of the coating.
Components that show abnormalities must be replaced.

5. Fit the new single brake disc [1] and the disc bell [2] together.
6. Insert the bell fastening ring [3].

7. Fit new M5 bolts [4] and tighten them in a crosswise sequence.

5 Nm

8. Check whether the brake disc has axial play. Tangential play is not permitted.

9. Fit the brake disc. See Installation of brake disc and brake caliper on page 378.

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 SUSPENSION | Brake system

Installation of brake hose

[1] Brake hose
▶ Install the brake hose free of twists and tensions, align centrally in the fork of the
16 Nm bracket [2].

[2] Bracket
[3] Bolts M6 x 16
10 Nm
[4] Sealing ring A10 x 14
[5] Connection 10 x 1-3D
16 Nm

3.9.2 Brakes on rear axle

WARNING OVERSIZED SCREW HEAD

An oversized screw head of the brake disc fixing screws can prevent a flush contact
between the rim and the brake disc bell. This can result in the wheel seating incorrectly.
▶ Only use screws [2] approved by Porsche to fix brake discs [1]. Purchase via Porsche
Motorsport parts catalogue.

A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service

Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Screw connection disc bell

V7,12/2022 911 GT3 Cup (2021–2023) 380

 SUSPENSION | Brake system

Installation of brake disc and brake caliper

[1] Brake disc
Dimensions: 380 x 32 mm
[2] Bolts M6 x 12

10 Nm

Loctite 243
[3] Studs

21 Nm

[4] Brake pad

[5] Brake caliper
[6] Nuts M10

65 Nm

[7] Bleeder valves with dust cap

14 Nm ± 2 Nm
(cold) When installing for the first time:
9 Nm ± 1 Nm ▶ Wet the bleeder valves with brake fluid before assembly.
(caliper After every bleeding:
temperature ▶ Tighten the bleeder valves with the specified torque.
> 100 °C)

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 SUSPENSION | Brake system

Single brake disc

The disc bell can be reused once with a new brake disc, providing the disc bell was not
previously used with ABS. The mounting bolts must also be replaced when the brake disc
is exchanged. If the brake bell’s disc has already been replaced, the entire brake disc must
be disposed with the next time the wear limit is reached.
▶ Reference is expressly made to the fact that the single brake discs are only seen as a
supplement to the existing product range.
Replacing single brake disc

b Brake disc removed. See Installation of brake disc and brake caliper on page 381.

1. Remove the M5 bolts [4].

2. Remove the bell fastening ring [3].
3. Remove the single brake disc [1] from the disc bell [2].

4. Clean disc bell and bell fastening ring.

NOTE Check the components for damage, deformation, distortion and wear of the coating.
Components that show abnormalities must be replaced.

5. Fit the new single brake disc [1] and the disc bell [2] together.
6. Insert the bell fastening ring [3].

7. Fit new M5 bolts [4] and tighten them in a crosswise sequence.

5 Nm

8. Check whether the brake disc has axial play. Tangential play is not permitted.

9. Fit the brake disc. See Installation of brake disc and brake caliper on page 381.

V7,12/2022 911 GT3 Cup (2021–2023) 382

 SUSPENSION | Brake system

Installation of brake hose

[1] Brake hose
The angled outlet must be positioned such that the brake hose passes centrally
16 Nm through the opening provided in the air scoop (see Fig. 51).
Be sure to install the brake hose before installing the air scoop.
▶ Install the brake hose free of twists and tensions.
[2] Stud M12 x 1.5 x 58.5

24 Nm
[3] Sealing ring A10 x 14
[4] Connection 10 x 1-3D
16 Nm [5] Adapter

Fig. 51: Position of brake hose

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 SUSPENSION | Brake system

3.9.3 Wear limits

Brake discs
The brake discs must be checked for cracking at regular intervals.
▶ Replace the brake discs in the following cases:
– The wear limit is reached when the counterbores are no longer visible.
– If the cracks reach the outer edge of the brake disc or the brake disc centre hub,
the brake discs must be changed before they reach the wear limit.
The risk of cracking can be reduced by running in the brakes gently and always
warming them up slowly.

V7,12/2022 911 GT3 Cup (2021–2023) 384

 SUSPENSION | Brake system

Brake pad
▶ Replace the brake pads in the following cases:
– When the wear limit is reached (friction material thickness < 5 mm).
The depth of the grooves is not an indication of wear.
– If excessive diagonal wear is evident.

Brake piston seal

Increased residual friction moment can occur, particularly at the front axle, if the vehicle is checked immediately after stopping.
The residual friction moment decreases after a few min. This behaviour is not a technical defect.
Extreme temperature loads can shorten the service life of the seal.
Repair kits are available for the brake pistons and piston seal. Available for purchase via the Porsche Motorsport parts catalogue.
▶ Replace the piston seal in the following cases:
– when the service intervals of the brake caliper are reached (see 3.1 Service intervals on page 291)
– if the brake caliper temperature has exceeded 210 °C – check using temperature measuring strips
– if the wheels do not rotate freely
– if the pistons are jammed
– if there are leaks

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 SUSPENSION | Brake system

3.9.4 Changing brake pads

NOTICE INCORRECT INSTALLATION OF BRAKE PADS
If brake pads are installed on a different wheel of the vehicle, this can result in large parts
of the brake pad breaking off.
▶ When reusing brake pads, make sure that they are installed at the same position
as before.

1. Remove the brake caliper (see Installation of brake disc and brake caliper on page 378
and see Installation of brake disc and brake caliper on page 381).
Isopropanol or 2. Open the brake fluid reservoir.
ethanol 3. Extract the brake fluid to prevent overflowing when the brake pistons are pushed back.
4. Clean the brake pistons with isopropanol or ethanol and push back using a suitable tool.

5. Insert new brake pads.

NOTICE ▶ Place the brake pad back plate [1] correctly into the pad guides [3] inside the brake
caliper [4].
→ The friction material [2] of the brake pads faces towards the brake disc.

6. Install the brake caliper (see Installation of brake disc and brake caliper on page 378
and see Installation of brake disc and brake caliper on page 381).
7. Top up brake fluid as required.
8. Apply the brake.
9. Bleed the brake system (see Bleeding brake system on page 391).

▶ After changing the brake pads, check the entire brake system for smooth operation.

Fig. 52: Example: Changing the brake pads on the front axle
(992 GT3 Cup)

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 SUSPENSION | Brake system

3.9.5 Replacing brake pistons/piston seal

CAUTION EXTENDING BRAKE PISTONS
Injuries caused by crushing can occur when the brake pistons are extended.
▶ Do not place your fingers between the brake pistons.
▶ Wear personal protective equipment.

When the brake pistons are changed, it is essential to replace the piston seals too.

Removing brake pistons/piston seal

1. Detach the brake caliper from the upright.
2. Remove the brake hose from the brake caliper.
Isopropanol or 3. Remove the brake pads.
ethanol 4. Place a plastic block in the brake caliper so that the pistons do not fall out.
5. Push out the brake pistons with low air pressure.
6. Pull the brake pistons completely out of the brake caliper by hand.
7. Clean all components with isopropanol or ethanol.
8. Check the brake caliper bores and seal grooves for damage and excessive wear.
If damage is present, the brake caliper must be replaced.

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 SUSPENSION | Brake system

Installing brake pistons/piston seal

1. Wet new pistons with brake fluid and insert new seals in brake fluid.
2. Insert the pistons into the brake caliper bores.
Brake fluid Due to the seal, slight resistance is felt when inserting the pistons into the bore.
DOT 4 Make sure that the seals are not squeezed or twisted during insertion.
3. Insert a plastic block in the brake caliper so that the pistons do not fall out.
4. Apply low pressure to the brake caliper a few times to ensure that the seals are seated
correctly.
5. Attach the brake caliper to the upright.
6. Attach the brake hose to the brake caliper.
7. Insert the brake pads.
8. Top up brake fluid and bleed the brake system.
See Bleeding brake system on page 391.

V7,12/2022 911 GT3 Cup (2021–2023) 388

 SUSPENSION | Brake system

3.9.6 Brake fluid

WARNING INCORRECT HANDLING OF BRAKE FLUID
Contact with brake fluid can cause skin irritation and eye damage.
▶ Wear personal protective equipment.
▶ Ensure good ventilation.
▶ Avoid contact with brake fluid.
▶ In the event of contact with skin, wash thoroughly with soap and water. In the event
of contact with eyes, rinse thoroughly for at least 15 min under flowing water with
eyelids held open; contact a doctor if necessary.

WARNING CONTAMINATED BRAKE FLUID

Risk of total brake failure caused by bubbles in the brake fluid or by contaminated brake
fluid.
▶ Change the brake fluid immediately if the water content has reached > 2 %.
▶ Bleed the brake system regularly.
▶ Replace the brake fluid immediately if the brake caliper temperature has exceeded
210 °C.
▶ Do not mix brake fluid with other fluids.
▶ Do not leave the brake fluid container open, and use or dispose of the brake fluid as soon
as possible after opening. Brake fluid is highly hygroscopic (attracts water) and can
therefore lead to premature blistering.

CAUTION BRAKE FLUID AT HYDRAULIC CONNECTIONS

Brake fluid (even diluted brake fluid) at electrical contacts leads to corrosion and can
cause faults in the system.
▶ Keep brake fluid away from electrical contacts.
▶ When performing assembly work at hydraulic connections, plug in all electrical
connectors in the area surrounding the disconnection point in order to prevent brake
fluid or water from getting inside the connectors.
▶ Remove any discharged brake fluid immediately; if necessary, rinse off with water
and dry.
▶ Clean connectors that have become dirty or wet as a result of disassembly and
assembly work, using a lint-free cloth.

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 SUSPENSION | Brake system

NOTICE INCORRECT HANDLING OF BRAKE FLUID

Damage to components due to contact with brake fluid.
▶ In the event of contact with painted surfaces, rinse immediately with water.
▶ In the event of contact with electrical components, remove immediately using a dry and
clean cloth.
▶ Avoid contaminating the brake fluid with brake cleaner.

▶ Use Racing Brake Fluid RH 665 (DOT 4) from Performance Friction Brakes.
Available for purchase via the Porsche Motorsport parts catalogue.

Replacing brake fluid

b Use new Racing Brake Fluid RH665 (DOT 4) from Performance Friction Brakes.
b Observe the brake fluid grade.
b Have a collecting bottle and transparent hose at hand.

1. Open both brake fluid reservoirs.

2. Extract the brake fluid.
3. Pour in new brake fluid.
4. Apply pressure to the rear right brake caliper.
– Pour in brake fluid for the rear axle again.
5. Apply pressure to the rear left brake caliper.
– Pour in brake fluid for the rear axle again.
6. Apply pressure to the front right brake caliper.
– Pour in brake fluid for the front axle again.
7. Apply pressure to the front left brake caliper.
– Pour in brake fluid for the front axle again.
8. Completely bleed the brake system.

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 SUSPENSION | Brake system

Bleeding brake system

b Use new Racing Brake Fluid RH 665(DOT 4) from Performance Friction Brakes.
b Observe the brake fluid grade.
b Have a collecting bottle and transparent hose at hand.
b Have a second technician at hand.

1. Remove the caps from the brake fluid reservoirs.

2. Top up brake fluid as required.

3. Bleed the brake system at the brake calipers:

a. Connect the collecting bottle with the transparent hose to the bleed valve.
b. Have the second technician depress and hold down the brake pedal.
c. Open one bleed valve at each of the two axles (to prevent the balance bar from
tipping) and allow fluid to escape.
d. Then close the bleed valve.
e. Have the second technician release the pressure on the brake pedal.
4. Repeat the steps [b–e] under point 3 at every bleed valve until clear and bubble-free
brake fluid is discharged.

The bleeding procedure is performed in the same sequence at all 4 brake calipers of the
vehicle. Each brake caliper has 2 bleed valves. The bleeding procedure always begins with
the outer bleed valve. The brake calipers can be bled in any order. The collecting bottle and
transparent hose are used to check that the discharged brake fluid is clean and free of
bubbles and to determine how much brake fluid has been used up.

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 SUSPENSION | Brake system

Bleeding brake system (with ABS)

The following steps must be taken after fitting or changing the ABS unit:
• Bleed the brake system (see Bleeding brake system on page 391).
• Check ABS unit and sensor functionality (see Function test on page 1000)
• Bleed ABS unit using Toolbox (ABS repair and bleed) to ensure that no air remains
trapped in the ABS unit reservoir.
• Pressure bleed the brake system again to purge, if necessary, any air from the brake
system that escaped the ABS unit (see Bleeding brake system on page 391).

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 SUSPENSION | Brake system

3.9.7 Bedding brakes on circuit

WARNING DAMAGE TO BRAKE DISCS
Losing control of the vehicle due to a loss of brake action.
High temperature differences on the brake disc in a very short time can lead to cracking or
tearing of the brake discs.
▶ If the car has been stationary for > 15 min, the brake system should be warmed up
gently, if the race situation allows this.
This minimises the risk of cracking.

If the car is driven for long periods, the friction coefficient decreases. This behaviour can
occur even before the wear limit is reached. It is normal and the driver/team must decide
whether the necessary brake force/deceleration is still sufficient.
When using new brake discs and/or brake pads, a braking process must be carried out.

Bedding in brakes

1. Increasing brake pressure: < 15 bar

Speed: Brake down from 100 km/h to 60 km/h
▶ Perform at least 10 braking operations.
2. Increasing brake pressure: < 25 bar
Speed: Brake down from 150 km/h to 60 km/h
▶ Perform at least 5 braking operations.
3. Maximum brake pressure
Speed: Brake down from 200 km/h to 60 km/h
▶ Perform at least 5 braking operations.
4. Cool-down lap (to cool down the brake system).

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 SUSPENSION | Brake system

3.9.8 Brake hydraulics

When operating with the ABS system fitted, increased wear of the brake master cylinders
can be observed.
It is therefore recommended that both brake master cylinders are checked on a regular
basis and the worn parts are replaced when necessary or after 2.500 km latest.
Repair kits are available for both brake master cylinders via spare parts sales.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service Infor-
mation" portal (PMRSI) at https://motorsport.porsche.com) in the technical informations:
→ Brake master cylinder

V7,12/2022 911 GT3 Cup (2021–2023) 394

 SUSPENSION | Brake system

ABS hydraulic unit to bodyshell

[1] Bodyshell bracket

[2] Bolts BM8 x 30

20 Nm

[3] ABS hydraulic unit

[4] ABS hydraulic unit bracket
[5] Bolt M10 x 1 x 17

25 Nm

[6] 3x buffers

▶ Insert the preassembled ABS hydraulic unit incl. bracket into the buffers.

V7,12/2022 911 GT3 Cup (2021–2023) 395

 SUSPENSION | Brake system

Intermediate piece to bodyshell (model without ABS)

[1] Bodyshell bracket

[2] Bolts BM8 x 30

20 Nm

[3] Intermediate piece

[4] Intermediate piece bracket
[5] Bolts M6 x 12

9.7 Nm

[6] 3x buffers

▶ Insert the preassembled intermediate piece incl. bracket into the buffers.

V7,12/2022 911 GT3 Cup (2021–2023) 396

 SUSPENSION | Brake system

Brake lines to ABS hydraulic unit

[1] Front-axle brake line, left

[2] Front-axle brake line, right
14 Nm [3] Rear-axle brake line, left front
[4] Rear-axle brake line, right front
[5] Hydraulic brake lines

16 Nm

[6] Holder
▶ Clip the holder to the body.

V7,12/2022 911 GT3 Cup (2021–2023) 397

 SUSPENSION | Brake system

Brake lines to intermediate piece (model without ABS)

[1] Front-axle brake line, left

[2] Front-axle brake line, right
14 Nm [3] Rear-axle brake line, left front
[4] Rear-axle brake line, right front
[5] Hydraulic brake lines

16 Nm

[6] Holder
▶ Clip the holder to the body.

V7,12/2022 911 GT3 Cup (2021–2023) 398

 SUSPENSION | Brake system

Brake pressure sensor to brake master cylinder

[1] Brake lines

16 Nm

[2] Brake pressure sensors

Make sure that the angle of the line outlets is such that there is no risk of collision
with other components.
[3] Distributor
[4] Sealing rings A10 x 15
[5] Banjo bolt

22 Nm

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 SUSPENSION | Brake system

Brake line to front end and front right wheel arch

[1] Front-axle brake lines, right

[2] Cable holder
▶ Clip the holder to the body and then clip the brake line into the holder.

Brake line to front end and front left wheel arch

[1] Front-axle brake lines, left
[2] Cable holder
▶ Clip the holder to the body and then clip the brake line into the holder.

V7,12/2022 911 GT3 Cup (2021–2023) 400

 SUSPENSION | Brake system

Brake lines to underbody

[1] Rear-axle brake lines, left

[2] Rear-axle brake lines, right
16 Nm

[3] Double holder

[4] Cable holder
▶ Clip all the holder to the body and then clip the brake lines into the holder.

Brake lines to rear end

[1] Rear-axle brake lines, left

[2] Rear-axle brake lines, right
[3] Cable holder
[4] Cable holder
[5] Cable holder
▶ Clip all the holder to the body and then clip the brake lines into the holder.

V7,12/2022 911 GT3 Cup (2021–2023) 401

 SUSPENSION | Balance bar system

3.10 Balance bar system

NOTICE Functional damage to the brake system due to incorrect installation.

▶ Only the brake master cylinder listed in the Porsche Motorsport parts catalogue
for the 911 GT3 Cup (992) may be installed.

The brake master cylinders from AP Racing have the following diameters:
• Front axle: 19.1 mm (marked with a green tie wrap)
• Rear axle: 15.9 mm (marked with a black tie wrap)
– or –
17.8 mm (marked with a blue tie wrap)

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 SUSPENSION | Balance bar system

3.10.1 Brake force distribution

Connected
The brake force between the front and rear axle can be adjusted using the knob in the
centre console.

It is important to note the following two points:

• Adjust the setting according to the weather conditions and vehicle configuration.
• Always test the new setting carefully.

If a brake master cylinder with 17.8 mm is used on the rear axle, the brake balance must be
adjusted backwards by three positions compared to the 15.9 mm variant.
EXAMPLE
Usual setting with 15.9 mm master brake cylinder (black cable tie): 2.75
New setting with 17.8 mm master brake cylinder (blue cable tie): -1,75

V7,12/2022 911 GT3 Cup (2021–2023) 403

 SUSPENSION | Balance bar system

3.10.2 Basic setting of balance bar

CAUTION CHANGING SETTING AT BALANCE BAR
Incorrect adjustment of the balance bar changes the braking behaviour.
▶ Adjust the setting to the weather conditions and the vehicle setup.
▶ Test a new setting carefully.

NOTICE INCORRECT POSITIONING OF PUSHROD RELATIVE TO BALANCE BAR JOINT

Failure to observe the clearance between the pushrod [1] of the brake master cylinder
and the joint [2] of the balance bar can result in damage to the components.
▶ The screw-in depth of both master brake cylinders is 20 mm.

V7,12/2022 911 GT3 Cup (2021–2023) 404

 SUSPENSION | Balance bar system

[1] Adjusting shaft

Make sure that the adjusting shaft is at the 0 position at the centre of the balance bar.
[2] Clips
[3] Brake master cylinders
[4] Pushrods
[5] Balance bar
[6] Joints
[A] Front axle
[B] Rear axle

Connected

V7,12/2022 911 GT3 Cup (2021–2023) 405

 SUSPENSION | Balance bar system

Calculation of brake force

[1] Brake force at front axle (FA)
[2] Brake force at rear axle (RA)
[3] Pedal force (F pedal)

Formula for calculating the brake force of the front axle (FA) and rear axle (RA):
Pedalkraft  y
Bremskraft HA = ----------------------------
l

Bremskraft VA = Pedalkraft – Bremskraft HA

Connected

V7,12/2022 911 GT3 Cup (2021–2023) 406

 SUSPENSION | Balance bar system

3.10.3 Repair kit for balance bar

CAUTION INCORRECT HANDLING OF RETAINING RINGS AND CIRCLIPS
Incorrect handling of retaining rings and circlips can result in failure of the brake system
as well as loss of vehicle control. Circlips and retaining rings can fall off.
▶ After disassembly, use only new circlips or retaining rings.

Repair kit for the balance bar is available for purchase via the Porsche Motorsport parts
catalogue.

V7,12/2022 911 GT3 Cup (2021–2023) 407

 SUSPENSION | Balance bar system

Components of repair kit

[1] Bearing journal
[2] Upper needle roller bearing
[3] Lower needle roller bearing
[4] Pushrod
[5] Lower circlip
[6] Upper circlip

Connected

[7] Cotter pin

[8] Locking sleeve
[9] Circlip
[10] Adjustment shim
[11] Plain bearing bushing
[12] Retaining ring
[13] Balance bar shaft
[14] Balance bar head

V7,12/2022 911 GT3 Cup (2021–2023) 408

 SUSPENSION | Balance bar system

Replacing balance bar

REPLACING BALANCE BAR

1. Remove the cotter pin [7], locking sleeve [8], circlip [9], adjustment shim [10]
and plain bearing bushing [11].
2. Remove the retaining ring [12].
3. Release the balance bar from the balance bar head [14] and bearing journal [1]
and screw out.
4. Remove the circlips. (Not shown in the figure!)
5. Using a suitable tool, push the bearing journal and needle roller bearings [2], [3] out
of the pushrod.
6. Before assembling, carefully clean the holes in the pushrod.
7. Insert the lower circlip [5].
Connected
8. Insert the lower needle roller bearing [3] from above.
9. Insert the bearing journal.
10. Insert the upper needle roller bearing [2].
11. Insert the upper circlip [6] (must engage audibly in the pushrod).
The bearing journal should have a small amount of play.
12. Screw the new balance bar all the way into the bearing journal in the balance bar head.
13. Push the retaining ring carefully onto the shaft.
Do not overstretch the retaining ring!
14. Centrally align the balance bar (see Basic setting of balance bar on page 404).
15. Reassemble the plain bearing bushing, adjustment shim, circlip, locking sleeve and
cotter pin on the balance bar.

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 SUSPENSION | Balance bar system

3.10.4 Installing and removing balance bar system/brake master cylinder

There are different master brake cylinders for front and rear axle.
These are marked as follows:
• Front axle: 19.1 mm (marked with a green tie wrap)
• Rear axle: 15.9 mm (marked with a black tie wrap)
– or –
17.8 mm (marked with a blue tie wrap)

NOTICE The master brake cylinders must not be interchanged.

b Brake master cylinder pre-filled with brake fluid.

b Running time specifications for the brake master cylinder observed
(see 3.1 Service intervals on page 291).

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 SUSPENSION | Balance bar system

[1] Bolts M8 x 30
[2] Nut M8
23 Nm [3] Bolts M8 x 200
Torx 45 Safety-relevant bolts!

[4] Bolt M8 x 45
Safety-relevant bolt!
CAUTION! Disregarding the insertion direction of safety-relevant bolts or incorrect
positioning of safety-relevant bolts will lead to brake failure and loss of vehicle control.
▶ Insert the safety-relevant bolt [4] from the right (and screw on the associated M8
nut [2] on the left), otherwise there will be a risk of collision.
[5] Brake pressure sensor
[6] Banjo bolt

For a detailed description of the assembly see Brake pressure sensor to brake master
cylinder on page 399.
[7] Brake line

16 Nm

[8] Reed sensor (brake light switch)

For a detailed description of the assembly see 6.6.3 Reed sensor mounting (brake light
switch) on page 769.

V7,12/2022 911 GT3 Cup (2021–2023) 411

 SUSPENSION | Pedals

3.11 Pedals
3.11.1 Installation of pedals
[1] Pedals (clutch and brake pedal)

[2] Nuts M8

23 Nm

[3] Bolts M8 x 25

23 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 412

 SUSPENSION | Pedals

3.11.2 Installation of balance bar system

1. Insert the foam element into the reservoirs.

2. Insert the balance bar [1] and secure with the M8 nuts [2].

23 Nm

3. Check that the display is at the zero position (brake balance) and check the basic
setting of the brake master cylinders (see Basic setting of balance bar on page 404).
4. Attach the adjusting shaft and secure with a cotter pin.

5. Loosen the M8 x 30 bolt [1].

6. Turn the left brake master cylinder [2].

7. Tighten the BM8 x 200 x 30 bolts [3].

8. Turn the left brake master cylinder back to its original position.
23 Nm 9. Tighten the M8 x 30 bolts [4].

10. Repeat the procedure for the right brake master cylinder.

V7,12/2022 911 GT3 Cup (2021–2023) 413

 SUSPENSION | Pedals

11. Place the balance bar (brake actuation) [1] against the brake pedal [2].
12. Position and tighten the M8 x 45 bolt [3] and M8 nut [4].
23 Nm

Install the bolt [3] from the right side of the vehicle.

3.11.3 Installation of accelerator pedal

1. Hook the underside of the accelerator pedal [1] into the bottom of the contour and
push into the shaped hole at the top.
8 Nm 2. Position and tighten the M6 x 18-TC bolt [2].

V7,12/2022 911 GT3 Cup (2021–2023) 414

 SUSPENSION | Clutch hydraulics

3.12 Clutch hydraulics

WARNING INCORRECT STORAGE
Incorrect storage poses a potential fire risk. Skin, eyes and respiratory tract can be injured
if inadequately protected.
▶ Work only outdoors or in well ventilated rooms.
▶ Wear personal protective equipment.
▶ Dispose of residue in an environment-friendly manner.
▶ Store fluids properly.

WARNING INCORRECT HANDLING OF BRAKE FLUID

Contact with brake fluid/clutch fluid can cause skin irritation and eye damage.
▶ Wear personal protective equipment.
▶ Ensure good ventilation.
▶ Avoid contact with brake fluid.
▶ In the event of contact with skin, wash thoroughly with soap and water. In the event
of contact with eyes, rinse thoroughly for at least 15 min under flowing water with
eyelids held open; contact a doctor if necessary.

A collision with the gearbox housing can damage the bleed line of the clutch. The bleed line
can be protected against chafing at the point shown [circle] by applying suitable chafing
protection.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Clutch bleed line protection

V7,12/2022 911 GT3 Cup (2021–2023) 415

 SUSPENSION | Clutch hydraulics

3.12.1 Clutch fluid

Clutch fluid/brake fluid:

PFC RH665 Racing DOT4
Dry boiling point: 325 °C
Wet boiling point: 195 °C

If one or more lines and/or other components are replaced, the clutch system must be bled.
See Clutch system – bleeding on page 142.

V7,12/2022 911 GT3 Cup (2021–2023) 416

 SUSPENSION | Clutch hydraulics

3.12.2 Installation of clutch line

Front end line
[1] Front clutch line
[2] 2-component holder
[3] Holder
[4] Return line
[5] Clamps

Underbody line

[1] Front clutch line

[2] Middle clutch line
[3] Holder for front and middle clutch line
[4] Holder for middle clutch line
[5] Connection of front and middle clutch line

17 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 417

 SUSPENSION | Clutch hydraulics

Rear end line

[1] Middle clutch line

[2] Rear clutch line (bayonet fastener)
[3] Bolt M6 x 25

10 Nm
[4] Bolt M8 x 25
[5] Pressure sensor
22 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 418

 SUSPENSION | Power unit mount

3.13 Power unit mount

3.13.1 Gearbox mount
Gearbox mount to gearbox

[1] Gearbox mounting bracket

[2] Gearbox support
[3] Bolts M10

65 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 419

 SUSPENSION | Power unit mount

Gearbox mount incl. gearbox to body

[1] Studs M10 x 110

20 Nm
[2] Nuts M10
[3] Bolts M10 x 40
30 Nm + 90°

V7,12/2022 911 GT3 Cup (2021–2023) 420

 SUSPENSION | Power unit mount

3.13.2 Engine mount

Engine mount to body

[1] Engine mount

[2] Bolts M8 x 50

23 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 421

 SUSPENSION | Power unit mount

Engine to engine mount

[1] Engine mount

[2] Bolts M12 x 1.5 x 70

30 Nm + 90°

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 SUSPENSION | Power unit mount

Assembly sequence engine mount

Engine mount [1] left without slotted holes.

Engine mount [2] right with slotted holes.
▶ Make sure that the motor bearing is mounted with the insertion phase on the motor
side.

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 SUSPENSION | Power unit mount

Scenario I: Drive train removal/installation

1. Loosen screws [2] on both sides.

2. Drain engine.

3. When reassembling, apply the new screws [2] and tighten them to the specified tight-
ening torque.
30 Nm + 90°

Fig. 53: Screw connection engine mount to engine

V7,12/2022 911 GT3 Cup (2021–2023) 424

 SUSPENSION | Power unit mount

Scenario II: Vehicle first body or after rear end repair

1. Fit the engine mount on the left [1] to the body and tighten the four screws [2] to the
specified tightening torque.
23 Nm

2. Fit the engine mount on the right [1] to the body and only tighten the four screws [2]
so that the engine mount can still be moved in a horizontal direction.
3. Retract drive train.

4. Screw the motor to the motor bearing on the left side (Fig. 53).
5. Screw the motor to the motor bearing on the right side (Fig. 53).
30 Nm + 90°

6. Tighten the four screws [2] of the right-hand motor bearing [1] to the specified tight-
ening torque.
23 Nm
Fig. 54: Screwing the engine mount to the body

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4 BODY EXTERIOR
4.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
4.2 Colour code body exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
4.3 Vehicle views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
4.4 Body add-on parts (bodywork) . . . . . . . . . . . . . . . . . . . . . . . . . . 430
4.5 Body shell and add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
4.6 Body repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
4.7 Air jack system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
4.8 Removing/installing the windscreen . . . . . . . . . . . . . . . . . . . . . 637
4.9 Removing/installing the rear window . . . . . . . . . . . . . . . . . . . . 648
4.10 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657

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 BODY EXTERIOR | Service intervals

4.1 Service intervals

Fuel tank
Components Service interval Max. runtime Instructions
Tank bladder before each race 5 years (+ 2 years after • Observe the expiry date specified by the
recertification) manufacturer.
• Check each time before deploying the vehicle in
a race.
• Can be recertified by the manufacturer (ATL)
once for further 2 years (see page 1025).
Safety foam before each race • Check each time before deploying the vehicle in
a race.
Main fuel pumps 60 h • It is recommended to replace the main fuel
(inside the catch tank) pump annually (even if the max. running time
has not yet been reached).
Fuel pump prefilter before each race • Check each time before deploying the vehicle in
a race.

Airjack system
Components Service interval Rebuild interval Instructions
Main valve 2 years or 2000 strokes • Rebuild after time or strokes.
• Rebuild by Krontec (see page 1027).
Lifting cylinder 2 years or 2000 strokes
• Observe shipping information (see page 631).
Counternuts 30 h Check all nuts, re-tighten if necessary.

Body parts
Components Service interval Max. runtime Instructions
Wing extensions 24 months Applies to spare parts only

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 BODY EXTERIOR | Colour code body exterior

4.2 Colour code body exterior

The body of the Porsche 991 GT3 Cup is painted in GT-silver metallic (M7Z).

4.3 Vehicle views

Front view

Side view

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 BODY EXTERIOR | Vehicle views

Rear view

Top view

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4 Body add-on parts (bodywork)

NOTICE INCORRECT INSTALLATION
Components can be damaged if installed incorrectly.
▶ Make sure that the components are seated correctly in the respective guides.
▶ Lock quick-release fasteners properly.
▶ Tighten bolts to the specified tightening torque.
▶ Use the specified tools.

4.4.1 Front lid

WARNING INSUFFICIENTLY FASTENED AIR DUCTS ON THE FRONT LID
Insufficiently fastened air ducts on the front lid can cause the front flap to lose its rigidity
and become under-inflated while driving. This can lead to uncontrolled opening of the
front lid.
▶ Check the sheet metal strips and air ducts for tightness and glue them if necessary.

A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service

Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Air ducts front bonnet

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 BODY EXTERIOR | Body add-on parts (bodywork)

Removing/installing front lid

1. Open the quick-release fasteners [1].

2. Fold up the front lid.

3. Remove the dampers [1] on both sides of the front lid.

Make sure that the front lid is supported (e.g. by a second mechanic).

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 BODY EXTERIOR | Body add-on parts (bodywork)

4. Remove the bolts [1] of the hinges on both sides.

5. Remove the front lid.
8 Nm

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.2 Wheel arch liners

Removing/installing front wheel arch liners

b Wheels removed.
Front section

1. Remove the bolts [1].

3.2 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

Rear section

2. Remove the nuts [1].

2.5 Nm

3. Remove the bolts [2].

3.2 Nm

▶ The two sections are installed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

Removing/installing rear wheel arch liners

b Wheels removed.
Front section

1. Remove the bolts [1].

The four upper

screws: 2 Nm

The two lower

screws: 3.2 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

Rear grille

2. Remove the bolts [1].

2 Nm

▶ The two components are installed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.3 Front section

Removing/installing front section

b Wheels removed.
b Front wheel arch liners removed. See Removing/installing front wheel arch liners
on page 433.

1. Disconnect the connectors [1] of the position lights on both sides and remove the
cable ties used to fix the cables in place.

2. Remove the bolt [2] on both sides.

3. Remove the bottom bolts [1].

3.2 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

4. Remove the top bolts [1].

3.2 Nm

5. Remove the retaining clips [1] on both sides.

6. Lift off the front section towards the front.

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.4 Front bumper

Removing/installing front bumper

b Front section removed. See 4.4.3 Front section on page 437.

1. Remove the bolt [1] and unhook the Bowden cable [2].

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 BODY EXTERIOR | Body add-on parts (bodywork)

2. Remove the bolts [1].

3. Remove the bumper.
55 Nm

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.5 Door
Removing/installing door
1. Remove the bolts [1].

13 Nm

2. Lift the door upwards out of the hinges.

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

Adjusting door

▶ Turn the adjusting element [1] anticlockwise or clockwise to adjust the door so that
it is flush with the rear side window.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.6 Installing door window

A new door panel is supplied with a pre-applied adhesive bead to save the primer curing
time (> 24 h) on the adhesive surface of the door panel when repairing during a racing
event. This procedure significantly reduces the repair time.

An incorrectly mounted door window can have a negative effect on the aerodynamics.
▶ The preparation of the new door window is done in the same way as for a new
windscreen. See Preparing a new windscreen (unheated) on page 644.
▶ The door window is fitted using the identical adhesive material as for fitting the
windscreen. See Installing the windscreen on page 645. Please observe the notes and
instructions.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.7 Outside mirror

▶ Adjust the mirror by moving the mirror glass.

Removing/installing outside mirror

b Door open.

1. Remove the bolts [1].

2. Remove the door trim panel and unhook the Bowden cable behind the panel.

3. Remove the bolt [2].

4. Remove the outside mirror [3].
23 Nm

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.8 Headlight
Removing/installing headlight

b Front wheels removed.

b Front wheel arch liner removed. See Removing/installing front wheel arch liners
on page 433.

1. Disconnect the connector [1].

2. Unclip the clip [2].

3. Remove the bolt [3+4].

8 Nm

4. Remove the headlight forwards out of the fender.

▶ When inserting the headlight, make sure that the centring pin [5] engages in the
body-side guide.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.9 Engine cover

Removing engine cover

1. Open the quick-release fasteners [1].

2. Pull off the engine cover towards the rear.

3. Pull off the engine cover towards the rear and hang it on the spoiler supports by the
guides [1] on both sides of the engine cover.

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 BODY EXTERIOR | Body add-on parts (bodywork)

Installing engine cover

1. Guide the engine cover under the rear spoiler and insert its guide pins [1] into the
body-side guides [2].

2. Push down the engine cover at its rear edge and close the quick-release fasteners [1].

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.10 Light panel

Removing/installing light panel

b Engine cover removed. See 4.4.9 Engine cover on page 446.

1. Remove the bolts [1].

6 Nm

2. Remove the bolts [2].

6 Nm

3. Remove the heat shield [3].

4. Carefully pull the light panel towards the rear.
5. Unlock and disconnect the connector [4] on both sides.

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.11 Tail lights

Removing/installing tail lights

b Engine cover removed. See 4.4.9 Engine cover on page 446.

b Light panel removed. See 4.4.10 Light panel on page 448.

1. Remove the bolts [1].

6 Nm

2. Pull out the tail light towards the rear.

3. Unlock and disconnect the connector [2].

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.12 Fender
Removing/installing fender

b Front lid open. See 4.4.1 Front lid on page 430.

b Front wheel arch liners removed. See Removing/installing front wheel arch liners
on page 433.
b Front section removed. See 4.4.3 Front section on page 437.
b Headlight removed. See 4.4.8 Headlight on page 445.

1. Remove the bolts [1+2].

8 Nm
To remove the bolts [1] (next to the front lid hinge), the cowl at this position must be bent
upwards slightly.

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 BODY EXTERIOR | Body add-on parts (bodywork)

2. Remove the bolts [1].

3. Remove the nut [2].
8 Nm

4. Lift the fender, pull it towards the rear in the direction of the door and out of the
guide [1] and remove.
▶ Installation is performed in the reverse order of removal.
Make sure that the fender engages in the guide [1].

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 BODY EXTERIOR | Body add-on parts (bodywork)

Installing wheel trim

b Front wheel arch liner removed. See Removing/installing front wheel arch liners
on page 433.
b Front section removed. See 4.4.3 Front section on page 437.

1. Clean the adhesive surface.

2. Position the wheel trim [1] on the fender (do not press on yet).
Isopropyl

3. Remove the protective film from the bonding surface on the left and right.
4. First position the wheel trim at the marked areas (left and right).
3M Acrylic Plus 5. Remove the protective films completely.
Tape PX5011 6. Stick on/press on the wheel trim starting at the outside and working inwards [arrows].

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 BODY EXTERIOR | Body add-on parts (bodywork)

7. Tighten screws [1].

2.5 Nm

8. Tighten screw [2].

2 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.13 Underbody panels

NOTICE INCORRECT INSTALLATION
Risk of damage to the components caused by incorrect removal and installation.
▶ Always remove and install large components with the aid of a second person.
INSTALLATION SEQUENCE FOR UNDERBODY PANELS
1. Secure the middle underbody panel (see Removing/installing middle underbody panel on page 455).
2. Secure the front underbody panel (see Removing/installing front underbody panel on page 454).
3. Secure the rear underbody panel (see Removing/installing rear underbody panel on page 456).

Removing/installing front underbody panel

1. Remove the bolts [1].

Torx 25,
3 Nm

2. Remove the nuts [2].

3. Remove the nuts [3].
AF 10,
2.5 Nm

When detaching the front underbody panel, make sure that the wheel arch liners are not
damaged.

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

Removing/installing middle underbody panel

b Front underbody panel removed. See Removing/installing front underbody panel

on page 454.

1. Open the bayonet fasteners [1].

2. Remove the bolts [2].

Torx 25,
3 Nm

3. Remove the nuts [3].

4. Remove the middle underbody panel.
AF 10,
2.5 Nm

▶ Installation is performed in the reverse order of removal.

▶ First attach the underbody panel to the bodyshell using the eight bayonet fasteners
[1].
▶ Make sure that the PET films [4] for sealing the holes are correctly positioned.

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 BODY EXTERIOR | Body add-on parts (bodywork)

Removing/installing rear underbody panel

b Front underbody panel removed. See Removing/installing front underbody panel

on page 454.
b Middle underbody panel removed. See Removing/installing middle underbody panel
on page 455.

1. Remove the bolts [1].

2. Remove the air duct [2].
Torx 30 ▶ Repeat the operations on the opposite side.

3. Undo the hose clamp [1] on both sides.

4. Pull the brake air hose [2] off the air duct [3].
▶ Repeat the operations on the opposite side.

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 BODY EXTERIOR | Body add-on parts (bodywork)

5. Remove the nuts [1].

AF 10,
2.5 Nm

6. Remove the bolts [2].

7. Remove the rear underbody panel.
Torx 25,
3 Nm

▶ Installation is performed in the reverse order of removal.

▶ Make sure that the sides of the underbody panel are pushed into the wheel arch liners.

Underbody trim to diagonal strut

[1] Underbody trim

[2] Bolts

30 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.14 Air deflectors

The following air deflectors must be removed before the vehicle is transported, and then reattached before each race or test.
The following operations must be performed on both sides.

Attaching air deflector I

1. Remove the bolts [1].

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 BODY EXTERIOR | Body add-on parts (bodywork)

2. Hold the air deflector [1] against the wheel arch liner.
3. Screw in but do not tighten the bolts [2].

4. Push the air deflector upwards slightly and towards the rear against the wheel
arch liner.
7.5 mm drill bit Use the holes of the air deflector as drilling templates.
5. Drill three holes (Ø 7.5 mm) at the top of the elongated holes.
→ Maximum penetration depth of the drill bit: 10 mm
6. Remove the drill burrs from the wheel arch liner.

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 BODY EXTERIOR | Body add-on parts (bodywork)

7. Secure the top of the air deflector [1] to the wheel arch liner using the expansion
rivets [2].
Make sure that there is clean contact with the wheel arch liner.

8. Tighten the bolts [2] to the specified torque.

3.2 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

Attaching air deflector II

1. Cut through the perforations [yellow dotting] in the front underbody panel.
2. Slide sheetmetal nuts [1] onto the openings.

3. Undo and remove the bolt [1].

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 BODY EXTERIOR | Body add-on parts (bodywork)

4. Slide the air deflector [1], tab first, into the cut-out perforation and screw flush onto
the front underbody panel.

5. Screw in the bolts [1] (incl. the previously removed bolt) evenly and then tighten
to the specified torque.
3.2 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.15 Sill trim

Removing/installing sill trim

1. Remove the bolts [1] from the front and rear wheel arch liner.
2. Unlock the bayonet fasteners [2] by turning 90° and remove.
3. Pull the sill trim out of the clips starting at the rear.
Check the clips and mounting clamps; replace if necessary.

▶ Installation is performed in the reverse order of removal.

▶ When installing, clip on the sill trim from the inside to the outside.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.16 Diffuser
Removing/installing diffuser

1. Remove the bolts [1].

E12,
20 Nm

2. Remove the bolts [2].

Torx 30,
8 Nm

Fig. 55: Threaded connection of diffuser

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 BODY EXTERIOR | Body add-on parts (bodywork)

3. Loosen (but do not remove) the bolts [3] through the diffuser [arrows].
4. Pull out the diffuser towards the rear.
8 Nm

▶ Installation is performed in the reverse order of removal.

If the hole pattern on the engine does not line up, proceed as follows:
1. Loosen the bolts [1] (Fig. 55).
2. Align the diffuser on the engine.
3. Screw in and tighten the bolts [2] (Fig. 55).
4. Screw in and tighten the bolts [1] (Fig. 55).

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.17 Rear apron

Removing/installing rear apron

b Engine cover removed. See 4.4.9 Engine cover on page 446.

b Light panel removed. See 4.4.10 Light panel on page 448.
b Tail lights removed. See 4.4.11 Tail lights on page 449.

1. Remove the bolts [1] on both sides.

3.2 Nm

2. Remove the top bolts [1].

3.2 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

3. Remove the bolts [1] on both sides.

5 Nm

4. Remove the bottom bolts [1] on both sides.

3.2 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

5. Remove the rear apron from the guides at the side and pull out towards the rear slightly.
6. Disconnect the connector of the rain light [1] from inside.
7. Remove the rear apron in the direction of the arrow.

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.18 Rear bumper

Removing/installing rear bumper

b Diffuser removed. See 4.4.16 Diffuser on page 464.

b Rear apron removed. See 4.4.17 Rear apron on page 466.

1. Remove the bolts [1].

2. Remove the bolts [2].

3. Remove the bumper incl. heat shield towards the rear.
23 Nm

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 BODY EXTERIOR | Body add-on parts (bodywork)

▶ Installation is performed in the reverse order of removal.

To prevent waste heat from dissipating towards the air filter housing, it must be
ensured when installing that the heat shield components overlap correctly and lie
tightly against each other.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.19 Rear side window

Removing rear side window

1. Open the door.

2. Grip the edge of the rear side window at the door.
3. Carefully remove the rear side window by pulling the locking pins out of the rubber
grommets.

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 BODY EXTERIOR | Body add-on parts (bodywork)

Installing rear side window

1. Open the door.

2. Push the locking pins [1] of the rear side window into the rubber grommets [2].
3. Press against the top and bottom of the rear side window in the area of the
Velcro strips [3].
→ Additional securing of the rear side window.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.20 Assembly carrier

Removing assembly carrier

b Engine cover removed. See 4.4.9 Engine cover on page 446.

b Light panel removed. See 4.4.10 Light panel on page 448.
b Tail lights removed. See 4.4.11 Tail lights on page 449.
b Rear apron removed. See 4.4.17 Rear apron on page 466.

1. Remove the quick-release coupling [1] incl. water hoses from the holder.
2. Detach the oil service dish [2].

3. Remove the bolts [3].

4. Lift out the assembly carrier [4].
Torx 45

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Installing assembly carrier

1. Insert the assembly carrier.

Make sure that the locking pins [1] on both sides are inserted at the correct position.

2. Screw in the bolts [3] evenly and tighten.

23.7 Nm

3. Attach the oil service dish [2].

4. Insert the quick-release coupling [1] incl. water hoses into the holder.

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 BODY EXTERIOR | Body add-on parts (bodywork)

4.4.21 Rear wing

Removing/installing rear wing

b Engine cover removed. See 4.4.9 Engine cover on page 446.

1. Remove the nuts [1].

AF 13,
30 Nm

2. Remove the rear wing incl. rear wing supports.

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

Rear wing adjustment

1. Loosen (but do not remove) the bolt [1] and nut [2].
2. Insert the bolts [3] and nuts [4] at the desired position.
9.7 Nm, Repeat the procedure on the opposite side.
Torx 25, 3. Tighten all bolts [1+3] and nuts [2+4].
AF 10 Make sure that the self-locking nuts are replaced with new ones each time they
are loosened.

[A] View of outside

[B] View of inside

There are 11 adjustment positions: from 4° to 14°.

In the example view, the rear wing is set at 4°.
NOTE The item numbers must be identical for both bolts (here in the example number 4).

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 BODY EXTERIOR | Body add-on parts (bodywork)

Removing/installing rear wing end plates

1. Remove the bolts [1].

2. Remove the rear wing end plates.
4.5 Nm,
Torx 25

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body add-on parts (bodywork)

Bonding rear wing edge (Gurney)

Surface condition:
b Surfaces are dry and free of dust, oil, oxides, release agents and other dirt or
contamination.
▶ Clean dirt from the surfaces using isopropanol or other suitable cleaning agents that
do not leave residue or attack the substrate.
▶ Use clean and lint-free cloths for cleaning.
▶ Avoid finger contact with the bonding surfaces (wear gloves).
Temperature:
▶ Bonding should take place at a temperature of min. 15 °C (object temperature and
ambient temperature).
▶ The temperature of the material should not be lower than the dew point temperature
(to avoid condensation).
Contact pressure:
▶ Apply brief and firm pressure to the bond to achieve optimum surface contact.
Adhesive tape ▶ Press the Gurney [1] respectively the adhesive tape [2] to the rear wing [3] with approx.
3M PT110 30 N/cm².

The illustration shows the bonding of the tail wing edge schematically as a sectional
drawing and not in exact scale.

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4.4.22 Roof hatch

Removing/installing roof hatch

1. Open the quick-release fasteners [1].

4 mm Allen key
with ball head

2. Lift off the roof hatch.

▶ Installation is performed in the reverse order of removal.

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 BODY EXTERIOR | Body shell and add-on parts

4.5 Body shell and add-on parts

4.5.1 Material overview of body parts
Aluminium components
[A] Aluminium sheet
Use/properties:
• Outer panels
– Good shape restorability
– Partial replacement in accordance with repair manual permissible
• Reinforcement parts
– Good shape restorability
– Shape restoration not permissible using mechanical or hydraulic pulling and pushing
devices
– Partial replacement in accordance with repair manual permissible
[B] Cast aluminium

If the aluminium castings are deformed more than 2 mm, the entire chassis must be
replaced. Exceptions are the front shock absorber mount and the front carriage, these parts
can be replaced individually.
Use/properties:
• Reinforcement parts
• Partial replacement not permissible
• Shape restoration not permissible
[C] Extruded aluminium section
Use/properties:
• Reinforcement parts
• Poor shape restorability
• Partial replacement in accordance with repair manual permissible
• Shape restoration not permissible using mechanical or hydraulic pulling and pushing
devices

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Steel parts

[A] Steel sheet

Use/properties:
• Outer panels
• Good shape restorability
• Inert-gas welding permissible
• Partial replacement in accordance with repair manual permissible
[B] High-strength steel
Use/properties:
• Reinforcement parts
• Moderate to poor shape restorability
• Inert-gas welding permissible
• Partial replacement in accordance with repair manual permissible
[C] Super-high-strength steel
Use/properties:
• Reinforcement parts
• No shape restorability
• Inert-gas welding permissible
• Resistance spot welding only with approved devices
• Partial replacement not permissible
[D] Ultra-high-strength steel
Use/properties:
• Pillars and members
• No shape restorability
• Inert-gas welding permissible in exceptional cases only
Please contact Technical Racing Support (see 7.1 Technical Racing Support
on page 1023).
• Resistance spot welding only with approved devices
• Partial replacement not permissible

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4.5.2 Roll cage

The roll cage is welded, bolted and bonded to the body.

Apart from its basic functions, it also provides e.g. connection points for recovery
attachments and for parts of the wheel suspension, steering column and seat belt.
The roll cage is FIA-certified.
This makes vehicle-specific certificates unnecessary.
Any modification to the roll cage can lead to non-admission or disqualification of the
vehicle.
In the event of an accident, inspection of the roll cage and approval by a technical
scrutineer is mandatory.
For further information on inspection and repair of the roll cage, please contact the
manufacturer:
Thyssenkrupp System Engineering GmbH
Weipertstraße 37
74076 Heilbronn
Germany
www.thyssenkrupp-system-engineering.com

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4.5.3 Recovery fixtures

Recovery loops

▶ Pull out the front recovery loop by the red tab [1].

▶ Pull out the rear recovery loop by the red tab [1].

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Recovery bar
WARNING VEHICLE ON RECOVERY BAR
Risk of injury when working on the vehicle without additional securing.
▶ When the vehicle is suspended by the recovery bar, work is only permissible if the
vehicle is additionally jacked up/secured.

1. Secure the recovery bar to a crane device.

2. Insert the securing pins of the recovery bar into the openings in the vehicle roof.

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4.5.4 Spare body

A spare body is provided with several paint protection measures (masking screws and nuts) during production, which may still be present on delivery.
Therefore, it is essential to check the delivered replacement body for these paint protection measures. Before mounting further components and parts,
remove existing paint protection measures and apply adhesive films as further paint protection. In addition, a blind rivet screw for fastening the pedals must
be inserted into the spare body before further assembly work is done.

Removing masking screws and nuts

1. Remove the masking screw [yellow].

2. Remove the nuts [1].

3. Remove the masking screws [2] and sleeves.

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4. Remove unpressed rivet nut [1] and masking nut [2] from the earth stud [3].

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5. Remove unpressed rivet nut [1] and masking nut [2] from the earth stud [3].

6. Remove unpressed rivet nuts [1] and masking nuts [2] from the earth studs [3].

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7. Remove unpressed rivet nuts [1] from the threaded bolts [2].

8. Remove the masking screw [1] on the driver‘s side

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9. Remove the masking screws [1].

10. Remove the masking screw [1] and spacer sleeve [2] on the driver's side.

11. Remove the masking screw [1] and spacer sleeve [2] on the driver's side.

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12. Remove the unpressed rivet nuts [1].

13. Remove the masking screw [1] on the passenger side.

14. Remove the masking screw [1] on the driver‘s side.

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15. Remove the unpressed rivet nuts [1] from the front lid.

16. Remove the masking screws [1] and paint protection washers [2] from the wishbone
mounts.
NOTICE Do not remove the screw-on surfaces [3] of the cast parts!
For target condition see Fig. 56.

Fig. 56: Target condition wishbone mounts

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17. Remove nuts [1] and fitting bolts [2] on the rear damper strut supports.

Installing adhesive films

To ensure good adhesion of the adhesive films, the surfaces of the corresponding adhesive
areas must be free of dirt and grease.

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[1] Adhesive film 40 x 0.05 (WHT.009.235)

4x adhesive film
40 x 0.05 The figure shows the driver's side. The individual adhesive films are positioned mirror-
(WHT.009.235) symmetrically on the passenger side.

[2] PET-film (AKL.442.D30)

2x PET-film
(AKL.442.D30)

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[3] Adhesive film 40 x 0.05 (WHT.009.235)

4x adhesive film
40 x 0.05
(WHT.009.235)

[4] Adhesive film 35 x 0.3 (WHT.010.137)

[5] Adhesive film 85 x 50 x 0.3 (WHT.010.138)
8x adhesive film
35 x 0.3
(WHT.010.137) The figure shows the driver's side. The individual adhesive films are positioned mirror-
4x adhesive film symmetrically on the passenger side.
85 x 50 x 0.3
(WHT.010.138)

[6] Adhesive film 40 x 0.05 (WHT.009.235)

4x adhesive film
40 x 0.05
(WHT.009.235)

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Fitting the blind rivet bolt for the pedals

[1] Blind rivet bolt WHT.008.419

1x blind rivet bolt

WHT.008.419

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4.6 Body repair

DANGER FALLING VEHICLE
If the vehicle is poorly secured, it can fall and lead to potentially fatal crushing injuries.
▶ Do not place any rigid objects underneath the raised vehicle.
▶ Secure the lift platform to prevent it from lowering.
▶ Lift the vehicle at the provided support points only.

WARNING GRINDING AND WELDING WORK

Spark generation can cause fire or an explosion.
▶ Avoid work close to flammable or explosive materials.
▶ Cover flammable or explosive materials.
TOXIC SUBSTANCES
S

WARNING
Risk of poisoning or asphyxiation. Contact with eyes or skin can lead to chemical burns.
▶ Ensure good ventilation at the workplace.
▶ Avoid swallowing or inhaling.
▶ Observe the specific instructions on the safety data sheet.
▶ Wear personal protective equipment.
▶ Do not smoke, eat or drink at the workplace.

CAUTION FLYING FOREIGN OBJECTS

Flying foreign objects produced when grinding, drilling and milling can cause eye injuries.
▶ Wear eye protection.

CAUTION SHARP OR SHARP-EDGED OBJECTS

Sharp or sharp-edged objects can cause lacerations, puncture wounds or cuts.
▶ Wear personal protective equipment.

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CAUTION RISK OF INJURY CAUSED BY HEAVY COMPONENTS

Handling heavy components poses an increased risk of injury.
▶ Perform work steps with the aid of a second person.

NOTICE EXCESSIVELY DEEP SEPARATING CUTS

Excessively deep separating cuts can damage the underlying metal sheet.
▶ Make separating cuts through the top metal sheet only.

NOTICE DAMAGED THREADS

Risk of damage to the threads in the bodyshell.
▶ Avoid cross-threading.
▶ Position the bolts correctly.

In case of deformations > 2 mm or also in case of cracks/holes in aluminium extruded sections and aluminium castings (see 4.5.1 Material overview of body
parts on page 480), the damaged components or the body must be replaced.

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4.6.1 Replacing damper strut support

Tools and materials

The following tools and materials are recommended for repairing the damper strut supports:

• Measuring and straightening system

• Resistance spot welding unit
• Stud welding unit
• Extraction unit
• Blind rivet setting tool for high-strength rivets
• Seaming pliers
• Spot weld releasing tool
• Laser weld seam milling tool
• Pneumatic body saw
• Oscillating body saw
• Countersink for rivets
• Flow drilling tool
• Belt grinder
• Spot weld drill
• Pneumatic cartridge gun
• Manual cartridge gun
• Hot-air gun
• Star gauges for body gap sizes
• Acetone
• Isopropanol
• Adhesive 3M DP490
• 30x rivets 6.5x14.5 mm (999.190.230.01)
• 4x rivets 6.5x12.5 mm (999.190.227.01)

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Preparatory work

1. Remove the add-on parts in the repair area according to the extent of the vehicle
damage.
2. Place the straightening bench on the straightening system (if available).
3. Place the vehicle on the straightening bench (if available).
4. Cover all add-on parts remaining in the vehicle, as well as adjacent areas with
fire-resistant covers.
5. Restore the shape of the connection surfaces of the sheet metal parts to be replaced.
When doing so, refer to the information on repairing aluminium components
(see Aluminium components on page 480).
6. Clean any body sealant, paints etc. from body joints using a hot-air gun or rotary brush.

Removing damper strut support

1. Remove the self-tapping screws [1].

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2. Remove the self-piercing rivets [yellow].

3. Heat up the bonding area [yellow].

4. Remove the damper strut support.

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Preparing damper strut support

1. Fit the damper strut support and fix in place on the body.
2. Make drill holes for rivets in the existing holes (Ø 6.6 mm).
6.6 mm drill bit 3. Remove the damper strut support.

4. Prepare the damper strut support for bonding and riveting.

a. The damper strut support and adhesive material should have the same processing
Isopropanol, temperature.
acetone – Minimum temperature: 15 °C
– Maximum temperature: 35 °C
b. Remove any oil, dirt, moisture and paint from the bonding surfaces.
Sandpaper grit size c. Roughen the bonding surfaces with sandpaper. Cross-sand the surfaces.
150, 180 d. Clean the bonding surfaces with a clean cloth and one of the specified cleaners.
Allow the clean surface to dry for 15 min.

The adhesive must be applied within 4 hours after the cleaning process in order to prevent
recontamination and the formation of an oxide layer.

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Preparing connection surfaces on body

1. Straighten the contact surfaces and joints on the body.

2. Deburr the connection surfaces and prepare them for joining.

3. Deburr the connection surfaces in the body area to be bonded and riveted.
a. The body and adhesive material should have the same processing temperature.
Isopropanol, – Minimum temperature: 15 °C
acetone – Maximum temperature: 35 °C
b. Remove any oil, dirt, moisture and paint from the bonding surfaces.
c. Roughen the bonding surfaces with sandpaper. Cross-sand the surfaces.
Sandpaper grit size d. Clean the bonding surfaces with a clean cloth and one of the specified cleaners.
150, 180 Allow the clean surface to dry for 15 min.

The adhesive must be applied within 4 hours after the cleaning process in order to prevent
recontamination and the formation of an oxide layer.

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Installing damper strut support

▶ Before final assembly, complete all operations and carry out a trial assembly without adhesive.
▶ The reliability of the bonded connection can be ensured only if processing is carried out seamlessly and rapidly.
▶ Do not commence bonding unless all materials and devices required for the repair are ready to hand.

1. Install the damper strut support and check that it fits precisely.

2. Apply adhesive to the joining area on the body [yellow].

Apply adhesive evenly over the entire bonding area.
Sika Power 477R Coating thickness: 0.5 mm

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3. Apply adhesive evenly over the entire bonding area [yellow] of the damper strut
support. Coating thickness: 0.5 mm
Sika Power 477R Additionally apply an adhesive bead around the edge of the bonding area.
Coating thickness: 3 mm

4. Fit in the damper strut support.

5. Fit the 6.5x12.5 mm (999.190.227.01) rivets [red].
Rivet gun for high- 6. Fit the 6.5x14.5 mm (999.190.230.01) rivets [yellow].
strength rivets,
4x rivets
6.5x12.5 mm
(999.190.227.01)
30x rivets
6.5x14.5 mm
(999.190.230.01)

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Subsequent operations

1. Remove the vehicle from the straightening system (if used).

2. Clean the joining areas and sheet metal flanges using a wire brush.
3. Apply primer to the joining areas and sheet metal flanges.
4. Restore the factory seals.
→ It is particularly important to carefully seal the repair area.
5. Paint the repair area and, if necessary, adjacent surfaces.
6. Refit the components originally removed from the repair area.

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4.6.2 Replacing wishbone mounting

Tools and Equipment

The following tools and equipment are recommended for use when repairing the wishbone mounting:

Tools and Equipment

• Battery powered drill / drill • Flat chisel
• Compressed air cartridge gun • Hammer
• Rivet-gun for high-strength rivets • Pry bar
• Vice grips • Marker pen
• Torx 25 • Pin punch
• 13 mm AF socket • Acetone
• Drill bit 6.7 mm • 1x adhesive Sika Power 477R
• Wire brush • 33x rivets 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm)
• Belt grinder • 10x rivets 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm)
• Hot air gun • 2x bolts M10x25 N 912.011.02

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Removing wishbone mounting

b Remove all components from the area to be repaired.

1. Remove joint sealing.

2. Remove FlowDrill screws [yellow].
Wire brush,
Torx 25

3. Grind the joins off [yellow].

Belt grinder

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4. Remove the FlowDrill screws [yellow] from the footwell.

5. Heat the bonded area.
Torx 25, 6. Separate wheel arch end plate [1] from the bonded area and bend away slightly.
hot air gun, 7. Separate wheel arch plate [2] from bonded area and remove.
flat chisel,
hammer
To prevent structural damage in the area to be repaired, heat the bonded area slowly and
uniformly to a maximum 90°C!

8. Remove the joint sealing in the area of the bolts [1].

9. Remove the bolts [1] from the inside of the longitudinal beam.
Wire brush,
13 mm AF socket

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10. Remove the FlowDrill screws [yellow].

Torx 25

11. Mark the installation position for the wishbone mounting.

12. Heat the bonded area [yellow] and remove the wishbone mounting.
Marker pen,
hot air gun,
hammer, To prevent structural damage in the area to be repaired, heat the bonded area slowly and
flat chisel, uniformly to a maximum 90°C!
pry bar

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Installing wishbone mounting

1. Remove residual adhesive.

2. Roughen and clean the mounting surfaces (metallicaly blank and free of grease).
13 mm AF socket, 3. Locate the new wishbone mounting in position.
belt grinder, 4. Mark the drill holes on the longitudinal beam.
6.7 mm drill bit 5. Remove the wishbone mounting.
6. Drill the holes with the 6.7 mm drill bit.
7. Apply the adhesive Sika Power 477R evenly on the mounting surfaces [yellow].
Acetone,
adhesive Sika
Power 477R Before applying the adhesive to the mounting surfaces, squeeze an adhesive bead
approximately 100 mm long to a piece of cardboard to ensure that the adhesive
components are correctly mixed.

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8. Fit the wishbone mounting in position.

9. Bolt the wishbone mounting to the longitudinal beam using the M10x25 [1] bolts.
55 Nm
13 mm AF socket,
2x M10x25 Use new M10x25 N 912.011.02 bolts!
N 912.011.02
bolts

10. Remove excess adhesive.

11. Fit the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) rivets [1] into the rivet gun before
Rivet gun for high- inserting through the wishbone mounting into the chassis.
strength rivets, 12. Fit the 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm) rivets [2] into the rivet gun before
11x rivets 6.5 mm inserting through the wishbone mounting and into the chassis.
(WHT.008.769 -
KL 3.0–6.5 mm),
3x rivets 6.5 mm First fit the rivets in the “Y” axis before fitting diagonally to ensure an even load distribution
(WHT.009.074 - across the wishbone mounting.
KL 5.0–8.5 mm)

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13. Remove the excess adhesive.

14. Trial fit the wheel arch panel to check the installation space required. If necessary, pull
Acetone, away the wheel arch end plate [1] slightly.
Sika Power 477R 15. Remove the wheel arch panel.
16. Roughen and clean the mounting surfaces (metallicaly blank and free of grease).
17. Apply Sika Power 477R [yellow] adhesive.

18. Fit the wheel arch panel and align using the existing drill holes.
19. Press the wheel arch panel into position and fix.
6.7 mm drill bit, 20. Dill the remaining 6.7 mm holes.
rivet gun for high- 21. Fit the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) rivets [1].
strength rivets, 22. Fit the 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm) rivets [2] and join the wheel arch
18x rivets 6.5 mm panel.
(WHT.008.769 - 23. Fit the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) rivets [3].
KL 3.0–6.5 mm),
7 x 6.5 mm
(WHT.009.074 -
Fit the rivet [3] closer towards the cockpit to prevent damaging the structure beneath.
KL 5.0–8.5 mm)

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24. Enlarge the rivet holes in the left footwell.

25. Fit the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) rivets [yellow].
6.7 mm drill bit,
rivet gun for high-
strength rivets,
4x rivets 6.5 mm
(WHT.008.769 -
KL 3.0–6.5 mm)

26. Roughen and clean the mounting surfaces (metallicaly blank and free of grease).
27. Apply the adhesive Sika Power 477R to the wishbone mounting bonding surfaces [1].
20 Nm 28. Insert the wishbone reinforcement, and fit and tighten the M8x25 bolts [2].
13 mm AF socket 29. After the adhesive has cured, remove the bolts and bond in the threaded studs.

Acetone, When inserting the double wishbone reinforcements, make sure that they rest on the
Sika Power 477R double wishbone mount without a gap and that the threads and the screw-on surfaces are
free of adhesive.
NOTICE The curing time is 96h at 18°C. At a temperature of 60°c (must be monitored with
a thermometer) the time until operational strength is 8h. A temperature of 60°C in the
repair area can be achieved with a mobile infrared heater, for example.

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Subsequent operations

1. Restore the factory seals.

It is particularly important to carefully seal the repair area.
2. Refit the components originally removed from the repair area.

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4.6.3 Thread repair

Tools
• Hot-air gun
• Thread repair kit 9843 – M12 installation depth 5 mm
• Thread repair kit 9843/1 – M10 installation depth 5 mm
• Thread repair kit 9843/2 – M10 installation depth 10 mm
• Thread repair kit 9843/3 – M8 installation depth 10 mm
• TIME-SERT thread repair No. 122-1, item 1
• TIME-SERT thread repair No. 122-1, item 2

Repair of threaded bushes without collar

1. Remove the wire thread insert/helicoil [1] using a suitable screwdriver.

Screwdriver

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2. Drill out the old thread using a 3-edged drill bit [A]
(the drill bit is included in the repair kit).

3. Cut the thread to dimension [Y] using a thread cutting tool.

Dimension [Y] is given in the documentation supplied with the repair kit.

4. Clean the thread.

Brake cleaner,
compressed air

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5. Screw the threaded bush [1] onto the inserting tool [2].
Make sure that the threaded bush is screwed onto the inserting tool correctly.

6. Install the threaded bush [1] using the inserting tool [2].
Observe a waiting time of approx. 3 - 4 h before attaching a threaded connection.

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7. Remove the inserting tool [E] from the threaded bush [A].

8. Briefly heat up the threaded bush (2 min at 80 °C).

Alternatively, do not fit a threaded connection at the repaired thread for
approx. 3–4 hours.

Heating or waiting is necessary to ensure that the threaded bush does not turn when
the bolt is screwed in.

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Repair of threaded bushes with collar

b Wire thread insert/helicoil removed.
b Old thread drilled out using the drill bit included in the kit.

1. Cut a recess [X] using the countersink miller [C].

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2. Cut the thread to dimension [Y] using a thread cutting tool.

Dimension [Y] is given in the documentation supplied with the repair kit.

3. Clean the thread.

Brake cleaner,
compressed air

4. Clean the thread on the bush and inserting tool.

5. Apply oil to the inserting tool [E].
6. Screw the threaded bush [A] onto the inserting tool by hand.

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7. Form and press in the threaded bush [A] in the base thread by turning further using
the inserting tool [E].

When the threaded bush is pressed into the base thread, perceptibly greater force must be
applied to the inserting tool to form the internal thread.
The pressing-in process is complete when the inserting tool turns more easily again.

8. Unscrew the inserting tool [E] from the threaded bush [A].

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Overview of thread repair points

[A] Impact absorber support
[B] Front end cross member
[C] Damper strut support
[D] Axle support
[E] Tunnel longitudinal member
[F] Tunnel connecting piece
[G] Subframe attachment
[H] Cross member mounting bracket

The sectional views of the thread repair are examples and intended to illustrate the installation dimensions of the threaded inserts. They do not always show
the exact component in which the threaded insert is installed.

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Thread repair – Impact absorber support

[1] Impact absorber support

[2] Thread M10
VAS 6916
Thread repair kit
M10 x 1.5

Thread [2] M10

– Dimension [X]: Seating depth 2.5 mm
– Dimension [Y]: Length 20 mm

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Thread repair – Front end cross member

[1] Front end cross member

[2] Thread M12

VAS 6627/8
Thread repair kit
M12 x 1.5
[3] Thread M6

VAS 6914
Thread repair kit
M6 x 1

Thread [2] M12

– Dimension [X]: Seating depth 5 mm
– Dimension [Y]: Length 22 mm
Thread [3] M6
– Dimension [X]: Seating depth 0 mm
– Dimension [Y]: Length 12 mm

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Thread repair – Damper strut support

[1] Damper strut support

[2] Thread M8

VAS 6915
Thread repair kit
M8 x 1.25
[3] Thread M6

VAS 6914
Thread repair kit
M6 x 1

Thread [2] M8
– Dimension [X]: Seating depth 1.5 mm
– Dimension [Y]: Length 15 mm
Thread [3] M6
– Dimension [X]: Seating depth 0 mm
– Dimension [Y]: Length 12 mm

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Thread repair – Axle support

[1] Axle support

[2] Thread M12

VAS 6627/8
Thread repair kit
M12 x 1.5

Thread [2] M12

– Dimension [X]: Seating depth 5 mm
– Dimension [Y]: Length 22 mm

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Thread repair – Tunnel longitudinal member

[1] Tunnel longitudinal member

[2] Thread M10

VAS 6916
Thread repair kit
M10 x 1.5

Thread [2] M10

– Dimension [X]: Seating depth 1 mm
– Dimension [Y]: Length 20 mm

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Thread repair – Tunnel connecting piece

[1] Tunnel connecting piece
[2] Thread M10

VAS 6916
Thread repair kit
M10 x 1.5

Thread [2] M10

– Dimension [X]: Seating depth 5 mm
– Dimension [Y]: Length 20 mm

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Thread repair – Subframe attachment

[1] Subframe attachment
[2] Thread M10

VAS 6916
Thread repair kit
M10 x 1.5
[3] Thread A7/16´

9397 TIME-SERT
thread repair kit
[4] Thread M12

VAS 6927/8
Thread repair kit
M12 x 1.5
[5] Thread M10

VAS 6916
Thread repair kit
M10 x 1.5
[6] Thread M8 (right subframe attachment only)

VAS 6915
Thread repair kit
M8 x 1.25

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[7] Thread M6

VAS 6914
Thread repair kit
M6 x 1

Thread [2] M10

– Dimension [X]: Seating depth 4.5 mm
– Dimension [Y]: Length 20 mm
Thread [3] A7/16´
– Dimension [X]: Seating depth 2.4 mm
– Dimension [Y]: Length 20 mm
Thread [4] M12
– Dimension [X]: Seating depth 5 mm
– Dimension [Y]: Length 22 mm
Thread [5] M10
– Dimension [X]: Seating depth 0 mm
– Dimension [Y]: Length 20 mm
Thread [6] M8
– Dimension [X]: Seating depth 0 mm
– Dimension [Y]: Length 25 mm
Thread [7] M6
– Dimension [X]: Seating depth 0 mm
– Dimension [Y]: Length 12 mm

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Thread repair – Impact absorber

[1] Impact absorber

[2] Thread M8

VAS 6915
Thread repair kit
M8 x 1.25
[3] Thread M6

VAS 6914
Thread repair kit
M6 x 1

Thread [2] M8
– Dimension [X]: Seating depth 0 mm
– Dimension [Y]: Length 15 mm
Thread [3] M6
– Dimension [X]: Seating depth 0 mm
– Dimension [Y]: Length 12 mm

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4.6.4 Removing/installing the roof module

WARNING RISK OF INJURY DURING REMOVAL AND INSTALLATION FROM INCORRECT HANDLING
OF TOOLS AND MATERIAL
Risk of minor to severe injury.
▶ Wear personal protection equipment (safety goggles and gloves).
▶ Always interrupt the power supply before replacing the cutting blade.

CAUTION SHARP OR SHARP-EDGED OBJECTS

Lacerations, puncture wounds or cuts.
▶ Wear personal protective equipment.

When processing the material from the two-component adhesive kit, the ambient and
material temperature should be at least 15 °C and not more than 28 °C.

Installing the roof module requires two persons.

A curing time of 10 min must be observed between cleaning the frame and applying the primer.
Once opened, the adhesive must be processed within 15 min.
When using a new mixer nozzle, squeeze an approx. 30 mm long bead out of the cartridge to ensure complete mixing.
NOTICE When installing the roof module, do not remove the emergency hatch.

Tools and material

• Electric special cutter • Two-component adhesive kit
• 25 mm blade for electric special cutter • Cutting cord
• U-shaped scraper blade for electric special cutter • Adhesive tape
• Cup suction tools • Isopropanol
• Dual-cartridge gun
• Window removal set VAS 861 001A

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Removing the roof module

1. Pull off the seals [1] left and right.

2. Cut and remove the seal holder [1].

Note: Cut only the front tab.
Cutter from
VAS 861 001A

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3. Remove nuts [1] from inside.

4. Cut the guide pins [1].

Electric special
cutter with 25 mm
blade

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5. Cut the inner adhesive bead [1].

Electric special
cutter with 25 mm
blade

6. Cut the adhesive bead [1] at the front of the roof:

a. Cut the cutting cord to a length of 3.5 m.
Awl from
VAS 861 001A
Cutting cord

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b. Penetrate the adhesive bead at the front right [2].

c. Push the awl [1] past the holder and stud [3] from
the vehicle inside to the outside.
d. Pull the cutting cord into the vehicle interior.

e. Guide the cutting cord [1] under and along the window seal [2] [arrows].

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f. Insert the awl [3] from the side at an acute angle from the inside to the outside.
g. Guide the cutting cord [1] under and along the plastic holder [2].
h. Pull the cutting cord [1] into the interior using the awl [3] [arrows].

i. Pull the cutting cord at the front left [1] to the center into the interior [arrows].

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j. Inside the vehicle, tie the hook [1] to the cutting cord [2] and hook it into the
centering bore.
Hook from
VAS 861 001A

k. Guide the free end of the cutting cord [1] at the front left out of the interior using
the awl [2] [arrows].
Awl from l. Guide the cutting cord [1] under and along the plastic holder [3].
VAS 861 001A

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m.Locate the suction cup on the windscreen.

n. Attach the cutting cord to the cutting device.
Cutting device o. Cut the adhesive bead at the front [1].
from
VAS 861 001A

7. Cut the adhesive bead [1] at the rear at the roof:

a. Cut the cutting cord to a length of 3.5 m.
Cutting cord

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b. Penetrate the adhesive bead at the rear left [2].

c. Push the awl [1] past the holder and stud [3] from
Awl from the vehicle inside to the outside.
VAS 861 001A d. Pull the cutting cord into the vehicle interior.

e. Guide the cutting cord [1] under and along the window seal [2].

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f. Insert the awl [3] from the side at an acute angle from the inside to the outside.
g. Guide the cutting cord [1] under and along the plastic holder [2].
h. Pull the cutting cord [1] into the interior using the awl [3].

i. Pull the cutting cord at the rear right [1] to the center into the interior [arrow].

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j. Inside the vehicle, tie the hook [1] to the cutting cord [2] and hook it into the
bore [3].
Hook from
VAS 861 001A

k. Guide the free end of the cutting cord [1] at the rear right out of the interior using
the awl [2] [arrow].
Awl from
VAS 861 001A

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l. Locate the suction cup [1] on the rear window.

m.Attach the cutting cord to the winding device.
Cutting device n. Cut the adhesive bead at the rear [2].
from
VAS 861 001 A

8. Lift off the roof.

Preparation for installation

NOTICE DAMAGE FROM INCORRECT PREPARATORY WORK
Risk of damage to the roof module from incorrect preparatory work.
▶ The residual adhesive covering the entire surface serves as primer surface for new
adhesive.
▶ Keep cutting surfaces clean and free of grease, and do not clean it with cleaning
solution.

NOTICE Loss of adhesion between roof module and body caused by cleaning solution residue
▶ A flash-off time between the cleaning of the bonding surface and the application
of the primer of at least 10 min must be observed.
▶ The body must be free of any residue of the cleaning solution.

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Preparing the car flange

1. Remove any coarse soiling from the bonding surface.

2. Clean the U-shaped scraper blade with isopropanol.
Electric special 3. Remove the adhesive [yellow] using the electric special cutter (with the U-shaped
cutter, scraper blade) from the body so that a residual coat of adhesive remains on the body.
U-shaped scraper
blade

Isopropanol

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CAR FLANGE WITH DAMAGED ADHESIVE RESIDUE

▶ If the cutting surface of the body is damaged or interrupted (body surface is visible),
Two-component the bonding surface must be renewed.
base coat, 1. If necessary, apply two-component base coat to any blank panel section.
adhesive tape, 2. Let the base coat cure.
Vehicle paint, 3. Mask the bonding surface of the car flange with adhesive tape.
Two-component ▶ Do not apply any coloring paint to the bonding surface.
adhesive kit 4. Paint and cure the car flange including the remaining affected parts by means
of standard repair paintwork method.
5. Remove adhesive from the masked area.
6. Clean the bonding surface with the cleaning cloth from the two-component
adhesive kit.
▶ Let the cleaning agent cure for 10 min.
Areas with damaged adhesive bead:
1. Shake up the primer from the two-component adhesive kit for 1 minute.
Note: The movement of the steel ball inside the primer cartridge must be noticeable
and audible.
2. Using the application brush, apply the primer once in a single stroke to the bonding
surface.
NOTICE The primer must not be applied to any undamaged section of the adhesive bead!
▶ Let the primer cure for 10 min.

If the curing time of 8 h is exceeded, the primer may be re-applied one single time and
within 96 h after the first application of the primer. Primed areas must be protected
against external effects and soiling within this period.
▶ Let the primer cure again for 10 min.
Areas with undamaged adhesive bead:
1. Apply the activator using the application brush (two-component adhesive kit) in one
single stroke to the bonding area.
Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
NOTICE The roof module must be bonded to the car flange within the next 2 h.

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CAR FLANGE WITH FULL-SURFACE ADHESIVE RESIDUE

1. Apply the activator using the application brush (two-component adhesive kit) in one
Two-component single stroke to the bonding area.
adhesive kit Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
NOTICE The roof module must be bonded to the car flange within the next 2 h.

CAR FLANGE WITHOUT FULL-SURFACE ADHESIVE RESIDUE

▶ If the cutting surface of the body is damaged or interrupted (body surface is visible),
the bonding surface must be renewed.
1. If necessary, apply two-component base coat to any blank panel section.
2. Let the base coat cure.
3. Mask the bonding surface of the car flange with adhesive tape.
▶ Do not apply any coloring paint to the bonding surface.
4. Paint and cure the car flange including the remaining affected parts by means
of standard repair paintwork method.
5. Remove adhesive from the masked area.
6. Clean the bonding surface with the cleaning cloth from the two-component
adhesive kit.
7. Let the cleaning agent cure for 10 min.
8. Shake up the primer from the two-component adhesive kit for 1 minute.
Note: The movement of the steel ball inside the primer cartridge must be noticeable
and audible.
9. Using the application brush, apply the primer once in a single stroke to the bonding
surface.
▶ Let the primer cure for 10 min.
NOTICE The roof module should be bonded to the car flange within the next 2 h.

If the curing time of 8 h is exceeded, the primer may be re-applied one single time and
within 96 h after the first application of the primer. Primed areas must be protected
against external effects and soiling within this period.
▶ Let the primer cure again for 10 min.

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Preparing the removed roof module

1. Remove any coarse soiling from the bonding surface.

2. Clean the U-shaped scraper blade with isopropanol.
Electric special 3. Cut the adhesive bead so that a strip of 1–3 mm remains
cutter, Note: The cutting surface must not be soiled.
U-shaped scraper 4. Apply the activator using the application brush (two-component adhesive kit) in one
blade single stroke to the bonding area.
Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
Isopropanol, 5. Apply two-component adhesive onto the removed adhesive bead.
Two-component ▶ The roof module must be bonded to the car within the next 2 h.
adhesive kit

Preparing a new roof module

1. Roughen the bonding surfaces [1] of the roof module in a cross-hatch pattern using
sanding paper.
80-grit sanding 2. Clean the bonding surfaces with the cleaning cloth from the two-component
paper adhesive kit.
▶ Let the cleaning agent cure for 10 min.
3. Shake up the primer from the two-component adhesive kit for 1 minute.
Two-component Note: The movement of the steel ball inside the primer cartridge must be noticeable
adhesive kit and audible.
4. Using the application brush, apply the primer once in a single stroke to the bonding
surface.
▶ Let the primer cure for 10 min.
NOTICE The roof module should be bonded to the car within the next 2 h.

If the curing time of 8 h is exceeded, the primer may be re-applied one single time and
within 96 h after the first application of the primer. Primed areas must be protected
against external effects and soiling within this period.
▶ Let the primer cure again for 10 min.

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Installing roof module

1. Prepare the two-component adhesive for processing.

2. Using the dual-cartridge gun, apply the two-component adhesive along the previously
Dual-cartridge gun applied base coat or onto the primer in a triangular bead of dimension [X] onto the roof
module.
Application height [X]: 15 mm.
Two-component ▶ Do not apply any adhesive to areas [A] (50 mm) and [B] (30 mm).
adhesive kit NOTICE When applying the adhesive, make sure that the beginning and end of the bead
overlap by approx. 30 mm.

3. Position the roof.

4. Screw on the nuts [1] evenly and then tighten.

5. Immediately remove any excess adhesive.
10 Nm

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4.6.5 Rear quarter panel repair

CAUTION SHARP OR SHARPEDGED OBJECTS
Risk of cuts, puncture or laceration injuries.
▶ Wear personal protective equipment.

CAUTION HOT SHEET METAL PANELS

Risk of scalding due to hot sheet metal panels.
▶ Avoid contact with hot metal panels.
▶ Wear personal protective equipment.

CAUTION OPERATING GRINDING AND CUTTING TOOLS

Risk of hearing disorders.
▶ Wear personal protective equipment.

CAUTION OPERATING DRILLING, GRINDING AND CUTTING TOOLS

Risk of injury from flying metal chips.
▶ Wear personal protective equipment.

NOTICE INCORRECT ASSEMBLY

Possibility of component damage due to incorrectly disassembly and/or assembly.
▶ Two people should always remove and/or refit large components.

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Tools and Equipment

The following and equipment are recommended for use when repairing the rear quarter panel:

Tools and Equipment

• Marker pen • Screw clamps
• Scriber • Manual cartridge gun
• Battery powered drill / drill • Hammer
• Torx 25 • Mortise chisel
• Drill bit 4.2 mm • Flat chisel
• Drill bit 5.0 mm • Pin punch
• Drill bit 6.0 mm • Plastic hammer
• Drill bit 6.7 mm • Hand anvil (dolly)
• Angle grinder with serrated grinding disc • Acetone
• Belt grinder • 1x adhesive Sika Power 477R
• Body jigsaw with 70 mm saw blade • 29x rivets 4.0 mm (N 900.978.02 - KL 3.0 mm)
• Rivet gun for high-strength rivets • 9x rivets 4.8 mm (N 902.866.04 - KL 3.0 mm)
• Hot air gun • 4x rivets 4.8 mm (N 902.876.01 - KL 3.0–6.0 mm)
• Wire brush • 11x rivets 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm)
• Vice grips • 16x rivets 6.5 mm (WHT.009.075 - KL 2.0–4.5 mm)

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Cutting-out rear quarter panel

The picture shows the maximum possible repair area [1].

Smaller patches are permitted.
Larger patches are NOT permitted.
Overlap between patch an original panel should be 30 mm.

b Remove all components from the area to be repaired.

1. Mark the section to be replaced with a marker pen.

Marker pen

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2. Drill out the joints on the sill return flange [yellow] in the area to be repaired.
3. Grind off from the inside the remaining joints on the sill return flange.
6.0 mm drill bit,
belt grinder

4. Remove the sheet metal on the sill return flange.

Hammer,
mortise chisel

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5. Remove the joint sealing [1].

6. Drill out the joints [2].
Wire brush, 7. Grind off the joint [3].
6.0 mm drill bit, 8. Heat the bonded area and separate the metal panels.
belt grinder,
hot air gun,
mortise chisel,
hammer

9. Grind the wheel arch flange until the orange coloured adhesive is visible.
10. Heat the panel on the wheel arch to loosen the bonded area.
Angle grinder with 11. Separate the panels with the mortise chisel.
serrated disc,
hot air gun,
hammer,
mortise chisel

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12. Drill a 6.0 mm hole to allow access for the jigsaw.

13. Cut the quarter panel from the window aperture downwards along the trim line.
6.0 mm drill bit, 14. Cut the quarter panel towards the rear along the trim line below the window aperture.
jigsaw with 70 mm
blade
To prevent damaging the sheet metal panels underneath do not cut too deep.

15. To release panel tension and create more working space occasionally cut off parts of
the quarter panel already free from the body.
Jigsaw with
70 mm blade
To prevent damaging the sheet metal panels underneath do not cut too deep.

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16. Drill a 6.0 mm hole to allow access for the jigsaw.

17. Cut the quarter panel along the trim line.
6.0 mm drill bit,
jigsaw with 70 mm
blade To prevent damaging the sheet metal panels underneath do not cut too deep.

18. Cut the quarter panel flange [1] at the rear.

19. Mark the installation position of the quarter panel to help later with panel alignment.
Jigsaw with 20. Grind quarter panel joints [2] on the flange at the rear of the quarter panel.
70 mm blade, 21. Heat bonded area.
scriber, 22. Remove the panel using the mortise chisel.
belt grinder,
hot air gun,
hammer,
mortise chisel

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23. Lift the quarter panel [1] and cut through the inner foam adhesive [2].
24. Remove the quarter panel.
Jigsaw with 25. Cut off the protruding residual foam.
70 mm blade

26. Mark [3] the outer rear wheel-arch [1] installation position on the sill [2].

Scriber

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27. Grind the joint [1] on the strike plate [2].

28. Heat the bonded area.
Belt grinder, 29. Separate and remove the strike plate [2] from the wheel arch.
hot air gun, 30. Drift out the remains of the joint.
flat chisel,
pin punch,
hammer

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31. Remove the joint sealing between the outer rear wheel-arch [1] and inner rear wheel-
arch.
Wire brush

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32. Grind off joints [1] on mating flange between outer rear wheel-arch and inner rear
wheel-arch [2].
Belt grinder, 33. Drift out the remains of the joint.
pin punch,
hammer

34. Grind off the joints [1] on outer rear wheel-arch [2].
35. Drift out the remains of the joint.
Belt grinder,
pin punch,
hammer

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36. Remove the FlowDrill screws [1].

Torx 25

37. Cut, from the outside to the inside, the outer rear wheel-arch above and below the
TPMS antennae bracket [1] to the inner rear wheel-arch flange.
Jigsaw with 38. Bend the section [2] inwards.
70 mm blade, 39. Remove the FlowDrill screws [3].
Torx 25 40. Cut the section [2] off the flange.

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41. Cut the outer rear wheel-arch [1] following the radius 20 mm from the inner rear
wheel-arch flange.
Jigsaw with
70 mm blade
The remaining 20 mm flange is required to fasten the new outer rear wheel-arch top panel.
DO NOT remove the 20 mm flange.

42. Grind off the joints on the front lower flange [1] and front inner flange [2].
43. Heat bonded area.
Belt grinder, 44. Separate panels and remove.
hot air gun, 45. Drift out the remains of the joint.
mortise chisel,
pin punch,
hammer

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46. Grind the joints [1] on the flange.

47. Heat bonded area.
Beltgrinder, 48. Separate panels.
hot air gun, 49. Remove outer rear wheel-arch [2].
flat chisel,
hammer

50. Remove the residual adhesive and sealing compound from the repair area.
51. Deburr the cut edges.
Angle grinder with 52. Drift out the remains of the joint.
serrated disc,
pin punch,
hammer Ensure that the marks on the sill are NOT removed. These marks are required to align the
outer rear wheel-arch.

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Replacing rear quarter panel

1. Trim the new wheel outer rear wheel-arch [1] to suit the area to be repaired.
2. Panel [2] is not required for the repair.
Jigsaw with 3. Deburr the trimmed panel [3] edges.
70 mm blade,
belt grinder

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4. Align outer rear wheel-arch [1] with the marks [2] and drilled holes [3].
5. Fasten the outer rear wheel-arch [1] with vice grips and/or screw clamps.
Vice grips, 6. Use the original drill holes on the chassis to drill 6.7 mm holes [4] through the outer rear
6.7 mm drill bit, wheel-arch [1].
jigsaw with 70 mm 7. Cut off the protruding sheet metal [5].
blade

8. Loosen and remove the outer rear wheel-arch [1].

9. Roughen and clean all the mating surfaces [2] (metallicaly blank and free of grease).
Belt grinder, 10. Apply adhesive 3M DP490 to the mating surfaces [2].
vice grips, 11. Realign the outer rear wheel-arch with the marks and drilled holes.
screw clamps, 12. Fasten the outer rear wheel-arch with vice grips and/or screw clamps.
6.7 mm drill bit, 13. Drill out the holes [3] to 6.7 mm.
rivet gun for high- 14. Rivet panels together with 6.5 mm (WHT.009.075 - KL 2.0–4.5 mm) [3] rivets.
strength rivets, 15. Rivet panels together with 6.5 mm (WHT.009.075 - KL 2.0–4.5 mm) [4] rivets.
14x rivets 6.5 mm
(WHT.009.075 -
KL 2.0–4.5 mm)

Acetone,
adhesive 3M
DP490

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16. Cut and remove the flange [1] on the outer rear wheel-arch top panel.
17. Deburr the trimmed panel edges.
Jigsaw with
70 mm blade,
belt grinder

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18. Flare the flange [1] in the forward area of the outer rear wheel-arch.
19. Swivel the top panel [2] into position and insert into the flared flange [1].
Mortise chisel, 20. Place the inner top panel [2] onto the flange.
hammer 21. Top panel [2] must lie on the outside of the outer rear wheel-arch [3].
22. Check the top panel fit and, if necessary, adjust to fit.

23. Roughen and clean all the mating surfaces (metallicaly blank and free of grease).
24. Apply adhesive 3M DP490 [1] to the mating surfaces.
Belt grinder, 25. Position top panel [2] and secure with vice grips.
vice grips,
6.7 mm drill bit
The holes [3] in the top panel [2] and flange [4] must align.

Acetone,
adhesive 3M
DP490

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26. Drill out the holes to 6.7 mm.

27. Rivet together the top panel [2] and flange with 6.5 mm
6.7 mm drill bit, (WHT.008.769 - KL 3.0–6.5 mm) [1] rivets.
5.0 mmm drill bit, 28. Drill 5.0 mm holes in the top panel [2].
rivet gun for high- 29. Rivet together the top panel [2] and outer rear wheel-arch with 4.8 mm
strength rivets, (N 902.866.04 - KL 3.0 mm) [3] rivets.
8x rivets 6.5 mm
(WHT.008.769 -
KL 3.0–6.5 mm),
3x rivets 4.8 mm
(N 902.866.04 -
KL 3.0 mm)

30. Drill 5.0 mm [1] holes.

31. Rivet together the outer wheel-arch [1] and top panel [2] with 4.8 mm
5.0 mm drill bit, (N 902.866.04 - KL 3.0 mm) rivets.
rivet gun for high-
strength rivets,
3x rivets 4.8 mm
(N 902.866.04 -
KL 3.0 mm)

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32. Drill 5.0 mm holes.

33. Rivet together the outer rear wheel-arch [2] and top panel [3] with 4.8 mm
5.0 mm drill bit, (N 902.866.04 - KL 3.0 mm) rivets.
rivet gun for high- 34. Mark with scriber TPMS antennae installation position.
strength rivets, 35. Cut the marked area on the outer rear wheel-arch.
scriber, 36. Remove the cut section.
jigsaw with 70 mm 37. Fit the TPMS antennae holder [4].
blade, 38. Drill 4.2 mm holes in the outer rear wheel-arch.
4.2 mm drill bit, 39. Remove the TPMS antennae holder.
belt grinder, 40. Roughen and clean mating surfaces (metallicaly blank and free of grease).
3x rivets 4.8 mm 41. Apply adhesive 3M DP490 to the mating surfaces.
(N 902.866.04 - 42. Fit TPMS antennae holder [4] and align with the drilled holes.
KL 3.0 mm), 43. Rivet together the panels with 4.0 mm (N 900.978.02 - KL 3.0 mm) [5] rivets.
6x rivets 4.0 mm
(N 900.978.02 -
KL 3.0 mm)

Acetone,
adhesive 3M
DP490

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44. Trim the new quarter panel to suit the repair area [1].

Jigsaw with
70 mm blade, The overlap between the quarter panel patch and chassis should be 30 mm.
belt grinder 45. Deburr the trimmed edges.

46. Heat the sheet metal doubler [1] on the window aperture and remove using the mortise
chisel.
Hot air gun,
mortise chisel,
hammer Do not damage the quarter panel when removing the metal doubler.

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47. Cut off the sound insulation and residual foam [1].

Jigsaw with
70 mm blade

48. Grind the joint [1] on the back of the metal doubler [2] flange.
49. Heat the bonded area and separate the metal doubler [2] from the quarter panel.
Belt grinder, 50. Straighten the flange if necessary.
hot air gun,
mortise chisel,
hammer

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51. Fit and align the quarter panel – two mechanics required.
52. Trim the quarter panel [2] in area [1]. Trim the flange to suit the chassis.
Vice grips, 53. Remove quarter panel.
jigsaw with 70 mm 54. Deburr the trimmed edges.
blade, 55. Roughen and clean all mating surfaces (metallicaly blank and free of grease).
4.2 mm drill bit, 56. Apply adhesive 3M DP490 to the mating surfaces.
rivet gun for high- 57. Fit, align and fix quarter panel in position with vice grips – two mechanics required.
strength rivets, 58. Drill 4.2 mm holes through the flange.
belt grinder, 59. Rivet together the panels with 4.0 mm (N 900.978.02 - KL 3.0 mm) [3] rivets.
3x rivets 4.0 mm
(N 900.978.02 -
KL 3.0 mm)

Acetone,
adhesive 3M
DP490

60. Drill 4.2 mm holes.

61. Rivet the quarter panel in position with 4.0 mm (N 900.978.02 - KL 3.0 mm) [1], [2],
4.2 mm drill bit, [3] rivets.
rivet gun for high-
strength rivets,
11x rivets4.0 mm
(N 900.978.02 -
KL 3.0 mm)

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62. Drill 4.2 mm holes at an equal distance from the window aperture along the door
opening to the sill.
4.2 mm drill bit, 63. Rivet the quarter panel in position with 4.0 mm (N 900.978.02 - KL 3.0 mm) [1] rivets.
rivet gun for high-
strength rivets,
6x rivets 4.0 mm
(N 900.978.02 -
KL 3.0 mm)

64. Drill 6.7 mm holes.

65. Rivet the panels together with 6,5 mm (WHT.009.075 - KL 2.0–4.5 mm) [1] rivets.
6.7 mm drill bit,
rivet gun for high-
strength rivets,
2x rivets 6,5 mm
(WHT.009.075 -
KL 2.0–4.5 mm)

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66. Drill 6.7 mm holes in the sill return flange [1].

67. Rivet together the panels with 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [2] rivets.
6.7 mm drill bit, 68. Drill 4.2 mm holes in the sill return flange.
rivet gun for high- 69. Rivet together the panels with 4.0 mm (N 900.978.02 - KL 3.0 mm) [3] rivets
strength rivets,
3x rivets 6.5 mm
(WHT.008.769 -
KL 3.0–6.5 mm),
3x rivets 4.0 mm
(N 900.978.02 -
KL 3.0 mm)

70. Bead-over the wheel-arch [1].

Hand anvil (dolly),

plastic hammer Wrap the dolly in a rag to prevent damaging the quarter panel.

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71. Use the existing drill holes to align the strike plate [2] in inner rear wheel-arch.
72. Mark the rivet positions on the outer rear wheel-arch panel.
Scriber, 73. Drill 5.0 mm holes.
5.0 mm drill bit, 74. Roughen and clean mating surfaces (metallicaly blank and free of grease).
belt grinder, 75. Apply adhesive 3M DP490 to mating surfaces.
rivet gun for high- 76. Rivet together the strike plate [2] in position with 4.8 mm
strength rivets, (N 902.876.01 - KL 3.0–6.0 mm) [1] rivets.
4x rivets 4.8 mm
(N 902.876.01 -
KL 3.0–6.0 mm)

Acetone,
adhesive 3M
DP490

Subsequent operations

1. Restore the factory seals.

It is particularly important to carefully seal the repair area.
2. Refit the components originally removed from the repair area.

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4.6.6 Front chassis section repair

Diagnosis

The illustration shows the maximum permissible repair area of the front chassis section
from outside.

The illustration shows the maximum permissible repair area of the front chassis section
from inside. The connection from the longitudinal beam to the bulkhead (marking line)
represents the repair limit. In case of damage beyond this limit, repair is not permitted.

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b Remove all the components from the area to be checked.

1. Fit the front chassis-section jig [1] without alignment brackets to the mounting
points [2].
Front chassis 2. If the front chassis-section jig [1] can be fitted without problems using the bolts
section jig, delivered with the jig, it is NOT necessary to replace the front chassis section-luggage
18 mm AF socket compartment.

The threaded inserts are Helicoils. Replace any damaged Helicoils.

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Remove the front chassis section-luggage compartment

CAUTION SHARP OR SHARP EDGED OBJECTS
Risk of cuts, puncture or laceration injuries.
▶ Wear personal protective equipment.
Tools and Equipment

The following tools and equipment are recommended for use when repairing the front chassis section-luggage compartment:

Tools and Equipment

• Front chassis section jig • Manually operated hydraulic rivet nut gun (Böllhoff RIVKLE ZS308)
• Trim line patterns • Hot air gun
• Marker pen • Wire brush
• Battery powered drill / drill • Vice grips
• Torx 25 • Manual cartridge gun
• 18 mm AF socket • Hammer
• 6 mm Allen key • Mallet
• 8 mm Allen key • Flat chisel
• Drill bit 5.0 mm • Centre punch
• Drill bit 6.7 mm • Pin punch
• Drill bit 7.0 mm • Wooden block
• Angle grinder with serrated disc • Acetone
• Belt grinder • 1x adhesive 3M DP490
• Jigsaw with 70 mm blade • 63x rivets 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm)
• Jigsaw with 200 mm blade • 13x rivets 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm)
• Rivet gun for high-strength rivets • 1x rivet stud WHS.001.913

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The trim line patterns can be obtained directly from the manufacturer.
▶ Offer reference 2021-31113
cirp GmbH
Römerstraße 8
71296 Heimsheim
Germany
+49 7033 30987 0
[email protected]
www.cirp.de
Contacts:
Mr. Sami Bensid +49 7033 30987 47
[email protected]
Mrs. Lucia DeSimone + 49 7033 30987 24
[email protected]

The working procedure described in this chapter are for the driver side and should be followed identically on the passenger side.

b Remove all the components from the area to be repaired.

1. Mark, 50 mm from the support 1 flange, the approximate cutting area.

2. Mark, 35 mm from the bulkhead flange, the approximate cutting area.
Marker pen, 3. Position the pattern “Trim line bulkhead” [1] relative to the contour and mark the trim
pattern “Trim line line approx. 35 mm from the pattern.
bulkhead”, 4. Smear the trim line area with suitable lubricant.
jigsaw with 5. Cut the front chassis section-luggage volume along the trim line.
200 mm blade,
jigsaw with 70 mm
blade

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6. Remove front chassis section-luggage volume [1].

Two mechanics are required for this task.

7. Remove residual adhesive [1] from the longitudinal beam [2].

8. Mark [3] the overlap to the upper longitudinal beam [2].
Angle grinder with
serrated disc,
marker pen The mark [3] is used later to align the front chassis section-luggage compartment.

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9. Position the pattern “Trim line bulkhead” [1] relative to the contour and mark trim line.

Marker pen,
pattern „Trim line
bulkhead“

10. Remove the joint sealant [1].

11. Position pattern „Trim line longitudinal beam upper outboard“ [2] relative to the
Wire brush, contour and mark trim line.
Pattern „Trim line
longitudinal upper
outboard“

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12. Position pattern “Trim line suspension strut left” [1] relative to the contour and mark
the trim line [2].
Marker pen,
pattern “Trim line
suspension strut Due to the radius of the pattern, it is possible that the trim line [2] must be extended.
left”, Mark the extended trim line using a steel rule and marker pen.
steel rule

13. Remove the Tucker stud [1] and grind projection flat.
14. Remove the bolts [2].
Torx 25,
pincers,
belt grinder The Tucker stud [1] to be removed is only fitted to the driver side.

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15. Position pattern “Trim line Support 1 left outboard” [1] relative to the contour and mark
the trim line on Support 1.
Marker pen,
pattern “Trim line
support 1 left
outboard”

16. Cut Support 1 [1] above the flange [2].

17. Cut the upper longitudinal beam [3] 10 - 15 mm from the trim line [4].
Jigsaw with 18. Remove the cut section.
70 mm blade,
jigsaw with
200 mm blade

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19. Remove the joint sealant sealing [1] in the area of the flange.
20. Grind off the welds [2].
Wire brush, 21. Heat up metal panels on the flange [3] to loosen the adhesive.
belt grinder, 22. Cut and remove the metal panels from Support 1 [4].
hot air gun, 23. Grind off the residual welds on Support 1.
flat chisel, 24. Remove residual adhesive.
angle grinder with
serrated disc

25. Position pattern “Trim line Support 1 left inboard” [1] relative to the contour and mark
trim line.
Pattern “Trim line 26. Cut Support 1 [2] exactly along the trim line.
Support 1 left
inboard“,
marker pen,
jigsaw with
200 mm blade

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27. Grind off the joint [1] from the outside.

28. Heat up metal panels on Support 1.
Belt grinder, 29. Use a flat chisel to remove sheet metal doubler [2] from Support 1 [3].
hot air gun, 30. Grind off residual adhesive.
flat chisel, 31. Drift out the remains of the joint.
hammer,
pin punch

32. Remove joint sealant [1].

33. Grind off the joints [2].
Wire brush, 34. Heat up the sheet metal plate [3].
belt grinder, 35. Use a flat chisel to remove the sheet metal plate [3] from the upper longitudinal beam.
hot air gun, 36. Remove residual adhesive.
flat chisel, 37. Drift out the remains of the joint.
hammer,
pin punch

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38. Make the final cut on the upper longitudinal beam [1].

Jigsaw with
70 mm blade To ensure that the front chassis section-luggage compartment sits correctly in position cut
exactly along the trim line [2].

39. Grind the joint [1].

40. Heat the residual trimmed sheet [2] from the sealing frame and remove from the upper
Belt grinder, longitudinal beam using a flat chisel.
hot air gun, 41. Drift out the remains of the joint.
flat chisel, 42. Remove residual adhesive.
hammer, 43. Deburr all the trimmed edges in the repair area.
pin punch

When removing the residual adhesive, ensure that the trim line marking on the upper
longitudinal beam remains clearly visible. This is required later to align the new front chassis
section-luggage compartment assembly.

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Replacing front chassis section-luggage compartment

1. Remove the Tucker stud [1] on the right side of the bulkhead [2] and grind projection
flat.
Pincers,
belt grinder

2. Insert the front chassis section-luggage compartment [1] into Support 1 [2].
3. Slide the front chassis section-luggage compartment [1] onto the upper longitudinal
Mallet, beam [3].
wooden block 4. If necessary, tap the chassis section-luggage compartment gently with the hammer/
wooden block to ensure it sits correctly in position.

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5. Fit the front chassis section jig [1] without the alignment brackets to the
mounting points [2].
Front chassis 6. Check the seat and position of the front chassis section-luggage compartment using
section jig, the front chassis section jig and marks on the upper longitudinal beam as reference.
18 mm AF socket 7. Remove the front chassis section jig.

8. Remove the front chassis section-luggage compartment [1].

9. Roughen and clean the mating surfaces (metallicaly blank and free of grease).
18 mm AF socket, 10. Apply adhesive 3M DP490 to the contact surfaces [2].
belt grinder, 11. Slide the front chassis section-luggage compartment [1] onto Support 1 [3].
mallet, 12. If necessary, tap the chassis section-luggage compartment gently on the front face to
wooden block ensure it sits correctly in position.

Acetone,
adhesive 3M
DP490

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13. Fit the front chassis section jig [1] without alignment brackets to the front suspension
subframe mounting points.
Front chassis 14. Use the front chassis section jig and marks on the upper longitudinal beam to align and
section jig, fasten the front chassis section-luggage compartment assembly in position.
front jig extension 15. Fit the front jig extension [2].
jig, 16. Fit the front jig [3] to the front chassis section-luggage compartment assembly and fit
wishbone and the front jig extension.
suspension strut 17. Fit the wishbone mounting and suspension-strut alignment jig [4] to the front chassis
jig, section jig.
18 mm AF socket, 18. Check and adjust if necessary the alignment of the front chassis section-luggage
6 mm Allen key, compartment assembly.
8 mm Allen key

The assembly of the front jig extension jig and the front chassis section jig must be done
without increased force. The components of the front chassis section jig must not be
mounted with tension. All locating points of the front chassis section jig and marks on the
upper longitudinal beam must be aligned before joining the new front chassis section-
luggage compartment.

19. Remove the wishbone mounting and suspension-strut alignment jig.

20. Position pattern “Trim line Support 1 left outboard” [1] relative to contour and mark and
Marker pen, drill holes.
pattern “Trim line
Support 1 left
outboard”

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21. Remove pattern “Trim line Support 1 left outboard”.

22. Drill 6.7 mm holes in Support 1.
Centre punch, 23. Fit the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [1] rivets and rivet the front chassis
hammer, section-luggage compartment [2] to Support 1.
6.7 mm drill bit,
rivet gun for high-
strength rivets,
18x rivets 6.5 mm
(WHT.008.769 -
KL 3.0–6.5 mm)

24. Drill a 6.7 mm hole in Support 1.

25. Fit the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [1] rivet.
5.0 mm drill bit, 26. .Drill the 6.7 mm holes on the inside of the front chassis section-luggage
6.7 mm drill bit, compartment.
rivet gun for high 27. Fit the 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm) [2] rivets and rivet the front chassis
strength rivets, section-luggage compartment [3] to Support 1.
2x rivets 6.5 mm
(WHT.008.769 -
KL 3.0–6.5 mm), On the right side of the car, the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [1] rivet is not
6x rivets 6.5 mm used. Instead, drill a 6.7 mm hole and fit the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [4]
(WHT.009.074 - rivet on the outside of the front chassis section-luggage compartment.
KL 5.0–8.5 mm)

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28. Drill the 6.7 mm holes in Support 1 [1].

29. Fit the 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm) [2] rivets and rivet the flange on
6.7 mm drill bit, Support 1 to the front chassis section-luggage compartment [3].
rivet gun for high- 30. Fit the 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [4] rivet.
stregth rivets, 31. Fit the 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm) [5] rivet.
7x rivets 6.5 mm
(WHT.009.074 -
KL 5.0–8.5 mm),
The rivets [4] and [5] cannot be fitted to Support 1 on the right hand side of the car due to
1x rivet 6.5 mm a lack of installation space.
(WHT.008.769 -
KL 3.0–6.5 mm)

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32. Roughen and clean the mating surfaces of the connecting metal sheet [1] and [2]
(metallicaly blank and free of grease).
Belt grinder, 33. Apply adhesive 3M DP490 on mating surfaces.
6.7 mm drill bit, 34. Align and fit connecting metal sheet.
rivet gun for high- 35. Drill the 6.7 mm holes.
strength rivets, 36. Starting with connecting metal sheet [1] rivet to upper longitudinal beam with 6.5 mm
28x rivets 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [5] rivets.
(WHT.008.769 -
KL 3.0–6.5 mm)

Acetone,
adhesive 3M
DP490

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37. Drill the 6.7 mm holes.

38. Fit 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [1] rivets and rivet connecting metal
6.7 mm drill bit, sheet to the upper longitudinal beam [2] and front chassis section-luggage
rivet gun for high- compartment [3].
strength rivets,
14x rivets 6.5 mm
(WHT.008.769 -
KL 3.0–6.5 mm)

39. Mark the new position for the rivet nuts [1].
40. Drill a 7.0 mm hole.
Steel rule, 41. Fit the new rivet nut WHS.001.913.
marker pen,
centre punch,
hammer,
7.0 mm drill bit,
manually operated
hydraulik rivet nut
gun (Böllhoff
RIVKLE ZS308),
1x rivet nut
WHS.001.913

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42. Remove the front chassis section jig and all alignment brackets.

18 mm AF socket,
6 mm Allen key,
8 mm Allen key

Subsequent operations

1. Restore the factory seals.

It is particularly important to carefully seal the repair area.
2. Refit the components originally removed from the repair area.

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4.6.7 Front chassis section-subframe repair

Diagnosis

b Remove all the components to the area to be checked.

1. Fit the front chassis-section jig [1] without alignment brackets to the mounting points.
2. Fit the front jig extensions [2].
Front chassis- 3. Fit the front jig [3] to the front chassis section-luggage compartment and front jig
section jig, extensions.
front jig extension, 4. Fit the wishbone and suspension strut jig [4] to the front chassis section jig.
front jig,
wishbone and
suspension strut The front jig extension must be fitted without using excessive force, and the alignment
jig, brackets fitted without tension or preload.
18 mm AF socket, ▶ Check if all the mounting points on the chassis align with the alignment brackets on the
6 mm Allen key, jig. If required, implement additional steps. For example, if the wishbone mounting does
8 mm Allen key not align replace before the front chassis section-subframe is repaired.

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Removing front chassis-subframe

CAUTION SHARP OR SHARP EDGED OBJECTS
Risk of cuts, puncture or laceration injuries.
▶ Wear personal protective equipment.
Tools and Equipment

The following tools and equipment are recommended for use when repairing the front chassis section-subframe:

Tools and Equipment

• Front chassis section jig • Manual cartridge gun
• Marker pen • Hammer
• Battery powered drill / drill • Plastic hammer
• Torx 25 • Mallet
• 18 mm AF socket • Flat chisel
• 6 mm Allen key • Dolly
• 8 mm Allen key • Scraper
• HSS drill bit 3.5 mm (due to blunting several drill bits required) • Tyre lever
• HSS drill bit 5.0 mm (due to blunting several drill bits required) • Centre punch (high-tensile)
• HSS drill bit 6.7 mm (due to blunting several drill bits required) • Pin punch
• Angle grinder with serrated disc • Acetone
• Angle grinder • 1x adhesive 3M DP490
• Belt grinder • 56x rivets 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm)
• Jigsaw with 70 mm blade • 16x rivets 4.8 mm (N .902.866.04 - KL 2.5–5.0 mm)
• Rivet gun for high-strength rivets • 8x rivets 4.8 mm (N .909.236.02 - KL 6.0–8.5 mm)
• Hot air gun • 4x rivets 6.5 mm (999.190.246.01 - KL7.0–10.5 mm)

The working procedure described in this chapter are for the driver side and should be followed identically on the passenger side.

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b Remove all the components to the area to be repaired.

1. Drill out the self-piercing rivets [yellow] on the bulkhead in the lower area of the air-
jack mounting.
8.0 mm drill bit, 2. Drift out the remains of the self-piercing rivets.
pin punch,
hammer

3. Drill out the self-piercing rivets [yellow] on the air jack mounting flange.
4. Drift out the remains of the self-piercing rivets.
8.0 mm drill bit,
pin punch,
hammer

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5. Drill out the self-piercing rivets [yellow].

6. Drift out the remains of the self-piercing rivets.
8.0 mm drill bit,
pin punch,
hammer

7. Heat the bonded area [yellow].

8. Remove the air jack mounting using a scraper.
Hot air gun,
hammer,
scraper When the bonded joint is separated, the air jack mount hangs loosely on the front chassis
section-luggage compartment floor panel. At this stage it is not possible to remove the air
jack mounting due to structural considerations.

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9. Spot mark the self-piercing rivets [yellow] on the bulkhead flange to the front chassis
section-luggage compartment using a high-tensile centre punch.
High-tensile 10. Drill through the self-piercing rivets [yellow] with a 3.5 mm drill bit.
centre punch, 11. Drill out the self-piercing rivets [yellow] with a 6.7 mm drill bit.
3.5 mm HSS drill
bit,
6.7 mm HSS drill When drilling out the rivets ensure that the drill bit is sufficiently cooled and, if necessary,
bit, apply pressure to the drill intermittently to help cooling.
hammer Alternatively, grind down the self-piercing rivet heads using a belt grinder before drifting
out the remains of the rivets.

12. Drill out the self-piercing rivets [yellow] in the reinforcement parts [1].
13. Drift out the remains of the rivets.
8.0 mm drill bit, 14. Heat the bonded area of the reinforcement parts.
pin punch, 15. Remove the reinforcement parts from the subframe.
hammer,
hot air gun,
flat chisel,
tyre lever

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16. Grind the weld [yellow] flat on the flange before cutting with the angle grinder.
NOTE When cutting the weld DO NOT cut too deep to avoid damaging the front chassis
Angle grinder with section-luggage compartment or even cutting it off! Only the weld should be removed
serrated disc, during this step! No material from the chassis should be removed/ground off!
angle grinder

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17. Grind off the self-piercing rivets [1] from the outside.
18. Spot mark the self-piercing rivets [2] with the high-tensile centre punch.
High-tensile 19. Drill through the self-piercing rivets [1] with the 3.5 mm HSS drill bit before drilling out
centre punch, with the 6.7 mm HSS drill bit.
belt grinder, 20. Spot mark the self-piercing rivets [2] with the high-tensile centre punch.
3.5 mm HSS drill 21. Drill through the self-piercing rivets [2] with the 3.5 mm HSS drill bit before drilling out
bit, with the 6.7 mm HSS drill bit.
6.7 mm HSS drill
bit,
hot air gun,
flat chisel

22. Grind off the self-piercing rivets [yellow] from the outside.
23. Spot mark the self-piercing rivets [yellow] from the inside with the high-tensile centre
Angle grinder with punch.
serrated disc, 24. Drill through the self-piercing rivets [yellow] with the 3.5 mm HSS drill bit before
high-tensile centre drilling out with the 6.7 mm HSS drill bit.
punch,
belt grinder,
3.5 mm HSS drill
bit,
6.7 mm HSS drill
bit

25. Grind the weld [1] flat on the front chassis section-luggage compartment before flange
before cutting with the belt grinder.
Angle grinder with NOTE In this step only remove the weld [1] within the stamped slots [2] in the chassis.
serrated disc, No material from the chassis should be removed/ground off!
belt grinder

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26. Drill 6.7 mm holes [yellow] to allow access for the jig saw.
27. Cut the front chassis section subframe [1] parallel to the front chassis section-luggage
6.7 mm HSS drill compartment flange [2].
bit, NOTE When cutting out the front chassis section-subframe sufficient distance must be
jigsaw with 70 mm retained to the front chassis section-luggage compartment flange to prevent damaging
blade the chassis!

28. Heat the bonded area [yellow] and remove the panel.

Hot air gun,

jigsaw with 70 mm
blade,
hammer,
scraper,
flat chisel,
mallet

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 BODY EXTERIOR | Body repair

29. Cut the front chassis section-subframe along the trim line (see Fig. 57).

Jigsaw with
70 mm blade

Fig. 57: Trim line

30. Slide (hammer gently) the front chassis section-subframe towards the rear and
remove.
31. Remove the remnants of the front chassis section-subframe from the chassis.

When removing the front chassis section-subframe ensure that the air jack mounting does
not fall out.

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32. Remove the air jack mounting.

33. Remove all the residual adhesive.
Belt grinder, 34. Deburr the panels in the repair area.
hammer, 35. Straighten the panels in the repair area.
dolly

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 BODY EXTERIOR | Body repair

Replacing front chassis section-subframe

1. Fit the new front chassis section-subframe in position and check the precision of fit
(two mechanics required for this step) and if required rework the chassis locally in the
Belt grinder repair area.
2. Remove the front chassis section-subframe again.
3. Roughen and clean the bonding area, including the air jack mounting bonding area. The
Acetone, bonding areas must be metallicaly blank and free of grease.
adhesive 3M 4. Apply adhesive 3M DP490 to the chassis section-subframe bonding area.
DP490 5. Fit and secure the air jack mounting in position.
6. Fit the new front chassis section-subframe in position (two mechanics required for this
step).
7. Fit the front chassis-section jig (see Diagnosis on page 594).

8. Use the chassis as jig to drill the 6.7 mm holes in the front chassis section-subframe.
9. Fit and close the 6.5 mm rivets [yellow] (WHT.008.769 - KL 3.0–6.5 mm).
6.7 mm HSS drill
bit,
rivet gun for high- Use a plastic hammer to tap the panel folds to seat against the front chassis section before
strength rivets, fitting and closing the rivets.
plastic hammer,
8x rivets 6.5 mm
(WHT.008.769 -
KL 3.0–6.5 mm)

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10. Fit the reinforcement part [1] and mark the installed position.
11. Drill the 6.7 mm holes.
Marker pen, 12. Fit and close the 6.5 mm rivets [yellow] (WHT.008.769 - KL 3.0–6.5 mm).
6.7 mm HSS drill 13. Use the chassis as jig to drill the 6.7 mm holes [2].
bit, → The holes are required in a later step to secure the reinforcement parts.
rivet gun for high-
strength rivets,
4x 6.5 mm rivets
(WHT.008.769 -
KL 3.0–6.5 mm)

14. Drill the 6.7 mm holes.

15. Fit and close the 6.5 mm rivets [1] (WHT.008.769 - KL 3.0–6.5 mm).
6.7 mm HSS drill 16. Fit and close the 6.5 mm rivets [2] 6.5 mm (999.190.246.01 - KL 7.0–10.5 mm).
bit,
rivet gun fot high-
strength rivets,
2x 6.5 mm rivets
(WHT.008.769 -
KL 3.0–6.5 mm),
2x 6.5 mm rivets
(999.190.246.01
- KL 7.0–
10.5 mm)

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 BODY EXTERIOR | Body repair

17. Drill the 6.7 mm holes [1] in the front chassis section-subframe from the inside.
18. Fit and close the 6.5 mm rivets [yellow] (WHT.008.769 - KL 3.0–6.5 mm) from the
6.7 mm HSS drill outside.
bit,
rivet gun for high-
strength rivets,
4x 6.5 mm rivets
(WHT.008.769 -
KL 3.0–6.5 mm)

19. Drill the 6.7 mm holes.

20. Fit and close the 6.5 mm rivets [yellow] (WHT.008.769 - KL 3.0–6.5 mm).
6.7 mm HSS drill 21. Remove front chassis section jig.
bit,
rivet gun for high-
strength rivets,
2x 6.5 mm rivets
(WHT.008.769 -
KL 3.0–6.5 mm)

22. Drill the 6.7 mm holes from the outside.

23. Fit and close the 6.5 mm rivets [yellow] (WHT.008.769 - KL 3.0–6.5 mm).
6.7 mm HSS drill
bit,
rivet gun for high- Before drilling the holes ensure that there is sufficient overlap between the chassis and
strength rivets, front chassis section-subframe!
8x 6.5 mm rivets
(WHT.008.769 -
KL 3.0–6.5 mm)

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24. Drill the 6.7 mm holes.

25. Fit and close the 6.5 mm rivets [yellow] (WHT.008.769 - KL 3.0–6.5 mm).
6.7 mm HSS drill
bit,
rivet gun for high- The existing holes [1] are NOT required as drill jig for the holes. The holes are sealed off after
strength rivets, finishing the repair.
14x 6.5 mm rivets
(WHT.008.769 -
KL 3.0–6.5 mm)

26. Align the air jack mounting.

27. Drill the 5.0 mm [1] holes.
5.0 mm HSS drill 28. Roughen and clean the bonding area on the bulkhead for the air jack mounting. The
bit, bonding area must be metallicaly blank and free of grease.
rivet gun for high- 29. Apply adhesive 3M DP490 to the air jack mounting bonding area.
strength rivets, 30. Insert the upper rivets [2] to position the air jack mounting.
7x 4.8 mm rivets 31. To secure the air jack mounting to the bulkhead fit the close the 4.8 mm rivets [3]
(N .902.866.04 - (N .902.866.04 - KL 2.5–5.0 mm).
KL 2.5–5.0 mm) 32. Fit and close the upper row of 4.8 mm rivets [2] (N .902.866.04 - KL 2.5–5.0 mm)
on the air jack mounting.

Acetone,
adhesive 3M
DP490

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33. Drill the 5.0 mm holes.

34. To secure the air jack mounting fit and close the 4.8 mm rivets [yellow]
5.0 mm HSS drill (N .902.866.04 - KL 2.5–5.0 mm).
bit,
rivet gun for high-
strength rivets,
9x 4.8 mm rivets
(N .902.866.04 -
KL 2.5–5.0 mm)

35. Fit and align the reinforcement parts.

36. Drill the 6.7 mm holes.
5.0 mm HSS drill 37. Fit and close the 6.5 mm rivets [1] (WHT.008.769 - KL 3.0–6.5 mm).
bit, 38. Fit and close the 4.8 mm rivets [2] (N .909.236.02 - KL 6.0–8.5 mm).
6.7 mm HSS drill 39. Drill from the outside the 6.7 mm in the reinforcement part.
bit, 40. Fit and close from the outside the 6.5 mm rivets [3]
rivet gun for high- (999.190.246.01 - KL 7.0–10.5 mm).
strength rivets,
2x 6.5 mm rivets
(WHT.008.769 -
KL 3.0–6.5 mm),
8x 4.8 mm rivets
(N .909.236.02 -
KL 6.0–8.5 mm),
2x 6.5 mm rivets
(999.190.246.01
- KL 7.0–10.5
mm)

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41. Drill from the inside the 6.7 mm holes in the front chassis section-subframe.
42. Fit and close the 6.5 mm rivets [yellow] (WHT.008.769 - KL 3.0–6.5 mm).
6.7 mm HSS drill
bit,
rivet gun for high-
strength rivets,
12x 6.5 mm rivets
(WHT.008.769 -
KL 3.0–6.5 mm)

Subsequent operations

1. Seal the two remaining holes in the bulkhead with any surplus adhesive or body sealing
compound.
2. Refit the components originally removed from the repair area.

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4.6.8 Rear chassis section repair

Diagnosis

b Remove all components in the area to be checked.

1. Fit the rear chassis-section jig to the suspension mounting points [1] and impact
absorber rear chassis section-rear frame [2].
13 mm AF socket,
18 mm AF socket
If the rear chassis-section jig does not align perfectly with the suspension mounting points
[1], a repair is not permitted.

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 BODY EXTERIOR | Body repair

Removing rear chassis section-rear frame

CAUTION SHARP OR SHARP EDGED OBJECTS
Risk of cuts, puncture or laceration injuries.
▶ Wear personal protective equipment.

Tools and Equipment

The following tools and equipment are recommended for use when repairing the rear chassis section-rear frame:

Tools and Equipment

• Rear chassis section jig • Screw clamps
• Battery powered drill / drill • Manual cartridge gun
• Angle drill • Hammer
• Torx 25 • Tyre lever
• 13 mm AF socket • Flat chisel
• 18 mm AF socket • Pin punch
• Drill bit 4.2 mm • Mallet
• Drill bit 5.0 mm • Wooden block
• Drill bit 6.7 mm • 1x Adhesive 3M DP490
• Angle grinder • Acetone
• Belt grinder • 6x rivets 4.0 mm (999.190.176.00 - KL 6.6 mm)
• Jigsaw with 70 mm blade • 16x rivets 4.8 mm (N 909.236.02 - KL 6.1 mm)
• Rivet gun for high-strength rivets • 4x rivets 4.0 mm (N 906.948.02 - KL 5.3 mm)
• Hot air gun • 4x rivets 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm)
• Wire brush • 38x rivets 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm)

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The working procedures described in this chapter are for the driver side and should be followed identically on the passenger side.

b Remove all components in the area to be repaired.

1. Remove the joint sealant from the area to be repaired.

2. Remove Flowdrill bolts [yellow].
Wire brush,
Torx 25
The image shows the area to be repaired from below.

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 BODY EXTERIOR | Body repair

3. Drill out rivets [1] on the retaining plate for the rear wing strut outer mounting bracket.
4. Remove the bolt [2] from the rear wing strut outer mounting bracket.
4.2 mm drill bit, 5. Twist the rear wing strut outer mounting bracket upwards.
13 mm AF socket, 6. Heat up the bonded area of the rear wing strut outer mounting bracket.
hot air gun, 7. Remove rear wing strut outer mounting bracket.
hammer, 8. Drift out the rivet body and mandrel.
flat chisel, 9. Remove residual adhesive.
pin punch,
belt grinder

10. Remove the rear wing strut inner lower mounting bracket bolt.
11. Detach and remove flange [1] retaining plate for rear wing strut inner lower.
13 mm AF socket, 12. Drill out the rivets [2] and [3] on the retaining plate for the rear wing strut inner lower.
5.0 mm drill bit, 13. Remove weld [4].
jigsaw with 70 mm 14. Heat the bonded area of the retaining plate connection rear wing strut inner.
blade, 15. Remove the retaining plate for the rear wing strut inner lower.
angle grinder, 16. Drift out the rivet body and mandrel.
hot air gun, 17. Remove the residual adhesive.
hammer, 18. Drill out the holes [3] to 6.7 mm.
pin punch,
flat chisel

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 BODY EXTERIOR | Body repair

19. Drill out the holes [yellow] to 6.7 mm

6.7 mm drill bit

20. Heat the bonding area for the support plate [1].
21. Separate support plate from rear chassis section-rear frame and bend away.
Hot air gun, 22. Drift out rear chassis section-rear frame.
hammer,
flat chisel,
tyre lever,
mallet,
wooden block

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 BODY EXTERIOR | Body repair

Replacing rear chassis section-rear frame

1. Roughen and clean the mating faces on the car and rear chassis section-rear frame
(metallicaly blank and free of grease).
Belt grinder, 2. Apply adhesive 3M DP490 [yellow].
mallet, 3. Fit the rear chassis section-rear frame and drift carefully into position.
wooden block

Acetone,
adhesive 3M
DP490

4. Fit rear-chassis section jig.

5. Align rear chassis section-rear frame on the jig.
Rear chassis 6. Positon and fix the support plates on the rear chassis section-rear frame.
section jig, 7. Drill the 6.7 mm holes in the rear chassis section-rear frame.
13 mm AF socket, 8. Fit and close rivets 6.5 mm (WHT.008.769 - KL 3.0–6.5 mm) [1].
18 mm AF socket, 9. Fit and close rivets 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm) [2].
wooden block,
mallet,
screw clamps, Do not use excessive force to fit the rear-chassis section jig. The jig components MUST fit
rivet gun for high- without preload or tension.
strength rivets,
14x rivets 6.5 mm
(WHT.009.074 -
KL 5.0–8.5 mm),
4x 6.5 mm rivets
WHT.008.769 -
KL 3.0–6.5 mm)

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 BODY EXTERIOR | Body repair

10. Drill the 6.7 mm holes in the rear chassis section-rear frame.
11. Fit and close rivets 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm) [yellow].
6.7 mm drill bit,
rivet gun for high-
strength rivets,
12x rivets 6.5 mm
(WHT.009.074 -
KL 5.0–8.5 mm)

12. Remove the rear-chassis section jig.

13. Drill the 6.7 mm holes in the rear chassis section-rear frame.
13 mm AF socket, 14. Fit and close rivets 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm) [yellow].
18 mm AF socket,
6.7 mm drill bit,
rivet gun for high-
strength rivets,
8x rivets 6.5 mm
(WHT.009.074 -
KL 5.0–8.5 mm)

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15. Roughen and clean the mating faces on the rear chassis section-rear frame and
retaining plate for the rear wing strut outer (metallicaly blank and free of grease).
Belt grinder, 16. Apply adhesive 3M DP490.
30 Nm 17. Fit and tighten the M8x45 bolt to the rear wing strut outer mounting bracket and
13 mm AF socket, retaining plate before fitting to the chassis.
screw clamp, 18. Position and fix the retaining plate on the chassis.
4.2 mm drill bit, 19. Drill the 4.2 mm holes.
6x rivets 4,0 mm 20. Fit and close rivets 4.0 mm (999.190.176.00 - KL 6.6 mm) [1].
(999.190.176.00 21. Fit and close rivets 4.0 mm (N 906.948.02 - KL 5.3 mm) [2].
- KL 6.6 mm),
4x rivets 4,0 mm
(N 906.948.02 -
KL 5.3 mm)

Acetone,
adhesive 3M
DP490

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 BODY EXTERIOR | Body repair

22. Roughen and clean the mating faces on the rear chassis section-rear frame and
retaining plate for the rear wing strut inner lower (metallicaly blank and free of grease).
Belt grinder, 23. Apply adhesive 3M DP490.
5.0 mm drill bit, 24. Position and fix the retaining plate using the rear wing strut outer inner lower mounting
6.7 mm drill bit, point as reference [1].
screw clamp, 25. Drill the 5.0 mm [2] holes.
rivet gun for high- 26. Fit and close the rivets 4.8 mm (N 909.236.02 - KL 6.1 mm).
strength rivets, 27. Drill the 6.7 mm [3] holes.
30 Nm 28. Fit and close the rivets 6.5 mm (WHT.009.074 - KL 5.0–8.5 mm).
13 mm AF socket, 29. Bolt together the retaining plate and rear wing strut outer inner lower mounting point
16x rivets 4.8 mm [1] with the M8x45 bolt.
(N 909.236.02 -
KL 6.1 mm),
4x rivets 6.5 mm
(WHT.009.074 -
KL 5.0–8.5 mm)

Acetone,
adhesive 3M
DP490

Subsequent operations

1. Restore the factory seals.

It is particularly important to carefully seal the repair area.
2. Refit the components originally removed from the repair area.

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 BODY EXTERIOR | Body repair

4.6.9 Repair rear wing mounting

Removing rear wing mounting
CAUTION SHARP OR SHARP EDGED OBJECTS
Risk of cuts, puncture or laceration injuries.
▶ Wear personal protective equipment.

Tools and Equipment

The following tools and equipment are recommended for use when repairing the rear wing mounting:

Werkzeuge und Materialien

• Rear wing jig • Rivet gun for high-strength rivets
• Battery powered drill / drill • Hot air gun
• Angle drill • Wire brush
• Torx 25 • Screw clamps
• 13 mm AF socket • Manual cartridge gun
• Drill bit 4.2 mm • Hammer
• Drill bit 5.0 mm • Flat chisel
• Drill bit 6.7 mm • Pin punch
• Angle grinder • 1x Adhesive 3M DP490
• Belt grinder • Acetone
• Jigsaw with 70 mm blade

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 BODY EXTERIOR | Body repair

The working procedures described in this chapter are for the driver side and should be followed identically on the passenger side.

b Remove all components in the area to be repaired and related to the damage to the car.

1. Remove the joint sealing.

2. Drill out the rivets [yellow].
Wire brush, 3. Heat the bonded area.
4.2 mm drill bit, 4. Separate strike plate and remove.
belt grinder, 5. Remove residual adhesive.
hot air gun, 6. Drift out the rivet body and mandrel.
hammer,
flat chisel,
pin punch

7. Remove bolt [1].

8. Drill out the rivets [2].
Torx 25, 9. Heat the bonded area.
4.2 mm drill bit, 10. Separate bracket [3] and remove.
hot air gun,
hammer,
flat chisel

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 BODY EXTERIOR | Body repair

11. Remove bolt [yellow].

12. Heat the bonded area.
13 mm AF socket, 13. Remove rear wing mounting struts inner upper and lower.
hot air gun,
hammer,
flat chisel

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 BODY EXTERIOR | Body repair

14. Grind off the weld on the retaining plate rear wing mounting strut inner upper.
15. Heat the bonded area.
4.2 mm drill bit, 16. Separate retaining plate rear wing mounting strut inner upper.
5.0 mm drill bit, 17. Drift out the residual weld/rivet.
hot air gun, 18. Remove residual adhesive.
hammer, 19. Drill out the holes [1] on the support to 4.2 mm.
flat chisel, 20. Drill out the holes [2] on the support to 5.0 mm.
pin punch,
belt grinder
The retaining plate inner upper only needs to be replaced if it is damaged.

21. Remove retaining plate rear wing mounting strut inner lower.See 11. Detach and
remove flange [1] retaining plate for rear wing strut inner lower. on page 613.

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 BODY EXTERIOR | Body repair

22. Heat the bonded areas [yellow].

23. Separate rear wing mounting frame from bonded areas.
Hot air gun, 24. Guide the rear-wing mounting frame towards the front of the car and remove.
hammer,
flat chisel
To ease removal of the rear-wing mounting support cut in half.

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 BODY EXTERIOR | Body repair

Fitting rear wing mounting

1. Remove residual adhesive and straighten the mating faces [yellow] of the rear wing
mounting frame on the car.
Hammer, 2. Drill out the holes to 4.2 mm on the strike plate.
4.2 mm drill bit, 3. Roughen and clean the mating faces on the strike plate (metallicaly blank and free of
belt grinder grease).

Acetone To prevent dirt and dust entering the cockpit when roughening the mating faces for
the strike plate on the chassis cover the working area.

4. Place the rear wing jig on the body and align it:
▶ The jig must be exactly aligned with the body at the support points [1] and lie on top
Rear wing jig of the shape stop.
▶ Support points [2] must be aligned with the body.
▶ Fix the jig using the clamping levers [3].

The body must be undamaged in the areas where the support points are placed to ensure
exact alignment of the jig.

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 BODY EXTERIOR | Body repair

5. Insert the rear wing mounting frame, bring it into position and check for a perfect fit.

6x M8x25 bolts
The drill holes of the jig must align with the threaded holes of the rear wing mounting frame
(check by using bolts M8x25 [yellow]).
The rear wing mounting frame should lie as flat as possible on the soft top compartment.
6. Remove the rear wing mounting frame again.

7. Bonding areas must be metallicaly blank and free of grease.

8. Apply adhesive 3M DP490 to the mating faces on the rear wing mounting frame
Acetone, [yellow].
adhesive 3M
DP490

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 BODY EXTERIOR | Body repair

9. Align the rear wing mounting frame together with the strike plate outer [1].

The strike plate outer [1] can not be added after the rear wing mounting frame has been
installed.

10. Fix the rear wing mounting frame by using M8x25 bolts [yellow] to the rear wing jig.

6x M8x25 bolts

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 BODY EXTERIOR | Body repair

11. Roughen and clean the mating faces for the rear wing strut mountings inner upper and
lower (metallicaly blank and free of grease).
Belt grinder, 12. Apply adhesive 3M DP490.
20 Nm 13. Position the rear wing strut mountings inner upper and lower and fasten the M8x25
13 mm AF socket, bolts to the rear wing strut mounting brackets.
3x M8x25 bolts

Acetone,
adhesive 3M
DP490

14. Fit the retaining plate rear wing strut mountings inner lower.See 22. Roughen and
clean the mating faces on the rear chassis section-rear frame and retaining plate for the
rear wing strut inner lower (metallicaly blank and free of grease). on page 618.

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 BODY EXTERIOR | Body repair

15. Roughen and clean the mating faces for the retaining plate rear wing strut mountings
(metallicaly blank and free of grease).
Belt grinder, 16. Apply adhesive 3M DP490 and align and fix the retaining plate relative to the strut.
rivet gun for high- 17. Fit and close rivet 4.0 mm - KL 6.5 mm [1].
strength rivets, 18. Fit and close rivet 4.8 mm - KL 6.5 mm [2].
20 Nm 19. Bolt the retaining plate and rear wing strut mounting together with the M8x45 bolt.
13 mm AF socket,
4x rivets 4.0 mm -
KL 6.5 mm,
The steps are only valid if the retaining plate needs to be replaced.
4x rivets 4.8 mm -
KL 6.5 mm,
1x bolt M8x45

Acetone,
adhesive 3M
DP490

20. Remove the rear wing jig.

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 BODY EXTERIOR | Body repair

21. Apply adhesive 3M DP490 to the mating faces.

22. Position the strike plate.
Rivetgun for high- 23. Fit and close rivet 4.0 mm - KL 3.0 mm [1].
strength rivets, 24. Fit and close rivet 4.0 mm - KL 2.0 mm [2].
5x rivets 4.0 mm - 25. Fit and close rivet 4.0 mm - KL 2.5 mm [3].
KL 3.0 mm, 26. Fit and close rivet 4.0 mm - KL 4.5 mm [4].
6x rivets 4.0 mm - 27. Fit and close rivet 4.0 mm - KL 6.0 mm [5].
KL 2.0 mm,
4x rivets 4.0 mm -
KL 2.5 mm,
1x rivet 4.0 mm -
KL 4.5 mm,
1x rivet 4.0 mm -
KL 6.0 mm

Adhesive 3M
DP490

28. Seal the circumference of the rear wing strut mounting aperture with sealant
Teroson 9320 SF [yellow].
15 Nm 29. Apply a drop of Loctite 270 to the M8x20 [1] stud. Fit and tighten.

Sealant Teroson
9320 SF,
Loctite 270

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 BODY EXTERIOR | Body repair

30. Fit and tighten bolt M6x20 [1].

31. Drill out the holes [2] to 4.2 mm.
8 Nm 32. Roughen and clean mating faces (metallicaly blank and free of grease).
Torx 25, 33. Apply adhesive 3M DP490 to the mating faces.
4.2 mm drill bit, 34. Position and align bracket [3] and fit and close rivets 4.0 mm - KL 2.5 mm.
belt grinder,
rivet gun for high-
strength rivets,
1x M6x20 bolt,
8x rivets 4.0 mm -
KL 2.5 mm

Acetone,
adhesive 3M
DP490

Subsequent operations

1. Restore the factory seals.

It is particularly important to carefully seal the repair area.
2. Refit the components originally removed from the repair area.

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 BODY EXTERIOR | Air jack system

4.7 Air jack system

DANGER LOWERING THE AIR JACK SYSTEM
Risk of injury through lowering air jack system.
▶ Never work underneath the vehicle when it is raised with the air jack system.
▶ Always secure the car against inadvertent lowering.

WARNING AIR JACK SYSTEM HIGH-PRESSURE SYSTEM

The air jack system is also under pressure in the retracted state.
▶ Never open the lifting cylinders.

WARNING HIGH-PRESSURE IN THE INNER CHAMBER OF THE LIFTING CYLINDER

The lifting cylinders are also under pressure in the inner chamber when retracted. Risk of
injury in case of improper bleeding.
▶ Never open the lifting cylinders.
▶ Wear personal protective equipment.
▶ Bleed the lifting cylinder by inserting a 3 mm Allen key into the cover and activating the
bleed valve against its resistance.

NOTICE INCORRECT HANDLING OF THE AIR JACK

Risk of damage to the end stops of the lifting cylinder.
▶ Never allow the lifting cylinder to extend freely (i.e. without a vehicle load).

▶ Leave the discharge valve open during driving in order to ensure full retraction of the lifting cylinder.
Separate air discharge via a plunger is possible to allow a raised vehicle to be lowered gradually. By pressing this plunger, the compressed air system can be
discharged in a controlled manner.
▶ Before shipping for rebuilding, bleed the lifting cylinders in observance of the warning instructions.
▶ Do not use mineral oil based cleaning agents.
The maximum operating pressure is 35 bar.

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 BODY EXTERIOR | Air jack system

4.7.1 Overview of air jack system

[1] Main valve, right [2] Air line/main valve, right [3] Air line, rear right [4] Air line, rear left
[5] Air line, centre right [6] Air line, front right [7] Air line, front [8] Lifting cylinder, front
[9] Lifting cylinder, rear

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 BODY EXTERIOR | Air jack system

4.7.2 Attachment of air jack system

Attachment of lifting cylinders to bodyshell

40 Nm (+5 Nm) Check and, if necessary, tighten all three nuts [1] of the lifting cylinders after 30 hours and
before every race weekend.

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 BODY EXTERIOR | Air jack system

Attachment of air lines to lifting cylinders

[1] Lifting cylinder, rear right

[2] T-piece, rear right
All T-pieces, plugs [3] Air line/main valve, right
and lines: [4] Air line, rear right
20 Nm [5] Lifting cylinder, rear left
[6] T-piece, rear left
[7] Air line, rear left
[8] T-piece plug
[9] Lifting cylinder, front
[10] Air line, front

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 BODY EXTERIOR | Air jack system

Attachment of air line connections

[1] Heel plate T-piece

[2] Nut
25 Nm
[3] Air line, rear right
[4] Air line, rear left
20 Nm [5] Air line, centre right (rear connection)
[6] Air line, centre right (front connection)
[7] Nut

25 Nm

[8] Connecting piece

[9] Air line, front right (rear connection)

25 Nm
[10] Air line, front right (front connection)

20 Nm
[11] Nut
[12] Connecting piece
25 Nm [13] Air line, front

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 BODY EXTERIOR | Air jack system

Attachment of main valve and handle recess

[1] Air line/main valve, right

20 Nm
[2] Nut

25 Nm

[3] Handle recess incl. mounting element, right

[4] Main valve
[5] Nut

25 Nm

[6] Handle recess incl. mounting element, left

[7] Plug

V7,12/2022 911 GT3 Cup (2021–2023) 636

 BODY EXTERIOR | Removing/installing the windscreen

4.8 Removing/installing the windscreen

WARNING INJURIES DURING REMOVAL AND INSTALLATION CAUSED BY INCORRECT HANDLING
OF TOOLS AND MATERIAL
Minor to severe injuries.
▶ Wear personal protective equipment (eyewear and gloves).
▶ Always disconnect the power supply before changing the cutting knife.

When processing the material from the two-component adhesive kit, the ambient and
material temperature should be at least 15 °C and not more than 28 °C.

Tools and material

• Electric special cutter • Cutting cord
• U-shaped scraper blade for electric special cutter • Adhesive tape
• Cup suction tools • Isopropanol
• Dual-cartridge gun • Cowl seal
• Window removal set VAS 861 001A • Windscreen seal
• Two-component adhesive kit

Removing the windscreen

NOTICE LOSS OF SUCTION CUP CONTACT
Damage to the windscreen caused by the suction cups losing contact.
▶ Moisten the suction cups slightly to increase the fixing force.
▶ Clean the outside and inside of the window to ensure optimum suction grip.

NOTICE RISK OF DAMAGE FROM CUTTING CORD

The cutting cord may damage the windscreen seal.
▶ When removing the windscreen with the window removal set, take care not to damage
the windscreen seal with the cutting cord (if the windscreen is to be reused).

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 BODY EXTERIOR | Removing/installing the windscreen

b Wiper arm removed. See 6.9 Windscreen wiper unit on page 778

1. Attach the cup suction tool to the outside of the windscreen.

2. Unwind the cutting cord and cut off a length of 600 cm.
Cup suction tools,
Cutting cord

3. Coat the entire windscreen seal [1] with soap water.

4. Pull the cutting cord [2] all around the windscreen into the gap to the body.
5. Pinch the free end of the cutting cord at the wiper linkage.

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 BODY EXTERIOR | Removing/installing the windscreen

6. Using the awl [1], penetrate the adhesive bead from the inside out [arrow A].
7. Thread the cutting cord [2] into the awl and pull it into the interior [arrow B].
Awl from Length: 100 cm.
VAS 861 001A

8. Thread the cutting cord [1] into the bore in the winding device [2].
9. Align the winding device [2] in the center of the windscreen and firmly press it together
Cutting device with the cup suction device against the windscreen [3].
from 10. Secure the cup suction device to the windscreen by turning the lever.
VAS 861 001A

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 BODY EXTERIOR | Removing/installing the windscreen

NOTICE Damage to the VIN [1] by cutting devices

▶ Place the protective film provided [2] between windscreen and VIN [1].
▶ Guide the cutting cord [3] over the protective film.

11. Cut out the windscreen [3] by winding in the cutting cord [1] at the cutting device [2]
in arrow direction.
12. To reduce the pulling force on the cutting cord [1] during windscreen removal relocate
the cutting device [2].

13. Remove the windscreen.

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 BODY EXTERIOR | Removing/installing the windscreen

Preparation for installation

Preparing the car flange

NOTICE DAMAGE CAUSED BY INCORRECT PREPARATORY WORK

Risk of damage to the windscreen caused by incorrect preparatory work.
▶ The coating of adhesive residue serves as an adhesive primer for new adhesive material.
▶ Keep the cut surfaces clean and free of grease and do not clean with a cleaning solution.

NOTICE Loss of adhesion between windscreen and body caused by cleaning solution residue
▶ A flash-off time between the cleaning of the bonding surface and the application
of the primer of at least 10 min must be observed.
▶ The body must be free of any residue of the cleaning solution.

1. Remove any coarse soiling from the bonding surface.

2. Clean the U-shaped scraper blade with isopropanol.
Electric special 3. Remove the adhesive [1] using the electric special cutter (with the U-shaped scraper
cutter, blade) from the body so that a residual coat of adhesive remains on the body [2].
U-shaped scraper
blade

Isopropanol

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 BODY EXTERIOR | Removing/installing the windscreen

CAR FLANGE WITH DAMAGED ADHESIVE RESIDUE

▶ If the cutting surface of the body is damaged or interrupted (body surface is visible),
Two-component the bonding surface must be renewed.
base coat, 1. If necessary, apply two-component base coat to any blank panel section.
adhesive tape, 2. Let the base coat cure.
Vehicle paint, 3. Mask the bonding surface of the car flange with adhesive tape.
Two-component ▶ Do not apply any coloring paint to the bonding surface.
adhesive kit 4. Paint and cure the car flange including the remaining affected parts by means
of standard repair paintwork method.
5. Remove adhesive from the masked area.
6. Clean the bonding surface with the cleaning cloth from the two-component
adhesive kit.
▶ Let the cleaning agent cure for 10 min.
Areas with damaged adhesive bead:
1. Shake up the primer from the two-component adhesive kit for 1 min.
Note: The movement of the steel ball inside the primer cartridge must be noticeable
and audible.
2. Using the application brush, apply the primer once in a single stroke to the bonding
surface.
NOTICE The primer must not be applied to any undamaged section of the adhesive bead!
▶ Let the primer cure for 10 min.

If the curing time of 8 h is exceeded, the primer may be re-applied one single time and
within 96 h after the first application of the primer. Primed areas must be protected
against external effects and soiling within this period.
▶ Let the primer cure again for 10 min.
Areas with undamaged adhesive bead:
1. Apply the activator using the application brush (two-component adhesive kit) in one
single stroke to the bonding area.
Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
NOTICE The windscreen must be bonded to the car flange within the next 2 h.

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 BODY EXTERIOR | Removing/installing the windscreen

CAR FLANGE WITH FULL-SURFACE ADHESIVE RESIDUE

1. Apply the activator using the application brush (two-component adhesive kit) in one
Two-component single stroke to the bonding area.
adhesive kit Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
NOTICE The windscreen must be bonded to the car flange within the next 2 h.

CAR FLANGE WITHOUT FULL-SURFACE ADHESIVE RESIDUE

▶ If the cutting surface of the body is damaged or interrupted (body surface is visible),
Two-component the bonding surface must be renewed.
adhesive kit 1. If necessary, apply two-component base coat to any blank panel section.
2. Let the base coat cure.
3. Mask the bonding surface of the car flange with adhesive tape.
▶ Do not apply any coloring paint to the bonding surface.
4. Paint and cure the car flange including the remaining affected parts by means of
standard repair paintwork method.
5. Remove adhesive from the masked area.
6. Clean the bonding surface with the cleaning cloth from the two-component
adhesive kit.
7. Let the cleaning agent cure for 10 min.
8. Shake up the primer from the two-component adhesive kit for 1 minute.
Note: The movement of the steel ball inside the primer cartridge must be noticeable
and audible.
9. Using the application brush, apply the primer once in a single stroke to the bonding
surface.
▶ Let the primer cure for 10 min.
NOTICE The windscreen should be bonded to the car flange within the next 2 h.

If the curing time of 8 h is exceeded, the primer may be re-applied one single time and
within 96 h after the first application of the primer. Primed areas must be protected
against external effects and soiling within this period.
▶ Let the primer cure again for 10 min.

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 BODY EXTERIOR | Removing/installing the windscreen

Preparing a removed windscreen

1. Remove the seals of the windscreen and the cowl from the old window.
2. Remove any coarse soiling from the bonding surface.
Electric special 3. Clean the U-shaped scraper blade with isopropanol.
cutter, 4. Cut the adhesive bead so that a strip of 1–3 mm remains
U-shaped scraper Note: The cutting surface must not be soiled.
blade 5. Apply the activator using the application brush (two-component adhesive kit) in one
single stroke to the bonding area.
Note: Avoid applying two coats to the same area.
Isopropanol, ▶ Let the activator cure for 10 min.
Two-component 6. Locate the seals.
adhesive kit 7. Apply two-component adhesive onto the removed adhesive bead.
▶ The windscreen must be bonded to the car flange within the next 2 h.

Preparing a new windscreen (unheated)

The new windscreen of this variant comes with a pre-applied adhesive bead that must be
trimmed before installation.

1. Remove any coarse soiling from the bonding surface.

2. Clean the U-shaped scraper blade with isopropanol.
Electric special 3. Cut the adhesive bead so that a strip of 1–3 mm remains
cutter, Note: The cutting surface must not be soiled.
U-shaped scraper 4. Apply the activator using the application brush (two-component adhesive kit) in one
blade single stroke to the bonding area.
Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
Isopropanol, 5. Locate the seals.
Two-component 6. Apply two-component adhesive onto the removed adhesive bead.
adhesive kit ▶ The windscreen must be bonded to the car flange within the next 2 h.

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 BODY EXTERIOR | Removing/installing the windscreen

Installing the windscreen

NOTICE FAILURE TO OBSERVE THE CURING TIME
Risk of damage of the windscreen if the curing time of the adhesive is not observed.
▶ The vehicle must not be used until the curing time has expired!
▶ Curing time: 2 h at 23 °C
▶ Temperature: min. 15 °C, max. 70 °C
▶ Fixing time: approx. 1 h at 23 °C

The adhesive must be applied and the parts be joined within 10 min.
To ensure complete mixing, squeeze out an approx. 30 mm long bead of the fresh adhesive
material before processing.

Locating the windscreen requires two persons.

An incorrectly installed windscreen may adversely affect aerodynamics.

1. Check the depth gages.

▶ Replace damaged or missing depth gages.
Cup suction tools 2. Attach the cup suction tools to the windscreen.
3. Prepare the two-component adhesive for processing.

Two-component
adhesive kit

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 BODY EXTERIOR | Removing/installing the windscreen

4. Using the dual-cartridge gun, apply the adhesive along the previously applied base coat
or onto the primer in a triangular bead of dimension [X] onto the windscreen.
Dual-cartridge gun Application height [X]: 15 mm.
NOTICE When applying the adhesive, make sure that the beginning and end of the bead
overlap by approx. 30 mm.
Two-component
adhesive kit

5. Guide the windscreen into the window opening.

6. Locate the windscreen along its bottom edge [arrows A] and set it down [arrow B].

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 BODY EXTERIOR | Removing/installing the windscreen

7. Adjust the gap dimensions [X] by moving the windscreen.

Circumferential gap dimensions: 3.0 mm
8. Remove the cup suction tools.

9. Secure the windscreen with adhesive tape [1] against slipping.

10. Immediately remove any excess adhesive and clean the affected visual areas using
Adhesive tape cleaning solution.

11. Using the dual-cartridge gun, apply the adhesive along the previously applied base coat
or onto the primer in a triangular bead of dimension [X] onto the windscreen.
Dual-cartridge gun Application height [X]: 15 mm.
NOTICE When applying the adhesive, make sure that the beginning and end of the bead
overlap by approx. 30 mm.
Two-component
adhesive kit

12. Install the wiper arm.

V7,12/2022 911 GT3 Cup (2021–2023) 647

 BODY EXTERIOR | Removing/installing the rear window

4.9 Removing/installing the rear window

WARNING INJURIES DURING REMOVAL AND INSTALLATION CAUSED BY INCORRECT HANDLING
OF TOOLS AND MATERIAL
Minor to severe injuries.
▶ Wear personal protective equipment (eyewear and gloves).
▶ Always disconnect the power supply before changing the cutting knife.

NOTICE RISK OF DAMAGE FROM CUTTING CORD

The cutting cord may damage the window seal.
▶ When removing the rear window with the window removal set, take care not to damage
the rear window seal with the cutting cord (if the rear window is to be reused).

When processing the material from the two-component adhesive kit, the ambient and
material temperature should be at least 15 °C and not more than 28 °C.

Tools and material

• Electric special cutter • Cutting cord
• U-shaped scraper blade for electric special cutter • Adhesive tape
• Cup suction tools • Isopropanol
• Dual-cartridge gun • Two-component base coat
• Window removal set VAS 861 001A • Automotive varnish
• Two-component adhesive kit

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 BODY EXTERIOR | Removing/installing the rear window

Removing rear window

b Engine cover removed. See 4.4.9 Engine cover on page 446.

b Rear wing removed. See 4.4.21 Rear wing on page 475.

1. Remove the bolts [1] and take off the panel [2].
▶ Repeat the procedure on the opposite side.

2. Remove the bolts [1] of the rear window.

3. Analogous with the description of the windscreen removal, cut out the rear window and
remove it. Siehe Removing the windscreen auf Seite 637.
Cup suction tools,
Cutting cord,
Awl from
VAS 861 001A,
Cutting device
from
VAS 861 001A

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 BODY EXTERIOR | Removing/installing the rear window

Preparation for installation

NOTICE DAMAGE CAUSED BY INCORRECT PREPARATORY WORK
Risk of damage to the rear window caused by incorrect preparatory work.
▶ The coating of adhesive residue serves as an adhesive primer for new adhesive material.
▶ Keep the cut surfaces clean and free of grease and do not clean with a cleaning solution.

NOTICE Loss of adhesion between rear window and body caused by cleaning solution residue
▶ A flash-off time between the cleaning of the bonding surface and the application of
the primer of at least 10 min must be observed.
▶ The body must be free of any residue of the cleaning solution.

Preparing the car flange

1. Remove any coarse soiling from the bonding surface.

2. Clean the U-shaped scraper blade with isopropanol.
Electric special 3. Remove the adhesive [1] using the electric special cutter (with the U-shaped scraper
cutter, blade) from the body so that a residual coat of adhesive remains on the body [2].
U-shaped scraper
blade

Isopropanol

Fig. 58: Removing the adhesive using the windscreen as an

example

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 BODY EXTERIOR | Removing/installing the rear window

CAR FLANGE WITH DAMAGED ADHESIVE RESIDUE

▶ If the cutting surface of the body is damaged or interrupted (body surface is visible),
Two-component the bonding surface must be renewed.
base coat, 1. If necessary, apply two-component base coat to any blank panel section.
adhesive tape, 2. Let the base coat cure.
Vehicle paint, 3. Mask the bonding surface of the car flange with adhesive tape.
Two-component ▶ Do not apply any coloring paint to the bonding surface.
adhesive kit 4. Paint and cure the car flange including the remaining affected parts by means
of standard repair paintwork method.
5. Remove adhesive from the masked area.
6. Clean the bonding surface with the cleaning cloth from the two-component
adhesive kit.
▶ Let the cleaning agent cure for 10 min.
Areas with damaged adhesive bead:
1. Shake up the primer from the two-component adhesive kit for 1 minute.
Note: The movement of the steel ball inside the primer cartridge must be noticeable
and audible.
2. Using the application brush, apply the primer once in a single stroke to the bonding
surface.
NOTICE The primer must not be applied to any undamaged section of the adhesive bead!
▶ Let the primer cure for 10 min.

If the curing time of 8 h is exceeded, the primer may be re-applied one single time and
within 96 h after the first application of the primer. Primed areas must be protected
against external effects and soiling within this period.
▶ Let the primer cure again for 10 min.
Areas with undamaged adhesive bead:
1. Apply the activator using the application brush (two-component adhesive kit) in one
single stroke to the bonding area.
Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
NOTICE The rear window must be bonded to the car flange within the next 2 h.

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 BODY EXTERIOR | Removing/installing the rear window

CAR FLANGE WITH FULL-SURFACE ADHESIVE RESIDUE

1. Apply the activator using the application brush (two-component adhesive kit) in one
Two-component single stroke to the bonding area.
adhesive kit Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
NOTICE The rear window must be bonded to the car flange within the next 2 h.

CAR FLANGE WITHOUT FULL-SURFACE ADHESIVE RESIDUE

▶ If the cutting surface of the body is damaged or interrupted (body surface is visible),
Two-component the bonding surface must be renewed.
adhesive kit 1. If necessary, apply two-component base coat to any blank panel section.
2. Let the base coat cure.
3. Mask the bonding surface of the car flange with adhesive tape.
▶ Do not apply any coloring paint to the bonding surface.
4. Paint and cure the car flange including the remaining affected parts by means
of standard repair paintwork method.
5. Remove adhesive from the masked area.
6. Clean the bonding surface with the cleaning cloth from the two-component
adhesive kit.
7. Let the cleaning agent cure for 10 min.
8. Shake up the primer from the two-component adhesive kit for 1 minute.
Note: The movement of the steel ball inside the primer cartridge must be noticeable
and audible.
9. Using the application brush, apply the primer once in a single stroke to the bonding
surface.
▶ Let the primer cure for 10 min.
NOTICE The rear window should be bonded to the car flange within the next 2 h.

If the curing time of 8 h is exceeded, the primer may be re-applied one single time and
within 96 h after the first application of the primer. Primed areas must be protected
against external effects and soiling within this period.
▶ Let the primer cure again for 10 min.

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 BODY EXTERIOR | Removing/installing the rear window

Preparing an old rear window

1. Remove any coarse soiling from the bonding surface.

2. Clean the U-shaped scraper blade with isopropanol.
Electric special 3. Cut the adhesive bead so that a strip of 1–3 mm remains
cutter, Note: The cutting surface must not be soiled.
U-shaped scraper 4. Apply the activator using the application brush (two-component adhesive kit) in one
blade single stroke to the bonding area.
Note: Avoid applying two coats to the same area.
▶ Let the activator cure for 10 min.
Isopropanol, 5. Locate the seals.
Two-component 6. Apply two-component adhesive onto the removed adhesive bead.
adhesive kit ▶ The rear window must be bonded to the car flange within the next 2 h.

Preparing a new rear window

1. Completely remove the backing film from the adhesive tape.

2. Clean the rear window's bonding surface with the cleaning cloth from the
Two-component two-component adhesive kit.
adhesive kit ▶ Let the cleaning agent cure for 10 min.
3. Shake up the primer from the two-component adhesive kit for 1 min.
Note: The movement of the steel ball inside the primer cartridge must be noticeable
and audible.
4. Using the application brush, apply the primer once in a single stroke to the bonding
surface.
▶ Let the primer cure for 10 min.
NOTICE The rear window should be bonded to the car flange within the next 2 h.

If the curing time of 8 h is exceeded, the primer may be re-applied one single time and
within 96 h after the first application of the primer. Primed areas must be protected
against external effects and soiling within this period.
▶ Let the primer cure again for 10 min.

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 BODY EXTERIOR | Removing/installing the rear window

Installing rear window

NOTICE FAILURE TO OBSERVE THE CURING TIME
Risk of damage of the rear window if the curing time of the adhesive is not observed.
▶ The vehicle must not be used until the curing time has expired!
▶ Curing time: 2 h at 23 °C
▶ Temperature: min. 10 °C, max. 70 °C
▶ Fixing time: approx. 1 h at 23 °C

NOTICE LOSS OF CONTACT WITH THE SUCTION CUPS

The rear window may become damaged if the suction cups loose contact.
▶ Slightly moisten the suction cups to increase their holding force.
▶ Clean the window on the outside and inside to ensure optimal holding force.

The adhesive must be applied and the parts be joined within 5 min.
To ensure complete mixing, squeeze out an approx. 30 mm long bead of the fresh adhesive
material before processing.

Installing the rear window requires two persons.

An incorrectly installed rear window may adversely affect aerodynamics.

b Car flange is free of sharp-edged dents, overlaps, steps or similar (> 0.5 mm).
The car flange can be adjusted by the following measures:
• In bodyshell construction through soldering, tinning or similar
• In the paintshop by fine-seam sealing or similar
• During assembly by equalizing with adhesive

1. Attach the cup suction tools to the outside of the rear window.

Cup suction tools

Slightly moisten the suction cups to increase their holding force.

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 BODY EXTERIOR | Removing/installing the rear window

2. Prepare the two-component adhesive for processing.

3. Using the dual-cartridge gun, apply the adhesive along the previously applied base coat
Dual-cartridge gun or onto the primer in a triangular bead of dimension [X] onto the rear window.
Application height [X]: 15 mm.
NOTICE When applying the adhesive, make sure that the beginning and end of the bead
Two-component overlap by approx. 30 mm.
adhesive kit

▶ The window must be located and pushed into its specified position within 5 min after
starting to apply the adhesive.

4. Place the rear window [1] along its bottom edge [arrows A] and set it down [arrow B].
5. Press the rear window slightly in.
6. Attach all countersunk-head bolts M6 x 30 including spacers and O-rings.

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 BODY EXTERIOR | Removing/installing the rear window

7. Press the rear window finally in:

Make sure that the rear window is not pressed into the opening in the hatched areas.
a. Start pressing at the top center and continue on the sides along the seal.
b. Press in the bottom corners.
c. Press in the area in the bottom center along the seal.

Holding time: > 10 s.

The pressing force must be high enough to press the window all around its edge onto the
depth gage.

8. Tighten the bolts [1–10] in the specified sequence.

9. Remove the cup suction tools.
5.6 Nm 10. Immediately remove any excess adhesive and clean the visual area.

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 BODY EXTERIOR | Fuel tank

4.10 Fuel tank

DANGER RISK OF FIRE OR EXPLOSION DUE TO IGNITION OF FUEL
When filling and handling the fuel tank, the fuel / fuel vapor can escape and ignite.
▶ Exclude open flames and sources of ignition in the handling and storage area.
▶ When working on the fuel system and when refueling, appropriate warning signs must
be set up in the work area.
▶ Position fire extinguishers within easy reach.
▶ Make sure that all components of the fuel system are correctly installed.
▶ Use a drip pan to catch any fuel escaping from the vent line.
▶ Pay attention to the tightness of all components of the fuel system (lines, pumps, etc.).
▶ Vehicle must be grounded.

DANGER RISK OF FIRE OR EXPLOSION WHEN DISASSEMBLY AND INCORRECTLY STORING

COMPONENTS OF THE FUEL SYSTEM
Fuel vapor may ignite during disassembly and storage.
▶ Exclude open flames and sources of ignition in the handling and storage area.
▶ Position fire extinguishers within easy reach.
▶ Completely empty the fuel tank.
▶ Disassemble the safety foam and the components inside the fuel tank.
▶ Clean safety foam with water and dry outdoors in a place without direct sunlight
(safety foam holds approx. 2 % of the fuel capacity in its pores).
▶ Wash the tank bladder with a clean cloth, soap and water and dry outdoors in a place
without direct sunlight. After cleaning, make sure that water and fuel are separated.
▶ Close the fuel tank and store it with suitable plugs on the connections.
Make sure that the opening of the roll-over valve is not closed to ensure venting.

DANGER RISK OF LUNG IRRITATION, FIRE OR EXPLOSION FROM IGNITION OF FUEL VAPORS
Dangerous fuel vapours may be formed.
▶ Exclude open flames and sources of ignition in the handling and storage area.
▶ Ensure sufficient ventilation in the vehicle.
▶ Make sure that the fuel tank vent works properly.

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 BODY EXTERIOR | Fuel tank

NOTICE DRY RUNNING OF FUEL PUMPS

Damage to the fuel pumps caused by dry running.
▶ Do not allow the fuel pumps to run dry.

NOTICE FUELS WITH A HIGH ALCOHOL CONTENT

Fuels with a high alcohol content can damage the fuel bladder or individual tank compo-
nents.
▶ For further information please contact the Technical Racing Support.
See 7.1 Technical Racing Support on page 1023.

NOTICE SAFETY FOAM

The components in the fuel can impair the service life and effectiveness.
▶ Check the safety foam before each use.
▶ Replace safety foam if the material condition changes.
▶ Remove safety foam after each race weekend and store separately.

NOTICE HIGH CONCENTRATION OF HARMFUL SUBSTANCES

The components of the fuel can damage the fuel bladder or other tank components.
▶ Empty the fuel tank completely after each use.
▶ Remove intank components.
▶ Clean safety foam with water and dry outdoors in a place without direct sunlight.
▶ Wash the tank bladder with a clean cloth, soap and water and dry outdoors in a place
without direct sunlight. After cleaning, make sure that water and fuel are separated.
▶ Close the fuel tank and store it with suitable plugs on the connections.
Make sure that the opening of the roll-over valve is not closed to ensure venting.
▶ Regularly maintain components in the fuel tank (e.g. filters).

NOTICE EXTREME AMBIENT TEMPERATURES

If the ambient temperature is too low (<-30 °C) or too high (> 50 °C), impairments may
occur.
▶ Consider impairments at extreme ambient temperatures.
The optimal operating ambient temperature is 0 °C–50 °C.

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 BODY EXTERIOR | Fuel tank

NOTICE EXTREME WEATHER CONDITIONS

Moisture, direct sunlight and other weather conditions can damage the fuel bladder and
the safety foam.
▶ Mount the fuel bladder in the associated housing.
▶ Protect the fuel bladder inside and outside from water, steam, direct sunlight and other
weather conditions.

Depending on the operating condition, overpressure may occur in the fuel tank.
The overpressure is released via the roll-over valve.
▶ Make sure that the roll-over valve is installed correctly and is functioning properly.

Further information can be found at the manufacturer's website:

https://www.atlltd.com/literature

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 BODY EXTERIOR | Fuel tank

4.10.1 Design and components of fuel tank

Overview of fuel lines

When installing new fuel lines, make sure that the transport/dust protection caps are not unscrewed until immediately before installation.
[1] Fuel tank 110L
[2] Flexible fuel line
[3] Vent pipe
20 Nm [4] Front fuel line
[5] Rear fuel line

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 BODY EXTERIOR | Fuel tank

Overview of fuel tank

[1] Top plate
[2] Bolts M6
4 Nm

[3] Filler neck

[4] Roll-over valve

46 Nm
[5] Fill level sensor

3 Nm
[6] Bowser de-fuelling coupling (Drain) - Dash 8 (counterpart Stäubli SBT8)
[7] Bowser ventilation coupling (Vent) - Dash 8 (counterpart Stäubli SBT8)
38 Nm
[8] De-fuelling coupling

35 Nm
[9] Fuel cut-off valve (FCOV)

20 Nm
[10] FIA label

Bolts M5x12
3 Nm

[11] Lift pump

[12] Catch tank
[13] Main fuel pump (bayonet fastener)

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 BODY EXTERIOR | Fuel tank

FIA roll-over valve

NOTICE INCORRECT HANDLING
Damage to the FIA roll-over valve.
▶ When removing and installing, position the tool on the lower hexagon only.
▶ Do not blow out the valve with compressed air (sensitive to pressure).

To avoid system leaks, all vehicles should be fitted with the latest version of the roll-over
valve from the Porsche Motorsport parts catalogue.

Apart from tank aeration and venting, the FIA roll-over valve (shown in blue in the figure)
also has the following safety functions:
• Overpressure protection: The valve opens at an overpressure inside the tank of 200 mbar
relative to atmospheric pressure in order to prevent damage to the tank caused by
overpressure.
• Float valve: Seals the valve if fuel escapes into the vent pipe.

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 BODY EXTERIOR | Fuel tank

Fuel cut-off valve (FCOV)

WARNING TAMPERING WITH FUEL CUT-OFF VALVE
Tampering with the fuel cut-off valve can result in uncontrolled fuel discharge in the event
of a leak and therefore poses an increased risk to safety.
▶ Tampering with the fuel cut-off valve is strictly forbidden!

NOTICE RUNNING FUEL TANK EMPTY

Running the fuel tank empty is unexpected driving behaviour, which causes the fuel
cut-off valve to shut off the fuel supply and the engine to stop.
▶ Never run the fuel tank empty.

If a loss of pressure occurs in the fuel line to the engine, the valve interrupts the fuel supply. The fuel system is designed without a return line (returnless
fuel). Air in the system can therefore only escape through the engine. In the case of extremely large air bubbles (e.g. after de-fuelling), the engine may stop
repeatedly. After complete de-fuelling, it is therefore recommended to warm up the engine so that all air bubbles escape from the system.
Opening valve mechanically
Causes of pressure loss:
• Mechanical fault.
• The vehicle has stood idle for a long period of time (hours/days).
• The fuel tank has run dry.
• Air bubbles in the system after de-fuelling.
1. Start the fuel pump at the centre console.
2. Pull the plunger [1].
→ The spring-operated plunger is released mechanically.

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 BODY EXTERIOR | Fuel tank

Fuel pump control unit

The control unit for regulating the power for the electric fuel pump [1] is attached at the
middle of the bulkhead. The electric fuel pump is actuated when the driver's door is opened,
when the ignition is switched on, when the engine is started and when the vehicle is being
driven. Depending on the amount of fuel required, the power consumption and therefore
the delivery rate of the electric fuel pump is regulated between 6 and 15 amps by the
engine control unit by means of a PWM signal. The power consumption can be measured
at the fuse of the electric fuel pump.

Safety foam

The picture shows the separate blocks of the safety foam inside the fuel tank.
▶ When disassambling, mark the blocks with a petrol proof pen to ease the reassambling.
▶ Always ensure cleanliness during removal and installation!

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 BODY EXTERIOR | Fuel tank

Catch tank
REMOVING/INSTALLING CATCH TANK
1. Remove the top plate from the tank:
a. Disconnect all electrical connections.
b. Disconnect the fuel line.
c. Disconnect the vent pipe from the roll-over valve.
d. Unscrew and remove the bolts along the edge of the top plate.
e. Lift the top plate carefully and disconnect the fuel line and de-fuelling hose as well
as the electrical connection to the fuel pump.
f. Remove the top plate.
2. Remove the tank foam (make sure it is clean and mark the individual blocks with a
petrol-proof pen to make installation easier).
3. Disconnect the fuel hose of the fuel pump.
4. Disconnect the connector from the fuel pump.
5. Unscrew and remove the nuts of the catch tank.

Installation is performed in the reverse order of removal.

▶ Tighten the screws of the catch tank and the top plate (crosswise) to the specified
4 Nm tightening torque.
Check the sealing rings of the top plate bolts for damage; replace if necessary.

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 BODY EXTERIOR | Fuel tank

Fuel pump

REPLACING FUEL PUMP

1. Remove the top plate:
a. Disconnect all electrical connections.
b. Disconnect the fuel line.
c. Disconnect the vent pipe of the roll-over valve.
d. Unscrew and remove the bolts along the edge of the top plate.
e. Lift the top plate carefully and disconnect the fuel line and de-fuelling hose as well
as the electrical connection to the fuel pump.
f. Remove the top plate.
2. Remove the tank foam (make sure it is clean and mark the individual blocks with a
petrol-proof pen to make installation easier).
3. Remove the cover of the catch tank:
a. Release all separating points on the cover.
b. Remove the bolt of the catch tank cover.
c. Remove the catch tank cover.
4. Remove the fuel hose of the lift pump.
5. Remove the fuel pump incl. swirl pot by turning (bayonet fastener).
CAUTION! Carelessness when removing the fuel pump can damage the tank components.
▶ Do not detach or damage the internal tubing.
6. Remove the wiring loom of the fuel pump.
Replace the old wiring loom with a new one.
7. Press in the three catch tabs on the fuel filter and lift out the filter in order to access
the fuel pump connector.
– Disconnect the connector

Installation is performed in the reverse order of removal.

▶ Tighten the screws of the top plate crosswise with the specified tightening torque.
4 Nm Check the sealing rings of the top plate bolts for damage; replace if necessary.

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 BODY EXTERIOR | Fuel tank

4.10.2 Fuel tank and lines

Removing/installing fuel tank

b Vehicle raised and secured.

b Front wheels removed.
b Fuel tank empty.
b Front underbody panel removed. See Removing/installing front underbody panel
on page 454

1. Remove the bolts [1].

2. Remove the diagonal struts incl. underbody protection.
55 Nm Make sure that the vent hose is removed from the underbody.

3. Remove the front axle (see 3.5 Front axle on page 300).

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 BODY EXTERIOR | Fuel tank

1. Unlock and remove the plug connection of the fuel pump [1] and fill level sensor [2].

2. Remove the fuel line [3] from the fuel cut-off valve and the vent pipe [4] from the roll-
over valve.
20 Nm

3. Unscrew and remove the bolts [5].

10 Nm

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 BODY EXTERIOR | Fuel tank

4. Support the fuel tank from underneath.

5. Unscrew and remove the bolts [1] from underneath.
23 Nm 6. Carefully lower and remove the fuel tank.

7. Installation is performed in the reverse order of removal.

8. Fill and bleed the cooling system. See 1.11.6 Filling the cooling system on page 104.
9. Perform wheel alignment (see 3.3 Wheel alignment on page 297).

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 BODY EXTERIOR | Fuel tank

Vent pipe

▶ Position the vent pipe [1] as shown and tighten.

20 Nm
The specified angle is a guide value. A tolerance of ±10° is permissible.

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 BODY EXTERIOR | Fuel tank

The vent pipe passes through the plug in the underbody.

The vent pipe protrudes by 10 mm.

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 BODY EXTERIOR | Fuel tank

4.10.3 De-fuelling
NOTICE DRY RUNNING OF FUEL PUMP DURING DE-FUELLING
Dry running will damage the fuel pump.
Porsche shall not accept liability for damage that may result.
▶ Dry running of the fuel pump must be prevented during de-fuelling.

Scenario I (with bowser) Scenario II (without bowser)

De-fuelling the fuel tank with bowser De-fuelling the entire fuel volume via the
catch tank using the tank pumps

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 BODY EXTERIOR | Fuel tank

Scenario I (with bowser)

1. Connect the de-fuelling hose to the bowser de-fuelling coupling (Drain).

2. Connect the vent hose to the bowser ventilation coupling (Vent).
3. Switch on the bowser and remove the fuel.
4. Detach the de-fuelling hose and connect to the coupling of the fuel cut-off valve.
5. Activate the main switch [MAIN].

6. Activate the main fuel pump.

▶ Press the FUEL PUMP button [7] once.
7. Stop de-fuelling as soon as the tank is empty.
Make sure that the fuel pump does not run dry.

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 BODY EXTERIOR | Fuel tank

Scenario II (without bowser)

1. Connect the de-fuelling hose to the de-fuelling coupling of the fuel cut-off valve.
2. Activate the main switch [MAIN].

3. Activate the main fuel pump and lift pumps.

▶ Press the FUEL PUMP button [7].
4. Pump off the fuel into a suitable container.

5. Stop de-fuelling as soon as the tank is empty.

Make sure that the fuel pump does not run dry.

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 BODY EXTERIOR | Fuel tank

4.10.4 Other tightening torques

Location Component Dimension Tightening torque

Casing exterior Fuel bladder at bottom of tank casing M5 bolt 3 Nm
Bodyshell bracket on tank casing M5 bolt 3 Nm
Grooved ring at top of casing M5 bolt 3 Nm
Top plate Pickup/connecting part Nut 38 Nm
SAE adapter on drain coupling - 33 Nm
Flange ring M5 bolt 3 Nm
Newton tank cap ring M5 bolt 3 Nm
Filling adapter on top plate (tower) M5 bolt 3 Nm
Intank Suction jet pump bracket on fuel M6 nut 4 Nm
bladder
Catch tank bracket on fuel bladder M6 nut 4 Nm
Catch tank cover M6 bolt 4 Nm
SAE connection 9.89 mm - 21 Nm
Inlet valve (catch tank) M3 bolt 1 Nm
Bayonet fastener (catch tank) M6 nut 2 Nm
Bayonet fastener (catch tank) M8 nut 2 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 675

5 BODY INTERIOR
5.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
5.2 Colour code body interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
5.3 Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
5.4 Seat system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
5.5 Safety nets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
5.6 Cage padding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
5.7 Leg protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
5.8 Additional weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
5.9 Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
5.10 Interior ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704

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 BODY INTERIOR | Service intervals

5.1 Service intervals

Seat system
Components Service interval Max. runtime Instructions
Seat • Observe the expiry date specified by the
manufacturer.
Seat belt
• Replace after any collision.
Safety net

5.2 Colour code body interior

The body interior of the Porsche 911 GT3 Cup is painted in GT-silver metallic (M7Z)
without clear lacquer finish.

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 BODY INTERIOR | Seat belt

5.3 Seat belt

WARNING MANIPULATED SEAT BELT SYSTEM
Risk of injury from compromised safety function if the seat belt system is manipulated.
▶ Do not make any modifications to the seat belt system.
▶ Always ensure that all belts are tight before driving off.

For further information, in particular about the correct fastening and unfastening of the seat belt, please refer to the instructions provided by the seat belt
manufacturer.
See 7.3 Addresses (service + equipment) on page 1025.

5.3.1 Attaching the shoulder belt to the cage

[1] Shoulder belt
[2] Bolts 7/16 - 20UNF-2A x 13 x 2

50 Nm

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 BODY INTERIOR | Seat belt

5.3.2 Attaching the lap and crotch belt to the bodyshell

[1] Lap belt buckle
Ensure that the lap belt is not pinched between bodyshell and seat riser.
[2] Shims 11.5 x 15.9 x 4.5 (lap belt)
[3] Crotch belt buckle
[4] 7/16 - 20UNF-2A x 13 x 2 (lap belt)
[5] 7/16 - 20UNF-2A x 13 x 2 (crotch belt)
50 Nm

Crotch belt basic adjustment

Adjust the crotch belt to the specified length before installation.

Hole centre to seam: 300 mm
Hole centre to adjuster: 100 mm

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 BODY INTERIOR | Seat system

5.4 Seat system

DANGER USE OF THE SEATS WITHOUT HANS SYSTEM
If the driver and front passenger seats are used without the HANS system, serious injury
or death may result.
▶ Use driver and passenger seat only in conjunction with the HANS system.

WARNING INCORRECTLY MOUNTED SEAT

Risk of injury from compromised safety function if the seat is not mounted correctly.
▶ Bolt the seat rail to the body and the seatback to the roll cage.

WARNING LOOSE BOLTED CONNECTIONS AT THE SEAT SYSTEM

Damaged bolted connections may cause the seat system to become detached from the
vehicle, causing the driver to lose control over the vehicle.
▶ Always replace bolts when removed.
▶ Do not lubricate the bolts.
▶ Use only the bolts specified in the Porsche Motorsport parts catalogue.

WARNING MODIFICATIONS TO THE SEAT

Risk of injury from unauthorised modifications to the seat.
▶ Foam elements attached to the seat shell underneath the black cover fall into the scope
of the homologation and must not be removed.

From 01 January 2022, due to an amendment to Appendix J, Article 257A, 1301.2 of the FIA Regulations, all parts added to the homologated seat must be
made of non-flammable material or be covered with non-flammable cladding.
The original spare parts available from Porsche Motorsport for all Porsche 911 GT3 Cup already meet this requirement.
For any further parts added to the seat (seat insert, padding, etc.) compliance with the requirement must be proven to the organizer of the event upon request.
Text of attachment J, article 257A, 1301.2 valid from 2022:
The surfaces or cladding materials of components added to the homologated seat must be non-flammable (e.g. flammability test in accordance with ISO
standard 3795 with a speed of combustion less than or equal to 75 mm/min).

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 BODY INTERIOR | Seat system

5.4.1 Driver seat – removal/installation

Seat riser to bodyshell

[1] Seat riser

Ensure that the lap belt is not pinched between bodyshell and seat riser.

Fig. 59: Lap belt position

[2] Front bolts M10 x 28 (two each)

[3] Rear bolts M10 x 28 (two each)
50 Nm

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 BODY INTERIOR | Seat system

Seat to seat riser

▶ When installing the seat shell, guide the front bolts into the upper holes in the seat
shell [1] and screw them into the lower threads of the seat riser [2].
▶ Guide the rear bolts into the holes in the seat shell [3] and screw them into the lower
threads of the seat riser [4].

[1] Seat shell

[2] Bolts M10 x 20

50 Nm
Ensure that the crotch belt is installed and threaded through the seat before final assembly
of the seat system.

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 BODY INTERIOR | Seat system

Adjust seat

The seat can be adjusted to the following two positions:

[1] STRAIGHT: Delivery state (straight)
[2] TILTED: Seat tilts by 1.5° and rises by 20 mm

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 BODY INTERIOR | Seat system

5.4.2 Seat pads

Basically, the following applies to the seat pads:
• Small, slim physique = S pad variant = thick pad
• Large, strong physique = XL pad variant = thin pad
The following seat pad kits can be ordered via the Porsche Motorsport parts catalogue:
[1] Shoulder pad kits in sizes
S = pad thickness 30 mm
M = pad thickness 25 mm
L = pad thickness 20 mm
XL = pad thickness 10 mm
[2] Rib pad kits in sizes
S = pad thickness 30 mm
M = pad thickness 25 mm
L = pad thickness 20 mm
XL = pad thickness 10 mm
[3] Pelvis pad kits in sizes
S = pad thickness 30 mm
M = pad thickness 25 mm
L = pad thickness 20 mm
XL = pad thickness 10 mm
[4] Buttock pad in sizes
S = pad thickness 30 mm
M = pad thickness 20 mm
[5] Leg support pads in sizes
S = pad thickness 30 mm
M = pad thickness 20 mm
[6] Lordosis pad (pad thickness 20 mm)
[7] Backrest padding (pad thickness 20 mm)

If the seat cover is damaged, it can be repaired by the manufacturer.

Contact the manufacturer Sabelt for more information.
See 7.3 Addresses (service + equipment) on page 1025.

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 BODY INTERIOR | Seat system

5.4.3 Seat adjustment

The Profi Seat Kit from the manufacturer SCHROTH can be used optionally to adjust the
seat to the body contour.
Purchase and a detailed description via SCHROTH Safety Products GmbH.
See 7.3 Addresses (service + equipment) on page 1028.
▶ When using this system in a car, it is essential to observe the dimensions for seat
inserts specified in the series regulations.
▶ A cover made of non-flammable material must be used. See information on Appendix
J, Article 257A, 1301.2 of the FIA Regulations on page 680.

5.4.4 Passenger seat

CAUTION HIGH TORQUES
Risk of injury from flying metal chips.
▶ Wear personal protective equipment.

NOTICE INCORRECT ASSEMBLY

Risk of damage to the threads.
▶ Align the self-tapping screw in the centre of their bores.
▶ Use an impact wrench only to tap the threads.
▶ After tapping the thread, remove the screw manually.

It is recommended that the 911 GT3 Cup (992) driver seat is also used as passenger seat.
For this purpose, only the seat riser for the passenger seat must be converted
(see Converting the seat riser for the passenger seat on page 686).

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 BODY INTERIOR | Seat system

Converting the seat riser for the passenger seat

1. Push the seat riser into its rearmost position.

2. Remove the bolts [1] with their washers.
3 mm Allen key 3. Pull out the adjuster lever [2] in the direction of the arrow.

4. Push the screwdriver into the guide of the adjuster lever to retain the adjuster in
its position.
Screwdriver
8 mm

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 BODY INTERIOR | Seat system

Ensure that the spring [1] remains in its guides [circles].

5. Remove the bolts [1] with their washers on the opposite side.
6. Pull out the guide [2] in the direction of the arrow.
3 mm Allen key

Ensure that the spring [3] remains in its guides [circles].

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 BODY INTERIOR | Seat system

7. Install the adjuster lever [1] on the right-hand side.

8. Install the bolt [2] and its washer and tighten it.
3 mm Allen key 9. Install the bolt [3] and its washer and tighten it.
6.4 Nm

Loctite 243

10. Remove the screwdriver on the left-hand side.

11. Install the guide [1] on the left-hand side.
Hexagon key 12. Install the bolt [2] and its washer and tighten it.
3 mm 13. Install the bolt [3] and its washer and tighten it.
6.4 Nm

Loctite 243

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 BODY INTERIOR | Seat system

Passenger seat – installation/removal

When assembling the crotch belt, ensure that the bolts required are already present in the bodyshell.

b Adjustment lever on the seat console is converted.

See Converting the seat riser for the passenger seat on page 686.

1. Centre the self-tapping screw.

2. Screw in the self-tapping screw with an impact wrench (Fig. left).
Impact wrench Make sure that there is a distance (approx. 5 mm) between the screw head and the
mounting surface (Fig. right).
3. remove the screw by hand after creating the thread.
4. Repeat steps 1–3 at all screwing points.

5. Install crotch and lap belt

(see 5.3.2 Attaching the lap and crotch belt to the bodyshell on page 679).
6. Install the seat riser and torque the bolts to specification
(see Seat riser to bodyshell on page 681).
7. Install the shoulder belt
(see 5.3.1 Attaching the shoulder belt to the cage on page 678).
8. Install the seat (see Seat to seat riser on page 682).

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 BODY INTERIOR | Seat system

Stipulations & guidelines for “Taxi” rides

The following points must be observed when giving taxi rides:

• It is recommended that the 911 GT3 Cup (992) driver seat is also used as passenger
seat.
• Taxi rides must only be given by professional racing drivers!
• Taxi rides must not be given during a race or competition and the car must not be driven
at the limit!
• The driver must observe all official rules and regulations when driving on track and in the
pit lane!
• No taxi rides for guest under 18 years of age!
• Wearing the following homologated safety equipment is mandatory for both the driver
and passenger:
– Overalls complying with FIA standard 8856-2000
– Shoes complying with FIA standard 8856-2000
– Gloves complying with FIA standard 8856-2000
– Crash helmet with HANS complying with FIA standard
• Guests MUST wear all the necessary safety equipment (see above) to be allowed to
participate in a taxi ride!
• Only guests in good physical condition are allowed to participate in a taxi ride.
An appropriate physical size is necessary to ensure that the safety harness fits properly
and functions correctly!
• The passenger must produce valid identification when signing a disclaimer before the taxi
ride. The organiser MUST demand and document the disclaimer!
• The participant / car owner must ensure that the car is in perfect technical condition!
• Suitably trained security staff must be in attendance on location (ambulance, doctor,
paramedic, fire service and track marshals)!
• Driver and passenger safety is of paramount importance and always takes precedence!

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 BODY INTERIOR | Safety nets

5.5 Safety nets

DANGER IMPROPERLY INSTALLED SAFETY NETS
Improper installation/adjustment can lead to impaired vision, severe injury or death.
▶ The driver must be positioned in the seat so that his/her eye level is within the
corridor [1] (Fig. 60).
▶ The eye level of each driver must be marked on the headrest!
▶ As seen from the side, the upper strap of the net may be located vertically (Z-direction)
at a maximum of 15 mm below and at a maximum of 80 mm above the eye (Fig. 61).
▶ The safety nets must contact the seat on the sides (Fig. 61).
▶ At least 2 of the vertical straps must cover the headrest (Fig. 61).
▶ Tighten the safety nets so that at any point along the longitudinally running straps
a transverse force induced by the driver of 50 N does not deflect the straps more
than 50 mm.

Fig. 60: Eye level corridor

Fig. 61: Example of outer safety net

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 BODY INTERIOR | Safety nets

WARNING NON-OPERATIONAL SAFETY NET RELEASE

Vehicle egress may be impaired.
▶ Always check the release function of the safety nets before using the vehicle.
▶ With the seat belts fastened, the driver must be able to operate the safety net release.

WARNING UNINTENDED OPENING OF THE OUTER SAFETY NET

The safety net may open by external intervention.
▶ The push button holder (PUSH) of the outer safety net must be pointing upwards.

After the installation has been completed, it is the team's responsibility to verify
compliance with the FIA "Racing Nets Installation Specification"!
https://www.fia.com/regulation/category/762
FIA.COM > SPORT > HOMOLOGATIONS > FIA STANDARDS > CATEGORY VIEW >
GENERAL > Select the latest version!

Chafing protective pads are available for the Porsche 911 GT3 Cup to protect the safety
nets and the seat. Cars from model year 2023 have the pads already installed on delivery.
Cars from model year 2021/2022 will receive the protective pads free of charge if they
state their chassis number.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Chafing protection safety net /seat

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 BODY INTERIOR | Safety nets

5.5.1 Outer safety net – installation/adjustment

Attachment
Front
1. Install the locking pin [1] into the roll cage.
50 Nm

2. Screw the nut [2] onto the locking pin [1] to the end of the thread.
3. Turn the push button holder [3] out against the motion stop and then reverse it about
one turn max. until the PUSH button points vertically upward.

4. After fitting the push button holder [3], turn the nut [2] fully against the push button
holder [3] to lock it.
50 Nm Make sure not to use the nut [2] to make adjustments.
Use only the three rearmost belt attachments for the adjustment.

5. Plug the outer net [4] into the push button holder.
▶ To open the outer net, pull tab [5] or press the PUSH button [6].

Rear
[1] Top belt attachment
[2] Centre belt attachment
[3] Bottom belt attachment

If the specified safety net setting is not possible, a 5° cranked locking pin is available to
compensate for the tolerances of the safety net connection point. See Porsche Motorsport
parts catalogue.

V7,12/2022 911 GT3 Cup (2021–2023) 693

 BODY INTERIOR | Safety nets

Looping the belt:

a. Route the belt through the adjuster as shown.
b. Route the belt web around the cage tube and through the adjuster as shown.
c. Fold back the belt web and pull it through the adjuster as shown.
d. Ensure that at least 100 mm of the belt end protrude from the adjuster.
If the loose belt end is shorter than 100 mm, the belt must be removed and the
installation be repeated.
▶ Roll up any excess length of the belt and secure it using a tie wrap.

V7,12/2022 911 GT3 Cup (2021–2023) 694

 BODY INTERIOR | Safety nets

Adjustment

b The car is stationary on level ground (zero position).

b The seat is in its rearmost adjustment position.

1. Align the outer safety net according to the specified angles and relative to the eye
point [1].
Spirit level with Ensure that the net contacts the seat on the side and is tight.
calibration 2. Tighten the safety nets so that at any point along the longitudinally running straps
function, a transverse force induced by the driver of 50 N does not deflect the straps more
Tape measure than 50 mm.
▶ Adjust the safety net at the rear three loops.

V7,12/2022 911 GT3 Cup (2021–2023) 695

 BODY INTERIOR | Safety nets

5.5.2 Inner safety net – installation/adjustment

Attachment

Front
b Cover [2] is unclipped.
[1] Belt attachment underneath cover [2] behind dashboard.

V7,12/2022 911 GT3 Cup (2021–2023) 696

 BODY INTERIOR | Safety nets

Rear
[1] Fastening ring
8 Nm [2] Screws M6 x 20
▶ Position the fastening ring flush against the weld seam of the roll cage.

[1] Top belt attachment

[2] Centre belt attachment
[3] Bottom belt attachment

V7,12/2022 911 GT3 Cup (2021–2023) 697

 BODY INTERIOR | Safety nets

Looping the belt:

a. Route the belt through the adjuster as shown.
b. Route the belt web around the cage tube and through the adjuster as shown.
c. Fold back the belt web and pull it through the adjuster as shown.
d. Ensure that at least 100 mm of the belt end protrude from the adjuster.
If the loose belt end is shorter than 100 mm, the belt must be removed and the
installation be repeated.
▶ Roll up any excess length of the belt and secure it using a tie wrap.

V7,12/2022 911 GT3 Cup (2021–2023) 698

 BODY INTERIOR | Safety nets

Adjustment

b The vehicle is stationary on level ground (zero position).

b The seat is in its rearmost adjustment position.

1. Align the inner safety net according to the specified angles and relative to the eye
point [1].
Spirit level with Ensure that the net contacts the seat on the side and is tight.
calibration 2. Tighten the safety nets so that at any point along the longitudinally running straps
function, a transverse force induced by the driver of 50 N does not deflect the straps more
Tape measure than 50 mm.
▶ Adjust the safety net at the rear three loops.
▶ To open the inner net, pull tab [2].

V7,12/2022 911 GT3 Cup (2021–2023) 699

 BODY INTERIOR | Cage padding

5.6 Cage padding

WARNING INCORRECT ASSEMBLY
Risk of injury from incorrect assembly of cage padding
▶ When assembling, observe the orientation of the padding on the roll cage tube.
[1] Tie wraps
[2] Cage padding

5.7 Leg protection

[1] Foam part
[2] Tie wraps

V7,12/2022 911 GT3 Cup (2021–2023) 700

 BODY INTERIOR | Additional weights

5.8 Additional weights

CAUTION HIGH TORQUES
Risk of injury from flying metal chips.
▶ Wear personal protective equipment.

NOTICE DAMAGED THREADS

Risk of damage to the threads.
▶ Centre the self-tapping screws in the holes.
▶ Only use impact wrenches for thread grooving.
▶ Remove the screws by hand after creating the thread.

5.8.1 Preparing the body for the base plate and additional weights

Only carry out the following steps if no passenger seat or additional weights have been
fitted beforehand.

1. Centre the self-tapping screw.

2. Screw in the self-tapping screw with an impact wrench (Fig. left).
Impact wrench Make sure that there is a distance (approx. 5 mm) between the screw head and the
mounting surface (Fig. right).
3. remove the screw by hand after creating the thread.
4. Repeat steps 1–3 at all screwing points.

V7,12/2022 911 GT3 Cup (2021–2023) 701

 BODY INTERIOR | Additional weights

5.8.2 Mounting base plate and additional weights

On all Porsche 911 GT3 Cup (992) models, the base plate [1] of the additional weights
must be checked with regard to its production batch number.
Base plates from batches 12M2020, 02M2021 and 03M2021 must not be equipped with
more than 40 kg. The base plates from these batches must be withdrawn from use as soon
as possible. New base plates will be issued free of charge upon return of the affected
components.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Base plate auxiliary weight

Base plate and additional weights are made of steel.

Maximum permissible load: 113 kg

V7,12/2022 911 GT3 Cup (2021–2023) 702

 BODY INTERIOR | Additional weights

[1] Base plate

[2] Bolts M10 x 40 incl. washers 10.5 x 25

55 Nm

[3] Threaded rods M12

[4] Additional weights

[5] Nuts M12 x 1.5

85 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 703

 BODY INTERIOR | Dashboard

5.9 Dashboard

The vehicle is not fitted with any airbags.

Any indications of an airbag (e.g. on the dashboard) are due to parts carried over from series
production vehicles.

5.10 Interior ventilation

The Porsche 911 GT3 Cup is factory-equipped with a particulate filter [1] in the air condi-
tioning unit. The use of the filter is left to the operating team. If used, the particulate filter
should be removed after two to three races of the car (see page 705) and cleaned or
replaced if necessary. Porsche Motorsport recommends that the particulate filter not be
used in rainy conditions or, if necessary, that the particulate filter be removed and dried
after rainy conditions.In any case, the cover of the filter compartment on the A/C unit must
be properly closed during use so that the air flow from the fan can reach the interior
correctly.

Air is guided into the cockpit by two flexible plastic hoses:

[1] Centrally, aimed at the driver
[2] Laterally at the centre console, aimed at the driver
[Arrows] windscreen
▶ Switching on the interior fan: See 6.11.3 Overview of instrument panel on page 789.

V7,12/2022 911 GT3 Cup (2021–2023) 704

 BODY INTERIOR | Interior ventilation

5.10.1 Removing/installing Interior particulate filter

b Ignition [IGN] is switched off.

b Main switch [MAIN] is switched off.
b Fire extinguisher bottle removed. See Removing/installing the fire extinguisher bottle
on page 774.

1. Unlock latching lugs and open cover.

2. Pull out particle filter from air conditioning unit.

▶ To install follow the above-mentioned sequence in reverse.

V7,12/2022 911 GT3 Cup (2021–2023) 705

6 ELECTRIC SYSTEM
6.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
6.2 Voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
6.3 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724
6.4 Wiring looms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752
6.5 Option separating points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753
6.6 Sensory system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765
6.7 Fire extinguisher system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770
6.8 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777
6.9 Windscreen wiper unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
6.10 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779
6.11 Centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785
6.12 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791
6.13 Porsche Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 876
6.14 Porsche Toolset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931
6.15 Radio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 975

V7,12/2022 911 GT3 Cup (2021–2023) 706

 ELECTRIC SYSTEM |

6.16 Transponder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 996

6.17 Options (ABS & TC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997
6.18 Video system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1017

V7,12/2022 911 GT3 Cup (2021–2023) 707

 ELECTRIC SYSTEM | Service intervals

6.1 Service intervals

Components Service interval Max. runtime Instructions
Wheel speed sensor FA & RA 50 h • Visual inspection and functional testing.
Brake pressure sender 50 h
Steering wheel 50 h
Brake light switch 50 h • Visual inspection.
Fire extinguisher system before each use of the car • Check the system.See Testing the system
on page 775.
Fire extinguisher system: before each use of the car • Check for function and ease of movement.
Emergency switches outside and inside
the car
Fire extinguisher system: 2 years • Replace component.
Extinguisher bottle
Extinguishing nozzles 50 h • Visual inspection.
Y-piece of fire extinguisher system 50 h
Fuel pump control units 50 h • Visual inspection of plug system.
Emergency switch, external, connection 50 h • Visual inspection:
cable of emergency switch
Interior wiring loom 1x per season • Visual inspection.
• Check for chafe marks.
Engine wiring loom
Gearbox wiring loom
Intank wiring loom
E-steering wiring loom
Wiring loom, wheel housing FA
Wiring loom, wheel housing RA

V7,12/2022 911 GT3 Cup (2021–2023) 708

 ELECTRIC SYSTEM | Service intervals

Components Service interval Max. runtime Instructions

Wiring loom fender adapter 1x per season • Visual inspection.
• Check for chafe marks.
Front section wiring loom
Wiring loom battery B+
(starter & alternator)
Ground cable (from engine to body)
Wiring loom battery/battery disconnect
switch
Ground cable (from battery to body)
Diagnosis adapter cable
ABS wiring loom
Adapter ADR (Accident Data Recorder)
Adapter cable USB
Centre console support plate 50 h • Visual inspection.
Wiper system 50 h
Main headlights 50 h • Visual inspection and functional testing.
Rear lights 50 h
Battery 150 h • Replace component.
Battery disconnect switch 50 h • Visual inspection.
Alternator: 50 h 100 h After 50 h:
• Visual inspection and functional testing as part
of the engine overhaul at PAG/PMNA.
After 100 h:
• Replacement of the component as part of the
engine overhaul at PAG/PMNA.

V7,12/2022 911 GT3 Cup (2021–2023) 709

 ELECTRIC SYSTEM | Voltage supply

6.2 Voltage supply

6.2.1 Battery
DANGER CONTACT WITH LIVE PARTS OR SHORT CIRCUIT
Touching live parts of the vehicle can cause electric shock. Work on the vehicle's electric
system can cause a short circuit.
Short circuits can cause fires. Many vehicle fluids are highly flammable, e.g. fuel, engine
and gearbox oil. Fuel vapours may explode.
▶ Wear protective clothing when carrying out service work.
▶ Do not open or disassemble the battery.
▶ Keep the battery away from open flames.
▶ Observe the separate product information provided by the battery manufacturer.

A new or previously completely discharged battery must be fully charged using an external
charger. This is necessary so that the battery's internal battery management system (BMS)
can learn the state of charge (SOC) based on the applied cell voltages.

The procedure is necessary as new lithium-ion batteries may only be transported outside
the car with max. 30 % SOC. The BMS recognizes the correct SOC only after a charging
cycle up to 100 % state of charge without simultaneous current draw.
The battery is fully charged when the charger signals the full state of charge.
→ Observe the charger manufacturer's instructions.

An incorrectly acquired SOC can cause the battery to discharge when running and thus to
the car stopping on track.

V7,12/2022 911 GT3 Cup (2021–2023) 710

 ELECTRIC SYSTEM | Voltage supply

If the battery is discharged too deeply, an isolating element between the cells and the
positive pole opens.
→ This does not mean that the battery is defective, but that it requires full recharge.

Technical data
Specification Value
Battery type Lithium-ion (LiFePO)
Manufacturer A 123
Nominal voltage 13.2 V
Number of cells 4S3P
Capacity 60 Ah
Nominal energy capacity 792 Wh
Weight 11.5 kg
Operating voltage 10~14.8 V

V7,12/2022 911 GT3 Cup (2021–2023) 711

 ELECTRIC SYSTEM | Voltage supply

Overview of connections
[1] Positive pole
[2] Negative pole
[3] Vent
[4] LIN connection

Installing the battery

A new battery is available. The use of the previous batteries is still possible without any
restrictions. When using the new battery, it is mandatory to use the new battery holder. The
new battery holder is also suitable for the previous batteries. The new holder is available for
at Motorsport and spare parts sales.
See 7.2 Motorsport and spare parts sales on page 1024.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Battery holder

V7,12/2022 911 GT3 Cup (2021–2023) 712

 ELECTRIC SYSTEM | Voltage supply

[1] Battery
[2] Mounting element
[3] Bolt M8 x 20

20 Nm

Installing the battery cover

[1] Battery cover

[2] Bolt M5 x 16

4.5 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 713

 ELECTRIC SYSTEM | Voltage supply

6.2.2 Battery disconnect switch

The battery disconnect switch isolates the battery from the vehicle's electric system if the main switch or the emergency switches are operated.
When the emergency switches are operated, the electronic battery disconnect switch interrupts the battery positive line from the vehicle's voltage supply.
The battery disconnect switch is located on the passenger side inside the battery compartment.

Battery disconnect switch – preassembly

[1] Battery disconnect switch

[2] Retaining plate
[3] Bolts M5 x 25-W

4.5 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 714

 ELECTRIC SYSTEM | Voltage supply

Battery disconnect switch to bodyshell

[1] Battery disconnect switch

[2] Bolts M5 x 10

4.5 Nm

Overview of fuses
[1] 80-A fuse, electric steering
[2] 80-A fuse, e-shift barrel

[3] Connection of electric system controller

V7,12/2022 911 GT3 Cup (2021–2023) 715

 ELECTRIC SYSTEM | Voltage supply

Actuation inside vehicle

Actuation in centre console [MAIN]
▶ Pull the switch slightly and tilt it to the desired position.
– Switch up: OFF
– Switch down: ON

Actuation outside vehicle

[1] Emergency switch
▶ Pull pin.
→ Main switch OFF
[2] Emergency switch + fire extinguisher system.
▶ Pull pin.
→ Main switch OFF and fire extinguisher system ON

V7,12/2022 911 GT3 Cup (2021–2023) 716

 ELECTRIC SYSTEM | Voltage supply

6.2.3 Resetting the main voltage supply

Only perform the following procedure if it is necessary to reset the main voltage supply.
▶ While driving, this procedure may only be performed on a long and safe, straight stretch of the track.
It must be observed that none of the electric consumers (lights, turn signals, wipers, ABS, TC, power steering, brake lights, telemetry system and radio)
are active while switching the system off and back on.

b Accelerator pedal released.

b Brake pedal released.
1. Press clutch.
2. Switch off ignition [IGN].
3. Switch off the main switch [MAIN].
4. Wait one second.
5. Switch on the main switch [MAIN].
6. Switch on the ignition [IGN].
7. If gear and speed match, release the clutch.
8. Press the accelerator pedal and drive on.

V7,12/2022 911 GT3 Cup (2021–2023) 717

 ELECTRIC SYSTEM | Voltage supply

6.2.4 Battery charger

DANGER IMPROPER HANDLING OF BATTERY
Improper handling or damage of the battery can lead to severe injury or death.
▶ Wear protective clothing when carrying out service work.
▶ Do not open or disassemble the battery.
▶ Keep the battery away from open flames.
▶ Charge lithium batteries only in well-ventilated rooms.
▶ Operate the battery charger only if correspondingly qualified.
▶ Observe the separate product information provided by the battery manufacturer.

NOTICE IMPROPER CHARGING OF BATTERY

If the battery is overcharged, an isolating element between the cells and the positive pole
opens to prevent the release of hazardous gas. This will damage the battery beyond repair,
and it must be replaced.
▶ Use only chargers that are suitable for the charging of lithium-ion batteries.
▶ Ensure that the charge mode for lithium-ion batteries is set
(to adjust charging parameters).
▶ Set the battery charger to the corresponding battery type (lithium-ion).
▶ Replace the battery if overcharged.

V7,12/2022 911 GT3 Cup (2021–2023) 718

 ELECTRIC SYSTEM | Voltage supply

Manthey-Racing CTEK PRO 25 S (14,4 V, 25 A)

This device can be used to charge, support (charge conservation) and restore over-
discharged batteries. The charger allows charging of the battery via the optionally available
remote charging loom without battery cover removal.
▶ Observe the manufacturer's instructions.

Purchase and further information via Manthey-Racing.

See 7.3 Addresses (service + equipment) on page 1028.
Deutronic, charging computer DBL (14.4 V, 90 A)

VAS 5908

V7,12/2022 911 GT3 Cup (2021–2023) 719

 ELECTRIC SYSTEM | Voltage supply

Closing of electric contactor

In this guide the process to close the electric contactor of a LiFePO4 battery is described.In this guide the process to close the electric contactor of a LiFePO4
battery is described.
Only use this method, if the contactor opened because of a too low discharge of the battery.
Only use this guide in combination with a Deutronic charger.
▶ To navigate between the lines on the display of the charger use the arrow keys.

1. Set Deutonic charger to FSV-Mode:

a. Charger is usually in „Auto-Mode”: Choose „Stop“  ENTER
→ Display now shows („Ready“).
b. Navigate to „Menü“  ENTER.
c. Insert Code.

V7,12/2022 911 GT3 Cup (2021–2023) 720

 ELECTRIC SYSTEM | Voltage supply

d. Navigate to the top field „Auto-Mode”  ENTER.

V7,12/2022 911 GT3 Cup (2021–2023) 721

 ELECTRIC SYSTEM | Voltage supply

e. Choose „FSV-Modus” with the arrow keys  ENTER.

f. Navigate to „Zurück”  ENTER.
→ Charger shows „FSV-Modus” and „Bereit”.
2. Build in Battery with opened contactor into the car;
Connect the charger-cables to the Battery.

V7,12/2022 911 GT3 Cup (2021–2023) 722

 ELECTRIC SYSTEM | Voltage supply

3. Switch on the main switch [MAIN] in the centre console.

4. Navigate to „Start" on the charger and confirm with ENTER.
→ Display of the Charger shows a current and voltage.
→ After < 30 s the contactor closes.
→ The current rises to >25 A.
→ The display shows „Versorgung”.

If the contactor is not closed after one minute (current <25 A):
▶ Stop the charger, disconnect it from the battery.
▶ Replace the battery.
5. Charge the Battery for maximum 15 min in „FSV-Mode“.
6. Choose „Stop”  Enter.
7. Switch off the main switch [MAIN] in the centre console..
8. Disconnect charger from Battery.
9. Bring charger back to „Auto-Mode“.
10. Connect charger to battery and charge in „Auto-Mode“.
11. Navigate to „Start”  Enter.

V7,12/2022 911 GT3 Cup (2021–2023) 723

 ELECTRIC SYSTEM | Control units

6.3 Control units

NOTICE WELDING
Welding may damage control units connected to the vehicle.
▶ Switch off main switch [MAIN].
▶ Disconnect control units from the wiring looms before commencing any welding work.

Due to the continuous optimisation of our products, new software versions and customer information
are published regularly. Porsche Motorsport recommends using the latest software versions in the
cars at all times.
Further information can be found in PMRSI („Porsche Motorsport Racecar Service Information“ Portal
(PMRSI) at https://motorsport.porsche.com).

To prevent chafing of the wiring loom on the fastening screw in the area of the connection
to the Porsche Logger, it is recommended to provide the wiring loom with suitable chafing
protection. Alternatively, the screw on the control unit bracket can be replaced with a pan-
head screw..
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Wiring loom protection

V7,12/2022 911 GT3 Cup (2021–2023) 724

 ELECTRIC SYSTEM | Control units

6.3.1 Porsche Powerbox

NOTICE IMPROPER USE
Improper handling may damage the Porsche Powerbox.
▶ Only flash setups when the ignition is OFF.
▶ Only flash firmware when the ignition is OFF and the power connector is disconnected.
▶ After successful flashing, send a setup command and perform a power cycle.

Pin assignment

The status LEDs show which of the 64 outputs is on or off.

A threaded ground connection is located on the side of the Porsche Powerbox [CN5] (M5 x 8 - 4,5 Nm).

V7,12/2022 911 GT3 Cup (2021–2023) 725

 ELECTRIC SYSTEM | Control units

Connector [CN1] – AS6 18-35 PN

Pin Name
A1 +12 V wheel speed front left/rear right
A2 ECATOUTTX+
A3 ECATOUTRX-
A4 PWM3
A5 Ground
A6 ECATOUTTX-
A7 ECATOUTRX+
A8 +12 V wheel speed front right/rear left
A9 EXT5/12PSU4
A10 AIN3
A11 PWM2
A12 PWMLSD4
A13 Ground, fire extinguisher system diagnostics
A14 EXT5/12PSU3, fire extinguisher system diagnostics
A15 ETH100-2TX-
A16 ETH100-2TX+
A17 AIN1
A18 AIN4
A19 PWM1, main fuel pump
A20 PWMLSD5
A21 FLXR-PA IN
A22 FLXR-MA IN
A23 ETH100-2RX+

V7,12/2022 911 GT3 Cup (2021–2023) 726

 ELECTRIC SYSTEM | Control units

Connector [CN1] – AS6 18-35 PN

Pin Name
A24 ETH100-2RX-
A25 Switch 2, brake status
A26 Switch 1, fire extinguisher system
A27 AIN2
A28 System active
A29 DEBTX zu PC RX
A30 FLXR-MA OUT
A31 FLXR-PA OUT
A32 LIN1, battery/alternator
A33 LIN2, LT rear
A34 + 12 V battery
A35 Switch 3, battery disconnect switch
A36 Switch 4, start button
A37 Ground
A38 DEBRX to PC TX
A39 ETH100-1TX+
A40 ETH100-1TX-
A41 ETH100-1RX+
A42 ETH100-1RX-
A43 Ground, battery
A44 Switch 6, fire extinguisher system
A45 Switch 5, ignition
A46 Ground

V7,12/2022 911 GT3 Cup (2021–2023) 727

 ELECTRIC SYSTEM | Control units

Connector [CN1] – AS6 18-35 PN

Pin Name
A47 CAN H1
A48 CAN L1
A49 CAN L2
A50 CAN H2
A51 pcu_10_teamlog terminal 15
A52 pcu_15_stw
A53 pcu_09_shiftbeep
A54 pcu_14_ECU terminal 15
A55 pcu_08_acflaps
A56 pcu_07_tpms_rr
A57 pcu_12_EPS terminal 15
A58 pcu_05_tpms_fr
A59 pcu_04_tpms_fl
A60 pcu_02_steerangle
A61 pcu_06_tpms_rl
A62 pcu_16_display
A63 pcu_13_ECU terminal 30
A64 pcu_03_sclu
A65 pcu_01_com_sply1
A66 pcu_11_ABS terminal 15

V7,12/2022 911 GT3 Cup (2021–2023) 728

 ELECTRIC SYSTEM | Control units

Connector [CN2] – AS6 18-32 PA

Pin Name
B1 pcu_25_video
B2 pcu_21_intank1
B3 pcu_29_com_sply2
B4 pcu_33_rainLT
B5 pcu_18_center_cons
B6 pcu_46_auxLT_l
B7 pcu_46_auxLT_l
B8 pcu_38_auxLT_r
B9 pcu_38_auxLT_r
B10 pcu_34_tailLTl
B11 pcu_30_log
B12 pcu_24_intank4
B13 pcu_22_intank2
B14 pcu_41_indic_l
B15 pcu_37_optH_1
B16 pcu_37_optH_1
B17 pcu_02_com_sply3
B18 pcu_23_intank3
B19 pcu_20_interiorLT
B20 pcu_19_IDLT
B21 pcu_17_tele
B22 pcu_44_dipLT_KL.15
B23 pcu_40_heatscrn

V7,12/2022 911 GT3 Cup (2021–2023) 729

 ELECTRIC SYSTEM | Control units

Connector [CN2] – AS6 18-32 PA

Pin Name
B24 pcu_40_heatscrn
B25 pcu_40_heatscrn
B26 pcu_40_heatscrn
B27 pcu_39_drinkpmp
B28 pcu_31_optH_2
B29 pcu_31_optH_2
B30 pcu_35_tailLTr
B31 pcu_36_brkLT
B32 pcu_43_indic_r

Connector [CN3] – AS6 20-16 PN

Pin Name
C1 pcu_49_ECUDYN
C2 pcu_52_wip
C3 pcu_58_opt_highpwr
C4 pcu_51_starter
C5 pcu_64
C6 pcu_53_sup_mp
C7 pcu_53_sup_mp
C8 pcu_58_opt_highpwr
C9 pcu_56_fandrv
C10 pcu_56_fandrv
C11 pcu_49_ECUDYN

V7,12/2022 911 GT3 Cup (2021–2023) 730

 ELECTRIC SYSTEM | Control units

Connector [CN3] – AS6 20-16 PN

Pin Name
C12 pcu_60_radio
C13 pcu_61_teamlog terminal 30
C14 pcu_63_dipLTfl
C15 pcu_59_dipLTfr
C16 pcu_55_PMDI

Connector [CN4] – ASHD6 14-1 SN

Pin Name
D1 +12 V (battery)

Connector [CN5] – ring terminal M5

Pin Name
E1 Chassis ground

V7,12/2022 911 GT3 Cup (2021–2023) 731

 ELECTRIC SYSTEM | Control units

IPS outputs
Conditions for the activation/deactivation of individual consumers:

Id Name Pin Destination Rating [A] Control Channel Control

1 pcu_01_com_sply1 A65 Start button lighting, brake light switch 2,5 pcu_state_main Active with MAIN
2 pcu_02_steerangle A60 Steering angle sensor 2,5 pcu_state_main Active with MAIN
3 pcu_03_sclu A64 Sensorcluster YAW Rate Sensor (Option) 2,5 pcu_state_main Active with MAIN
4 pcu_04_tpms_fl A59 TPMS FL 2,5 pcu_state_main Active with MAIN
5 pcu_05_tpms_fr A58 TPMS FR 2,5 pcu_state_main Active with MAIN
6 pcu_06_tpms_rl A61 TPMS RL 2,5 pcu_state_main Active with MAIN
7 pcu_07_tpms_rr A56 TPMS RR 2,5 pcu_state_main Active with MAIN
8 pcu_08_acflaps A55 Climatic flaps 2,5 pcu_state_main Active with MAIN
9 pcu_09_shiftbeep Shiftbeep (Option) 2,5 log_shiftbeep 12 V active with shiftbeep signal
10 pcu_10_teamlogCT15 Team Logger Ct. 15 2,5 pcu_state_ign Active with IGN
11 pcu_11_ABS_CT15 A66 ECU ABS Kl. 15 (Option) 2,5 pcu_ctrl_absCT15 Delayed IGN for ABS
12 pcu_12_EPS_CT15 A57 Servotronic EPS Kl. 15 2,5 pcu_ctrl_epsCT15 Delayed IGN for EPS
13 pcu_13_ECU_CT30 A63 Bosch MS6.6 Ct. 30 2,5 pcu_state_main Active with MAIN
14 pcu_14_ECU_CT15 A54 Bosch MS6.6 Ct. 15 2,5 pcu_state_ign Active with IGN
15 pcu_15_stw Steering wheel 2,5 pcu_state_main Active with MAIN
16 pcu_16_display A62 Cosworth CDU 10.3 2,5 pcu_one Always ON
17 pcu_17_tele B21 Telemetry (Option) 7,5 pcu_state_main Active with MAIN
18 pcu_18_center_cons B5 Center console 7,5 pcu_state_main Active with MAIN
19 pcu_19_IDLT B20 ID lights (Startnummer/Option) 7,5 pcu_state_ign Active with IGN
20 pcu_20_interiorLT B19 Interior Lighting (Option) 7,5 pcu_state_ign Active with IGN
25 pcu_25_video B1 V-box 7,5 pcu_state_main Active with MAIN
27 pcu_27_com_sply3 B17 Option CAN 3 (TPMS DIAG) / Option CAN 4 7,5 pcu_state_main Active with MAIN
29 pcu_29_com_sply2 B3 ADR (Option), Laptrigger, Oil LED (Option) 7,5 pcu_state_main Active with MAIN
30 pcu_30_log B11 Cosworth Badenia Logger 7,5 pcu_one Always ON
31 pcu_31_opt3 B28, B29 Option output customer 3 (15A) 15 pcu_state_opt3 Activated via Center Console
33 pcu_33_rainLT B4 Rain light 7,5 pcu_ctrl_rainLT Activated via Center Console
34 pcu_34_tailLTl B10 Rear light left 7,5 pcu_state_main Active with MAIN
35 pcu_35_tailLTr B30 Rear light right 7,5 pcu_state_main Active with MAIN
36 pcu_36_brkLT B31 Break light 7,5 pcu_ctrl_brkLT Active while braking
37 pcu_37_opt2 B15, B16 Option output customer 2 (15A) 15 pcu_state_opt2 Activated via Center Console
38 pcu_38_auxLT_r B8, B9 Aux. Light Right (Option) 15 pcu_ctrl_auxLT Activated via Center Console
39 pcu_39_drinkpmp B27 Drink pump (Option) 7,5 pcu_ctrl_drinkpmp Active while button on STW is pressed (IGN needs to be on)
Flashing:
- While indicator button on STW is pressed
41 pcu_41_indic_l B14 ,QGLFDWRUOHIWb IURQW UHDU 7,5 pcu_ctrl_indic_l
- While hazard is on (activates automatically when engine stalls or fuel pump
mechanic mode is on)
Flashing:
- While indicator button on STW is pressed
43 pcu_43_indic_r B32 ,QGLFDWRUULJKW IURQW UHDU 7,5 pcu_ctrl_indic_r
- While hazard is on (activates automatically when engine stalls or fuel pump
mechanic mode is on)

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 ELECTRIC SYSTEM | Control units

44 pcu_44_dipLT_CT15 B22 HSW Front Kl. 15 (WakeUp) 7,5 pcu_state_ign Active with IGN
46 pcu_46_auxLT_l B6, B7 Aux. Light Left (Option) 15 pcu_ctrl_auxLT Activated via Center Console

49 pcu_49_ECUDYN C1, C11 MS6.6 Dyn Power (Main supply motor electrics) 50 pcu_ctrl_ecudyn Active with IGN and used to kill engine via STW

51 pcu_51_starter C4 Starter Kl. 50 (WIPER (PEAK)) 25 pcu_ctrl_starter Active when engine is starting

52 pcu_52_wiper C2 Wiper (WIPER (PEAK)) 25 pcu_state_ign Active with IGN

53 pcu_53_sup_mp C6, C7 Fuel pump control unit / main fuel pump 50 pcu_state_ign Active with IGN

55 pcu_55_PMDI C16 OTA Modul (Exklusiv / Option) 12 pcu_state_main Active with MAIN
56 pcu_56_fandrv C9, C10 FAN Climatic / FAN Driver 50 pcu_state_ign Active with IGN
58 pcu_58_opt1 C3, C8 Cool Box / Suit (Option 1) 50 pcu_state_opt1 Activated via Center Console
59 pcu_59_dipLTfr C15 Main headlight right (Kl. 30) 12 pcu_state_main Active with MAIN
60 pcu_60_radio C12 Radio control unit / radio 12 pcu_state_main Active with MAIN

61 pcu_61_teamlogCT30 C13 Teamlogger interface & transponder 12 pcu_state_main Active with MAIN

63 pcu_63_dipLTfl C14 Main headlight left (Kl. 30) 12 pcu_state_main Active with MAIN
64 pcu_64_empty not connected 25

65 pcu_65_pwm_mp C19 PWM fuel pump control unit 0,2 pcu_ctrl_PWM_fpump PWM signal to fuel pump

66 pcu_66_pwm not connected 0,2

67 pcu_67_pwm not connected 0,2
68 pcu_68_pwm not connected 0,2
69 pcu_69_pwm not connected 0,2

V7,12/2022 911 GT3 Cup (2021–2023) 733

 ELECTRIC SYSTEM | Control units

6.3.2 Engine control unit (Bosch MS 6.6)

The engine control unit (Bosch MS 6.6) is located in the rear on the passenger side.
The control unit can be programmed using a specific software (Racecon) and permits the diagnostics of faults.
Engine control units are programmed by Porsche Motorsport only.

Function
• Cylinder bank-selective A/F ratio control
• Pit speed limiter
• Ignition control for full-load shifting of sequential gearbox
• Asymmetric injection and ignition control
• Knock control
• E-gas and throttle blip
• Traction control
• Gearbox control

Selectable accelerator pedal mapping

The position of ATH, located in the display,

switches between two accelerator pedal modes using the two rotary switches on the steering wheel.

ATH = 1: linear torque curve, less aggressive (e.g. for use in the rain).
ATH = 2: more aggressive torque curve, more torque is provided at less pedal travel (e.g. during qualifying and when grip is high).

V7,12/2022 911 GT3 Cup (2021–2023) 734

 ELECTRIC SYSTEM | Control units

ECU error code list

Error number Error Description

0 No error Internal ECU errors
1 LOGGER Internal ECU errors
2 SYNC Internal ECU errors
3 TELEMTRY Internal ECU errors
4 CARDMEM Internal ECU errors
5 CAN Internal ECU errors
6 USB Internal ECU errors
7 DISPLAY Internal ECU errors
8 GPS Internal ECU errors
9 FTP Internal ECU errors
10 CCPMASTER Internal ECU errors
11 MARSHALLING Internal ECU errors
12 SYSTEM Internal ECU errors
13 SUPPLY Internal ECU errors
14 CCA Internal ECU errors
15 IO_PIN Internal ECU errors
18 EVENTSOURCE Internal ECU errors
19 EVENTLOGGING Internal ECU errors
62464 CAN01 Internal ECU errors
62465 CAN02 Internal ECU errors
62466 CAN03 Internal ECU errors
62467 CAN04 Internal ECU errors

V7,12/2022 911 GT3 Cup (2021–2023) 735

 ELECTRIC SYSTEM | Control units

Error number Error Description

62468 CAN05 Internal ECU errors
62469 CAN06 Internal ECU errors
62470 CAN07 Internal ECU errors
62471 CAN08 Internal ECU errors
62472 CAN09 Internal ECU errors
62473 CAN10 Internal ECU errors
62474 CAN11 Internal ECU errors
62475 CAN12 Internal ECU errors
62476 CAN13 Internal ECU errors
62477 CAN14 Internal ECU errors
62478 CAN15 Internal ECU errors
62479 CAN16 Internal ECU errors
65535 No error No error
32 E_accx Error of acceleration sensor x-direction
33 E_accy Error of acceleration sensor y-direction
34 E_accz Error of acceleration sensor z-direction
35 E_yaw Yaw rate error
38 E_canmsg_acc_1 Error of CAN message acceleration sensor
39 E_canmsg_acc_2 Error of CAN message acceleration sensor
40 E_canmsg_acc_3 Error of CAN message acceleration sensor
41 E_accy_can Error of CAN message acceleration sensor
42 E_yaw_can Error of CAN message acceleration sensor
43 E_accx_can Error of CAN message acceleration sensor
44 E_accz_can Error of CAN message acceleration sensor

V7,12/2022 911 GT3 Cup (2021–2023) 736

 ELECTRIC SYSTEM | Control units

Error number Error Description

45 E_poil_sent Error of oil pressure sensor (SENT sensor)
46 E_toil_sent Error of oil temperature sensor (SENT sensor)
48 E_canmsg_cmd_disp Error of accelerator pedal selector switch (athstage)
49 E_athstagesw Error of MULTI switch
50 E_funcsw Error of shift pedal – downshift
52 E_shiftdnsw Error of reverse gear switch
54 E_shiftrevsw Error of gbx emergency button
55 E_shiftemgcysw Error of shift pedal – upshift
56 E_shiftupsw Error of pitspeed/FCY switch
60 E_pitspeedsw Error of wet/dry switch
64 E_wetsw Error of TC selector switch
67 E_tcsw Error in CAN1 (ECU, CLU, ACC, IPS)
71 E_can1 Error in CAN2 (ESW)
72 E_can2 Error in CAN3 (organiser logger)
73 E_can3 Error of camshaft control intake B1
74 E_camctrl Error of camshaft control intake B2
75 E_camctrl2 Error of camshaft control exhaust B1
76 E_camctrl_out Error of camshaft control exhaust B2
77 E_camctrl_out2 Error of camshaft control adjustment intake B1
78 E_camadap Error of camshaft control adjustment intake B2
79 E_camadap2 Error of camshaft control adjustment exhaust B1
80 E_camadap_out Error of camshaft control adjustment exhaust B2
81 E_camadap_out2 Error of power stage of camshaft actuator intake B1
82 E_psdia_camctrl Error of power stage of camshaft actuator intake B2

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 ELECTRIC SYSTEM | Control units

Error number Error Description

83 E_psdia_camctrl2 Error of power stage of camshaft actuator exhaust B1
84 E_psdia_camctrl_out Error of power stage of camshaft actuator exhaust B2
85 E_psdia_camctrl_out2 Error of power stage of resonator flap 2
88 E_psdia_intflap2 Error of power stage of resonator flap 1
89 E_psdia_intflap Error of power stage of ignition output 1
90 E_psdia_ign01 Error of power stage of ignition output 2
91 E_psdia_ign02 Error of power stage of ignition output 3
94 E_psdia_ign03 Error of power stage of ignition output 4
95 E_psdia_ign04 Error of power stage of ignition output 5
96 E_psdia_ign05 Error of power stage of ignition output 6
97 E_psdia_ign06 Error of injector – power stage 1
103 E_psdia_hpinj01_a Error of injector – power stage 1
104 E_psdia_hpinj01_b Error of injector – power stage 6
105 E_psdia_hpinj06_a Error of injector – power stage 6
106 E_psdia_hpinj06_b Error of injector – power stage 2
111 E_psdia_hpinj02_a Error of injector – power stage 2
112 E_psdia_hpinj02_b Error of injector – power stage 3
113 E_psdia_hpinj03_a Error of injector – power stage 3
114 E_psdia_hpinj03_b Error of injector – power stage 4
115 E_psdia_hpinj04_a Error of injector – power stage 4
116 E_psdia_hpinj04_b Error of injector – power stage 5
117 E_psdia_hpinj05_a Error of injector – power stage 5
118 E_psdia_hpinj05_b Error of power stage of HDP B1
131 E_psdia_msv_1_a Error of power stage of camshaft actuator exhaust B2

V7,12/2022 911 GT3 Cup (2021–2023) 738

 ELECTRIC SYSTEM | Control units

Error number Error Description

132 E_psdia_msv_2_a Error of power stage of HDP B2
133 E_psdia_msv_2_b Error of power stage of HDP B2
134 E_psdia_msv_1_b Error of power stage of HDP B1
135 E_oillevel_a Error of oil level sensor
136 E_oillevel_b Error of oil level sensor
139 E_p21 Error of sensor p21 (plenum pressure)
141 E_p22 Error of sensor p22 (intake manifold pressure B1)
142 E_p22_2 Error of sensor p22 (intake manifold pressure B2)
144 E_pamb Error of ambient pressure sensor
145 E_pclutch Error of clutch pressure sensor
146 E_pcrank Error of crankcase pressure sensor
147 E_pfuel Error of low fuel pressure sensor
149 E_pgear Error of gearbox oil pressure sensor
151 E_prail Error of high-pressure sensor B1
152 E_prail2 Error of high-pressure sensor B2
162 E_tgear Error of gearbox oil temperature sensor
163 E_tint Error of intake air temperature sensor
165 E_tmot Error of coolant temperature sensor
169 E_ub Error of voltage supply
170 E_ks1 Error of knock sensor B1
171 E_ks2 Error of knock sensor B2
174 E_lsuh Error of oxygen sensor heater B1
175 E_lsuh2 Error of oxygen sensor heater B2
176 E_lsu Error of oxygen sensor B1

V7,12/2022 911 GT3 Cup (2021–2023) 739

 ELECTRIC SYSTEM | Control units

Error number Error Description

177 E_lsu2 Error of oxygen sensor B2
178 E_aps_sig Error of accelerator pedal sensor – signal
179 E_aps_sent1 Error of accelerator pedal sensor – SENT signal 1
180 E_aps_sent2 Error of accelerator pedal sensor – SENT signal 2
181 E_psdia_etc Error of power stage of EDK B1
182 E_psdia_etc2 Error of power stage of EDK B2
183 E_psdia_etc3 Error of power stage of ZDK
184 E_etcdiff Error of standard deviation EDK1
185 E_etcdiff2 Error of standard deviation EDK2
186 E_etcdiff3 Error of standard deviation ZDK
187 E_thr Gross error EDK B1
188 E_thr2 Gross error EDK B2
189 E_thr3 Gross error EDK B3
190 E_etccal Error of calibration EDK B1
191 E_etccal2 Error of calibration EDK B2
192 E_etccal3 Error of calibration ZDK
195 E_ecu_internal_error1 Internal ECU errors
196 E_ecu_internal_error2 Internal ECU errors
197 E_ecu_internal_warning1 Internal ECU errors
198 E_ecu_internal_warning2 Internal ECU errors
199 E_tecu_sys Internal ECU errors
200 E_sc900_2_a Internal ECU errors
201 E_dcdc_1 Internal ECU errors
202 E_dcdc_2 Internal ECU errors

V7,12/2022 911 GT3 Cup (2021–2023) 740

 ELECTRIC SYSTEM | Control units

Error number Error Description

203 E_sc900_1_a Internal ECU errors
204 E_sc900_1_b Internal ECU errors
205 E_sc900_2_b Internal ECU errors
206 E_sens5v_4 Internal ECU errors
207 E_sens5v_1 Internal ECU errors
208 E_sens5v_2 Internal ECU errors
209 E_sens5v_3 Internal ECU errors
210 E_ecusec ECU tampering detected/defective
211 E_cam Error of camshaft signal intake bank 1
212 E_cam2 Error of camshaft signal intake bank 2
213 E_cam_out Error of camshaft signal exhaust bank 1
214 E_cam_out2 Error of camshaft signal exhaust bank 2
215 E_crank Error of crankshaft speed detection
217 E_nmotcond Error of engine angle indicator
218 E_psdia_mainrelay Internal ECU errors
1056 E_paddle_dn_pin Error of paddle down analogue
1057 E_paddle_up_pin Error of paddle up analogue
1058 E_oillevel Error of oil level/gross error
1059 E_speed_fl Error of wheel speed front left
1060 E_speed_fr Error of wheel speed front right
1061 E_speed_pt Gross error of speed signals
1062 E_speed_rl Error of wheel speed rear left
1063 E_speed_rr Error of wheel speed rear right

V7,12/2022 911 GT3 Cup (2021–2023) 741

 ELECTRIC SYSTEM | Control units

6.3.3 Diagnostics connection

[1] Diagnostics connection

Use only the diagnostics cable approved for the 911 GT3 Cup (992).
See Porsche Motorsport parts catalogue.

V7,12/2022 911 GT3 Cup (2021–2023) 742

 ELECTRIC SYSTEM | Control units

6.3.4 Control units – installation

Installing the engine control unit and electric system control unit
[1] Engine control unit
[2] Electric system control unit
[3] Bracket
[4] Nuts M4

2 Nm

[5] Nuts M6
[6] Bolts M6 x 10
8 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 743

 ELECTRIC SYSTEM | Control units

Fuel pump control unit – installation

[1] Fuel pump control unit

[2] Bolts M6 x 20

8 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 744

 ELECTRIC SYSTEM | Control units

6.3.5 CAN bus

Overview of vehicle network

V7,12/2022 911 GT3 Cup (2021–2023) 745

 ELECTRIC SYSTEM | Control units

Overview of CAN

V7,12/2022 911 GT3 Cup (2021–2023) 746

 ELECTRIC SYSTEM | Control units

Overview of Ethernet network

V7,12/2022 911 GT3 Cup (2021–2023) 747

 ELECTRIC SYSTEM | Control units

Overview of LIN

V7,12/2022 911 GT3 Cup (2021–2023) 748

 ELECTRIC SYSTEM | Control units

Overview of FlexRay network

V7,12/2022 911 GT3 Cup (2021–2023) 749

 ELECTRIC SYSTEM | Control units

Description of bus devices

Component Description Technology
Arithmetic Gateway Logger (LOG) calc. Gateway with logger function CAN, Ethernet, LIN, FlexRay
Porsche Logger
Power Control Unit (PCU) Electric system control unit CAN, Ethernet, LIN, FlexRay
Porsche Power Box
Electronic Control Unit (ECU) Engine control unit (Bosch MS 6.4) CAN, Ethernet, LIN
Battery Management System (BMS) Battery management LIN
Alternator (ALT) Bosch series alternator with LIN regulator LIN
(CR665BC)
Sensor cluster (SCLU) Yaw rate and acceleration sensor CAN
Accident Data Recorder (ADR) Accident data recorder CAN
Central Display Unit (CDU) Graphic display Ethernet
Porsche Display
Steering wheel (STW) CAN module steering wheel CAN
Center panel (Center) CAN module centre console CAN
Tire pressure monitoring system (TPMS) Tire pressure monitoring system CAN, serial
Steering Angle Steering angle sensor CAN (500K)
Electrically Powered Steering (EPS) Electric steering FlexRay
E-Shift Barrel (ESW) Electric shift barrel CAN
AC Unit Ventilation doors LIN
Light Control Unit (LCU) ECU of headlight modules CAN
Tx (terminals) Junctions CAN, serial
RearLT Rear lights/light strip LIN
DRV FAN Driver fan LIN

V7,12/2022 911 GT3 Cup (2021–2023) 750

 ELECTRIC SYSTEM | Control units

CAN IDs

The following table shows the CAN IDs, the specific channel names and the properties required to program any external data device.
The devices are connected via a plug connected to CAN5.
Many more channels (CAN5 DBC) are available.
Further information can be found in PMRSI („Porsche Motorsport Racecar Service Information“ Portal (PMRSI) at https://motorsport.porsche.com) in the
software area.

Name ID Start bit Length [bit] File type Gain Offset Unit
RPM 1F1 0 16 Unsigned 1 0 RPM
gear 1F1 16 8 Signed 1 0 -
throttle_pos 1F1 24 8 Unsigned 0.5 0 %
pbrake_front 1F1 32 16 Unsigned 0.01 0 bar
asteer 1F1 48 16 Signed 0.0625 0 °
accx 1F2 0 16 Signed 0.025 0 G
accy 1F2 16 16 Signed 0.025 0 G
accz 1F2 32 16 Signed 0.025 0 G
yaw_rate 1F2 48 16 Signed 0.01 0 °/s
lapnumber 1F3 0 8 Unsigned 1 0 -
laptime 1F3 8 16 Unsigned 0.01 0 s

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 ELECTRIC SYSTEM | Wiring looms

6.4 Wiring looms

Detailed wiring diagrams are available in the PMRSI ("Porsche Motorsport Racecar Service Information" portal (PMRSI) at https://motorsport.porsche.com).
Ensure to always download the latest version.
[1] Interior
[2] Engine
[3] Gearbox
[4] Intank
[5] E-steering
[6] Front axle wheel arch
[7] Rear axle wheel arch
[8] Fender adapter
[9] Front covering
[10] Battery B+ (starter and alternator)
[11] Ground cable (engine to body)
[12] Battery/battery disconnect switch
[13] B+ separating point to battery disconnect switch
[14] Ground cable (battery to body)
[20] Diagnostics adapter line
[21] ABS
[22] Adapter for ADR (Accident Data Logger)
[23] Adapter line USB

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 ELECTRIC SYSTEM | Option separating points

6.5 Option separating points

The option separating points ([13], [17], [19], [20], [21]) located at the front of the trans-
mission tunnel must be fastened securely when they are not in use.
A detailed description can be found in PMRSI ("Porsche Motorsport Racecar Service
Information" portal (PMRSI) at https://motorsport.porsche.com) in the technical
informations:
→ Fastening optional connector points

V7,12/2022 911 GT3 Cup (2021–2023) 753

 ELECTRIC SYSTEM | Option separating points

6.5.1 Overview of separating points

[1] Transponder [2] Auxiliary light lh/rh [3] ID [4] Cockpit lighting [5] Video [6] ADR
lighting
[7] Radio [8] Helmet [9] Supply for option 1 [10] Supply for option 2 [11] Supply for option 3 [12] Windscreen heater
(50 A) (15 A) (15 A) ON/OFF
[13] Team Logger [14] GPS [15] Sensors for front [16] Sensors for rear [17] Diagnostics CAN 4 [18] Drink pump
(25 A) option option
[19] Telemetry [20] Diagnostics of tire pressure [21] USB logging
control system

V7,12/2022 911 GT3 Cup (2021–2023) 754

 ELECTRIC SYSTEM | Option separating points

Separating point 1 – Transponder

Connector: 1-1418390-1 (Tyco)

Mating connector: 1-1703808-1 (Tyco)
Pin Name
1 +12 V
2 Ground
3 CAN 5 High
4 CAN 5 Low

Separating point 2 – Auxiliary light lh/rh

Connector: DT 06-2S (Deutsch)

Mating Connector: DT 04-2P (Deutsch)
Pin Name
1 +12 V
2 Ground

Separating point 3 – ID lighting

Connector: DTM06-2S (Deutsch)

Mating Connector: DTM04-2P (Deutsch)
Pin Name
1 +12 V
2 Ground

V7,12/2022 911 GT3 Cup (2021–2023) 755

 ELECTRIC SYSTEM | Option separating points

Separating point 4 – Cockpit lighting

Connector: DTM06-2S (Deutsch)

Mating connector: DTM04-2P (Deutsch)
Pin Name
1 +12 V
2 Ground

Separating point 5 – Video

Connector: DTM 06-4S (Deutsch)

Mating connector: DTM04-4P (Deutsch)
Pin Name
1 +12 V
2 Ground
3 CAN 5 High
4 CAN 5 Low

Separating point 6 – ADR

Connector: 1-1418390-1 (Tyco)

Mating connector: 1-1703808-1 (Tyco)
Pin Name
1 +12 V
2 Ground
3 CAN 5 Low
4 CAN 5 High

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 ELECTRIC SYSTEM | Option separating points

Separating point 7 – Radio

To filter interference from the vehicle, it is recommended,

insert a 33 Ohm 1W resistor between pin 9 and 10 in the wiring harness to the radio.

Connector: 3-1703639-1 (Tyco)

Mating connector: 3-1564520-1 (Tyco)
Pin Name
1 +12 V
2 Ground
3 CAN 5 High
4 CAN 5 Low
5 PTT
6 Driver ID
7 Microphone +
8 Microphone -
9 Speaker +
10 Speaker -
11 Shielding
12 Shift beep

V7,12/2022 911 GT3 Cup (2021–2023) 757

 ELECTRIC SYSTEM | Option separating points

Separating point 8 – Helmet

Connector: 1-1418469-1 (Tyco)
Mating connector: 1-1703773-1 (Tyco)
Pin Name
1 Microphone +
2 Microphone -
3 Driver ID
4 Speaker +
5 Speaker -
6 Shielding

Separating point 9 – Supply for option 1 (50 A)

Connector: 2-1564542-1 (Tyco)

Mating connector: 2-1564546-1 (Tyco)
Pin Name
1 +12 V
2 Ground

Separating point 10 – Supply for option 2 (15 A)

Connector: 1-1418483-1 (Tyco)

Mating connector: 1-1703841-1 (Tyco)
Pin Name
1 +12 V
2 Ground

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 ELECTRIC SYSTEM | Option separating points

Separating point 11 – Supply for option 3 (15 A)

Connector: 1-1418483-1 (Tyco)
Mating connector: 1-1703841-1 (Tyco)
Pin Name
1 +12 V
2 Ground

Separating point 12 – Windscreen heater

Windscreen heater ON

Connector: 6N0_971_921
Pin Name
1 +12 V

Windscreen heater OFF

Connector: 6N0_971_921
Pin Name
1 Ground

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 ELECTRIC SYSTEM | Option separating points

Separating point 13 – Team Logger (25 A)

Connector: DTM06-6S (Deutsch)

Mating connector: DTM04-6P (Deutsch)
Pin Name
1 Ground (2.5 A)
2 Ground (25 A)
3 +12 V term. 15 (2.5 A)
4 +12 V term. 30 (25 A)
5 CAN 5 High
6 CAN 5 Low

Separating point 14 – GPS

Connector: 1-178346-2 (Tyco)

Mating connector: 1-178128-2 (Tyco)
Pin Name
1 +5 V
2 Ground
3 Signal, TX1

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 ELECTRIC SYSTEM | Option separating points

Separating point 15 – Sensors for front option

Connector: 1-1703639-1 (Tyco)

Mating connector: 1-1564414-1 (Tyco)
Pin Name
1 +12 V
2 Ground
3 AIN9 front left
4 AIN10 front right
5 +5 V sensor
6 Sensor ground
7 AIN17 front left
8 AIN18 front right
9 AIN7 front left
10 AIN8 front right
11 Not assigned
12 Not assigned

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 ELECTRIC SYSTEM | Option separating points

Separating point 16 – Sensors for rear option

Connector: 1-1703639-1 (Tyco)
Mating connector: 1-1564414-1 (Tyco)
Pin Name
1 +12 V
2 Ground
3 AIN11 rear left
4 AIN12 rear right
5 +5 V sensor
6 Sensor ground
7 AIN14 rear left
8 AIN15 rear right
9 AIN16 rear left
10 AIN19 rear right
11 Not assigned
12 Not assigned

Separating point 17 – Diagnostics CAN 4

Connector: 1-1418390-1 (Tyco)

Mating connector: 1-1703808-1 (Tyco)
Pin Name
1 +12 V
2 Ground
3 CAN 4 High
4 CAN 4 Low

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 ELECTRIC SYSTEM | Option separating points

Separating point 18 – Drink pump

Connector: DTM 06-2S (Deutsch)

Mating connector: DTM04-2P (Deutsch)
Pin Name
1 +12 V
2 Ground

Separating point 19 – Telemetry

Connector: 1-1418390-1 (Tyco)

Mating connector: 1-1703808-1 (Tyco)
Pin Name
1 +12 V
2 Ground
3 RS232 TX2
4 RS232 RX2

Separating point 20 – Diagnostics for tire pressure monitoring system

Connector: 1-1418390-1 (Tyco)

Mating connector: 1-1703808-1 (Tyco)
Pin Name
1 +12 V
2 Ground
3 CAN 3 High
4 CAN 3 Low

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 ELECTRIC SYSTEM | Option separating points

Separating point 21 – USB logging

Connector: 262645 (MD) 01002633 (KS)

Pin Name
1 USB D+
2 USB +5 V
3 USB D-
4 USB ground
5 Shielding

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 ELECTRIC SYSTEM | Sensory system

6.6 Sensory system

6.6.1 Overview of sensors
Sensor name Channel name Installation location
TPM sensors at front axle tpms_press_xx At tire valve (see Assembly of TPMS sensor/valve
TPM sensors at rear axle tepms_temp_xx on page 373)
Wheel speed sensor FL At upright front (see Installation of speed sensor
Wheel speed sensor FR on page 303)
ecu_speed_xx
Wheel speed sensor RL At upright rear (see Installation of speed sensor
Wheel speed sensor RR on page 342)
Fuel level sensor log_fuellevel Inside fuel tank (see Overview of fuel tank
on page 661)
Clutch pressure sensor ecu_pclutch At bodyshell near gearbox (see Rear end line
on page 418)
Brake pressure sensor front log_pbrake_f At the master brake cylinders (see Brake pressure
Brake pressure sensor rear log_pbrake_r sensor to brake master cylinder on page 399)
Yaw rate sensor (X, Y, Z acceleration) sclu_acc_xx On the centre tunnel
Start button pcu_sw_start_btn In the dashboard, left of the steering wheel
Lap trigger log_beacon In the rear quarter window
Emergency switch for electric system, exterior, - On left-hand side below windscreen, as seen in
on front left driving direction (see Actuation outside vehicle
Emergency switch for fire extinguisher system, - on page 716)
exterior
Steering angle sensor log_asteer On the steering column (see Steering angle
sensor on steering column on page 335)

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 ELECTRIC SYSTEM | Sensory system

Sensor name Channel name Installation location

Accelerator pedal angle sensor ecu_aps
Brake balance potentiometer log_brkbias On the side of the instrument panel
(see 6.11.3 Overview of instrument panel
on page 789)
Fuel low-pressure sensor ecu_pfuel

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 ELECTRIC SYSTEM | Sensory system

6.6.2 Calibrating the sensors

Steering angle sensor
CAUTION NOT OR INCORRECTLY CALIBRATED ROTATION ANGLE SENSOR
An insufficient calibration of the rotation angle sensor will cause unexpected driving
behaviour and/or a malfunction of the steering angle sensor.
▶ The rotation angle sensor must be recalibrated whenever the following work has been
performed:
– Work on the suspension parts
– Repairs and/or work on suspension/steering
– Replacement of rotation angle sensor/electronic unit
▶ Correct calibration of the rotation angle sensor:
b Suspension geometry has been measured, tracking stability is ensured.
a. Place vehicle on measuring platform or use wheel load weigher (levelled).
b. Turn steering wheel precisely in straight-ahead position, and align front wheels
exactly in straight-ahead position on the measuring platform (see Fig. 46
on page 338).
c. Teach in the electric steering stops (see Teach steering stops on page 327).

NOTICE DAMAGE TO THE CONTROL UNIT CAUSED BY VOLTAGE FLUCTUATION

U
Voltage fluctuation causes damage to the control unit, error logs in the control unit,
cancellation of the coding in the control unit and malfunctions of the control unit, even
while programming is in progress.
▶ Before disconnecting the control unit, switch off the ignition.
▶ Ensure that voltage supply is always present during coding or calibration procedures.
▶ Connect a battery charger to the vehicle battery
(see 6.2.4 Battery charger on page 718).

▶ Perform the calibration using the calibration routine in the Porsche Toolset.

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 ELECTRIC SYSTEM | Sensory system

CALIBRATION

1. Switch on ignition.
2. Move the steering wheel to the straight-ahead position.
3. Follow the instructions in the Porsche Toolset under Your Porsche (Vehicle Settings).
4. After successful calibration, switch off the ignition.
5. Then switch the ignition ON-OFF-ON.

Accelerator pedal
CALIBRATION

1. Connect RaceCon to the vehicle.

2. Leave the accelerator pedal in the 0% position and press the CAL 0% PEDAL button in
RaceCon.
3. Depress the accelerator pedal fully (100%) and press the CAL 100% PEDAL button in
RaceCon.

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 ELECTRIC SYSTEM | Sensory system

6.6.3 Reed sensor mounting (brake light switch)

[1] Nut M6

3 Nm

[2] Magnet Reed (brake light switch)

[3] Reed Sensor (brake light switch)

▶ Lock the sensor with two flat nuts.
5 Nm ▶ Secure the sensor with small drops of Loctite [4].

Loctite 243

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 ELECTRIC SYSTEM | Fire extinguisher system

6.7 Fire extinguisher system

DANGER OPERATING THE CAR WITH A DEACTIVATED OR DEFECTIVE FIRE EXTINGUISHING
SYSTEM
If the car is operated with a deactivated or defective fire extinguishing system, serious or
even deadly injuries may occur.
▶ Only operate the car with a technically perfect and functioning fire extinguishing
system!
▶ Switch position on the release unit: ARM.

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 ELECTRIC SYSTEM | Fire extinguisher system

6.7.1 Actuation of fire extinguisher system

Exterior

The exterior actuation element is located on the left-hand and right-hand side below the windscreen.
Actuating the fire extinguisher system also interrupts the vehicle's electric system.
[2] Emergency switch + fire extinguisher system.
▶ Pull pin.
→ Main switch OFF and fire extinguisher system ON

On all Porsche 911 GT 3 Cup, the fire extinguisher switches installed in the plenum panel
cover must be checked for function and ease of movement before every use of the car.
The function of the fire extinguisher switch must be tested in test mode of the fire
extinguisher in order to not deploy the extinguisher. When pressing the switch, the
electrical system of the car will be shut down as well (FIA requirement). This function must
be checked accordingly.
→ In case the switch needs excessive force to be pressed or is not functioning at all, it
must be exchanged immediately

Interior
Actuation in centre console

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 ELECTRIC SYSTEM | Fire extinguisher system

6.7.2 Design of the fire extinguisher system

Overview of the fire extinguisher system

Regulations prohibit lines and wiring looms to be routed between roll cage and bodyshell.

[1] Extinguisher bottle

[2] Extinguishing nozzle in cockpit
[3] Extinguishing nozzles in engine bay

Installing the extinguishing nozzles in the engine bay

[1] Extinguishing nozzle in engine bay

9 Nm

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 ELECTRIC SYSTEM | Fire extinguisher system

Installing the trigger unit

[1] Trigger unit
[2] Cover on lower passenger side
[3] Bolts M4 x 14

4 Nm

Installing the extinguishing nozzle in the cockpit

[1] Extinguishing nozzle in cockpit

[2] Bolts M5 x 10

4.5 Nm

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 ELECTRIC SYSTEM | Fire extinguisher system

6.7.3 Fire extinguisher bottle

Service the system if the expiry date on the service label is reached or if the system was triggered.
FIA regulations have priority over the service interval specified by the manufacturer.
Properties:
• N-TEC 2950R
• ADS (Advance Discharge System)
• Electric trigger unit
• Pressureless
• Aluminium cylinder

The Advance Discharge System (ADS) consists of a rubber bladder with extinguishant
in the bottle. When triggered, the cylinder is pressurised, forcing the extinguishant out
of the bladder. The flow rate remains constant throughout the entire discharge, and the
entire extinguishant is discharged, independent of the vehicle setting.

Removing/installing the fire extinguisher bottle

[1] Fire extinguisher bottle
[2] Metal straps

8 Nm

[3] Coupling
[4] Pipe fire extinguisher

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 ELECTRIC SYSTEM | Fire extinguisher system

6.7.4 Trigger unit

Testing/activating the system

Before putting the system into operating mode, it is mandatory to perform the test in order to rule out any errors in the system.
The battery (9V block battery) has a life of 300 hours or 12 days (1000 hours or 41 days in sleep mode).

TESTING THE SYSTEM

▶ Pull the switch and set it to its bottom position (TEST).
▶ Actuate the fire extinguisher system.
a. See Actuation outside vehicle on page 716.
b. See Actuation inside vehicle on page 716.

→ LED lights up orange for 10 s: Test was successful.

→ LED flashes orange for 10 s or longer: Test was not successful.
▶ Check the possible causes: Battery low, electric fault.
Remedy:
▶ Change battery.

When the switch is in bottom position (TEST), sleep mode is activated after 30 min to save
the battery. To cancel sleep mode, arm the system (see below).
ARMING THE SYSTEM
▶ Pull the switch and set it to its top position (ARM).
→ LED flashes red: System is in operation.

The upper LED (ARM) does not light up in the following cases:
• Error in the circuit
• Pressure cartridge not connected
• Pressure cartridge empty

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 ELECTRIC SYSTEM | Fire extinguisher system

Replacing the battery

1. Disconnect the wiring loom from the trigger unit.

2. Remove the trigger unit (see Installing the trigger unit on page 773).
3. Remove the rear cover from the trigger unit.
4. Exchange/replace the battery.
5. Install in reverse order of removal.

6.7.5 Contact
Fire Extinguisher Valve Company Ltd (FEV)
Unit 10 Ford Lane Business Park
Ford Nr Arundel
West Sussex
BN18 OUZ
United Kingdom
Tel.: +44(0) 12 43-55 55 66

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 ELECTRIC SYSTEM | Lighting

6.8 Lighting

The headlights are designed for race track use only (daylight racing).
Night-time racing requires specific auxiliary lights. Available from Manthey Racing (see 7.3 Addresses (service + equipment) on page 1025).

Main lights+ auxiliary

Function
Ignition OFF Ignition ON Main lights ON lights ON Pitspeed ON,
Position lights OFF ON ON ON ON
Daytime running lights OFF ON ON ON ON
Main lights OFF OFF ON ON OFF
Auxiliary lights OFF OFF OFF ON OFF

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 ELECTRIC SYSTEM | Windscreen wiper unit

6.9 Windscreen wiper unit

6.9.1 Removing/installing the windscreen wiper unit
[1] Wiper arm

Puller
Removing the wiper arm may require a puller.
[2] Wiper motor
[3] Bolts M6 x 12

8 Nm
[4] Nut M10

40 Nm,
AF 13

▶ Before installing the wiper arm, switch the wiper motor on and off to determine
the 0 position.

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 ELECTRIC SYSTEM | Steering wheel

6.10 Steering wheel

WARNING DAMAGE TO ELECTRONIC CONTACTS
Incorrect removal or installation of the steering wheel may damage the electronic
contacts. This may impair the functions and control elements or lead to their failure.
▶ When removing and installing the steering wheel, make sure not to damage the
contacts of the Deutsch connector.

Controlling the steering wheel functions: See 6.10.2 Function description: Buttons/
switches on page 781.

• Pulling off the steering wheel requires pulling the quick-release coupling [1].

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 ELECTRIC SYSTEM | Steering wheel

6.10.1 Overview of buttons and switches

All functions that are directly related to the driving and control of the vehicle, that affect the handling of the vehicle and that can be changed repeatedly during
a stint or a lap, are located on the steering wheel.

[1] High-beam lights [HB]

[2] Radio [RAD]
[3] Crank [CRK]
[4] Function setting left
[5] Acknowledge [ACK]
[6] Reverse gear [RVS]
[7] Joker [hash symbol]
[8] Pitspeed [PIT]
[9] Mark [MRK]
[10] Wipers [WIP]
[11] Function setting right
[12] Full Course Yellow [FCY]
[13] Drink [DRK]
[14] Display page selection [DISP]

[15] Turn signal right

[16] Shift paddle right (upshift)
[17] Turn signal left
[18] Shift paddle left (downshift)

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 ELECTRIC SYSTEM | Steering wheel

6.10.2 Function description: Buttons/switches

Buttons

[1] HB/High Beam – high-beam lights on/off

▶ Push the button to flash.

The number of flashes can be set in the Porsche Toolset.

[2] RAD/Radio – enable radio transmission

▶ Push and hold the button.

→ Radio transmission is enabled.

[3] CRK/Crank – start engine

▶ Push the button to start the engine (see 0.6.1 Starting the engine on page 42).

[4] ACK/Acknowledge – acknowledge alarm/display tire inflation pressures

▶ Push the button to acknowledge an alarm.
▶ Push the button to display tire inflation pressures at standstill.

[5] RVS/Reverse – engage reverse gear

▶ Push the button to engage reverse gear
(see 0.6.4 Engaging reverse gear on page 44).

[6] Hash/Joker – enable steering mode

▶ Press the button to activate the shunting mode

(see 0.7.2 Steering shunt mode on page 45).

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 ELECTRIC SYSTEM | Steering wheel

[7] PIT/Pitspeed – enable pitspeed

b First gear is engaged.

▶ Push the button.
→ Pitspeed is enabled.

[8] MRK/Mark – reset fuel consumption meter/trip distance

▶ Push the button for an extended period.

→ Fuel consumption meter and trip distance are reset.

[9]WIP/Wiper – turn wiper on

▶ Push the button briefly:
→ It is wiped once.
▶ Push and hold the button:
→ Full wiper power.
Push the button repeatedly to deactivate the mode.

[10] FCY – enable Full Course Yellow

▶ Push the button to enable Full Course Yellow mode.

[11] DRK/Drink – turn drink pump on

▶ Push and hold the button.

→ Drink pump is running.

[12] DISP/Display – browse display pages

▶ Push the button to browse the individual display pages.

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 ELECTRIC SYSTEM | Steering wheel

[13] Indicator Right

▶ Push and hold the button.

→ Indicator Right is active.

[14] Indicator Left

▶ Push and hold the button.

→ Indicator Left is active.

[15] Shift paddle right

▶ Pull shift paddle right = upshift.

[16] Shift paddle left

▶ Pull shift paddle left = downshift.

Rotary switch

[1] Function switch left

▶ Turn the rotary switch to switch through the functions.
[2] Function switch right
▶ Turn the rotary switch to set the values.

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 ELECTRIC SYSTEM | Steering wheel

Concept of the function switches

The current values are shown on the left side of the display.

The following values can be adjusted with the function switches on the steering wheel:
• ABS – anti-lock brake system (only displayed when the function is activated)
• TC – traction control (only displayed when the function is activated)
• DIM – dimmer (display illumination and LEDs)
• ATH – accelerator pedal/throttle (sensitivity adjustment)
• MUL – backup function

▶ Turn the left rotary switch to show the displays.

The display always starts with the top function.
▶ Use the left rotary switch to select a function.
▶ Use the right rotary switch to set the values.

To prevent an unintentional change of settings during steering, function settings can only
be made up to a steering angle of 45°.
Exception: defect or malfunction of the steering angle sensor.

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 ELECTRIC SYSTEM | Centre console

6.11 Centre console

6.11.1 Overview of buttons and switches

[1] Main switch

▶ Pull the switch out and put it in up or down position.

Switching the main voltage supply on/off
– Switch up: OFF
– Switch down: ON

[2] Ignition

▶ Pull the switch out and put it in up or down position.

Switches the ignition on/off
– Switch up: OFF
– Switch down: ON

[3] Fire extinguisher system

Deploy and test the fire extinguisher system.

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 ELECTRIC SYSTEM | Centre console

6.11.2 Replacing main switch and ignition switch

DANGER CONTACT WITH LIVE PARTS OR SHORT CIRCUIT
Touching live parts of the vehicle can cause electric shock. Work on the vehicle's electric
system can cause a short circuit.
Short circuits can cause fires.
▶ Disconnect the power supply to the car. See 6.2.2 Battery disconnect switch
on page 714.

The main switch and the ignition switch can be ordered as spare parts and replaced
accordingly.
Purchase via Porsche Motorsport parts catalogue.

b Switch plate removed.

1. Disconnect electrical connections [1] from the switch to be replaced.

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 ELECTRIC SYSTEM | Centre console

2. Remove the nut [yellow] from the the switch to be replaced [blue].
3. Remove the switch from the switch plate [1].

4. Position the washer [1] to the new switch [2].

5. Insert the new switch into the switch plate [3].

6. Fix the switch to the switch plate with the nut [4].

2 Nm

7. Apply a small drop of Loctite 243 to the screws [5] for the electrical connections.
8. Hand-tighten the electrical connections to the switch with fastening screws and M3
hand-tight ring shoes
→ See Wiring diagram main switch and ignition switch on page 788.

Loctite 243

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 ELECTRIC SYSTEM | Centre console

Wiring diagram main switch and ignition switch

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 ELECTRIC SYSTEM | Centre console

6.11.3 Overview of instrument panel

[1] LIGHT – headlights
▶ Push the button once – headlights ON
▶ Push the button twice – headlights + auxiliary lights ON
This function is only available when the auxiliary lights are enabled via the parameters
in the Porsche Toolset.
[2] FAN – interior fan
▶ Push the button once – driver fan
▶ Push the button twice – driver/window fan
▶ Push the button three times – window fan
[3] OPTION 1
▶ Push the button – ON/OFF

[4] WET TYRE – tyre selection

▶ Push the button if wet-tyres are mounted.

The ABS system must be informed about the type of tyres fitted. For a detailed description
see Change between wet & dry on page 1005.
[5] GBX – gearbox
▶ Push the button – emergency mode ON/OFF

The gearbox emergency button allows driving to be continued in the case

of gearbox-relevant sensor malfunctions.
▶ When the Gearbox Emergency function is activated, gear changes (up and down) can
only be done using the clutch.

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 ELECTRIC SYSTEM | Centre console

[6] RAIN LIGHT – rain light

▶ Push the button – rain light ON/OFF

[7] FUEL PUMP – fuel pumps

▶ Push the button to enable technician mode (manual activation of fuel pumps)

[8] OPTION 2
▶ Push the button – ON/OFF

[9] OPTION 3 or TC
OPTION 3
▶ Push the button – ON/OFF
TC

Traction control is available as an option.

Remove the sticker for OPTION 3 and stick on the TC sticker.
▶ 0 = OFF = Dry (Dry conditions)
▶ 1 = ON = (Wet conditions)
[10] HAZARD – hazard flashers
▶ Push the button – hazard flashers ON/OFF

[11] Brake balance adjustment

▶ Turn the adjustment wheel forward to increase the brake force of the front axle.
▶ Turn the adjustment wheel backward to increase the brake force of the rear axle.

Depending on the master brake cylinder used for the rear axle, the brake balance must be
adjusted accordingly.

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 ELECTRIC SYSTEM | Display

6.12 Display

Use the DIS button on the steering wheel to scroll through the display pages.

6.12.1 Display pages

Display pages Warmup, Vitals, Chassis and Trackmap are only accessible at standstill (pit lane).
When the vehicle is moves, the display switches automatically to page Race 1.

Race 1 (Driver)
Description Channel
[1] Page indicator log_display_pos
[2] Light indicator

– Main light OFF

pcu_state_LTmode
– Main light ON

– Main + auxiliary light ON

[3] Speed (unit selectable in Setup) log_speed

[4] Lap lap_number
[5] Tire indicator

– Slicks log_B_wet =
pcu_state_tyre
– Rain tires

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 ELECTRIC SYSTEM | Display

Description Channel
[6] Lap time (Duration selectable in Setup) lap_time_dis [min]
[7] Time diff (to reference lap), Predicted lap time log_qm_cum_segtime_diff
[min]
[8] Brake bias log_brkbias
[9] Oil temp (unit selectable in Setup) ecu_toil
[10] Oil press (unit selectable in Setup) ecu_poil
[11] Water temp (unit selectable in Setup) ecu_twat
[12] Water press (unit selectable in Setup) ecu_pwat
[13] Gear indicator ecu_gear
[14] ABS stage (only displayed if activated) log_abs_pos
[15] TC - TC stage (only displayed if activated) log_tc_pos
[16] DIM - Dimmer log_dim_pos
[17] ATH - Throttle sense
→ Position 1: Moderate log_ath_pos
→ Position 2: Aggressive
[18] MUL - Backup functions log_multi_pos
[19] Tyre pressure FL (unit selectable in Setup) tpms_press_fl
[20] Tyre pressure RL (unit selectable in Setup) tpms_press_rl
[21] Tyre pressure RR (unit selectable in Setup) tpms_press_rr
[22] Tyre pressure FR (unit selectable in Setup) tpms_press_fr
Tyre pressure indicator [19-22] is not visible when the
vehicle is stationary. To display the tyre pressures, press log_sw_ack
the ACK button on the steering wheel.

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 ELECTRIC SYSTEM | Display

Description Channel
[23] Alarm engine
– Alarm ON

alarm_engine
– Alarm OFF

[24] Alarm gearbox

– Alarm ON

alarm_gearbox
– Alarm OFF

[25] Alarm systems

– Alarm ON

alarm_systems
– Alarm OFF

[26] Alarm tyre

– Alarm ON

alarm_tyre
– Alarm OFF

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 ELECTRIC SYSTEM | Display

Race 2 (Driver)

Description Channel
[1] Page indicator log_display_pos
[2] Fuel used (unit selectable in Setup) ecu_fuelcons
[3] Fuel used per lap (unit selectable in Setup) ecu_fuellap
[4] Fuel pressure (unit selectable in Setup) ecu_pfuel
[5] Fuel level (unit selectable in Setup) log_fuellevel

Quali (Driver)

Description Channel
[1] Page indicator log_display_pos
[2] Lap time (min) lap_time_dis [min]
[3] Time difference to reference lap (min) log_qm_cum_segtime_diff
[min]

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 ELECTRIC SYSTEM | Display

Warmup (Mechanic)

Description Channel
[1] Page indicator log_display_pos
[2] Engine RPM (rpm) ecu_nmot
[3] Oil temp value (unit selectable in Setup)
ecu_toil
– Bar display engine oil temperature
[4] Oil pressure (unit selectable in Setup) ecu_poil
[5] Oil level (%) ecu_oillevel_prop
[6] Battery state of charge (%) BZE_SOC_K20
[7] Water temp (unit selectable in Setup)
ecu_tmot
– Bar display cooling water temperature
[8] Water pressure (unit selectable in Setup) ecu_pwat
[9] Fuel pressure (unit selectable in Setup) ecu_pfuel
[10] Fuel level (unit selectable in Setup) log_fuellevel
[11] Gearbox info
– Gearbox temp (unit selectable in Setup) ecu_tgear
– Barrel position (°) esw_sbpos
– Clutch pressure (unit selectable in Setup) ecu_pclutch
– Pad down not pulled
ecu_B_paddn
– Pad down pulled

– Pad up not pulled

ecu_B_padup
– Pad up pulled

V7,12/2022 911 GT3 Cup (2021–2023) 795

 ELECTRIC SYSTEM | Display

Vitals (Mechanic)

Description Channel
[1] Page indicator log_display_pos
[2] Odometer
– Total distance(km) log_odometer [km]
– Trip distance(km) log_odometer_trip [km]
– Engine lifetime (h) ecu_lteng2 [h]
[3] Throttle
– Throttle sense log_ath_pos
– Accelerator pedal sensor (%) ecu_aps [%]
– Accelerator throttle (%) ecu_ath [%]
[4] Systems
– Battery voltage (V) log_ubat
– State of charge BZE_SOC_K20
– Battery diagnosis pcu_BAT_diag
– Alternator diagnosis pcu_GEN_diag
– Power box state pcu_output_diag,
pcu_output_2_diag
[5] Steering
– EPS check log_eps_check
– Steering sesnor (°) log_aster [°]
– Staeering state log_asteer_diag_dash
– Steering angle bar (°) log_aster [°]

V7,12/2022 911 GT3 Cup (2021–2023) 796

 ELECTRIC SYSTEM | Display

Chassis (Mechanic)

Description Channel
[1] Tyre indicators front left
– Speed (unit selectable in Setup) log_speed_fl
– Tire circ (mm) log_circ_f [mm]
– TPMS pressure (unit selectable in Setup) tpms_press_fl
– TPMS state tpms_state_fl_dash
[2] Tyre indicators front right
– Speed (unit selectable in Setup) log_speed_fr
– Tire circ (mm) log_circ_f [mm]
– TPMS pressure (unit selectable in Setup) tpms_press_fr
– TPMS state tpms_state_fr_dash
[3] Tyre indicators rear left
– Speed (unit selectable in Setup) log_speed_rl
– Tire circ (mm) log_circ_r [mm]
– TPMS pressure (unit selectable in Setup) tpms_press_rl
– TPMS state tpms_state_rl_dash
[4] Tyre indicators rear right
Fig. 62: TPMS status display
– Speed (unit selectable in Setup) log_speed_rr
– Tire circ (mm) log_circ_r [mm]
– TPMS pressure (unit selectable in Setup) tpms_press_rr
– TPMS state tpms_state_rr_dash

V7,12/2022 911 GT3 Cup (2021–2023) 797

 ELECTRIC SYSTEM | Display

Trackmap

Description Channel
[1] Page indicator log_display_pos
[2] Track map

V7,12/2022 911 GT3 Cup (2021–2023) 798

 ELECTRIC SYSTEM | Display

6.12.2 Display messages

Brake bias

The brake bias overlay appears when the brake is applied at standstill (< 5 km/h).

Description Channel
– Brake Bias log_brkbias
– Brake pressure front (bar) log_pbrake_f
– Brake pressure rear (bar) log_pbrake_r
– Brake balance (%) log_brkbal_prop

Brake bias change

Description Channel
– Brake bias position after change log_brkbias
(arrow depending on direction of change)

V7,12/2022 911 GT3 Cup (2021–2023) 799

 ELECTRIC SYSTEM | Display

Pit speed

The pit speed is activated and deactivated via the PIT button on the steering wheel.
When pit speed is activated, the set target speeds are only maintained in 1st and 2nd gear. If the speed exceeds the configured pit speed,
the display background changes to red.
When pit speed is activated, Full Course Yellow (FCY) mode (if activated) is automatically deactivated.
▶ When the pit speed mode is activated from the Full Course Yellow mode, the pit speed must first be undercut in order for the pit speed limiter to maintain
the set pit speed.

Description Channel
[1] Pit speed
– Speed OK
log_pitspeed_col
– Speed not OK

[2] Engine speed (rpm) ecu_nmot

[3] Speed (unit selectable in Setup) log_speed
[4] Gear indicator ecu_gear

V7,12/2022 911 GT3 Cup (2021–2023) 800

 ELECTRIC SYSTEM | Display

Setting pit speed target speeds

The target speeds can be set via RaceCon software under the CAR tab in the
SPEEDLIMIT_NOM option.

1. Connect the car to the RaceCon software (ECU = green).

2. Select tab CAR.
3. Select option SPEEDLIMIT_NOM (km/h).
4. Set the target speed in the 0.00 tap.
Confirm the entries with the Return key.
5. Set the target speed in the 1.00 tap.
Confirm the entries with the Return key.
6. Save changes with Save to ECU.

V7,12/2022 911 GT3 Cup (2021–2023) 801

 ELECTRIC SYSTEM | Display

Reverse gear request overlay

Description Channel
[1] Gear indicator ecu_gear
[2] Progress of reverse gear request
– Progress

– Accepted log_brev_status

– Denied

[3] Progress of reverse gear request log_brev_time [s]

[4] Hint: Release brake or turn ignition on log_brev_dash

V7,12/2022 911 GT3 Cup (2021–2023) 802

 ELECTRIC SYSTEM | Display

Overview digital overlays

Each status change is shown for 3 s after a setting has been changed via one of the
buttons in the centre console or on the steering wheel.

Channel display: log_digital_change

The following indicators may occur:
• Ignition OFF
• Ignition ON
• Rain light OFF
• Rain light ON
• Hazard OFF
• Hazard ON
• Tyre dry
• Tyre wet Fig. 63: Example: ignition off [IGN OFF]
• TC dry
• TC wet
• Gearbox normal
• Gearbox emergency
• Option 1 OFF
• Option 1 ON
• Option 2 OFF
• Option 2 ON
• Option 3 OFF
• Option 3 ON
• Option 2+3 OFF
• Option 2+3 ON
• Oil crank OFF
• Oil crank ON
• Starter OFF
• Starter ON

V7,12/2022 911 GT3 Cup (2021–2023) 803

 ELECTRIC SYSTEM | Display

Fan control

Description Channel
Fan control pcu_state_fandrv
– Signal 0 = OFF

– Signal 1 = to driver
– Signal 2 = to driver and screen
– Signal 2 = to screen

Light mode

Description Channel
Light mode pcu_state_LTmode
– Signal 0 = OFF

– Signal 1 = Main light ON

– Signal 2 = Aux light ON

V7,12/2022 911 GT3 Cup (2021–2023) 804

 ELECTRIC SYSTEM | Display

Wiper state

Description Channel
Wiper state pcu_state_wiper
– Signal 0 = OFF

– Signal 1 = wipe once

– Signal 2 = wipe permanently

Fuel consumption counter

After each refuelling, the fuel consumption counter should be reset by a FUEL RESET.
Without a reset, the Fuel level indicator may show incorrect values while driving and the
fuel level alarm (Low Fuel) cannot be triggered.
▶ Indicator [FUEL RESET] is displayed after the MRK button on the steering wheel has
been held down for an extended period.
→ The fuel consumption counter is reset.
Channel: ecu_fuelcons

V7,12/2022 911 GT3 Cup (2021–2023) 805

 ELECTRIC SYSTEM | Display

Steering shunt mode

Prerequisite: Vehicle must be standing on its wheels!

Available when the engine is switched off and the ignition is switched on: press and hold the joker button on the steering wheel to activate the shunting mode.
To deactivate, press and hold the joker button again or after 180 s the steering switches off automatically.
If the battery is not charged enough, the steering remains off and the display shows 'BAT LOW'.

Description Channel
Steering shunt mode
– Countdown pcu_ti_steering_m [s]

– Battery too low warning pcu_steering_m

V7,12/2022 911 GT3 Cup (2021–2023) 806

 ELECTRIC SYSTEM | Display

Fuel pump mechanic mode

▶ Available when the engine is off: press the FUEL button on the centre console to activate the manual fuel pump mode.
Description Channel
Fuel pump mode
– Countdown pcu_ti_fuelpmp_m [s]

– Battery too low warning pcu_fuelpmp_m

Car variant

Description Channel
[1] Display car variant
– 0 = Error
– 1 = Basis
– 2 = ABS log_car_variant
– 3 = TC
– 4 = ABS & TC
– 9 = ECU Manipulation
[2] Licence state of TC

V7,12/2022 911 GT3 Cup (2021–2023) 807

 ELECTRIC SYSTEM | Display

Full Course Yellow (FCY)

Full Course Yellow (FCY) is activated and deactivated via the FCY button on
the steering wheel.
When FCY mode is active, the set target speeds are only maintained in 2nd–4th gear.
When full course yellow (FCY) function is activated the pit speed limiter is deactivated
automatically and the set target speeds are automatically maintained.
Channel: log_state_FCY

Setting FCY mode target speeds

The target speeds can be set via RaceCon software under the CAR tab in the
SPEEDLIMIT_NOM option.

1. Connect the car to the RaceCon software (ECU = green).

2. Select tab CAR.
3. Select option SPEEDLIMIT_NOM (km/h).
4. Set the target speed for 2nd gear in the 2.00 tap.
Confirm the entries with the Return key.
5. Set the target speed for 3rd gear in the 3.00 tap.
Confirm the entries with the Return key.
6. Set the target speed for 4th gear in the 4.00 tap.
Confirm the entries with the Return key.
7. Save changes with Save to ECU.

V7,12/2022 911 GT3 Cup (2021–2023) 808

 ELECTRIC SYSTEM | Display

Virtual safety car

Description Channel
[1] Radio check log_sw_ack

[2] Turn rad_corner_num1

V7,12/2022 911 GT3 Cup (2021–2023) 809

 ELECTRIC SYSTEM | Display

[3] Display of the flag (large overlay)

[4] VSC flag log_vSC_flag

[5] VSC note log_vSC_enum

V7,12/2022 911 GT3 Cup (2021–2023) 810

 ELECTRIC SYSTEM | Display

ABS reset

The ABS system must know, which tires are used on the car (wet / dry) to calculate with
correct tire circumferences. If tires are being changed during a pit stop, the driver must
press the switch WET TYRE to set it correctly (white = dry / blue = wet).
See 6.11.3 Overview of instrument panel on page 789.
If the change is forgotten during the pit stop, it can be set while driving, but the ABS must
be reset to accept the change. Therefore set the WET TYRE to the desired position, then
hold the button for 3 s on the next occasion of driving straight with no brake pressure
applied, as the ABS will reset for 3 s. In this time, there will not be an ABS function.
→ The overlay is shown to remind about the reset.

V7,12/2022 911 GT3 Cup (2021–2023) 811

 ELECTRIC SYSTEM | Display

6.12.3 Alarm signals

NOTICE DISREGARDING ALARM SIGNALS
Disregarding alarm signals may cause damage to the vehicle.
▶ If one of the following alarm signals occurs, execute a detailed fault analysis.

Alarm signals are always shown in text form.

This indicator is independent of the set page.
In addition to the text form, all LEDs on the driver display flash once (black/red) and the lower LEDs remain active until acknowledged.
The alarm can be acknowledged by pressing the ACK button.

Overview alarm signals

Description Channel
Alarm message category 3 (high) alarm_ABS_error
alarm_eps
warn_ABS_OFF
alarm_ubat

V7,12/2022 911 GT3 Cup (2021–2023) 812

 ELECTRIC SYSTEM | Display

Description Channel
Alarm message category 2 (medium) alarm_poil
alarm_lowfuel
alarm_tmot
warn_eps
warn_oillvl_low
alarm_tpms_hard
warn_SOC
alarm_pfuel
alarm_toil
alarm_pwat
alarm_pcrank
alarm_tgear
alarm_alt_stopped
alarm_tpms_soft
alarm_watlev
alarm_etcsel
alarm_prail

V7,12/2022 911 GT3 Cup (2021–2023) 813

 ELECTRIC SYSTEM | Display

Description Channel
Alarm message category 1 (low) alarm_starter
alarm_esw
warn-eps-derating
warn_brk_swich
warn_start_btn
warn_ecu_manipulation
warn_abs_diag
warn_pcrank_rev_lim
warn_abs_setting
warn_hazard_on

V7,12/2022 911 GT3 Cup (2021–2023) 814

 ELECTRIC SYSTEM | Display

ABS alarm
ALARM ABS Error
Channel: alarm_ABS
Category: [1]

Conditions:
• Ignition on.
• ABS light is on (signal from ABS via CAN).
• ABS CAN time-out.
• Error must be active for 0.5 s.
Meaning:
• Fault in ABS.
• ABS not functional.
Remedial action:
• Check ABS.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

V7,12/2022 911 GT3 Cup (2021–2023) 815

 ELECTRIC SYSTEM | Display

EPS alarm
ALARM EPS
Channel: alarm_eps
Category: [1]

Conditions:
• Engine is running, vehicle is in motion.
• Fault must be active for 0.5 s (signal from EPS via FlexRay).
Meaning:
• Fault in EPS.
Remedial action:
• Check EPS.

Acknowledging the warning message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the warning recurs after 30 s.

V7,12/2022 911 GT3 Cup (2021–2023) 816

 ELECTRIC SYSTEM | Display

Engine oil pressure alarm

ALARM Oil Press
Channel: alarm_poil
Category: [2]
Conditions:
• Engine control lamp is on (signal from engine control unit via CAN).
• Engine speed > 1000 rpm.
• Error must be active for 0.1 s.
Meaning:
• Engine oil pressure too low.
Remedial action:
• Stop the vehicle immediately and have it towed to the box.
• Check engine.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 11 s.

V7,12/2022 911 GT3 Cup (2021–2023) 817

 ELECTRIC SYSTEM | Display

Fuel level alarm

ALARM Low Fuel

Channel: alarm_lowfuel
Category: [2]
Conditions:
• Ignition on.
• If deactivated by parameter, the overlay is only displayed at standstill.
• Measured fill level < set threshold [litres].
• Error must be active for 0.5 s.

The threshold for the fuel level can be set in the lookup tables.
Meaning:
• Fuel level too low.
Remedial action:
• Check fuel level and fill up.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

V7,12/2022 911 GT3 Cup (2021–2023) 818

 ELECTRIC SYSTEM | Display

Coolant temperature alarm

ALARM Water Temp

Channel: alarm_tmot
Category: [2]
Conditions:
• Engine temperature > 110°C.
• Error must be active for 5 s (signal from engine control unit via CAN).
• Engine is running (10 s after start).
Meaning:
• Coolant temperature too high.
Remedial action:
• Check whether air ducts to radiator are not restricted.
• Check coolant level.
• Bleed the cooling system.
• Check thermostat and replace it, if required.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

V7,12/2022 911 GT3 Cup (2021–2023) 819

 ELECTRIC SYSTEM | Display

Starter alarm
Check starter
Channel: alarm_starter
Category: [3]
Conditions:
• Push and hold the start or crank button for more than 3 s.
• Diagnostic of start button is active.
• Error must be active for 0.5 s (signal from Porsche Powerbox via CAN).
Meaning:
• Vehicle cannot be started via the start or crank button.
Remedial action:
• Push-start the vehicle.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

V7,12/2022 911 GT3 Cup (2021–2023) 820

 ELECTRIC SYSTEM | Display

ABS off warning

WARN ABS OFF

Channel: warn_ABS_OFF
Category: [1]

Conditions:
• Engine is running.
• ABS switch is in position 0
• Error must be active for 0.5 s.
Meaning:
• The ABS function is disabled by means of manual deactivation or a system error.
Remedial action:
• Switch ABS to a desired position.
• Check ABS.

Acknowledging the warning message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the warning recurs after 2 s.

If the warning message is acknowledged twice, the large warning message disappears
and the ABS map box is highlighted in red.

V7,12/2022 911 GT3 Cup (2021–2023) 821

 ELECTRIC SYSTEM | Display

EPS warning

WARN EPS OFF

Channel: warn_eps
Category: [1]

Conditions:
• Engine is running, vehicle is in motion.
• Error must be active for 0.5 s.
Meaning:
• The EPS function is deactivated.
Remedial action:
• Check EPS.

Acknowledging the warning message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the warning recurs after 60 s.

V7,12/2022 911 GT3 Cup (2021–2023) 822

 ELECTRIC SYSTEM | Display

Battery voltage alarm

ALARM Battery Volt.

Channel: alarm_ubat
Category: [2]
Conditions:
• Measured battery voltage < 12 V
• Error must be active for 5 s.
Meaning:
• Battery voltage below 12 V.
Remedial action:
• Check, charge or replace the battery, if required.
• Check the alternator and replace it, if required.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 60 s.

V7,12/2022 911 GT3 Cup (2021–2023) 823

 ELECTRIC SYSTEM | Display

Low oil level warning

WARN Oil level <MIN

Channel: warn_oillv_low
Category: [2]
Conditions:
• Engine speed between 1700 and 2200 rpm.
• Error must be active for 0.5 s.
(Signals from engine control unit via CAN)
Meaning:
• Oil level too low.
Remedial action:
• Check engine oil level and fill up, if required.

Acknowledging the warning message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the warning recurs after 4 s.

V7,12/2022 911 GT3 Cup (2021–2023) 824

 ELECTRIC SYSTEM | Display

Tire inflation pressure alarm (Flat Tyre)

ALARM Flat Tyre

Channel: alarm_tpms_hard
Category: [2]
Conditions:
• Engine is running, vehicle is in motion.
• Error must be active for 1 s.
(Signal from TPMS via CAN)
Meaning:
• Tyre damage
Affected tyre is shown in the display incl. overlay.
Remedial action:
• Reduce speed, return to the box and have the affected tyre checked or replaced,
if required.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 20 s.
In addition to the alarm indicator, the indicator [TYRE PRESS] of the affected tyre is
highlighted in red.

V7,12/2022 911 GT3 Cup (2021–2023) 825

 ELECTRIC SYSTEM | Display

Battery low state-of-charge warning

WARN SOC low
Channel: warn_SOC
Category: [2]
Conditions:
• Engine is running.
• Battery state of charge < 40%
• Error must be active for 3 s.
(Signal from battery via LIN – via PRP via CAN)
Meaning:
• Charge state of the battery has fallen below 40%.
Remedial action:
• Check, charge or replace the battery, if required.
• Check the alternator and replace it, if required.

Acknowledging the warning message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the warning recurs after 30 s.

V7,12/2022 911 GT3 Cup (2021–2023) 826

 ELECTRIC SYSTEM | Display

Fuel low-pressure warning

ALARM Fuel Press
Channel: alarm_pfuel
Category: [2]
Conditions:
• Vehicle is in motion.
• Engine speed > 2000 rpm.
• Fuel pressure < 3 bar.
• Error must be active for 1 s.
(Signals from engine control unit via CAN)
Meaning:
• Fuel low pressure too low (< 3 bar).
Remedial action:
• Switch on the fuel pump and verify fuel low pressure.
If the error persists, check the entire fuel system.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

V7,12/2022 911 GT3 Cup (2021–2023) 827

 ELECTRIC SYSTEM | Display

Engine oil temperature alarm

ALARM Oil temp
Channel: alarm_toil
Category: [2]
Conditions:
• Engine oil temperature > 130°C.
• Error must be active for 5 s (signals from engine control unit via CAN).
• Engine is running (10 s after start).
Meaning:
• Engine oil temperature to high (> 130 °C).
Remedial action:
• Check the coolant level.
• Bleed the cooling system.
• Check the engine oil heat exchanger and replace it, if required.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

V7,12/2022 911 GT3 Cup (2021–2023) 828

 ELECTRIC SYSTEM | Display

Coolant pressure alarm

ALARM Water Press
Channel: alarm_pwat
Category: [2]
Conditions:
• Engine is running (10 s after start) and the car is in motion.
• Engine speed > 5.000 rpm.
• Coolant temperature (tmot) > 68 °C.
• Coolant pressure < 0.15 bar (MIN-Monitoring).
• Coolant pressure > 2.5 bar (MAX-Monitoring)
• Error must be active for 0.5 s (signals from engine control unit via CAN).
Meaning:
• Coolant pressure too low (< 0.15 bar).
• Coolant pressure too high (> 2.5 bar).
Remedial action:
• Check the coolant level.
• Bleed the cooling system.
If the error persists, check the entire cooling system.
Acknowledging the alarm message:
▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 5 s.

V7,12/2022 911 GT3 Cup (2021–2023) 829

 ELECTRIC SYSTEM | Display

Crankcase pressure alarm

ALARM Crank Press
Channel: alarm_pcrank
Category: [2]
Conditions:
• Engine has been running for 10 s.
• Engine speed > 3500 rpm.
• Crankcase pressure > 600 mbar.
• Error must be active for 0.5 s.
(Signals from engine control unit via CAN)
Meaning:
• Pressure in crankcase too high.
Remedial action:
• Stop the vehicle immediately and have it towed to the box.
• Check engine.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

V7,12/2022 911 GT3 Cup (2021–2023) 830

 ELECTRIC SYSTEM | Display

Gearbox temperature alarm

ALARM Gear Temp
Channel: alarm_tgear
Category: [2]
Conditions:
• Engine speed > 2500 rpm.
• Gearbox oil temperature >/= 130 °C.
• Error must be active for 5 s.
(Signals from engine control unit via CAN)
Meaning:
• Gearbox oil temperature too high (>/= 130 °C).
Remedial action:
• Allow the gearbox to cool down.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 45 s.

V7,12/2022 911 GT3 Cup (2021–2023) 831

 ELECTRIC SYSTEM | Display

Fuel level alarm II

Low Fuel
Channel: alarm_lowfuel2, log_fuellevel
Category: [2]
Conditions:
• Ignition on.
• Measured fill level < set threshold [litres].
• Error must be active for 3 s.

The threshold for the fuel level can be set in the lookup tables.
Meaning:
• Fuel level too low.
Remedial action:
• Check fuel level and fill up.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 30 s.

V7,12/2022 911 GT3 Cup (2021–2023) 832

 ELECTRIC SYSTEM | Display

Alternator alarm
ALARM Check Belt
Channel: alarm_alt_stopped
Category: [2]
Conditions:
• Battery voltage drops more than 1 V (check every 5 s, and the error is active
after another 25 s of running time at an engine speed > 2500 rpm).
• Error must be active for 40 s.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 60 s.

V7,12/2022 911 GT3 Cup (2021–2023) 833

 ELECTRIC SYSTEM | Display

Tyre inflation pressure alarm (slow puncture)

ALARM Slow Puncture

Channel: alarm_tpms_soft
Category: [2]
Conditions:
• Engine is running, vehicle is in motion.
• Error must be active for 1 s.
(Signal from TPMS via CAN)
Meaning:
• Slow loss of tyre inflation pressure.
Remedial action:
• Reduce speed, return to the box and have the affected tyre checked or replaced,
if required.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 20 s.
In addition to the alarm indicator, the indicator [TYRE PRESS] of the affected tyre
is highlighted in red.

V7,12/2022 911 GT3 Cup (2021–2023) 834

 ELECTRIC SYSTEM | Display

Coolant level alarm

ALARM Water level
Channel: alarm_watlev
Category: [2]
Conditions:
• Engine speed > 2000 rpm.
• Engine temperature > 68 °C.
• Voltage of fill level sensor >/= 4 V.
• Error must be active for 2 s.
(Signals from engine control unit via CAN)
Meaning:
• Coolant fill level too low.
Remedial action:
• Top up coolant.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

V7,12/2022 911 GT3 Cup (2021–2023) 835

 ELECTRIC SYSTEM | Display

Rail pressure alarm

ALARM Rail press
Channel: alarm_prail
Category: [2]
Conditions:
• Ignition on.
• Deviation of monitoring between prail and prail2.
• Error must be active for 0.1 s.
(Signals from engine control unit via CAN)
Meaning:
• Deviations of rail pressures of bank 1 and bank 2.
Remedial action:
• Stop the vehicle and have it towed to the box.
• Check the fuel system.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 5 s.

V7,12/2022 911 GT3 Cup (2021–2023) 836

 ELECTRIC SYSTEM | Display

Throttle alarm

ALARM Throttle
Channel: alarm_etcsel
Category: [2]
Conditions:
• Ignition on.
• Error must be active for 5 s.
Meaning:
• Single throttle system in error mode, control in limp mode via central throttle butterfly.
Continuation to the pit possible.
Remedial action:
• Read out and evaluate the error memory.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 30 s.

V7,12/2022 911 GT3 Cup (2021–2023) 837

 ELECTRIC SYSTEM | Display

Electric shift barrel alarm

ALARM SHIFT BARREL
Channel: alarm_esw
Category: [2]
Conditions:
• Component limit temperature >/= 100 °C.
• Error must be active for 5 s.
Meaning:
• Temperature of electric shift barrel too high (>/= 100 °C).
Remedial action:
• Let electric shift barrel cool down, check and replace it, if required.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 30 s.

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EPS Derating warning

Warn EPS Derating

Channel: warn_eps_derating
Category: [1]
Conditions:
• Ignition on.
• Vehicle is in motion.
• Error must be active for 2 s.
Meaning:
• EPS support power <81% (signal from steering via FlexRay).
Continuation to the pit possible.
Remedial action:
• Read out and evaluate the error memory.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 60 s.

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 ELECTRIC SYSTEM | Display

Electric shift barrel alarm II

ALARM SHIFT BARREL
Channel: warn_esw
Category: [3]
Conditions:
• Component limit temperature >/= 90 °C.
• Error must be active for 5 s.
Meaning:
• Temperature of electric shift barrel too high (>/= 90 °C).
Remedial action:
• Let electric shift barrel cool down, check and replace it, if required.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 60 s.

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Brake light switch alarm

WARN BRAKE SWITCH
Check brake switch
Channel: warn_brk_switch
Category: [3]
Conditions:
• Ignition on.
• Brake pressure front > 10 bar.
• Brake pressure rear > 10 bar.
• Brake light switch active for 0.2 s.
• Road speed = 0 km/h
• Error must be active for 0.5 s.
Meaning:
• Brake light switch is not detected even though brake pressure is present.
• Brake light switch is defective.
Remedial action:
• Replace brake light switch.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

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Start button alarm

Start button stuck

Channel: warn_start_btn
Category: [3]
Conditions:
• Ignition on.
• Error must be active for 0.5 s.
Meaning:
• Start button is stuck.
Remedial action:
• With the ignition off, push the start button repeatedly to release it.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

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ECU alarm
ALARM ECU MANIPULATION
Channel: warn_ecu_manipulation
Category: [3]
Conditions:
• Ignition on.
• Error must be active for 1 s.
Meaning:
• Tampering/modification detected.
Remedial action:
• Restore default settings.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 60 s.

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ABS diagnostic alarm

ALARM ABS DIAG

Channel: warn_abs_diag
Category: [3]
Conditions:
• Ignition on.
• Error must be active for 0.25 s.
Meaning:
• ABS diagnoses an error.
Remedial action:
• Check system.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 2 s.

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Alarm PCRANK REV LIM

ALARM PCRANK REV LIM
Channel: warn_pcrank_rev_lim
Category: [3]
Conditions:
• Ignition on.
• Error must be active for 0.5 s.
(Signals from engine control unit via CAN)
Meaning:
• Speed limitation active due to low crankcase pressure.
Remedial action:
• Wait until the display goes out or check the crankcase pressure.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 60 s.

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ABS setting alarm

ALARM ABS SETTING

Channel: warn_abs_setting
Category: [3]
Conditions:
• Ignition on.
• Error must be active for 1 s.
Meaning:
• ABS installed but not activated.
Remedial action:
• Activate ABS.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 30 s.

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Alarm warn hazard on

ALARM Warn Hazard On

Channel: warn_hazard_on
Category: [1]
Conditions:
• Vehicle is in motion.
• Error must be active for 0.1 s.
• pcu_state_hazard = 1
Meaning:
• Hazard flashers automatically activated.
Remedial action:
• Deactivate hazard flashers.

Acknowledging the alarm message:

▶ Press the ACK button on the steering wheel.
If the problem persists, the alarm recurs after 10 s.

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6.12.4 Function description of the display LEDs

Overview of display LEDs

[1] Shift lights

Cahnnel: log_shiftlights
Channel on warm up page: ecu_nmot
[2] LED indicators on the sides

Shift lights

• The shift lights assist the driver in finding the optimal shift point.
• The shift lights start lighting up from the sides until they join in the centre.
• LED colours change from green via yellow to red.
• When the optimal shift point is reached, all LEDs change to blue and start flashing.

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LEDs on the sides

Alarm active
All LEDs flash once, the two bottom LEDs remain on until the alarm is acknowledged.

Front left wheel locked (flashes)

Front right wheel locked (flashes)

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Rear left wheel locked (flashes)

Rear right wheel locked (flashes)

Traction control (TC) active (flashes)

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High-beam lights ON (lights up)

Turn signal right ON (flashes)

Turn signal left ON (flashes)

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6.12.5 Virtual Safety Car

VSC display pages

VSC = Virtual Safety Car, SC = Safety Car

VIRTUAL SAFETY CAR HOME PAGE

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IMPLEMENTATION – EXAMPLE: RED FLAG

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (red) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (red) [2] can be acknowledged. The small overlay [3] (see Fig. 64) is then
shown at the bottom left for as long as the race director maintains it in active state.

Fig. 64: Red Flag, small overlay

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IMPLEMENTATION – EXAMPLE: VIRTUAL SAFETY CAR

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow) [2] can be acknowledged. The small overlay [3] (see Fig. 65) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 65: VSC small overlay

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IMPLEMENTATION – EXAMPLE: VIRTUAL SAFETY CAR ENDING

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow) [2] can be acknowledged. The small overlay [3] (see Fig. 66) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 66: VSC ending, small overlay

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IMPLEMENTATION – EXAMPLE: SAFETY CAR

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow) [2] can be acknowledged. The small overlay [3] (see Fig. 67) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 67: SC small overlay

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IMPLEMENTATION – EXAMPLE: SAFETY CAR IN THIS LAP

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow) [2] can be acknowledged. The small overlay [3] (see Fig. 68) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 68: SC in this lap, small overlay

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IMPLEMENTATION – EXAMPLE: FULL COURSE YELLOW

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow) [2] can be acknowledged. The small overlay [3] (see Fig. 69) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 69: FCY small overlay

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IMPLEMENTATION – EXAMPLE: FULL COURSE YELLOW END

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow) [2] can be acknowledged. The small overlay [3] (see Fig. 70) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 70: FCY ending, small overlay

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IMPLEMENTATION – EXAMPLE: DOUBLE YELLOW FLAG

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow) [2] can be acknowledged. The small overlay [3] (see Fig. 71) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 71: Double yellow flag, small overlay

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IMPLEMENTATION – EXAMPLE: YELLOW FLAG

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow) [2] can be acknowledged. The small overlay [3] (see Fig. 72) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 72: Yellow flag, small overlay

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IMPLEMENTATION – EXAMPLE: SLIPPERY TRACK

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (yellow/red) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (yellow/red) [2] can be acknowledged. The small overlay [3] (see Fig. 73)
is then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 73: Slippery track, small overlay

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IMPLEMENTATION – EXAMPLE: CODE 60

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (pink/white) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (pink/white) [2] can be acknowledged. The small overlay [3] (see Fig. 74)
is then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 74: Code 60, small overlay

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IMPLEMENTATION – EXAMPLE: CLEAR TRACK

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (green) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (green) [2] can be acknowledged. The small overlay [3] (see Fig. 75) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 75: Clear track, small overlay

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IMPLEMENTATION – EXAMPLE: GREEN FLAG

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (green) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (green) [2] can be acknowledged. The small overlay [3] (see Fig. 76) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 76: Green flag, small overlay

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IMPLEMENTATION – EXAMPLE: BLACK FLAG

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (black) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (black) [2] can be acknowledged. The small overlay [3] (see Fig. 77) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 77: Black flag, small overlay

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IMPLEMENTATION – EXAMPLE: WET SESSION

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (black) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (black) [2] can be acknowledged. The small overlay [3] (see Fig. 78) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 78: Wet session, small overlay

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IMPLEMENTATION – EXAMPLE: TECHNICAL PROBLEM

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (black/orange) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (black/orange) [2] can be acknowledged. The small overlay [3]
(see Fig. 79) is then shown at the bottom left for as long as the race director maintains it
in active state.

Fig. 79: Technical problem, small overlay

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IMPLEMENTATION – EXAMPLE: TRACK LIMIT

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (black/white) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (black/white) [2] can be acknowledged. The small overlay [3]
(see Fig. 80) is then shown at the bottom left for as long as the race director maintains it
in active state.

Fig. 80: Track limit, small overlay

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IMPLEMENTATION – EXAMPLE: DRIVING CONDUCT

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (black/white) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (black/white) [2] can be acknowledged. The small overlay [3]
(see Fig. 81) is then shown at the bottom left for as long as the race director maintains it
in active state.

Fig. 81: Driving conduct, small overlay

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IMPLEMENTATION – EXAMPLE: BLUE FLAG

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (blue) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (blue) [2] can be acknowledged. The small overlay [3] (see Fig. 82) is
then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 82: Blue flag, small overlay

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IMPLEMENTATION – EXAMPLE: LAPTIME CANCELLED

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (stopwatch) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (stopwatch) [2] can be acknowledged. The small overlay [3] (see Fig. 83)
is then shown at the bottom left for as long as the race director maintains it in active state.

Fig. 83: Laptime cancelled, small overlay

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IMPLEMENTATION – EXAMPLE: DRIVE-THROUGH PENALTY

The left and right LEDs [1] flash yellow three times when a VSC change is detected.
A flag overlay (exclamation mark) [2] is shown instead of the vital values.
The vital values cannot be monitored until the driver acknowledges the VSC.
The large overlay (exclamation mark) [2] can be acknowledged. The small overlay [3]
(see Fig. 84) is then shown at the bottom left for as long as the race director maintains
it in active state.

Fig. 84: Drive-through penalty, overlay

IMPLEMENTATION – EXAMPLE: RADIO CHECK

▶ Push the ACK button on the steering wheel if you hear the race director on the radio.

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VSC CAN overview

The display can show warnings from the race director.

To be displayed, a message from the following table must be sent via CAN5, e.g. the radio connector.

Name ID Start bit Length [bit]

Black Flag 0x201 0 1
Mechanical problem 0x201 1 1
Track limit 0x201 2 1
Driving conduct 0x201 3 1
Blue flag 0x201 4 1
Laptime cancelled 0x201 5 1
Drive-through penalty 0x201 6 1
Red Flag 0x201 16 1
Safety Car in this lap 0x201 17 1
Safety Car 0x201 18 1
FCY ending 0x201 19 1
Full Course Yellow 0x201 20 1
VSC ending 0x201 21 1
Virtual Safety Car 0x201 22 1
Double Yellow Flag 0x201 23 1
Yellow Flag 0x201 24 1
Slippery Track 0x201 25 1
Code 60 0x201 26 1
Clear Track 0x201 27 1
Green Flag 0x201 28 1
Radio check 0x201 29 1

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Name ID Start bit Length [bit]

Wet Session 0x201 30 1
Investigation ongoing 0x201 31 1
Curve number pos. 1 0x201 32 8
Curve number pos. 2 0x201 40 8
Curve number pos. 3 0x201 32 8
Curve number pos. 4 0x201 40 8

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 ELECTRIC SYSTEM | Porsche Toolbox

6.13 Porsche Toolbox

The PC on which the Porsche Toolset and/or Porsche Toolbox software is to be used must be operating on Windows 10 or higher.
Always load the latest version of the Cosworth software 'Porsche Toolbox' from PMRSI ("Porsche Motorsport Racecar Service Information" Portal (PMRSI)
at https://motorsport.porsche.com).

6.13.1 Installation

The latest version of the Porsche Toolbox is available for download from the
Cosworth website together with other software from Porsche Motorsport.
Supported operating systems: Microsoft Windows 10 (32 or 64 bit.
https://www.cosworth.com/race-electronics/porsche-motorsport/

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6.13.2 Licensing
Configuring the Porsche Toolbox license

The licensing of the Porsche Toolbox is configured via the Cosworth Software Licensing
Configuration Tool.
▶ It is accessible via the Porsche Toolbox: Help > Configure Licensing.
If you have purchased a Plus, Pro or Ultra licence, you will have received a product key from
Cosworth. To add this key to the Porsche Toolbox, click button + Add in the Cosworth
Software License Configuration Tool.

1. Enter the product key into the field shown and click Add.
Your licence is activated for using the Porsche Toolbox.

If you have not purchased a Porsche Toolbox licence, you may alternatively request a free
Lite licence from the Cosworth website and add it to the Porsche Toolbox following the
steps described above.

2. To request a Lite licence, follow the link provided and enter your details into the fields
shown.
https://www.cosworth.com/race-electronics/porsche-motorsport/

If you wish to purchase a Plus, Pro or Ultra licence or if you wish to request more
information about the available licences, please contact [email protected].

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Transferring the Porsche Toolbox licence

Licences may be transferred between computers,

however, a licence may only be used on one computer at a time.

As a first step, create a recipient file on the destination PC:

1. In the Cosworth Software Licensing Configuration Tool, click button Import.

2. Click Generate Recipient File to create an ID file.

3. Save the ID file to a USB stick and transfer it to the PC donating the licence.

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Then transfer the licence into the recipient file created beforehand:
1. In the Cosworth Software Licensing Configuration Tool on the computer donating the
licence, click button Transfer and select recipient file .id on the USB stick.
2. Click button Generate Transfer File and save the .h2h file to the USB stick.

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Import the licence to the destination PC:

1. On the destination PC, open the Cosworth Software Licensing Configuration Tool and
click button Import.
2. Locate the .h2h file on the USB stick and click Import.

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6.13.3 Starting the Porsche Toolbox

Quick-Start Guide

The Quick Start Guide assists new users in quickly creating displays and plot data.
When the Porsche Toolbox is first opened, a default workbook with one single task is provided.
In the following steps it is assumed that the task is started with a blank workbook.

▶ To open a blank workbook, click the new button in the toolbar.

Creating a task

1. Open the task window in the Explorer (ALT+1) and select Add Task.

2. In the details area, double-click Name and overwrite the default name.
3. Press the enter key or click outside the editing field to accept the name.

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Loading an outing

▶ Highlight the task and select Add Outing.

In dialogue field Load Outing, locate a PDS (Pi data set).

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Selecting laps

If an outing is initially related to a task, the data from the fastest lap of the outing are loaded.

Highlight the outing whose laps are selected as follows:

▶ Select Select and then Regions to select dialogue field Select
(alternatively, press the Enter key or double-click the outing).

Dialogue field Select shows a list of all laps contained in the outing.
▶ Select a lap or several laps.
To highlight a group of laps, proceed as follows:
1. Click the first lap in the group, then press and hold the shift key on the keyboard and
click the last lap in the group.
2. Press Select to select the group.

Alternatively, select all laps using option All Regions (CTRL + E), or the fastest lap using
option Fastest Lap (CTRL + Q).

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Adding a display to a workbook

▶ In the toolbar, click button Insert Display and select a display type from the list.
Note that this button saves the display type last added and that it shows the
corresponding icon.

Connecting the display to a task

The display of plot data requires these data to be connected or assigned to a task.
▶ At the top left of the display's title bar, click icon No Task and select the created task
from the dropdown list of available tasks.

Selecting channels for display

1. Select channel explorer (ALT + 2) to show the channels in the outing.

2. Double-click the channels to be displayed.
→ The channels selected are shown in the bottom area of the explorer, and the data
are shown in the screen.

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In channel Explorer, all channels assigned to the loaded outing data set are listed in
Available Channels.
To apply or remove a filter to or from the channel list, proceed as follows:
▶ Enter the first letter of the channel.
The list is narrowed down as you enter more characters.
▶ To remove a filter character, press the Backspace key.
▶ To remove the filter, press ESC.

Advanced filters can be used with a mixture of standard characters and

wildcard characters.
Wildcard characters:
* Any character or a character string
? Individual characters
?? Two characters, etc.
To enter a wildcard character, press the following keys:
CTRL + SHIFT + * or CTRL + SHIFT + ?

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Changing channel properties

The explorer for channel properties (ALT + 3) is used to show and edit channel properties
that affect how the data of a channel are presented on screen. As in the channel explorer,
the channel groups are shown at the top of the area.
The Global Channel Properties explorer shows all available channels and groups.
The properties edited here are applied to the entire workbook, not only to the page
displayed at this moment.

The Display Channel Properties explorer shows only the channels provided on the active
page. The properties edited here are applied to the shown page only and overwrite the
properties specified for the workbook in the Global Channel Properties explorer.

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Saving and opening the workbook

▶ Save the workbook using the icon shown or option Save/Save as.

A saved workbook can only be opened and used after the Porsche Toolbox has been
relaunched.
▶ To open a saved workbook, click the button shown and navigate to the location where
the workbook file is saved.

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The explorer

In the explorer you can create tasks, load outing data sets, and select channels from the outings in order to display and edit channel properties.
When finished, the work in the explorer can be hidden quickly to maximise the screen area for the data analysis.
Navigation within the explorer is facilitated using the links from the following table:

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Tasks/Task explorer

When launching the Porsche Toolbox, the Task explorer is opened automatically.
This is where tasks are created.
Tasks are a convenient method of saving outing data.
▶ Right-click into the area shown and select option Add Task.
▶ When a task is highlighted, the properties (colour name and description) are shown
in the details area beneath.

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TASK PROPERTIES

When a task is highlighted or selected, the properties are shown in the details area.
Appearance

Color: Colour selection for the tasks.

▶ Double-click the colour field to select a different colour from the colour chart.
Description: Change the description of the task.
▶ Double-click the description of the task to make changes to it.
▶ Press Enter to close the dialogue.
Name: Change the name of the task.
▶ Double-click the name of the task to change it.
▶ Press Enter to close the dialogue.

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AUTO UPDATE

Command Auto Update is used to execute a task in order to monitor a directory for new outings.
Depending on the parameter settings, the task automatically adds the outing or replaces the current outing.
This feature can be used to update displays with the latest data downloaded to a network server.

Enabled: Enable/disable automatic updates.

▶ Click Enable and select Yes or No from the dropdown list to enable or disable automatic
updates.
Source: Show the source of a task.
▶ Click Source and then button Browse.
Use dialogue field Browse for Folder to find the directory.
The path to a directory that does not yet exist can be entered into the text box underneath
the explorer view.

A dialogue field shows that the path cannot be found.

▶ Click Yes to enable the path.

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Target

The target property can be used to determine how the automatic update responds to new outings.
▶ Click Target and select an option from the dropdown list.
Data selection caption: Designation of the data selection.
This is where the outings added to the current task are listed. The task is updated when the
outing selected in the source directory is updated.
Add always: Each new outing added to the source directory is also added to the task.
Add Initial: This is the default option. The last data set added to the source directory is also
added to the task.
The target is then set to the current outing.

SECTOR TIMES

Initial Selection: Use the selection property to specify the sector to be shown of a data
selection added to a task or to replace an existing data selection in a task.
Fastest Lap: Shows the fastest lap of the outing.
All regions: Shows the entire outing.
Last region: Shows the lap leading to the last marking of the lap.
Unchanged: If outings are updated or added, the currently selected sector is not changed.
Comparison: Designates the current task as comparison task to allow several outings to be
easily compared.

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OUTING PROPERTIES

If an outing in the upper area is highlighted, the outing properties are shown in the lower
details area. Properties can be listed in categories, expanded or reduced or listed in
alphabetic order.
▶ Select alphabetic/categorized to change the mode.

Appearance

Color: Shows the default colour of the outing.

If a task contains two or more outings, all channels assume the default colour of the outing
they are contained in. This does not affect any of the individual properties of the channels.
Data Selection: Shows the outing designation and the data (lap(s)) selected for display. The
outing designation can be configured in the Outings tab in dialogue field Options.
▶ Click Tools and then Options to open the dialogue field.

DETAILS

In section Details you can change various properties, e.g. driver name or name of
the racetrack.

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COMMENTS

Short Comments/Long Comments:

▶ Double-click an outing to add a comment.

Long comments can exceed one line. If memory space is not sufficient, long comments are
shown as a Quick Info.

LAP INFORMATION

Lap information cannot be edited.

OUTING

Outing information cannot be edited.

DATA

Show Hidden Regions: Designation of the data selection.

▶ Double-click an outing and then Yes or No to show/hide hidden sectors
(e.g. warm-up or cool-down laps).
Time Offset: If a task contains more than one outing, an offset may be added to change
the position of one outing relative to another outing.
▶ Double-click an outing to enter an offset, then press Enter to confirm.
The offset can be set manually in a time/distance diagram.

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Channel/Event explorer

The available data and event channels in the loaded outings are listed in windows Channels and Events (press ALT + 2 to toggle between Channels and
Events). This includes channels and events of outings as well as mathematical channels and events created in the Porsche Toolbox.

The selection explorer is used to select channels for presentation on the screens in the
display area. The filter can be used to narrow down the channels, and it can be used by
means of entries if the selection explorer is in the foreground. The lower details area shows
the channels and events selected for individual representations.
In the details area, channels in the selected representations can be arranged in ascending
or descending order or manually using the arrow keys (see red outline).

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Channel properties explorer

The channel properties explorer is used to show and edit channel properties affecting the on-screen representation of channel data. As with the selection
explorer, channel groups are shown at the top of the display area.
There are two explorer windows, Global and Display. They are opened by pressing ALT + 3.

• Window Global Channel Properties shows all available channels and groups.
The properties edited here are applied to the entire workbook.
• Window Display Channel Properties shows only channels displayed by the active
representation. Properties edited here are applied to the shown representation and
overwrite those defined for the workbook in window Global Channel Properties.

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The following properties can be changed for channels:

APPEARANCE

Color: Default colour of the channel.

Color Gradation: This feature is used to set a grade of a channel's plotted colour according
to the channel value at this point.
Name: Channel name.

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PLOT

Autoscale: Enables/disables automatic scaling.

If automatic scaling is enabled, the measurement curve is expanded over the entire length
of the axis. This axis is based on the channel data in order to maximise the data within the
represented area.
Auxiliary axis: Enables or disables the display of several axes in time/distance diagrams,
histograms, etc.
A display shows a Y-axis for the active channel and Y-axis for each channel enabled with
this property.
Display maximum: The maximum expansion of the axis based on the channel data is shown
in the display. When Autoscale is enabled, this parameter is disabled.
Display minimum: The minimum expansion of the axis based on the channel data if shown
in a display. When Autoscale is enabled, this parameter is disabled.
Interpolation: This feature defines the interpolation method applied between
measurement points.
▶ Select and hold option Linear or Sample.
Y-axis percent enabled: Enables or disables the Y-axis percentage of the channel. When
activated, the percentage of the Y-axis assumed by the channel and its vertical position on
the scale can be adjusted.
Y-axis percent max/min: Defines the maximum and minimum percentage of the Y-axis
applied to the channel. Use this function to move a channel track so that it is free of other
overlaying tracks.

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ALARM

Alarm color: The colour of the alarm.

Alarm condition: Defines the limit value condition triggering the alarm. The alarm can be
configured in such a way that it is triggered if the channel value falls below the minimum
value, if the channel value exceeds the maximum value or if both the minimum and the
maximum alarm values are exceeded.
Alarm max.: The threshold value that the channel value must exceed to trigger the alarm.
Alarm min.: The threshold value under which the channel value has to fall to trigger
the alarm.

DATA

Decimal Places: Number of decimal places up to which channel values are shown.
Quantity: Measurement results of the channel (e.g. pressure, road speed, etc.)
Units: °C, MPH, km/h, litres, mm, bars, volt.

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FILTER

Filter: Select a filter type from the dropdown list.

The default options are:
– No filter
– Band pass filter
– Gating function filter
– Filter for floating mean value
A filter is enabled by selecting it and setting the indicator to Yes. User-defined filters
developed with the SDK are also shown in the dropdown list.
Filter enabled: Indicates whether a filter is enabled or disabled.
Filter Properties: Double-clicking this property opens the properties dialogue field for
the selected filter type.

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Display types

The following display types are most frequently used:

Time/Distance Chart

The time/distance chart can show one or more channels either above the time or above the
calculated distance.

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X-Y Chart

The X/Y chart shows a point cloud representing two channels in comparison.

Histogram

The histogram chart shows how often the value range of a channel occurs.
The scope of the value ranges can be adjusted to reduce or increase the number of bars.

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Reports

Reports are used to analyse tendencies of outings. They can be created and saved for specific analysis requirements and be executed again at each outing.

EXCEL OUTING REPORT

Layout and print are made in Microsoft Excel. Excel can be used for the simple editing
of data and the development of complex report integrations using comprehensive
mathematical and statistical functions.

TABULAR OUTING REPORT

The tabular outing report shows the channel values lap by lap for the entire outing.
The report is ideal for the analysis of values during an outing (e.g. engine temperature
or pressures).

SPLIT REPORT
The split report is based on the track sections. Each track section is marked by a split
marking point. This can be either a physical marker or a marker set using the software.
By dividing the track into sections, it can be quickly determined how fast and consistently
a driver performs in each section.
By comparing laps, it is possible to determine how adjustments to the setup affect
performance.
Creating a split report using the time elapsed will create a very helpful split time report.
The split time report provides two unique performance indicators:
– The fastest lap in theory
– The fastest lap driven
The fastest lap in theory defines the lap times that could be achieved if the best
intermediate times of an outing would be achieved in one single lap.
The fastest lap driven is the fastest lap using a start and finish point that must not
necessarily be the end-of-lap beacon at the lap finish. The comparison of the lap times
achieved and the fastest lap in theory shows the driver's consistency.

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EVENT REPORT
Event reports show the point in time when an event occurred as well as all associated
channel values.

Maps

Shows an image of the track generated from recorded data.

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Aerial Map Display

This is an image created using GPS tracking coordinates laid over a satellite image.

Video Displays

Facilitates the display of MPEG files synchronously with the task cursor time.
Bit Indicators

Facilitates the investigation of system status channels for fault conditions.

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Channel Displays

Shows the numerical values of the selected channels for real-time (last point) or historic
data.

Event Displays

Shows events both as real-time and also as historic data based on the type of data stream
the data are linked with.

Chart Recorders

Shows real-time data from the vehicle as it moves along the track.
The diagram is continuously updated with the latest data.
Navigators

Offers a quick and easy way of selecting sectors within an outing and changing the shown
range of the data.

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Dash Display

Facilitates the real-time and PDS file representation of Cosworth displays

(with PRO dongle).

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6.13.4 Math Channels and Soft Events

Introduction to math channels and soft events

Pi Math allows users to perform complex data analyses.

In general, a math channel uses one or more input channels to create one output channel.
Input channels can be either real channels or other math channels.
The operators and functions available for math channels are also available for soft events.
Soft events are simply math channels with a Boolean value.
If the event occurs for a specific example point, it is rated as On/True.
If the event does not occur, it is rated as Off/False.

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What is a math channel?

For a better understanding of the performance, "real" channel data, mathematical equations and functions for the creation of math channels can be combined.
These can be described as user-created "virtual" channels derived from the result of a mathematical operation. Math channels can be used in the same way
as "real" channels. The results are shown in the Time/Distance Graph, Histograms, Reports, etc.

In the explorer, a math channel is shown as follows:

A simple math channel can be identified by its following notation:

Math Channel = ƒ (Input1, Input2,)
The aerodynamic downforce acting on the vehicle is a typical case of a math channel:
TotalAero = AeroF + AeroR
AeroF = FL Pushrod Load + FR Pushrod Load
AeroR = RL Pushrod Load + RR Pushrod Load

TotalAero is a math channel whose inputs AeroF and AeroR are also math channels.
However, these are derived from the "real" input data channels:
FL Pushrod Load, FR Pushrod Load, RL Pushrod Load and RR Pushrod Load.

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What is a soft event?

Engineers must create their own events within the channel data, based on fixed conditions. This is what Soft Events are for. Contrary to Hard Events that are
part of the outing data, Soft Events are always calculated on the basis of the runtime.
Example: The following conditions must be excluded when accelerating the vehicle or when testing a circuit to determine the efficiency of the gearbox oil
pickup: Braking, standstill and driving through curves.
Event parameters excluding lateral acceleration data exceeding 0.5 g or less than –0.5 g as well as engine speed data exceeding 10,000 RPM are defined
in dialogue field Soft Events Management.

A soft event is shown in the explorer as follows:

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Creating and editing math channels and soft events

Equation marks for math channels and soft events are created in field Equation or the Management dialog.
Path: Tools > Pi Math > Edit or Tools > Soft Events > Edit

▶ Press the icon shown to create a new channel.

Creating equations is facilitated by integrated mathematical functions and operators.

Operators or channels are selected from a dropdown list.
▶ In the equation field, press CTRL + blank space to gain access to the dropdown list.
▶ Use the up and down arrows to highlight a selection and press Enter to confirm.
→ The channel or operator is inserted into the equation at the cursor position.
This list can be filtered if required.

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The contents of the dropdown list depends on the context of the equation:
– Following '[' or between '[' and']', a list of available channels is shown.

A list of operators is shown between two subordinate terms.

If an operator is marked or if the cursor is held down, a tooltip will show the syntax and
description of the operator.

▶ A blank space must be entered after character “]“ to facilitate access to the list of
operators using key combination CTRL + blank space.

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Operands
The following objects can be used in the equation as operands:
• Channels
• Global mathematical constants (name)
• Outing constants (name)
Constants
Constants are referenced with the following syntax:
• CONST (constant name)
• GLOBALCONST (constant name)
• OUTINGCONST (constant name)
Error checking
When creating the equation, Definition evaluates successfully or Invalid Definition is
shown in the status bar underneath the equation field to indicate the accuracy of the
equation syntax.

An invalid definition is also shown by the math channel icon changing from [+] for a valid
definition to [x] in the case of an invalid definition.

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Porsche Math Channel Management

In dialogue field Porsche Math Management, the following properties for the math channel
can be edited:

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CHANNEL LIST
This is a list of all available math channels.
If a math channel in the list is highlighted, its details are shown in the fields on the right.
The function also adds a default name for a new math channel to the math channel list.

The function also deletes the currently highlighted math channel from the math channel
list.

▶ One or more channels can be selected using the following key/mouse combinations:
SHIFT + click and CTRL + click
▶ Alternatively, all channels can be selected by pressing CTRL + A.
In the case of a multiple selection, the filter function deselects non-compliant data
sets while compliant data sets are maintained.
CAUTION! A math channel can be a subordinate term of another math channel equation,
i.e. the math channel depends on another math channel.
Deleting the first channel would render the dependent channel globally invalid.

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NAME
Shows the name of the math channel highlighted in the channel list.
Its name can be edited in this field.
CAUTION! Math channel names are case-sensitive. Ensure that no math channel is created
by the same name of an already existing one but with differing upper/lower case spelling.

QUANTITY/UNIT
By default, math channel units are user-defined units.
These are directly entered into the field "Unit of dialogue field Pi Math Management".
The quantity of a math channel can be changed into a predefined quantity in the extended
section of the dialogue field. When the quantity is defined, the user can define the unit.

RATE
Math channels consist of one or more input channels that are usually read via different
frequencies.
The user defines the calculation and sampling rate of a math channel. This can be either the
same valuation as one of the individual channels or it can be user-defined.
Inherit rate from: Facilitates the selection from a dropdown list containing the individual
channels of the equation. The calculation rate of the math channel corresponds with the
data rate of the channel selected here.
Fixed: This function facilitates the definition of a data rate from a range of fixed frequencies
between 1 and 1000 Hz. This option can be used if a math channel does not have constant
real channels.

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EQUATION
This field is used to enter the equation mark sequence of the math channel.
The syntax is highlighted in colours as follows:
• Red = error
• Green = comment
• Blue = keyword

If required, a description can be added to facilitate identification.

▶ Enter a description between or after the following characters:
– *Description*
– //Description

When creating the equation, Definition evaluates successfully or Invalid Definition is

shown in the status bar underneath the equation field to indicate the accuracy of the
equation syntax.

INPUT CHANNELS
The input channel list is a list of all real channels referenced in the math channel equation.
Here, the quantities and units of the individual channels can be changed.
▶ Double-click a quantity or unit, and select a list of options suitable for the channel from
a dropdown list.

The properties of the math channel are defined in area Default Properties on the right
in the Management Dialog. The properties shown correspond with the channel selected
in the channel list. These properties are shown in the Properties Explorer and define the
appearance of the math channel monitoring.

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Importing and exporting math channels

Math channels can be imported into a workbook and can be exported from the
following link:
Tools > Pi Math > Export/Import

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Lookup Tables

1D Lookup Table

2D Lookup Table

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Lookup Table Syntax

1D and in 2D tables are defined in the equation for math channels/soft events using the following syntax:
table #name = path\filename\sheet\!cellfrom:cellto;

Table:
A keyword is used to define lookup tables.
Name:
This is the name of the lookup table.
It must always begin with a # symbol.
Path:
This is the driver plus the directory path of the Excel file. Relative network paths may also
be used.
Sheets:
This is the name of the Excel table.
Cellfrom:
This is the cell at the top/top left in the lookup table.
Cellto:
This is the cell at bottom/bottom left in the lookup table.

Cellto and cellfrom arguments can be specified using the Excel cell syntax,
e.g. $ A $ 3 for cell A3.

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Intended use of lookup tables

Lookup tables can be used in channel/event definitions using the following syntax:
• #name (exp[,mode])
• #name (exp1, exp2[, mode])

Name:
This is the name of the lookup table.
Exp:
This is the input parameter used in 1D lookup tables.
exp1 and exp2 are input parameters that are used in 2D lookup tables.
exp1 indicates the index column, and exp2 the index row.
Mode:
This parameter is optional. It defines the modes of interpolation/extrapolation.
Unless explicitly specified, the Snap value is assumed.
Interpolation:
This function executes an interpolation.
Extrapolation:
This function executes an extrapolation.
Both:
This function executes an interpolation as well as an extrapolation.
Snap (default value):
Neither interpolation nor extrapolation is executed.
The nearest value is returned.
Hold:
As in snap mode, but with the value always being returned to the previous value.

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Register
What is a register?

Registers are used to save discrete variables (real numbers). The value of a register is propagated as value for the subsequent random sample valuation after
the current random sample has been valuated.
Registers are calculated for each random sample.
Registers are typically used to:
• Simplify equations by providing means to define local variables. For example:
– AveSpeedFront = ([SpeedFL] + [SpeedFR]) / 2
– AveSpeedRear = ([SpeedRL] + [SpeedRR]) / 2
– (AveSpeedFront + AveSpeedRear) / 2
• To define recurring definitions, retain the registers sample by sample. For example:
– Summ = Summ + [Speed]
Sets Summ to the same value of Summ as in the preceding sample plus the value of the speed channel in the current sample.
Working with registers

EXPLANATION
A register must be declared before it can be used, for example: Register @R;
Register names are case-sensitive and must begin with the @ character.
As part of the declaration, the user can specify a start value for the register: Register
@R=1;
If not specified, the start value is set to zero by default.

Register declarations must precede all other declarations in an equation.

INITIAL VALUE
A register adopts its initial value only for the first measurement of the math channel
(which corresponds with the initialisation of static variables in C++).

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ORDER
When a register has been declared, its values can be changed using an allocation operator:
– <register> = <expression>;
– For example: @R = @R + 1;

REGISTERS IN EXPRESSIONS
The value of a register can be used in any expression by simply specifying the register
name:
– Sin( @R);
– @R3 = log (@R1+@r2);

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Pop-Up Alarms
What are pop-up alarms?

Pop-up alarms are visual indicators showing that specific channels have reached a defined value.
When this happens, a pop-up prompt is shown that requests a confirmation.
Configuration

The configuration of pop-up alarms is started via the Tools menu (this function requires
a real-time license):

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The configuration dialogue contains two tabs, one for the configuration of global qualifiers,
and one for the configuration of the individual alarms. Tab Qualifier is inspired by the
toolset editor for logic channels; here, only supported channel and bit field comparisons are
available.

Individual alarms are configured with an editor inspired by the toolset alarm editor.
You can select which global qualifier shall be also applied to each alarm to enable or disable
the alarms. For Channel conditions, the min/max values of the alarm min/max values
of the channel database are defined as default comparison values if comparisons
with '<', '<=' or '>=', '>' are selected.

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The header shown when an alarm is triggered can be configured, with Custom Text
allowing any character string to be entered:

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Triggered alarms

Triggered alarms are shown in a popup dialogue field with the following features:
• It can be configured to always overlay other windows.
• It allows the selection of multiple triggered alarms by clicking the entries or by using the
checkboxes and then cancelling the alarms selected.
• It is not possible to close the dialogue field manually; it is closed automatically as soon
as all alarms are cancelled.
• When closing, the dialogue field retains its position and will be displayed in its previous
position the next time it pops up.
If the previous mode is no longer available, it will be displayed on the screen showing the
main window of the Porsche Toolbox.

Import/export

Popup alarm definitions can be imported and exported via the Tools menu. These entries
start the Standard import/export assistant of the Porsche Toolbox.

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Constants
What is a constant?

A constant is a denominated, time-varying value used in a global or outing context.

Constants can be used in a math channel; if e.g. several math channels use a spring rate value, this value can be represented by a constant created in the
Porsche Toolbox.
If the spring rate must be changed by changing the constant to the new value, all channels using the constant are calculated with the new value.
Types of constants

GLOBAL CONSTANTS
Global constants apply across all data sets and are saved as part of a workbook.
They are available for all math channels.
Examples of constant values: Tyre dimensions that do not vary between outings are
defined as global constants.

OUTING CONSTANTS
Outing constants apply only within one outing and are saved as part of a data set.
Examples of constant values: Track temperatures that may vary between outings are
defined as outing constants.

SIMPLE CONSTANTS AND EXCEL CONSTANTS

There are two constant variants:
• Simple constants: These are defined as a numerical value.
• Excel constant: These constants source their values from an Excel cell.
When calculating math channels containing the constant, the value is retrieved from
a spreadsheet cell, e.g. a component value in the setup sheet. Specific actions can be
performed in Excel before the cell value is retrieved, e.g. the execution of a macro.

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Constants management

Global constants and outing constants are defined in the Constants Editor.
The scope of the constant depends on where in the editor the value is entered.
To open the dialogue field, use the following path: Tools > Constants > Edit

This icon adds a default name for a new constant to the constants list.

This icon deletes the constant highlighted in the constants list.

NAMES
The constants existing for the current workbook or for an outing contained in the workbook
are listed in the Names column.
▶ Double-click the default name of the constant and enter a new name.
GLOBAL
A constant value entered here will create a global constant.
▶ Double-click field Global and enter a new value.
OUTING
The columns following Global represent the outings currently loaded in the workbook.
A constant value entered here will create an outing constant.
▶ Double-click field Outing and enter a new value.

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Excel constants

The Constants Editor expands when button More is pressed. These commands are used to create Excel constants.
The left window shows the details of the constant currently highlighted in the main window of the dialogue.
▶ In the input field Type, select Excel and enter the name of the Excel workbook to be used to create an Excel constant.
▶ Enter the cell address of the cell containing the constant value into field Cell, making sure that the default Excel format is used.
Excel cell:
▶ Enter the position of the cell containing the constant value; the position is provided in
the form: Name of the sheet! A1 or A1, (column letter, row number).
Excel file:
Opens a dialogue window for the search for an Excel file.

Command:
The right-hand window provides further command and argument options. The commands
are enabled every time the Porsche Toolbox tries to retrieve a value from a cell before the
value is read. It is possible to add any number of commands; the sequence can be changed
using the arrow-up/down keys.
▶ Right-click the Commands column to add a command from the available list.
▶ Enter Commands directly into the fields.
The following commands are available:
• Move to Sheet: Enables an Excel sheet (argument: sheet number)
• Execute Macro: Executes an Excel macro (argument: name of the Excel macro)
• Set Cell Value: Defines a value in a cell in the active Excel workbook
(argument: A1 = value).

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6.14 Porsche Toolset

Always load the latest version of the Cosworth software 'Porsche Toolbox' from PMRSI ("Porsche
Motorsport Racecar Service Information" Portal (PMRSI) at https://motorsport.porsche.com).

6.14.1 Connecting the vehicle

The Porsche Toolset and the devices from Cosworth Electronics communicate via Ethernet.
▶ Connect the download cable to the diagnostics port of the vehicle and to the Ethernet port of the computer hosting the Porsche Toolset.
▶ Antivirus and firewall software can block the Toolset from detecting devices. It is best to turn them off to ensure smooth operation.

Establishing the Ethernet connection

When the computer is connected to a vehicle for the first time, the Ethernet port must be
configured with the correct IP address. This can be done via the Porsche Toolset as follows:
1. Open the Porsche Toolset.
If the Toolset shortcut is not found, enter Porsche Toolset in the Windows Start menu.

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2. When the Porsche Toolset is open, navigate to the grey tab Settings on the right end of
the toolset window.

3. Tab Settings shows all available adapters connected to the computer in

option Network.
▶ Select the adapter used to connect the vehicle, and click button Use Selected Adapter.

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4. Click Yes when the prompt asks you to permit user account control.

5. Click OK when the Porsche Toolset shows the message Update Successful.
The configuration may take several minutes.

Reverting ethernet adapters

Reverting the Ethernet adapter used by Toolset to its original setting can be done via the
Restore button at the bottom the “Network” page.

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Alternatively, the adapter can be reset manually vie the following process:
1. Navigate to Control Panel\All Control Panel Items\Network Connections on the PC
2. Right click on the Ethernet Adapter being used by Toolset and navigate to properties.
3. In properties, under Networking double click on Internet Protocol Version 4.

The TCP/IPv4 settings will show the IP address and subnet mask set by Toolset for the
adapter. This can be changed manually or the “Obtain an IP address Automatically” tick box
will allow the PC to pick up an IP address automatically form a network when connected to
the Ethernet port.

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6.14.2 Adding devices

Cosworth devices must be added to the software before they can be addressed in the toolset.
Proceed as follows:

1. Select tab Device.

2. Click the button shown to add a device.

Devices visible to the Porsche Toolset are shown in the menu displayed.
3. Select a device in the menu and click Add to add this device.

4. Select the device and click Activate to start interacting with it.

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6.14.3 Auxiliary devices

Auxiliary devices do not contain Toolset setups and are configured through the setup on a
main device. When an Auxiliary device is detected by Toolset it is shown in the Devices tab
automatically – displays like the CDU10.3 are such devices.
To send a setup to a main device that contains and auxiliary device configuration the two
devices need to be associated with each other.

▶ To do this select the Auxiliary device and using the “Edit Device Properties” button
associate it with the correct CHP device - Badenia 3xx SN #0 in the example below.

When the button is pressed to confirm the association the auxiliary device - CDU10.3 in
the example - will go through a soft reset (can take ~20s) after which it will show as associ-
ated with the Badenia while the Badenia will show as having one Auxiliary device.

Attempting to send a setup that contains a display configuration to a main device – in the
below example the Badenia 3xx - that does not have a display associated with it will throw
the following warning. If the setup send is continued the main device will be updated with
the setup but the CDU10.3 display will not be until a setup is sent with the two associated
and connected.

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6.14.4 Importing/exporting setups

There are two methods of importing setups into the Porsche Toolset.

Importing from a file

1. Navigate to tab Setups.
2. Click button Import.
3. Navigate to the memory location where the toolset setup is saved.
4. Select the setup and click Open.
→ The setup should now be shown under Existing Setups; it is highlighted by default.

Importing from a connected device

1. Navigate to tab Devices.
2. Select the device on which the setup is to be executed.
Make sure that this is the Active Device. It is indicated by a tick in the upper right corner
of the device selection.

3. Navigate to tab Setups.

4. Click button Read from Active Device.
→ The setup originally existing in the device is now shown under Existing Setups
and is highlighted by default.

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6.14.5 Shift lights

The node controls the split shift light pattern in the instrument panel.

Shift light table

This is a 2D table where each row represents a gear and each column an
LED pattern. Each cell in the table represents a different LED pattern, and the value in each
cell represents the engine speed at which this pattern becomes active.
▶ The number of different patterns can be increased or decreased by clicking + or the
waste bins; the engine speed thresholds are changed by clicking into the individual
cells and entering a number.

LED pattern

A visual representation of the shift lights in the instrument cluster is shown below the 2D
table. Each cell in the 2D table has its own LED pattern which is shown when the cell is
selected by clicking it.
▶ The patterns of the individual cells can be changed by first selecting the cell in the
table and then clicking the circles to turn these green = On or black = Off.

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6.14.6 Sensors

The sensor node is used to set up and calibrate all analogue (AIN) and digital (DIN) inputs
of the device. Virtual inputs can be shown as well. These are AIN voltages DIN states
communicated via the CAN and which are, in terms of calibration, handled in the same way
as physical inputs at the device.
To display the submenus Input Sensor Pairs, click the corresponding dropdown menu.
These submenus are split in two halves. On the left, the physical input pin is shown together
with some additional information, the sensor calibration is shown on the right.
▶ To add a sensor calibration to an input, navigate to button Import and then click
Import Individually.
The following popup menu contains a number of sensor-dependent functions.
It also shows the sensor calibration exported beforehand.
▶ Select a sensor and click Import.
→ The selected sensor is shown in submenu Input Sensor Pairs as connected to the
input; with the sensor calibration menu filling the previously blank area on the right.

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Analogue inputs

The toolset offers three types of analogue sensors.

These are explained in the following table:

Sensor type Usage

Analogue push button sensor A push button used to set the shift voltage
threshold.
It creates a button-channel bit field
with 8 states.
Analogue voltage sensor Standard 0-5V sensors.
Most commonly used sensor.
Switch sensor 0-5V sensor for rotary switches with
discrete positions.

Analogue push button sensor

• Sensor name
– Is used when the sensor calibration is exported.
• Button name
– This is the name of the bit field channel created by the sensor.
It is additionally provided with a Button suffix.
– The example shows button AIN_3.
• Button mode
– This mode determines whether the switch is normally closed or normally open
when not activated.
• Button threshold
– The voltage to be handed over for the button activation to be registered (0-5V).

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Analogue voltage sensor

SENSOR PROPERTIES

• Sensor name
– Is used when the sensor calibration is exported.
• Sensor termination
– Some AINs permit a pull-up termination. The termination available is shown at the
input pins in the submenu of the input sensor pairs.
– To establish a termination, select the termination type and manually enter the
termination value.

CALIBRATED AND NON-CALIBRATED CHANNELS

• Calibrated channel
– Name – property defines the output channel of the sensor calibration.
– Quantity – defines the quantity into which the sensor calibration converts
the 0–5V input voltage.
– Data Type – defines the data type the calibrated channel will assume.
• Uncalibrated channel
– Name – is set if an identical channel with the same name is created.

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SENSOR CALIBRATION
Overview of the calibration interfaces:

• Area 1 – the unit into which the input voltage must be converted, must be selected
at the top.
– The available units depend on the quantity selected in section Calibrated Channel.
• Area 2 – there are three calibration types that can be applied to an AIN: Coefficients,
Gain & Offset and Lookup Table.
– This area also shows the linear sensor equation.
• Area 3 – while working on the calibration, the generated linear sensor curve is shown
in real-time on the right.
– When the device is connected to the toolset and active, a purple crosshairs cursor
is shown that indicates the sensor voltage present at the input. This facilitates the
verification and calibration of the functionality.

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Calibration types:

• Coefficients:
– Provides a table that can be used to create an equation of multiple orders by adding
new rows of which each correlates with an order in the calibration equation.
– Each order and each multiplier can be changed by clicking into the table cells.
– The calculated sensor curve is shown on the right next to the calibration table.

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• Gain & Offset:

– Simple gain & offset values can be entered.
– Checkboxes for inverted gain values
– Tick the checkbox to apply offset prior to gain.

• Lookup Table:
– The most versatile calibration option.
– Defines the voltage and the calibrated sensor points in the table.
– Facilitates extrapolated, intrapolated or sample & hold methods for the determination
of values between defined calibration points.

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Digital inputs

For Cosworth devices, digital inputs are divided into three classes. The inputs can be
configured as one of three classes in node Hardware Settings under Digital Inputs.

Level DINs

This DIN type facilitates the calibration of digital input sensors connected to the input pin.
As with its analogue counterpart, a prefix is created for the Name of the created button bit
field channel.

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Beacon DINs

Input pins set for the beacon type cannot be assigned to a sensor. Instead, these pins can
be selected in the setup in node Beacon to specifically interact with Cosworth IR beacon
receivers.

The settings for the beacon can be made in the Parameter node.

Pulse DINs

The pulse inputs accept digital rotation sensors or sensors of type Df11i.
DIGITAL ROTATION SENSOR

• Facilitates the use of active as well as passive Hall-effect sensors.

• The output channel is provided in RPM.
• Configurable pulses per rotation permit customer-specific decoding plates.

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DF11I ROTATION SENSOR

• Decoded Df11i rotation sensors able to identify the sense of rotation.

• The output channel is provided in RPM.
• Configurable pulses per rotation permit customer-specific decoding.

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6.14.7 GPS beacons

Using GPS map coordinates it is possible to create a start finish lines that can be used to generate beacon events within Toolset.

GPS beacon from online maps

Using any online map, it’s possible to define a GPS start/finish line within Toolset.
For the purposes of this example Google Maps* was used to define a start line for Silverstone GP circuit.

1. Using Google Maps* navigate to the Silverstone main straight and zoom in as close as
possible on the start line.
Clicking on anywhere on Google Maps* brings up the coordinates of the clicked
location.
2. To define a “Start Finish” line click either side of the racetrack and note down the
coordinates of the two points. The line drawn between these points will define the
“Start Finish” line.
3. Make sure the defined line is substantially wider than the track width to account for
potential GPS drift from the on-car GPS receiver.

▶ To allow the use of GPS Beacons the receiver type needs to be changed to GPS Beacon
receiver in the Beacons node.

4. Under the Beacon Location enter the coordinates for the two points.

*Google Maps is a trademark of Goolge LLC.

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GPS Beacon start/finish line from Google Earth*

Using Google Earth*, it is possible to create a start finish line that can be used to generate beacon events.
The following will guide you through this process:

1. Download Google Earth*.

2. Open Google Earth*.
3. Right click on My Places.
4. Navigate to Path via Add.
→ The Edit path window appears.
5. Enter the name for your "Start Finish Line".
6. Using the mouse draw the start finish line as you wish it to be used.

This line (red) should completely cross the track in the are you need. A beacon will be
triggered every time this line is crossed.

*Google Earth is a trademark of Google LLC.

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You can add multiple "Start Finish" lines to a single file is the circuit in question has
multiple.

Once you have created your "Start Finish" line you will need to export it:
▶ Right click on the path and click Save Place As.

It is important that you select the *.kml file format that is available with the drop-down box.
Once you have created you "Start Finish" .kml file this can be imported into Toolset using
the Beacons Tab.

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▶ Select the following beacon type: GPS Beacon Receiver

▶ You can then import your .kml file using the import button beside Track Name.
▶ Once you have added the track you will be able to select the Beacon, if you have added
multiple paths to a single .kml you will be able to select the one you want from the drop
down menu.

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6.14.8 Toolset actions

Actions are available in the “Your Porsche” tab that allows direct interaction with connected & activated devices. Changes made through “Actions” are held
on the device outside of the setup meaning they will not be affected by a send setup, as such any changes you make must be written to the device for them
to take effect.

Qualifying Mode

▶ To configure QM the target device needs to be connected and activated. Once

connected “Your Porsche [1] followed by the QM Node [2] needs to be selected.

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Auto learn

Learning Mode defines what the QM is learning.

▶ The Distance Based -Auto mode needs to have the following parameters configured:
LEARN FASTEST LAP:
With this format selected the QM will look to learn the fastest lap and hold this as the QM
reference lap. This lap will be updated if a new fastest lap is achieved.
LEARN FASTEST SEGMENT:
With this format selected the QM will look to learn the fastest segments and uses them to
create a theoretical fastest lap to use as the QM reference lap Each segment will be
updated if a new faster segment is recorded.
SEGMENTS:
This allows you to choose how many segments you want the track split into. This can be a
number between 2 and 128. The more segments you add the faster the QM generated
channels will be updated.

Once the QM mode has been configured the settings should be written to the device. The
setting needs updated and re-written to the device every time the car goes to a new track.
The above configuration takes place the device is waiting to learn the track and the channel
"QM Status" will show the state "Quiescent".

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For the device to learn the track the following must occur:
– Complete an out lap (Pit box to End of Lap beacon).
– 1 full lap, the first full lap is the Initial learn lap. On this lap the QM app will look to learn
the distance of a lap, EOL to EOL.
– A second full lap. This is the Distance check lap. On this lap the QM app compares the
distance of the Initial Learn Lap (item 2)(EOL to EOL) to the last completed full lap
(EOL to EOL).
– If the distance of the Distance check lap is within 5 % of the Initial Learn Lap, then the
QM app will automatically split the lap into the number of segments defined and start
to show the information as required.
– If the distance of the Distance Check lap is NOT within 5 % of the Initial Learn Lap,
then the QM app will repeat the distance check lap. This will continue until 2 consec-
utive laps are within 5 % of each other.
During each of these stages the QM Status channel will display the current state that
it is operating under.

PDS file reference

The PDS File Reference QM format uses a lap in a previously recorded Toolbox data set (PDS) as a reference lap.

Configuration:
• Select Distance Based - PDS Reference mode.
• Navigate to the chosen PDS file, the file properties will be displayed for reference.

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• Select which lap to use as a reference.

Note the red flag denoting the fastest lap.

• Learning mode can be configured as per the other qualifying mode options.
– Initial segment times, uses only the time from the reference lap and does not learn any
new faster laps or segments.
– Learn fastest lap, updates the reference lap only when a new fastest lap is recorded.
– Learn fastest segment, updates each individual segment if a faster segment is
recorded and creates a theoretical fastest lap.
• Segments allows you to choose a number of segments from 2-128. Note that a 128
segment lap more or less updates continuously.
• Finally write the settings to the device.

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QM file reference

The Distance based - QM File Generation format uses a QM file generated in Toolbox as a
reference lap. Each segment can be of a different length which allows matching official
track sectors.
▶ Generating a QM file.
▶ A track map needs to be created from the dataset and cast on a Map display.
▶ Right clicking the map choosing "Edit Map" [1] and right click a chosen segment and
choose "Insert Split Beacon" [2].
▶ Once all split beacons are inserted click the map again and choose "Edit – Done”.

Now that the splits have been completed the QM file can be generated.
▶ Right click on a Time/Distance display control and select "Export->Qualifying Mode"
[1].

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▶ Select Soft Splits to make the splits visible.

▶ Select a location and name for the QM file.

This file can now be imported into Toolset and used as a reference lap, the same informa-
tion as in the Distance based - PDS reference lap is displayed apart from that there is only
one lap selectable and the number of segments is fixed to the number defined in the QM
file.

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Custom segments

Custom segments allow for custom distances to be defined in QM without the need to
produce a QM reference lap in Toolbox. This can be helpful when setting up QM mode on a
track without previous data available.

Split Beacons

Split Beacons QM mode is only available for use if Split Beacons have been configured in
the Beacons Node in the Toolset setup that’s on the device.

Once this is done the splits will appear in the QM actions as table. Each segment can have
its own target time entered separately while the cumulative target lap time is displayed on
the rightmost column.
▶ After the target times have been entered the setting can be written to the device.

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Zeroing

Zeroing is can accessed by clicking on the “zeroing” icon in the “Your Porsche” tab in
Toolset. Each Zeroing group set up in the Toolset setup can be zeroed here manually while
connected to the device.
Selecting a zeroing group on the left - Susp travel in the above example - and pressing the
zeroing button [1] will zero all the sensor values in the group to the target values set up in
the Toolset Setup. The zeroing can be reverted with the Clear Zeroing button [2]. Zeros are
stored on the device and persist over a setup send but not a firmware update.

Changing outing and lap numbers

Custom outing and Lap numbers can be set under the “lap” icon in “Your Porsche” which
will take effect starting with the next logged outing.
Clicking on the icon will present the following interface.
To change the Outing and Lap numbers for the next logged outing the corresponding tick
boxes need to be ticked, custom values entered into the value boxes and the values need
to be written to the devices using the tick button highlighted in the example above.

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Logging

Under the “tape” icon the logging state of the currently active device is displayed, and the
device can be forced to log or if its currently logging the process can be forced to stop using
the highlighted buttons in the example below.
This can be very helpful when trying to work on the car in the pits as logging can be initiated
without having to turn the engine on.

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6.14.9 Downloading data

The Porsche Toolset facilitates the definition of user-defined file names and data library structures when downloading data.

PDS designation and structure of data library

These parameters are shown in tab Settings in submenu Data Offload.

In the first area Offload Paths, Root Path and Relative Path can be defined.

Root Paths:
The folder defined here contains all data downloaded from the toolset client.
It contains structure Relative Path.
Relative Path:
Regarding the structure, the relative path exists within the folder defined in the root path.
The Porsche Toolset offers a great number of relative offload path properties that can be
used to create subfolders or .pds file names in accordance with user requirements.
The properties can be displayed by clicking the button shown on the right of the relative
offload path.

Each property can be used either for the folder structure or the designation of files and
must be enclosed by angle brackets (< >).
Using (\) creates new folders, with all characters preceding .pds being used in the file
name. The preview row can be used to verify the structure entered.

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Offload conditions

This area is used to configure general offload settings.

• Short outings – anything shorter than the period defined in the automatic offload
setting. By default, this is anything shorter than 60 s.
• Deleted outings are only marked as to be deleted and are then no longer displayed in
the Data tab. They are not deleted until a new outing log is started. This means that
in the case of a defective offload, the outings can be viewed and offloaded again if option
Show deleted outings still on device is ticked.
• Here, the automatic deletion of outings can be configured. When the offload is
successful, the Porsche Toolset automatically highlights an outing for deletion.
• Here, the default setting for the automatic offloads can be enabled. If a variation is
required, it can be changed for each device in tab Devices.

To apply the change, click Save in the right bottom corner of the page.

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Offload data

Connected devices are shown in tab Data, with each output available for offload on the
device being visible.

Button Settings at the top edge of the window sets the global Track Name and
Session Number for all outings offloaded from the toolset client.

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Car Name and Driver Name can be set for each device in tab Devices. The names defined
at these two points are used to specify the Relative Folder Path in the settings. Tab Devices
can be used to also enter short and long comments for each device. These are shown for
each outing created by this device in the Porsche Toolbox in section Comments.

All data can be changed individually for each outing in tab Data by selecting an outing and
changing the settings on the right-hand side prior to the offload.

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Individual outings can be downloaded by clicking the arrow within an outing; all outings can
be selected for download by clicking button Download all at the top of the page.
While a download is in progress, a download bar is shown above the outing.
A green tick indicates that the outing has been successfully offloaded.

As soon as an outing has been offloaded, the file path for the outing is shown at the bottom
in window Outing settings.
Clicking the button will copy the outing's entire file path to the clipboard. This path must
be pasted to replace the file name in order to add the outing to a toolbox task.

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6.14.10 Working with live data

In tab Live Data, users can view real-time values for all channels of "active" devices at the moment at which the device is connected to the toolset client.
Channels available via telemetry can be displayed here as well.

The tab may have several pages that can be added by clicking the + button at the top right.
The page names can be edited by clicking the default page name. Pages can also be
imported and exported to facilitate the transfer between toolset clients.

There are 4 types of displays that can be added. Live Data, Channel Lists Outing Reports,
Map Controls and Chart Recorders can be added to the diagram recorders. To add a display
to the page, open the editing options of the page by clicking Toggle edit mode in the left
upper corner of the page.

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To add channels, click the Wrench icon in the left upper corner. This action opens popup
menu Settings where channels can be added and display options be configured.
The list Available channels on the right-hand side contains all channels on the active
device, while the Displayed channels contains all channels available on the display.
Channels can be moved between the two lists by selecting them and then using the
arrow buttons. The lists also have a search function. To use it, click the list and then enter
a channel name.

Channel Lists:
• Any channel can be added and shown as a simple value or a bar graph.

• Bit field channels are shown as graphs and not with their decimal values.

Map Control:
• Maps generated with and exported from the Porsche Toolbox can be imported here.
Tubular Outing Report:
• Messages created by node Telltales in the setup can be displayed.

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Chart Recorder:
• Scalable chart with the X-axis showing the time and the Y-axis showing the
channel value.
• 4 channels per diagram and 4 charts per live data page are available.

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 ELECTRIC SYSTEM | Porsche Toolset

6.14.11 Telemetry

Within the Cosworth system, the telemetry is shown in the following flow chart.

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 ELECTRIC SYSTEM | Porsche Toolset

The connection between device and telemetry radio can be established either by serial
data stream or via UDP Ethernet. The connection between telemetry receiver and toolset
client can be realised via any serial or Ethernet protocol.
The primary toolset client is the one that sent the setup to the device. Telemetry data
streams created by Cosworth devices are encoded for security reasons and can only be
decoded by the toolset client that sent the setup to the device.
The telemetry system must be configured at two points.
The sender is configured in the device setup, while the receiver is configured in submenu
Telemetry in tab Setting of the Primary Toolset Client.
Adding a telemetry table to a toolset setup using the + button in node Telemetry creates
an option field on the right of the table and a new rates table in node Channel Rates.
The channel rates selected in the table of created rates define the rate at which the channel
data are transferred via telemetry. Channels without a rate are not transmitted.
The selection of option Custom Serial Telemetry or Ethernet (UDP) Telemetry in the
dropdown menu shows various output settings. There are also pre-configured serial
streaming options facilitating the use of standard Cosworth telemetry radio devices.

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 ELECTRIC SYSTEM | Porsche Toolset

When a serial data stream is selected, the necessary serial interface as well as baud rate
and data bits must be selected.

If data are transmitted to the telemetry radio via Ethernet, IP address and port number
must be configured.

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 ELECTRIC SYSTEM | Porsche Toolset

On the toolset page, the telemetry is configured in tab Settings in submenu Telemetry.
When adding a source, an option interface similar to the one in node Telemetry is shown in
the setup. It is mandatory that the settings are identical with the settings the telemetry
receiver uses to transmit data to the toolset client.

The system provides a telemetry source option for toolset servers. This is used to connect
toolset clients to the Primary Toolset Client. The remote location should be defined as the
IP address of the PC hosting the Primary Toolset Client, whereas the port number should
be the one set for the shared use of the telemetry for toolset clients.

The server settings can be configured under the source settings. There are separate port
options for the shared use of data between other Porsche Toolset clients and
Porsche Toolbox clients.

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 ELECTRIC SYSTEM | Porsche Toolset

There are options for the resetting of the data stream when the outing number changes.
If historic telemetry data are ticked in the toolbox, these will be lost when the outing
number changes.
The option of routing telemetry data via Ethernet means that the telemetry rates table is
transmitted to the toolset instead of all channels being made available in the live data.
The Porsche Toolset can also log received telemetry data. Logged telemetry data use the
same file structure as created for the standard data offload.
The relative offload path property Source can be used to differentiate .pds files saved by
the telemetry system.

6.14.12 Troubleshooting
Connection to device cannot be established:

1. Make sure the device is correctly connected to the Ethernet port of the PC.
a. The LED activity indicators at the Ethernet port must flash.
b. Make sure the correct Ethernet adapter shows status Connected in system
Control Panel\All Control Panel Items\Network Connections.
c. Perform a ping test by opening the command prompt and entering the following
command:
- ping 172.16.46.0 for Porsche logging devices
- ping 172.16.50.0 for Porsche Powerbox devices
→ Correctly connected devices respond within 1 – 5 ms.
2. Make sure that only one single instance of the Porsche Toolset is open.

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 ELECTRIC SYSTEM | Porsche Toolset

Setup transmission or firmware update error:

The transmission of setups is occasionally blocked by antivirus software and firewalls.

▶ Make sure that these are disabled.

No live data available:

1. Make sure the device is connected.

2. Make sure the connected device is the active device shown in tab Devices.
3. Make sure that the option for the forwarding of telemetry data via Ethernet is not ticked
in the Settings in submenu Telemetry.

Contacting the support:

When contacting the support for assistance with the Porsche Toolset, be sure to always
provide the latest toolset logfiles. These are created when closing the Toolset client and are
saved in the following path:
C:\Pi Research\Porsche Toolset\8.1\Logs

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 ELECTRIC SYSTEM | Radio

6.15 Radio

It is recommended to insert a 33 Ohm resistor between pin 9 (Speaker+) and pin 10

(Speaker-) to filter interference entering via the vehicle's electrical system.

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 ELECTRIC SYSTEM | Radio

6.15.1 Ground connection antenna

Since the roof panel is bonded to the body, there is no electrically conductive connection
to the body. If an antenna is to be attached to the roof, an earth connection must be made
from the roof to the body. For this purpose, an earth point in the form of a stud bolt [1] is
available on the body side.

6.15.2 Radio attachment

For fixing the radio, there are two screw-in points [1] for M6 x 20 screws on the right-hand
side of the centre tunnel.

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 ELECTRIC SYSTEM | Radio

6.15.3 Mounting antenna

It is recommended to align the hole for the radio roof antenna [1] centrally to the rear
window (see Fig. 85). If a GPS antenna and a radio antenna are to be installed, they must
be mounted on the side of the roof (see 6.15.4 Installation GPS and Radio Antennae
on page 978).

As this is an aluminium roof, it is recommended that a strip of copper tape [1] at least 5 cm
wide is placed under the roof (see Fig. 86).

Fig. 85: Alignment antenna

Fig. 86: Copper tape

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 ELECTRIC SYSTEM | Radio

6.15.4 Installation GPS and Radio Antennae

Only implement the following instructions if both systems (GPS and radio) are fitted.

1. Measure and mark mounting position.

2. Drill a Ø12 mm hole for the radio antenna.
3. Drill a Ø16 mm hole for the GPS antenna.

4. Insert the antennae through the hole from the outside and fasten with nut.
5. Connect the radio antenna to the wiring loom.
6. Connect the GPS antenna to the existing wiring loom.

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 ELECTRIC SYSTEM | Radio

6.15.5 Radio Equipment Directive (RED) - TPMS

The certificates are attached to the end of the chapter.

Radio Equipment in accordance with 2014/53/EU

Declaration of conformity

Your car is equipped with different radio equipment.

The various radio equipment manufacturers declare that their radio equipment complies with the 2014/53/EU statutory requirements according to their
applications.

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 ELECTRIC SYSTEM | Radio

Technical Data Specification – Control Devices/Antennae (BF24G1CE)

Information Value
Power supply Car battery – supply cable current limited to maximum 3 A
Operating voltage 6.5 V - 18 V
Current – CAN bus not connected 40 mA
Current – CAN bus connected 20 mA
Operating temperaturer 0 °C to+105 °C
RF frequency range 2.4 GHz - 2.8 GHz
Number of channels 40
Channel width 2 MHz
RF Power 2 mW
Type of modulation Gaussian frequency shift keyring (GFSK)
RF data rate 1 Mbps
Antennae type Inverted-F antennae
Antennae amplification 2.9 dBi
CAN bus data rate 1 Mbps
IP rating IP6K7
Dimensions 130 mm x 70 mm x 30 mm
Weight 80 g

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 ELECTRIC SYSTEM | Radio

Technical Data Specification - Sensor (TP24G1WE)

Information Value
Power supply Integrated battery, 3 V, Lithium
Current RF transmission Peak value 13 mA
Quiescent current 5 uA
Operating temperature 15 °C to+125 °C (with brief peaks of maximum 150°C)
RF frequency range 2,4 GHz - 2,48 GHz
Number of channels 40
Channel width 2 MHz
Transmission power 1 mW
Type of modulation Gaussian frequency shift keyring (GFSK)
RF data rate 1 Mbps
Message rate max. 5Hz (subject to customer configuration)
Antennae type Integrated SMT antennae with metal mounting bracket
Antennae amplification max. -10 dBi
Dimensions 48 mm x 32 mm x 23 mm
Weight 15 g

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 ELECTRIC SYSTEM | Radio

Radio Equipment Outside the EU

Characteristics and declaration of conformity

AUSTRALIA

BELIZE

JAPAN

Certificate No.
2021076/01
2021077/01

Japanese Radio Law Compliance.

This device is granted pursuant to the Japanese Radio Law. This device should not be
modified (otherwise the granted designation number will become invalid).

HONG KONG

HKCA 1035: Vehicle radar: Radio equipment exempt from licencing.

HK21020781
HK21020782

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 ELECTRIC SYSTEM | Radio

UNITED STATES OF AMERICA

This device complies with part 15 of the FCC regulations & guidelines.
Operation is permitted subject to following two conditions:
(1) This device must not cause any harmful interference.
(2) This device must accept all received interference, including interference that can cause
undesirable operation. Changes or modifications made to this device, which are not
officially approved by the manufacturer, can lead to termination of the FCC authorisation
for operation of the device.
Information regarding exposure to high-frequency radiation:
The radiated output power of the device is far below the FCC threshold values for radio-
frequency radiation. However, the device must be used in such a way that the potential for
human contact during is minimised during normal operation.

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 ELECTRIC SYSTEM | Radio

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 ELECTRIC SYSTEM | Radio

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 BCPL SDoC_2933-02

V7,12/2022
Supplier’s declaration of conformity

As required by the following Notices:

x Radiocommunications (Compliance Labelling - Devices) Notice 2014 made under section 182 of the Radiocommunications Act 1992;
x Radiocommunications Labelling (Electromagnetic Compatibility) Notice 2017 made under section 182 of the Radiocommunications
Act 1992;
x Radiocommunications (Compliance Labelling – Electromagnetic Radiation) Notice 2014 made under section 182 of the
Radiocommunications Act 1992; and
x Telecommunications (Labelling Notice for Customer Equipment and Customer Cabling) Instrument 2015 made under section 407 of
the Telecommunications Act 1997.
Instructions for completion
Do not return this form to the ACMA. This completed form must be retained by the supplier as part of the documentation required for the compliance records and
must be made available for inspection by the ACMA when requested.
Supplier’s details
Company Name (OR INDIVIDUAL) RCM Responsible Supplier number

Braco Compliance Pty Ltd E304

Street Address (Australian) OR

Unit 308, 469-481 High St ACN/ARBN

Northcote, VIC 3070 84156023504

Product details
Product description – brand name, type, current model, lot, batch or serial number (if available), software/firmware version (if applicable)

Sensor ECU
Model Type Ref. TP24G1WE Model Type Ref. BF24G1EC
Description 1SYSTEM TPMS Wheel Sensor Description 1SYSTEM ECU Lite (Type G1)

911 GT3 Cup (2021–2023)

Compliance – applicable standards and other supporting documents
Evidence of compliance with applicable standards may be demonstrated by test reports, endorsed/accredited test reports, certification/competent body statements.
Having had regard to these documents, I am satisfied the above mentioned product complies with the requirements of the relevant ACMA Standards made under the
Radiocommunications Act 1992 and the Telecommunications Act 1997.
List the details of the documents the above statement was made, including the standard title, number and, if applicable, number of the test report/endorsed test
report or certification/competent body statement.

Radiocommunications (Electromagnetic Compatibility) Standard 2017, refer Element Materials Technology Warwick Ltd.
EN 61326-1:2013 test report No. TRA-049589-35-00C dated 3 October 2020.
Radiocommunications (Short Range Devices) Standard 2014, refer Element Materials Technology Warwick Ltd.
ETSI EN 300 328 v2.2.2 test report Nos. TRA-049589-47-00C dated 5 October 2020 and TRA-049589-47-01B dated
30 September 2020.
Radiocommunications (Electromagnetic Radiation – Human Exposure) Standard 2014, refer Element Materials Technology
Warwick Ltd. EN 62479:2010 certificate No. TRA-049589-47-02B dated 30 September 2020.
Declaration
I hereby declare that:
1. I am authorised to make this declaration on behalf of the Company mentioned above,
2. the contents of this form are true and correct, and
3. the product mentioned above complies with the applicable above mentioned standards and all products supplied under this declaration will be identical to
the product identified above.
Note: Under section 137.1 of the Criminal Code Act 1995, it is an offence to knowingly provide false or misleading information to a Commonwealth entity.
Penalty: 12 months imprisonment

Bruce Maule
Director
15 January 2021
The Privacy Act 1988 (Cth) (the Privacy Act) imposes obligations on the ACMA in relation to the collection, security, quality, access, use and dis closure of personal information. These obligations are detailed in the Australian
Privacy Principles.
The ACMA may only collect personal information if it is reasonably necessary for, or directly related to, one or more of the ACMA’s functions or activities.
The purpose of collecting the personal information in this form is to ensure the supplier is identified in the ‘Declaration o f conformity’. If this Declaration of Conformity is not completed and the requested information is not provided, a
compliance label cannot be applied.
Further information on the Privacy Act and the ACMA’s Privacy Policy is available at www.acma.gov.au/privacypolicy. The Privacy Policy contains details about how you may access personal information about you that is held by the
ACMA, and seek the correction of such information. It also explains how you may complain about a breach of the Privacy Act and how we will deal with such a complaint.
Should you have any questions in this regard, please contact the ACMA’s privacy contact officer on telephone on 1800 226 667 or by email at [email protected]
ACMA form – C02 Page 1 of 1 January 2018
986
ELECTRIC SYSTEM | Radio
 ELECTRIC SYSTEM | Radio

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 ELECTRIC SYSTEM | Radio

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 ELECTRIC SYSTEM | Radio

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 ELECTRIC SYSTEM | Radio

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 ELECTRIC SYSTEM | Radio

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 ELECTRIC SYSTEM | Radio

2/18/2021 FCC - OET TCB Form 731 Grant of Equipment Authorization

TCB GRANT OF EQUIPMENT

AUTHORIZATION TCB
Certification
Issued Under the Authority of the
Federal Communications Commission
By:

Element Materials Technology Warwick Ltd

Date of Grant: 02/18/2021
Unit 1 Pendle Place
Skelmersdale, WN8 9PN
Application Dated: 02/18/2021
United Kingdom
bf1systems Ltd.
Technical Centre, Owen Road
Diss, IP22 4ER
United Kingdom

Attention: John Bailey , Managing Director

NOT TRANSFERABLE
EQUIPMENT AUTHORIZATION is hereby issued to the named GRANTEE, and is VALID ONLY for the equipment identified hereon for use
under the Commission's Rules and Regulations listed below.

FCC IDENTIFIER: USX-BF24G1EC

Name of Grantee: bf1systems Ltd.
Equipment Class: Digital Transmission System
Notes: 1SYSTEM ECU Lite (Type G1). Model BF24G1EC
Frequency Output Frequency Emission
Grant Notes FCC Rule Parts Range (MHZ) Watts Tolerance Designator
15C 2402.0 - 2480.0 0.0014

Output power is conducted.

https://apps.fcc.gov/oetcf/tcb/reports/Tcb731GrantForm.cfm 1/1

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 ELECTRIC SYSTEM | Radio

2/18/2021 FCC - OET TCB Form 731 Grant of Equipment Authorization

TCB GRANT OF EQUIPMENT

AUTHORIZATION TCB
Certification
Issued Under the Authority of the
Federal Communications Commission
By:

Element Materials Technology Warwick Ltd

Date of Grant: 02/18/2021
Unit 1 Pendle Place
Skelmersdale, WN8 9PN
Application Dated: 02/18/2021
United Kingdom
bf1systems Ltd.
Technical Centre, Owen Road
Diss, IP22 4ER
United Kingdom

Attention: John Bailey , Managing Director

NOT TRANSFERABLE
EQUIPMENT AUTHORIZATION is hereby issued to the named GRANTEE, and is VALID ONLY for the equipment identified hereon for use
under the Commission's Rules and Regulations listed below.

FCC IDENTIFIER: USX-TP24G1WE

Name of Grantee: bf1systems Ltd.
Equipment Class: Digital Transmission System
Notes: 1SYSTEM TPMS Wheel Sensor. Model TP24G1WE
Frequency Output Frequency Emission
Grant Notes FCC Rule Parts Range (MHZ) Watts Tolerance Designator
15C 2402.0 - 2480.0 0.008

Output power is conducted.

https://apps.fcc.gov/oetcf/tcb/reports/Tcb731GrantForm.cfm 1/1

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 ELECTRIC SYSTEM | Transponder

6.16 Transponder

There are two screw-in points [1] with a screw-in thread in the wheel housing on the right-
hand side for attaching the transponder.

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 ELECTRIC SYSTEM | Options (ABS & TC)

6.17 Options (ABS & TC)

6.17.1 Licensing of ABS/TC

To enable the function, the chassis number and the ECU identifier must be stated directly when ordering parts.

1. Connect the vehicle to the Bosch RaceCon software (ECU = green).

2. Double-click MS6.6-ECU (left) and select Features info.

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 ELECTRIC SYSTEM | Options (ABS & TC)

→ The ECU identifier is displayed.

3. Select the ECU-ID and copy it.

4. Send the copied ECU-ID to the Porsche Motorsport parts sales department.

5. The Porsche Motorsport parts sales department returns an activation code (by e-mail).

6. Click the desired licence function (TC or ABS) and enter the activation code.

→ The licence is active.

7. Perform a power cycle (toggle main switch off and back on) before first use.

8. Enable the logging of the channel by the Porsche logging device via the Porsche Toolset
(SETUP).

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 ELECTRIC SYSTEM | Options (ABS & TC)

6.17.2 Antilock brake system (ABS)

NOTICE HIGH STRESS ON COMPONENTS
The brake master cylinders in an ABS-equipped racing car are subject to strong piston vibra-
tions due to the ABS return pump.
▶ Check the brake master cylinders regularly for function and tightness to ensure safety
and to prevent damage to the ABS unit.

NOTICE INSTALLATION OF WRONG SENSORS

Using a different brake pressure sensor will destroy the hydraulic unit. ABS M4 sensors are
not compatible with ABS M5 sensors.
▶ Only use the brake pressure sensor from the Porsche Motorsport parts catalogue.
▶ Before installation, fill the brake pressure sensor with brake fluid.

The antilock brake system prevents the wheels from locking up when braking hard, which may cause the driver to lose control of the vehicle.
The ABS logs faults in the memory. The ABS functionality is available from the Porsche Motorsport parts catalogue.
The function must be enabled once after its purchase using Racecon (not required for vehicles ordered with ABS).
The licensing procedure is explained in see 6.17.1 Licensing of ABS/TC on page 997.
The hydraulic unit is filled with brake fluid.
▶ Ensure that as little brake fluid as possible is lost during installation (see ABS hydraulic unit to bodyshell on page 395).
The 1 MBaud sensor is required for the system combination with the MS6 or MS7 ECU.
The ABS system will not work if another yaw rate sensor is installed.
▶ Make sure that the wheel brake line connections point upwards.
▶ Fit rubber bumpers/blocks to reduce vibration.
Leave a gap of 10 mm or more between the vehicle chassis and the underside of the mounting plate.

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 ELECTRIC SYSTEM | Options (ABS & TC)

Function test

After assembling the ABS system, a function test must be carried out before the first ride.
This function test ensures that all components (electrical and hydraulic) are correctly assembled and function properly.

b Vehicle is on the lifting platform and all four wheels are free to move.
b Second mechanic required.
b Assignment of the hydraulic connections on the hydraulic unit checked.

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 ELECTRIC SYSTEM | Options (ABS & TC)

1. Check communication between laptop and ABS M5 Porsche Cup Kit ECU.
2. Check wheel speed assignment:
▶ Turn all four wheels individually clockwise and check whether the assignment (front,
rear, left and right) is correct.
→ When the respective wheel turns, the corresponding value is displayed in the Race
ABS software under the "Test" tab.
→ This step is only to check if a signal is received from the ABS M5 Porsche Cup Kit
ECU.
3. Check hydraulic assignment:
▶ Have a second mechanic apply the brake pedal so that all four wheels are locked. A
brake pressure of 15 to 20 bar is sufficient.
Click on "Release brake" to release each wheel individually one by one.
→ The selected wheel should now run freely.
4. Check electrical pump motor:
▶ Click the pump button.
→ The pump motor should run for 10 sec. or until the button is clicked again.
5. Check brake pressure sensor and brake light switch.
a. Start RaceABS with connection to the MSA-Box II and press the brake pedal for a
few seconds with slowly increasing pressure.
→ The "Brake switch" bit of the digital display should switch from 0 to 1.
b. If the bit does not switch, check the pressure sensor.
The brake light switch is a function of the pressure sensor..
→ The digital display "Pressure sensor" should show a logical value.
If the software does not show a value or a logical value, open the "ECU Info" and
check the error memory. If one or more faults related to the brake pressure sensor
are found, go to the "ECU Info" (Diagnostic) section. For more information, go to the
ECU Diagnostic Fault section..
6. Check setting switch:
▶ Turn the switch one full turn (cycle through all 12 positions).
→ With each step, the number of measuring points should increase by 1.

The engine control lamp lights up permanently in diagnostic mode.

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 ELECTRIC SYSTEM | Options (ABS & TC)

ABS Repair and Bleeding

The bleeding assistant should be used to bleed the ABS M5 Porsche Cup Kit hydraulic unit.
Other parts of the braking system such as pipes and brake master cylinders MUST not be bled using bleeding assistant.
Ensure that the other brake system hydraulic components are bled before and after bleeding the hydraulic unit with the Repair and Bleeding Assistant (Repair
Bleeding Wizard).

▶ Open the “ABS Repair and Bleed” function in Toolset and implement the procedure on
both sides of the car(see Bleeding brake system (with ABS) on page 392).

Indicator Lamp

When the ignition or the ABS M5 Porsche Cup Kit is switched on, the warning lamp (MIL) glows briefly before going out. The lamp indicates that the self-
test procedure is active.
If the warning lamp (MIL) does not glow after the ignition or ABS M5 Porsche Cup Kit is switched on, the reason must be determined before further steps are taken
or before the car is driven.

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 ELECTRIC SYSTEM | Options (ABS & TC)

Error Memory

The ABS writes errors to the memory, which can be downloaded or viewed using the RaceABS (BOSCH software) when connected to the car via the MSA box
interface. In addition, the following channels assist with error analysis in the ABS:

• ABS_Malfunction
→ Bit 1 is displayed if the ABS control is deactivated by an error.
• ABS_Lamp
→ Bit 1 is displayed if the ABS control is deactivated due to an error.
• Diag_ABSUnit
→ Bit indicates whether an ABS error exists in relation to the hydraulic unit.
• Diag_FusePump
→ Bit indicates whether an ABS error exists in relation to the fuse or power supply
for the ABS pump.
• Diag_FuseValve
→ Bit indicates whether an ABS error exists in relation to the fuse or power supply
for the ABS valves.
• Diag_YRS
→ Bit indicates whether the yaw rate sensor functions correctly.
If an error exists, “1” is displayed.
• Diag_P_FA
→ Bit indicates whether the front axle pressure-sensor functions correctly.
If an error exists, “1” is displayed.
• Diag_P_RA
→ Bit indicates whether the rear axle pressure-sensor functions correctly.
If an error exists, “1” is displayed.
• Diag_FL/FR/RL/RR
→ Bit 0: Signal OK, Bit 1: Error wiring loom, Bit 2: Signal error
• Wheel Quality_FL/FR/RL/RR
→ Bit 5: „InvalidUnderVoltage“, Bit 4: „NotCalculated“, Bit 3: „ReducedMontitored“,
Bit 2: „Faulty“, Bit 1: „Normal“, Bit 0: „NotInitialized“

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Downloading / Viewing Error Memory

The MIL lamp glows as long as the diagnostic tool is switched on.
▶ Implement a system reset after an operational malfunction.
Operational malfunctions, e.g. due to a wheel speed sensor error, require an ABS M5 Porsche Cup Kit ECU reset (turn main switch off and on again).
▶ After resetting the system, accelerate the car to more than 12km/h to check the system.
SAVE THE ERROR PROTOCOL ENTRIES

If error protocol entries appear, which are not listed above, please contact a Porsche Partner or the OEM customer service. The communication is simplified
if a copy of the error protocol entries is also sent.
▶ Click on the “Save Faults” button on the right hand side to generate a copy of the error protocol entries.
DELETE ERROR PROTOCOL ENTRIES
▶ After solving the problem, click on the “Clear Faults" button to delete error memory protocol.
▶ Switch the ABS M5 Porsche Cup Kit off and on again.
→ The control lamp does not glow anymore when the software is deactivated.

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 ELECTRIC SYSTEM | Options (ABS & TC)

ABS Settings

The ABS controls the tyre slip during braking and can be adjusted by the driver via the ABS rotary switch. The recommended settings for various track
conditions are listed in the following table.

Einstellung Beschreibung
0 Off
1 Setting with later initial regulation and high slip values during ABS regulation
2 More stable front and rear axles due to earlier initial regulation, lower slip level than setting 1
3 More stable rear axle when braking in a straight line and especially when “trail braking” than setting 2
4 More stable front and rear axle regulation than setting 3
5 More stable rear axle regulation than setting 4, front axle regulation comparable with setting 3
6 More stable front and rear axle regulation due to faster pressure reduction than setting 5
7 Slightly more stable front axle regulation than setting 6
8 More stable front axle than setting 7 due to earlier regulation and lower slip level on the front axle
9 Wet conditions: earlier regulation and lower slip for more stable handling when grip is low
10 Wet conditions: more stable front axle for improved steering control and for slightly earlier rear axle regulation than setting 9
11 Rain setting: more stable front axle for better steering control than setting 10

Change between wet & dry

The ABS system must know, which tires are used on the car (wet / dry) to calculate with correct tire circumferences. If tires are being changed during a pit
stop, the driver must press the switch WET TYRE to set it correctly (white = dry / blue = wet). See 6.11.3 Overview of instrument panel on page 789.
If the change is forgotten during the pit stop, it can be set while driving, but the ABS must be reset to accept the change. Therefore set the WET TYRE to the
desired position, then hold the button for 3 s on the next occasion of driving straight with no brake pressure applied, as the ABS will reset for 3 s. In this time,
there will not be an ABS function. An overlay is shown to remind about the reset. See ABS reset on page 811.

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 ELECTRIC SYSTEM | Options (ABS & TC)

Mounting ABS wiring loom

Further information on the shoring of the hydraulic unit see 3.9.8 Brake hydraulics on page 394 and Brake lines to ABS hydraulic unit on page 397.

Fig. 87: Overview ABS wiring loom

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 ELECTRIC SYSTEM | Options (ABS & TC)

The ABS wiring loom is routed along the passenger compartment wiring loom and secured
by means of cable ties.

b Main switch [MAIN] and ignition [IGN] switched off.

b Battery disconnected.

▶ Mount the acceleration sensor [1] on the centre tunnel with the screws [2] and connect
it to the main wiring loom [3] on the vehicle side.
5 Nm

Fig. 88: Mounting of the acceleration sensor

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 ELECTRIC SYSTEM | Options (ABS & TC)

[1] Coupling point passenger compartment wiring loom

[2] Mounting ground point

9,7 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 1008

 ELECTRIC SYSTEM | Options (ABS & TC)

[3] Laying supply line

[4] Laying the diagnostic line

V7,12/2022 911 GT3 Cup (2021–2023) 1009

 ELECTRIC SYSTEM | Options (ABS & TC)

[5] Mounting part

[6] Bolts M3 x 8
1.2 Nm

[7] Fastening fuse (M4 x 14)

1.2 Nm
[8] Fastening supply line (nut M8)

10 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 1010

 ELECTRIC SYSTEM | Options (ABS & TC)

6.17.3 Traction control (TC)

The ECU includes a prepared, optional traction control that can be ordered separately.
Available from the Porsche Motorsport parts catalogue.
The function must be enabled once after its purchase using Racecon (not required for vehicles ordered with TC).
The licensing procedure is explained in see 6.17.1 Licensing of ABS/TC on page 997.
The traction control can then be enabled or disabled as required using the Porsche Toolset.
The intervention of the traction control can be adjusted according to track conditions, tyre grip level and driver preference.

Function description

24 control levels are available:

– 12 positions in DRY mode
– 12 positions in WET mode

The changeover between TC – DRY and WET is necessary in addition to the TIRE – DRY/
WET switch (tyre circumferences) as it allows an expanded intervention range,
e.g. by applying the WET intervention strategy while using slicks (rain setting in while
running dry tyres).
The gradation of the 12 positions is proportional to the TC intervention.
The lower the TC position, the later and softer TC intervention will be, permitting more
wheel slip (e.g. position 1 + 2 = qualifying with optimal
tyre temperature / pressure).
In terms of slip, modes DRY and WET overlap, with the torque reduction and release being
generally more aggressive in DRY mode than in WET mode. Position 0 disables the function
(DRY and WET mode).

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 ELECTRIC SYSTEM | Options (ABS & TC)

6.17.4 Logging on USB storage systems

Data is continuously stored on the inserted USB storage device while the engine is running.
If the storage device is removed while the engine is running, data may be lost.
▶ Only remove the storage device when the engine is switched off.

Configure USB storage

1. Launch PI-Toolset as administrator and connect the USB storage.

(For PAG computer: Only with Windows 10 and deactivated BitLocker).
2. Select the Data tab and click on Configure RLU.

3. Select the desired USB storage device.

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 ELECTRIC SYSTEM | Options (ABS & TC)

4. Confirm data deletion with Yes.

5. Click on + to add a new control unit.

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 ELECTRIC SYSTEM | Options (ABS & TC)

6. Select desired control unit and confirm with Select.

7. Adapt IP address (only if the IP address of the control unit was changed).

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 ELECTRIC SYSTEM | Options (ABS & TC)

8. If you would like to add a new unit, the steps as from step 5 must be repeated.

9. Change the storage location (Storage Allocation) as desired.

10. Confirm changes with Configure and wait until the USB storage device configuration
is complete.

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 ELECTRIC SYSTEM | Options (ABS & TC)

→ The USB storage device is now visible in the Pi Toolset under Data.

Download will function in the usual way as soon as the USB storage device contains data.

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 ELECTRIC SYSTEM | Video system

6.18 Video system

6.18.1 Function

The video system (Vbox from Racelogic) is configured so that it switches on when the main switch [MAIN] in the car is turned on.
The teams are responsible for ensuring that a constant system voltage is supplied at all times (always connect and use the battery charger). The video system
starts recording as soon as the GPS car speed exceeds 30 km/h. The system features a 30-second video puffer to ensure the 30 s before the car reaches
30 km/h are also recorded.
E.g. standing start: 30 s after the car is moving below 30 km/h the recording stops. The camera remains in standby mode for another 15 min.
For further information contact the manufacturer Racelogic.
See 7.3 Addresses (service + equipment) on page 1025.

6.18.2 Installing video system

1. Fit the six anti-vibration mounts [1] (3 above, 3 below) to the chassis.
2. Position the Vbox [2] with the SD card slot facing the passenger door. Fasten the Vbox
8 Nm in position with the bracket [3] and the nuts [4] (3 above, 3 below).

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 ELECTRIC SYSTEM | Video system

3. Fit the four anti-vibration mounts [1] to the brackets of the Vbox.
4. Place the battery [2] on the anti-vibration mounts [1] and fit it with the nuts [3].
8 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 1018

 ELECTRIC SYSTEM | Video system

3. Fit the four anti-vibration mounts [1] to the brackets of the Vbox.
4. Place the battery [2] on the anti-vibration mounts [1] and fit it with the nuts [3].
8 Nm

V7,12/2022 911 GT3 Cup (2021–2023) 1019

 ELECTRIC SYSTEM | Video system

5. Fit the camera [1], with the lens facing forwards, to the roll.cage using the hose clamps.
Mount the camera as close as possible to the driver.
Helicopter tape Apply a strip of helicopter tape to the roll-cage before fittung the hose clamps [2].
The helicopter tape protects the paint on the roll-cage.
6. Fasten the camera wiring-loom, as shown along the dotted line, using cable ties.

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 ELECTRIC SYSTEM | Video system

7. Fit the second camera including microphone [1] to the A-pillar using the hose clamps
[2].
Ensure that the camera [1] is mounted sufficiently low on the A-pillar towards the front
screen to prevent impending entry or exit through the passenger door.

8. Fasten the camera wiring-loom, as shown along the dotted line, using cable ties.

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7 CONTACTS
7.1 Technical Racing Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1023
7.2 Motorsport and spare parts sales . . . . . . . . . . . . . . . . . . . . . . .1024
7.3 Addresses (service + equipment) . . . . . . . . . . . . . . . . . . . . . . .1025

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 CONTACTS | Technical Racing Support

7.1 Technical Racing Support

Europe region E-Mail
Dr. Ing. h.c. F. Porsche AG [email protected]
Motorsport Vertrieb
Porschestraße 911
71287 Weissach
Germany

North America region Phone E-Mail

Porsche Motorsport North America Inc. +1 770 290 7050 [email protected]
19800 South Main Street
Carson, CA 90745
USA

Asia region Phone E-Mail

Porsche Motorsport Asia Pacific +86 21 6156 5772 [email protected]
Porsche (China) Motors Limited
13/F, Tower 3, Lujiazui Financial Plaza,
826 Century Avenue, Pudong, Shanghai
P.R. China 200120

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 CONTACTS | Motorsport and spare parts sales

7.2 Motorsport and spare parts sales

Europe/Asia region
[email protected]

Motorsport and spare parts are sold via the Porsche Motorsport Portal.
In order to order patrs, it is necessary to create a customer account and submit a user application.
You can request this via the e-mail address [email protected].

North America region

[email protected]

Series-identical spare parts can be obtained from your local Porsche partner.

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 CONTACTS | Addresses (service + equipment)

7.3 Addresses (service + equipment)

CONTACT Service scope Equipment / Spare part / Material
Aero Tec Laboratories Ltd. • Tank bladder,
ATL Technology Centre see 4.1 Service intervals
Denbigh Road on page 427
Bletchley
Milton Keynes, England MK1 1DF
+44 (0) 1908 351700
[email protected]
www.atltd.com
Bosch Engineering GmbH • Engine control unit MS 6.6,
Bosch Motorsport see 6.3.2 Engine control unit (Bosch MS 6.6) on page 734
Robert-Bosch-Allee 1
74232 Abstatt
Germany
+49 7062 911 9101
[email protected]
www.bosch-motorsport.com
cirp GmbH • Trim line patterns,
Römerstraße 8 see ▶ Offer reference 2021-31113 on page 578
71296 Heimsheim
Germany
+49 7033 30987 0
[email protected]
www.cirp.de
Contacts:
Sami Bensid +49 7033 30987 47
[email protected]
Lucia De Simone +49 7033 30987 24
[email protected]

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 CONTACTS | Addresses (service + equipment)

CONTACT Service scope Equipment / Spare part / Material

CP Tech • Roll cage,
Dornierstraße see 4.5.2 Roll cage on page 482
733142 Büren
Germany
+49 2955 4849 500
Cosworth Electronics Ltd. • Porsche Toolbox,
Brookfield Technology Centre see 6.13 Porsche Toolbox on page 876
Twentypence Road • Porsche Toolset,
Cottenham see 6.14 Porsche Toolset on page 931
Cambridge CB24 8PS
United Kingdom
+44 1954 253600
[email protected]
Fire Extinguisher Valve Company Ltd (FEV) • Fire extinguisher system,
Unit 10 Ford Lane Business Park see 6.7 Fire extinguisher system on page 770
Ford Nr Arundel
West Sussex
BN18 OUZ
United Kingdom
+44 12 43 55 55 66
HAZET • Dampers,
Hermann Zerver GmbH Co. KG see Damper strut to bottom wishbone on page 318
Güldenwerther Bahnhofstraße 25-29
42857 Remscheid
Germany
+49 2191 792 0
[email protected]
HIRSCHMANN GMBH • Special tool for spherical bearings
Kirchentannenstraße 9 (transverse control arm and trailing arm, track rod),
78737 Fluorn-Winzeln see Wishbone/trailing arm on page 313, see Wishbone and top
Germany trailing arm to side section on page 347 and see Track rod and
+49 7402 1830 bottom wishbone to side section on page 345
[email protected]

V7,12/2022 911 GT3 Cup (2021–2023) 1026

 CONTACTS | Addresses (service + equipment)

CONTACT Service scope Equipment / Spare part / Material

Krontec Maschinenbau GmbH • Main valve/Lifting cylinders air • Safeties for air jack system
Walhallastraße 19 jack system, Ordering numbers for safeties:
93083 Obertraubling see 4.1 Service intervals
Germany on page 428 Part Front Rear
+49 9401 5253 0 Airlift support LL-91 LL-90
[email protected]
Carlifter LL-30CL-991-front LL-20CL-991-rear
www.krontec.de
Manthey-Racing GmbH • Revision engine, • Battery charger CTEK PRO 25 S,
Rudolf-Diesel-Straße 11-13 see Engine on page 48 see 6.2.4 Battery charger on page 718
53520 Meuspath • Battery charging loom (LiFePo)
Germany • Car skate set
+49 2691 9338 851 • Coolant exchange system
[email protected] • Driveshaft installation tool
• Fuel tank filling system for filler gun use
• Lightweight drinking system
• Pressurised air bottle for air jack system
• Pressurised air bottle with impact wrench
• Restrictor apertures,
see 1.8.2 Restrictor aperture on page 83
• Tire heating tent
• Tire skate
• USB stick holder
• Windscreen tear-off (windscreen protection)
• Wheel alignment system
• 24 H additional lightning
MEGA-Line Racing ELECTRONIC GmbH • Electronic shift barrel,
Haunersdorf Str. 3 see 2.2.7 Electronic shift barrel
93342 Saal a.d. Donau on page 129
Germany
+49 9441 6866 0
[email protected]

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 CONTACTS | Addresses (service + equipment)

CONTACT Service scope Equipment / Spare part / Material

Dr. Ing. h.c. F. Porsche AG • Gearbox overhaul, AVAILABLE FROM THE PORSCHE MOTORSPORTS PARTS
Motorsport Vertrieb see 2.1 Service intervals CATALOGUE:
Porschestraße 911 on page 120 • Vehicle cover (heat shield for interior)
71287 Weissach • Pressing rings
Germany • Gearbox tools,
+49 711 911 0 see 2.7 Special tools on page 286
www.porsche.com • Special tool for transportation nuts,
see 3.8.3 Transport nut on page 371
Racelogic Deutschland • Videosystem,
Am Postplatz 5 see 6.18 Video system on page 1017
35781 Weilburg
Germany
+49 6471 927 966
[email protected]
Sabelt • Seat pads,
Motorsport see 5.4.2 Seat pads on page 684.
Via Guido Rossa 8/10/12
10024 Moncalieri (TO)
Italy
+39 011 6477911
[email protected]
[email protected]
www.sabelt.com/motorsport
SCHROTH Safety Products GmbH • Seat belt,
Postfach 2440 see 5.3 Seat belt on page 678
59714 Arnsberg
Germany
+49 (0) 2932 9742 0
www.schroth.com

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 CONTACTS | Addresses (service + equipment)

CONTACT Service scope Equipment / Spare part / Material

Siegfried Spiess Motorenbau GmbH • Revision engine,
Dieselstr. 11 see Engine on page 48
71254 Ditzingen
Germany
+49 7156 95 61 0
[email protected]
www.spiess-racing.de
Stäubli Tec-Systems GmbH • Couplings/adapters for:
Connectors – Engine cooling system
Sales – Gearbox cooling system
Theodor-Schmidt-Str. 25
Postfach 10 10 37
95410 Bayreuth
Germany
+49 921 883 0
SOBEK Motorsporttechnik GmbH & Co. KG • Coolant filling device,
Industriestraße 8 see 1.11.6 Filling the cooling system on page 104
68542 Heddesheim • Pressure bottle “Oilstick Magnum”, see 1.4.5 Engine oil quick-
+49 62 03-40 43 90 0 fill on page 62
[email protected]
ZF Race Engineering GmbH • Clutch,
Ernst-Sachs-Straße 62 see 2.3 Clutch on page 133
97424 Schweinfurt
Germany
+49 9721 984300

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8 PERFORMANCE
8.1 Basic values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1031
8.2 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1033
8.3 Body exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1048

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 PERFORMANCE | Basic values

8.1 Basic values

8.1.1 Setup

The standard setup must be adjusted to the individual race and track conditions.
Camber values must be coordinated with the tyre manufacturer beforehand.

Front axle Rear axle

Tank volume 50 l
Driver weight 75 kg
Pos. rear wing. 6°
Tyres Michelin S8M 30/65-18 Michelin S8M 31/71-18
Rim APP Tech 12.0 x 18 APP Tech 13.0 x 18
Brake Brake caliper Brembo Brembo
Brake disc 380 mm 380 mm
Brake pad Pagid Pagid
Inflation pressure 1.85
1 bar = 14.5035 psi
Ride height 80.0 113.0
(slicks 1.85 bar)
Anti-roll bar pos. 3/3 4/4
(left/right)
Camber (deg) -4.20 -3.70
Toe (min) per wheel -1.0 +2.0
Dampers Multimatic fix Multimatic fix
Master brake cylinder:
Brake balance Indication in display Master brake cylinder: 19.1 mm (green)
15.9 mm (black) / 17.8 mm (blue)

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 PERFORMANCE | Basic values

8.1.2 Data sheet

Data sheet
Vehicle weight 1260 kg
Weight distribution FA 36 %
Track FA 1684 mm
Track RA 1601 mm
Wheelbase 2468 mm
Height of roll centre FA -4 mm
Height of roll centre RA 34 mm
Ratio 0,77
damper/wheel FA
Ratio 0,85
damper/wheel RA

V7,12/2022 911 GT3 Cup (2021–2023) 1032

 PERFORMANCE | Chassis

8.2 Chassis
8.2.1 Tyres

Ensure that the correct tyre circumferences are saved in the CDU.

Rolling Rolling
Tyre manufacturer Designation Slick/rain Tyre dimensions FA Tyre dimensions RA
circumference FA circumference RA
Michelin Cup N3 Slick 30/65-18 2020 mm 31/71-18 2200 mm
Competition
Michelin P2L Rain 30/65-18 2024 mm 31/71-18 2194 mm

8.2.2 Toe/camber
Setting

Toe adjustment [mm] Camber gain [°]

Front axle Deflection -0.45 mm/cm -0.329 °/cm
Track rod 1 turn (+ 1 mm) -3.32mm/Turn +0.084 °/Turn
Rear axle Deflection +0.63 mm/cm -0.340 °/cm
Track rod 1 turn (+ 3 mm) -4.94mm/Turn +0.100 °/Turn

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 PERFORMANCE | Chassis

8.2.3 Brake air duct front axle

The brake air guide [2] must be used on all race tracks!
If brake temperatures permit and are constantly monitored, the brake air duct [2], at the
discretion of the team, may be removed on the following tracks:

Brake air duct

Race track Without ABS With ABS
Abu Dhabi Without Without
Aragaon FIM Aero Without Without
Assen Without Without
Bahrain Without Without
Bathurst Without Without
Budapest Without Without
Cota Without Without
Daytona Without Without
Detroit Without Without
Fuji Without Without
Gold Coast Without Without
Hockenheim Without Without
Indianapolis Without Without
Jerez Without Without
Lausitzring Without Without
Le Mans Without Without

V7,12/2022 911 GT3 Cup (2021–2023) 1034

 PERFORMANCE | Chassis

Brake air duct

Race track Without ABS With ABS
Lime Rock Without Without
Magny Cours Without Without
Melbourne Without Without
Mexiko Without Without
Mid Ohio Without Without
Monaco Without Without
Monza Without Without
Mosport Without Without
Most Without Without
Oschersleben Without Without
Paul Ricard Without Without
PGW Without With
Portimao Without Without
Red Bull Ring Without Without
Road Atlanta Without Without
Road America Without Without
Sachsenring Without Without
Sebring Without Without
Shanghai Without Without
Silverstone Without Without
Singapur Without Without

V7,12/2022 911 GT3 Cup (2021–2023) 1035

 PERFORMANCE | Chassis

Brake air duct

Strecke Without ABS With ABS
Sonoma Without Without
Spa Francorchamps Without Without
Suzuka Without Without
Sydney Motorsport Park Without Without
Toronto Without Without
Townsville Without Without
Valencia Without With
Vallelunga Without Without
Virginia Without Without
Watkins Glen Without Without
Zandvoort 2020 Without Without
Zolder Without With
Zhuhai Without Without

V7,12/2022 911 GT3 Cup (2021–2023) 1036

 PERFORMANCE | Chassis

8.2.4 Anti-roll bar

The adjustable double-blade anti-roll bar at the rear axle can be adjusted to 7 positions on each side.
Each position changes the angle of the anti-roll bar blade by 15°.
Assembly see 3.5.3 Assembly of front axle on page 305 and see 3.7.3 Assembly of rear axle on page 343.
MAXIMUM STIFFNESS OF THE ANTI-ROLL BAR
▶ Set the anti-roll bar blade in the direction of the anti-roll bar drop link.
MINIMUM STIFFNESS OF THE ANTI-ROLL BAR
▶ Set the anti-roll bar blade at a 90° angle to the anti-roll bar drop link.

Fig. 89: Blade position front axle pos. 6 Fig. 90: Blade position rear axle pos. 6

V7,12/2022 911 GT3 Cup (2021–2023) 1037

 PERFORMANCE | Chassis

Characteristic curve front and rear axle

Fig. 91: Characteristic curve front axle Fig. 92: Characteristic curve rear axle

V7,12/2022 911 GT3 Cup (2021–2023) 1038

 PERFORMANCE | Chassis

8.2.5 Springs

Spring rate FA Maximum length

Weight [kg] Spring design Material
[N/mm] [mm]
260 150.5 1.7 Coil spring Steel

Spring rate RA Maximum length

Weight [kg] Spring design Material
[N/mm] [mm]
300 180.5 2.4 Coil spring Steel

Preload spring Maximum length

Weight [kg] Spring design Material
[N/mm] [mm]
2.4 75 0.1 Coil spring Steel

V7,12/2022 911 GT3 Cup (2021–2023) 1039

 PERFORMANCE | Chassis

8.2.6 Dampers
Front axle

Damper free travel without Travel between bump stop

Max. length [mm] Min. length [mm]
bumpstop [mm] and rebound stop [mm]
Dampers FA 610.6 525.6 85 72.5

Ride height and damper free travel must be adjusted to the individual race track and track conditions.

[1] Suspension travel limiter

V7,12/2022 911 GT3 Cup (2021–2023) 1040

 PERFORMANCE | Chassis

Rear axle

For further information about the installation refer to the main chapter

Damper free travel without Travel between bump stop

Max. length [mm] Min. length [mm]
bumpstop [mm] and rebound stop [mm]
Dampers RA 449.3 350.5 98.8 86.3

Ride height and damper free travel must be adjusted to the individual race track and track conditions.

[1] Suspension travel limiter

V7,12/2022 911 GT3 Cup (2021–2023) 1041

 PERFORMANCE | Chassis

Characteristic curve damper front axle

V7,12/2022 911 GT3 Cup (2021–2023) 1042

 PERFORMANCE | Chassis

Characteristic curve damper rear axle

V7,12/2022 911 GT3 Cup (2021–2023) 1043

 PERFORMANCE | Chassis

Characteristic curve spring travel limiter front and rear axle

V7,12/2022 911 GT3 Cup (2021–2023) 1044

 PERFORMANCE | Chassis

8.2.7 Spring/damper
Rebound travel/bump travel

Total travel FA 85 mm and RA 98.8 mm.

Design values cannot be changed.

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 PERFORMANCE | Chassis

The rebound travel represents the difference between the distance of hub/fender in full
rebound and KO position.
The damper free length (bump travel) can be determined using the rebound travel.
Bump travel = total suspension travel –rebound travel

V7,12/2022 911 GT3 Cup (2021–2023) 1046

 PERFORMANCE | Chassis

Characteristic curve

The following graphic shows a spring characteristic curve for a linear vehicle suspension.
Increasing the pre-load reduces rebound travel and increases bump travel.

V7,12/2022 911 GT3 Cup (2021–2023) 1047

 PERFORMANCE | Body exterior

8.3 Body exterior

8.3.1 Vehicle dimensions

V7,12/2022 911 GT3 Cup (2021–2023) 1048

 PERFORMANCE | Body exterior

V7,12/2022 911 GT3 Cup (2021–2023) 1049

 PERFORMANCE | Body exterior

V7,12/2022 911 GT3 Cup (2021–2023) 1050

 PERFORMANCE | Body exterior

V7,12/2022 911 GT3 Cup (2021–2023) 1051

 PERFORMANCE | Body exterior

V7,12/2022 911 GT3 Cup (2021–2023) 1052

 PERFORMANCE | Body exterior

8.3.2 Aerodynamics
Change in aerodynamics as a function of vehicle height

In general, a negative value means less aero balance on the front axle.
Bal - (Front axle balance)

RRH** (mm)
110 115 120 125
75 0.0 % 2.0 % 4.1 % 5.9 %
FRH* (mm)

80 -3.3 % -1.1 % 1.1 % 3.0 %

85 -6.7 % -4.4 % -2.1 % -0.1 %

* FRH = Vehicle height front axle

** RRH = Vehicle height rear axle

V7,12/2022 911 GT3 Cup (2021–2023) 1053

 PERFORMANCE | Body exterior

Rear wing position

With a 5 mm Gurney.

Rear wing position Front axle balance

P14 -6.0 %
P13 -5.3 %
P12 -4.6 %
P11 -3.9 %
P10 -3.2 %
P9 -2.4 %
P8 -1.6 %
P7 -0.8 %
P6 0.0 %
P5 1.1 %
P4 2.3 %

Brake air duct

This refers to the brake air duct on the lower wishbone of the front axle.

Front axle balance

Without brake air duct 1.9 %
With brake air duct 0.0 %

V7,12/2022 911 GT3 Cup (2021–2023) 1054

9 SERVICE INTERVALS
9.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1056
9.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1056
9.3 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1057
9.4 Body exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1059
9.5 Body interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1060
9.6 Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1060

V7,12/2022 911 GT3 Cup (2021–2023) 1055

 SERVICE INTERVALS | Engine

9.1 Engine
Engine
Components Overhaul interval Max. runtime Instructions
Engine 100 h 200 h • Overhaul (see 7.3 Addresses (service +
equipment) on page 1025).
Components Service intervals Max. runtime Instructions
Air filter before every race weekend 50 h • Before every race weekend, remove the air
filters, tap them carefully out and clean them
with the BMC-Cleaning kit, if necessary.
Oil and Oilfilter 50 h • Change the engine oil and oil filter.
Spark plugs 50 h • Change the spark plugs.

9.2 Gearbox
Gearbox
Components Overhaul interval Max. runtime Instructions
Gearbox 60 h - • Overhaul by Porsche Motorsport.
Electronic shift barrel 60 h - • Mileage relates to the mileage counter in the
Bosch ECU (Iteng2), Service by MEGA-Line
Racing ELECTRONIC GmbH (see Addresses
(service + equipment) on page 1027).

V7,12/2022 911 GT3 Cup (2021–2023) 1056

 SERVICE INTERVALS | Chassis

9.3 Chassis
Components Service interval Max. runtime Instructions
Wheel speed sensor FA & RA 50 h • Visual inspection and functional testing.
Brake pressure sender 50 h
Steering wheel 50 h
Brake light switch 50 h • Visual inspection.
Fire extinguisher system before each use of the car • Check the system.See Testing the system
on page 775.
Fire extinguisher system: before each use of the car • Check for function and ease of movement.
Emergency switches outside and inside
the car
Fire extinguisher system: 2 years • Replace component.
Extinguisher bottle
Extinguishing nozzles 50 h • Visual inspection.
Y-piece of fire extinguisher system 50 h
Fuel pump control units 50 h • Visual inspection of plug system.
Emergency switch, external, connection 50 h • Visual inspection:
cable of emergency switch
Interior wiring loom 1x per season • Visual inspection.
• Check for chafe marks.
Engine wiring loom
Gearbox wiring loom
Intank wiring loom
E-steering wiring loom
Wiring loom, wheel housing FA
Wiring loom, wheel housing RA

V7,12/2022 911 GT3 Cup (2021–2023) 1057

 SERVICE INTERVALS | Chassis

Components Service interval Max. runtime Instructions

Wiring loom fender adapter 1x per season • Visual inspection.
• Check for chafe marks.
Front section wiring loom
Wiring loom battery B+
(starter & alternator)
Ground cable (from engine to body)
Wiring loom battery/battery disconnect
switch
Ground cable (from battery to body)
Diagnosis adapter cable
ABS wiring loom
Adapter ADR (Accident Data Recorder)
Adapter cable USB
Centre console support plate 50 h • Visual inspection.
Wiper system 50 h
Main headlights 50 h • Visual inspection and functional testing.
Rear lights 50 h
Battery 150 h • Replace component.
Battery disconnect switch 50 h • Visual inspection.
Alternator: 50 h 100 h After 50 h:
• Visual inspection and functional testing as part
of the engine overhaul at PAG/PMNA.
After 100 h:
• Replacement of the component as part of the
engine overhaul at PAG/PMNA.

V7,12/2022 911 GT3 Cup (2021–2023) 1058

 SERVICE INTERVALS | Body exterior

9.4 Body exterior

Fuel tank
Components Service interval Max. runtime Instructions
Tank bladder before each race 5 years (+ 2 years after • Observe the expiry date specified by the
recertification) manufacturer.
• Check each time before deploying the vehicle in
a race.
• Can be recertified by the manufacturer (ATL)
once for further 2 years (see page 1025).
Safety foam before each race • Check each time before deploying the vehicle in
a race.
Main fuel pumps 60 h • It is recommended to replace the main fuel
(inside the catch tank) pump annually (even if the max. running time
has not yet been reached).
Fuel pump prefilter before each race • Check each time before deploying the vehicle in
a race.

Airjack system
Components Service interval Rebuild interval Instructions
Main valve 2 years or 2000 strokes • Rebuild after time or strokes.
• Rebuild by Krontec (see page 1027).
Lifting cylinder 2 years or 2000 strokes
• Observe shipping information (see page 631).
Counternuts 30 h Check all nuts, re-tighten if necessary.

Body parts
Components Service interval Max. runtime Instructions
Wing extensions 24 months Applies to spare parts only

V7,12/2022 911 GT3 Cup (2021–2023) 1059

 SERVICE INTERVALS | Body interior

9.5 Body interior

Seat system
Components Service interval Max. runtime Instructions
Seat • Observe the expiry date specified by the
manufacturer.
Seat belt
• Replace after any collision.
Safety net

9.6 Electric System

Components Service interval Max. runtime Instructions
Wheel speed sensor FA & RA 50 h • Visual inspection and functional testing.
Brake pressure sender 50 h
Steering wheel 50 h
Brake light switch 50 h • Visual inspection.
Fire extinguisher system before each use of the car • Check the system.See Testing the system
on page 775.
Fire extinguisher system: before each use of the car • Check for function and ease of movement.
Emergency switches outside and inside
the car
Fire extinguisher system: 2 years • Replace component.
Extinguisher bottle
Extinguishing nozzles 50 h • Visual inspection.
Y-piece of fire extinguisher system 50 h
Fuel pump control units 50 h • Visual inspection of plug system.
Emergency switch, external, connection 50 h • Visual inspection:
cable of emergency switch

V7,12/2022 911 GT3 Cup (2021–2023) 1060

 SERVICE INTERVALS | Electric System

Components Service interval Max. runtime Instructions

Interior wiring loom 1x per season • Visual inspection.
• Check for chafe marks.
Engine wiring loom
Gearbox wiring loom
Intank wiring loom
E-steering wiring loom
Wiring loom, wheel housing FA
Wiring loom, wheel housing RA
Wiring loom fender adapter 1x per season • Visual inspection.
• Check for chafe marks.
Front section wiring loom
Wiring loom battery B+
(starter & alternator)
Ground cable (from engine to body)
Wiring loom battery/battery disconnect
switch
Ground cable (from battery to body)
Diagnosis adapter cable
ABS wiring loom
Adapter ADR (Accident Data Recorder)
Adapter cable USB
Centre console support plate 50 h • Visual inspection.
Wiper system 50 h
Main headlights 50 h • Visual inspection and functional testing.
Rear lights 50 h

V7,12/2022 911 GT3 Cup (2021–2023) 1061

 SERVICE INTERVALS | Electric System

Components Service interval Max. runtime Instructions

Battery 150 h • Replace component.
Battery disconnect switch 50 h • Visual inspection.
Alternator: 50 h 100 h After 50 h:
• Visual inspection and functional testing as part
of the engine overhaul at PAG/PMNA.
After 100 h:
• Replacement of the component as part of the
engine overhaul at PAG/PMNA.

V7,12/2022 911 GT3 Cup (2021–2023) 1062

TOOLS
MAIN GROUP
Component Tool Page

ENGINE
Belt ..................................................................................................... AF 16 ............................................................................................................................................................................................................................................... 63
AF30 ................................................................................................................................................................................................................................................ 65
E10............................................................................................................................................................................................................................................ 64, 66
Cooling system ............................................................................... 6 mm Allen key ...........................................................................................................................................................................................................................103
Engine................................................................................................ 6 mm Allen key ............................................................................................................................................................................................................................. 58
Engine/gearbox .............................................................................. 6 mm Allen key ............................................................................................................................................................................................................................. 71
AF 13 ............................................................................................................................................................................................................................................... 74
AF 16 ........................................................................................................................................................................................................................................ 74, 77
AF 18 ............................................................................................................................................................................................................................................... 78
AF 8.................................................................................................................................................................................................................................................. 74
SW 16 ............................................................................................................................................................................................................................................. 72
SW 18 ............................................................................................................................................................................................................................................. 72
Torx 12............................................................................................................................................................................................................................................ 73
Torx 30............................................................................................................................................................................................................................................ 71
Spark plugs ...................................................................................... Extension 3/8“.............................................................................................................................................................................................................................. 96
Spark plug socket ........................................................................................................................................................................................................................ 96

INTAKE SYSTEM
Protective cover throttle butterfly system ............................. E 10........................................................................................................................................................................................................................................... 87, 88
E 12.................................................................................................................................................................................................................................................. 87

GEARBOX
Backlash............................................................................................ Special tool 9F1.012.277.L....................................................................................................................................................................................................253
Special tool 9F1.012.277.N ...................................................................................................................................................................................................253
Special tool 9F1.012.279.M ..................................................................................................................................................................................................253
Backlash/angle drive..................................................................... Dial gauge.....................................................................................................................................................................................................................................253
Plastic pry bar ...................................................................................................................................................................................................................253, 254

V7,12/2022 911 GT3 Cup (2021–2023) 1063

 TOOLS

MAIN GROUP
Component Tool Page

Bearing .............................................................................................. Special tool 9F1.012.277.D ...................................................................................................................................................................................................191

Special tool 9F1.012.279 .......................................................................................................................................................................................................189
Special tool 9F1.012.279.A....................................................................................................................................................................................................190
Special tool 9F1.012.279.B ...................................................................................................................................................................................................192
Special tool 9F1.012.279.D ...................................................................................................................................................................................................193
Special tool 9F1.012.279.E....................................................................................................................................................................................................192
Special tool 9F1.012.279.H ...................................................................................................................................................................................................190
Bearing and sleeves....................................................................... Special tool 9F1.012.277.A....................................................................................................................................................................................................204
Special tool 9F1.012.277.B ...................................................................................................................................................................................................204
Special tool 9F1.012.279.AB.................................................................................................................................................................................................203
Special tool 9F1.012.279.Q ...................................................................................................................................................................................................204
Bearing housing.............................................................................. Special tool 9F1.012.277.E....................................................................................................................................................................................................175
Special tool 9F1.012.278.B ...................................................................................................................................................................................................176
Special tool 9F1.012.279.AA.................................................................................................................................................................................................177
Special tool 9F1.012.279.AC.................................................................................................................................................................................................175
Special tool 9F1.012.279.AN ................................................................................................................................................................................................175
Bearing removal.............................................................................. Internal puller ....................................................................................................................................................................................................................176, 177
Slide hammer .......................................................................................................................................................................................................... 175, 176, 177
Checking shift play ........................................................................ Electronic torque wrench.........................................................................................................................................................................................................242
Feeler gauge ................................................................................................................................................................................................................................244
Graduated disc............................................................................................................................................................................................................................242
Clutch ................................................................................................ Outside micrometre ..................................................................................................................................................................................................................136
Special tool 9F1.012.277.AH ................................................................................................................................................................................................139

V7,12/2022 911 GT3 Cup (2021–2023) 1064

 TOOLS

MAIN GROUP
Component Tool Page

Cross shaft ....................................................................................... Aluminium sleeve.............................................................................................................................................................................................................161, 162

Electronic torque wrench.........................................................................................................................................................................................................250
Feeler gauge ................................................................................................................................................................................................................................247
Graduated disc............................................................................................................................................................................................................................250
Hydraulic press .................................................................................................................................................................................................................161, 162
Pry bar ...........................................................................................................................................................................................................................................159
Slide hammer ..............................................................................................................................................................................................................................159
Special tool 9F1.012.277.AA.................................................................................................................................................................................................250
Special tool 9F1.012.277.AD.................................................................................................................................................................................................250
Special tool 9F1.012.277.AE .................................................................................................................................................................................................161
Special tool 9F1.012.277.AQ ............................................................................................................................................................................ 248, 249, 250
Special tool 9F1.012.277.S............................................................................................................................................................ 161, 248, 249, 250, 251
Special tool 9F1.012.278 .......................................................................................................................................................................................................247
Special tool 9F1.012.278.A....................................................................................................................................................................................................162
Special tool 9F1.012.278.AQ ................................................................................................................................................................................................161
Special tool 9F1.012.278.AR.................................................................................................................................................................................................161
Special tool 9F1.012.278.C .........................................................................................................................................................................................160, 249
Special tool 9F1.012.279.C ...................................................................................................................................................................................................247
Cross shaft bearing........................................................................ Depth gauge ................................................................................................................................................................................................................................246
Special tool 9F1.012.279.T....................................................................................................................................................................................................245
Differential ....................................................................................... Depth gauge .................................................................................................................................................................................................. 260, 261, 265, 266
Plastic mandrel ...........................................................................................................................................................................................................................259
Pry bar ...........................................................................................................................................................................................................................................154
Soft-faced hammer...................................................................................................................................................................................................................259
Special tool 9F1.012.278.D .........................................................................................................................................................................................273, 274
Special tool 9F1.012.279.AM......................................................................................................................................................................................259, 260
Special tool 9F1.012.279.AP.......................................................................................................................................................................................265, 266
Special tool 9F1.012.279.P................................................................................................................................................................................ 258, 259, 260
Torque wrench............................................................................................................................................................................................................................274
Vernier caliper ...................................................................................................................................................................................................................258, 262
Differential ball bearing ................................................................ External puller .............................................................................................................................................................................................................................156
Special tool 9F1.012.279.AG.................................................................................................................................................................................................156
Differential bearing........................................................................ Feeler gauge ................................................................................................................................................................................................................................209
Special tool 9F1.012.279.AF .................................................................................................................................................................................................209

V7,12/2022 911 GT3 Cup (2021–2023) 1065

 TOOLS

MAIN GROUP
Component Tool Page

Differential cover............................................................................ Soft-faced hammer...................................................................................................................................................................................................................210

Special tool 9F1.012.279.AH ................................................................................................................................................................................................210
Special tool 9F1.012.279.AJ..................................................................................................................................................................................................210
Differential package ...................................................................... Special tool 9F1.012.278.D ...................................................................................................................................................................................................155
Driveshaft output flanges ............................................................ Special tool 9F1.012.277.G ...................................................................................................................................................................................................279
Special tool 9F1.012.277.Q .........................................................................................................................................................................................153, 279
Special tool 9F1.012.279.AK.......................................................................................................................................................................................153, 279
Gear housing.................................................................................... Special tool 9F1.012.277.Q ...................................................................................................................................................................................................163
Special tool 9F1.012.277.T....................................................................................................................................................................................................163
Gear housing bearing .................................................................... Internal puller ..............................................................................................................................................................................................................................180
Special tool 9F1.012.277.F....................................................................................................................................................................................................180
Special tool 9F1.012.277.P....................................................................................................................................................................................................180
Gear set............................................................................................. Special tool 9F1.012.277.AE .................................................................................................................................................................................................164
Special tool 9F1.012.277.AF .................................................................................................................................................................................................164
Special tool 9F1.012.277.AM................................................................................................................................................................................................164
Special tool 9F1.012.277.AP.................................................................................................................................................................................................164
Special tool 9F1.012.277.AQ ................................................................................................................................................................................................164
Special tool 9F1.012.277.AR.................................................................................................................................................................................................164
Special tool 9F1.012.277.H ...................................................................................................................................................................................................164
Special tool 9F1.012.277.R....................................................................................................................................................................................................164
Special tool 9F1.012.277.S....................................................................................................................................................................................................164
Gearbox housing............................................................................. Slide hammer ..............................................................................................................................................................................................................................152
Input shaft........................................................................................ Slide hammer ..............................................................................................................................................................................................................................169
Special tool 9F1.012.279.G ...................................................................................................................................................................................................237
Mainshaft.......................................................................................... Offset circlip pliers.....................................................................................................................................................................................................................169
Needle roller bearing of driveshaft output flange ................. Circlip pliers .................................................................................................................................................................................................................................176
Oil filter.............................................................................................. Slide hammer ..............................................................................................................................................................................................................................149
Oil spray pipe................................................................................... Slide hammer ..............................................................................................................................................................................................................................157

V7,12/2022 911 GT3 Cup (2021–2023) 1066

 TOOLS

MAIN GROUP
Component Tool Page

Pinion shaft ...................................................................................... Aluminium sleeve.......................................................................................................................................................................................................................168

Depth gauge ................................................................................................................................................................................................................................219
Dial gauge + dial gauge holder ...............................................................................................................................................................................................217
Electronic torque wrench.........................................................................................................................................................................................................217
Graduated disc............................................................................................................................................................................................................................217
Hydraulic press ...........................................................................................................................................................................................................................168
Special tool 9F1.012.277.AM................................................................................................................................................................................................216
Special tool 9F1.012.277.AQ ................................................................................................................................................................................................217
Special tool 9F1.012.277.H ...................................................................................................................................................................................................216
Special tool 9F1.012.277.S....................................................................................................................................................................................................217
Special tool 9F1.012.278.A....................................................................................................................................................................................................168
Special tool 9F1.012.279.K ...................................................................................................................................................................................................219
Special tool 9F1.012.279.L....................................................................................................................................................................................................214
Special tool 9F1.012.279.N ...................................................................................................................................................................................................215
Special tool 9F1.012.279.P....................................................................................................................................................................................................218
Pinion shaft + mainshaft .............................................................. Special tool 9F1.012.277.AA.................................................................................................................................................................................................243
Special tool 9F1.012.277.AB.................................................................................................................................................................................................243
Special tool 9F1.012.277.AC.................................................................................................................................................................................................243
Special tool 9F1.012.277.AM................................................................................................................................................................................................240
Special tool 9F1.012.277.AP.................................................................................................................................................................................................242
Special tool 9F1.012.277.AQ ................................................................................................................................................................................................242
Special tool 9F1.012.277.H ...................................................................................................................................................................................................240
Special tool 9F1.012.277.Q ...................................................................................................................................................................................................241
Special tool 9F1.012.277.R....................................................................................................................................................................................................242
Special tool 9F1.012.277.S....................................................................................................................................................................................................242
Special tool 9F1.012.277.T....................................................................................................................................................................................................243
Special tool 9F1.012.279.AD.................................................................................................................................................................................................241
Special tool 9F1.012.279.AK.................................................................................................................................................................................................241
Pinion shaft bearing....................................................................... Dial gauge + dial gauge holder ...............................................................................................................................................................................................212
Plugs .................................................................................................. Special tool 9F1.012.279.AL .................................................................................................................................................................................................206
Removing/attaching the gearbox ............................................. AF 14 .............................................................................................................................................................................................................................................147
Reverse idler gear........................................................................... Special tool 9F1.012.279.R....................................................................................................................................................................................................229

V7,12/2022 911 GT3 Cup (2021–2023) 1067

 TOOLS

MAIN GROUP
Component Tool Page

Shaft sealing ring ........................................................................... Pry bar ...........................................................................................................................................................................................................................................173

Soft-faced hammer.........................................................................................................................................................................................................198, 207
Special tool 9F1.012.279.AE .................................................................................................................................................................................................207
Special tool 9F1.012.279.F....................................................................................................................................................................................................198
Shift barrel........................................................................................ Openended wrench AF 30.......................................................................................................................................................................................................172
Openjaw spanner AF30............................................................................................................................................................................................................228
Special tool 9F1.012.279.J ..........................................................................................................................................................................................172, 228
Shift play........................................................................................... Special tool 9F1.012.279.AD.................................................................................................................................................................................................244
Special tool 9F1.012.279.AK.................................................................................................................................................................................................244
Sleeves/cylinder pins.................................................................... Aluminium mandrel .........................................................................................................................................................................................................194, 195
Studs.................................................................................................. Stud assembly tool ..........................................................................................................................................................................................................187, 188

SUSPENSION
Axial joint .......................................................................................... Special tool V.A.G. 1923 - Open-ended spanner AF 38.................................................................................................................................................333
Balance bar ...................................................................................... Torx 45..........................................................................................................................................................................................................................................411
Damper strut ................................................................................... HAZET special tools...................................................................................................................................................................................................................318
Wheel nut ......................................................................................... Drift punch ...................................................................................................................................................................................................................................371
Hammer ........................................................................................................................................................................................................................................371

BODY EXTERIOR
Air deflectors ................................................................................... 7.5 mm drill bit ...........................................................................................................................................................................................................................459
Assembly carrier............................................................................. Torx 45..........................................................................................................................................................................................................................................473
Damper strut support ................................................................... 6.6 mm drill bit ...........................................................................................................................................................................................................................501
Rivet gun for high-strength rivets.........................................................................................................................................................................................504
Sandpaper grit size 150.................................................................................................................................................................................................501, 502
Sandpaper grit size 180.................................................................................................................................................................................................501, 502

V7,12/2022 911 GT3 Cup (2021–2023) 1068

 TOOLS

MAIN GROUP
Component Tool Page

Front chassis section .................................................................... 18 mm AF socket......................................................................................................................................................................................... 576, 587, 588, 593

5.0 mm drill bit ...........................................................................................................................................................................................................................589
6 mm Allen key .................................................................................................................................................................................................................588, 593
6.7 mm drill bit ....................................................................................................................................................................................................... 589, 591, 592
7.0 mm drill bit ...........................................................................................................................................................................................................................592
8 mm Allen key .................................................................................................................................................................................................................588, 593
Angle grinder with serrated disc..................................................................................................................................................................................579, 583
Belt grinder .......................................................................................................................................................................581, 583, 584, 585, 586, 587, 591
Centre punch.....................................................................................................................................................................................................................589, 592
Flat chisel ................................................................................................................................................................................................................. 583, 584, 585
Front chassis section jig....................................................................................................................................................................................... 576, 587, 588
Front jig extension jig................................................................................................................................................................................................................588
Hammer .......................................................................................................................................................................................................... 584, 585, 589, 592
Hot air gun................................................................................................................................................................................................................ 583, 584, 585
Jigsaw with 200 mm blade................................................................................................................................................................................. 578, 582, 583
Jigsaw with 70 mm blade.................................................................................................................................................................................... 578, 582, 585
Mallet...................................................................................................................................................................................................................................586, 587
Manually operated rivet nut gun (Böllhoff RIVKLE ZS308) ...........................................................................................................................................592
Marker pen .............................................................................................................................................................. 578, 579, 580, 581, 582, 583, 588, 592
Pattern "Trim line bulkhead" .........................................................................................................................................................................................578, 580
Pattern "Trim line support 1 left outboard"........................................................................................................................................................................588
Pattern “Trim line support 1 left inboard“...........................................................................................................................................................................583
Pattern “Trim line support 1 left outboard”........................................................................................................................................................................582
Pattern “Trim line suspension strut left” .............................................................................................................................................................................581
Pattern „Trim line longitudinal beam upper outboard“....................................................................................................................................................580
Pin punch............................................................................................................................................................................................................................584, 585
Pincers.................................................................................................................................................................................................................................581, 586
Rivet gun for high-strength rivets..................................................................................................................................................................... 589, 591, 592
Steel rule.............................................................................................................................................................................................................................581, 592
Torx 25..........................................................................................................................................................................................................................................581
Wire brush................................................................................................................................................................................................................ 580, 583, 584
Wishbone and suspension strut jig.......................................................................................................................................................................................588
Wooden block ...................................................................................................................................................................................................................586, 587

V7,12/2022 911 GT3 Cup (2021–2023) 1069

 TOOLS

MAIN GROUP
Component Tool Page

Front chassis section-subframe repair .................................... 18 mm AF socket.......................................................................................................................................................................................................................594

3.5 mm HSS drill bit........................................................................................................................................................................................................598, 600
5.0 mm HSS drill bit........................................................................................................................................................................................................607, 608
6 mm Allen key ...........................................................................................................................................................................................................................594
6.7 mm HSS drill bit................................................................................................................................... 598, 600, 601, 604, 605, 606, 607, 608, 609
8 mm Allen key ...........................................................................................................................................................................................................................594
8.0 mm drill bit ....................................................................................................................................................................................................... 596, 597, 598
Angle grinder ...............................................................................................................................................................................................................................599
Angle grinder with serrated disc..................................................................................................................................................................................599, 600
Belt grinder .............................................................................................................................................................................................................. 600, 603, 604
Dolly ...............................................................................................................................................................................................................................................603
Flat chisel ................................................................................................................................................................................................................. 598, 600, 601
Front chassis section jig...........................................................................................................................................................................................................594
Front jig.........................................................................................................................................................................................................................................594
Front jig extension .....................................................................................................................................................................................................................594
Hammer ................................................................................................................................................................................................ 596, 597, 598, 601, 603
High-tensile centre punch.............................................................................................................................................................................................598, 600
Hot air gun...................................................................................................................................................................................................... 597, 598, 600, 601
Jigsaw with 70 mm blade..............................................................................................................................................................................................601, 602
Mallet.............................................................................................................................................................................................................................................601
Marker pen ...................................................................................................................................................................................................................................605
Pin punch.................................................................................................................................................................................................................. 596, 597, 598
Plastic hammer...........................................................................................................................................................................................................................604
Rivet gun for high-strength rivets........................................................................................................................................604, 605, 606, 607, 608, 609
Scraper................................................................................................................................................................................................................................597, 601
Tyre lever......................................................................................................................................................................................................................................598
Wishbone and suspension strut jig.......................................................................................................................................................................................594

V7,12/2022 911 GT3 Cup (2021–2023) 1070

 TOOLS

MAIN GROUP
Component Tool Page

Rear chassis section...................................................................... 13 mm AF socket............................................................................................................................................................................... 610, 613, 616, 617, 618

18 mm AF socket.............................................................................................................................................................................................................610, 616
4.2 mm drill bit .................................................................................................................................................................................................................613, 617
5.0 mm drill bit .................................................................................................................................................................................................................613, 618
6.7 mm drill bit ............................................................................................................................................................................................. 614, 615, 616, 618
Angle grinder ...............................................................................................................................................................................................................................613
Belt grinder .............................................................................................................................................................................................................. 615, 617, 618
Flat chisel ...........................................................................................................................................................................................................................613, 614
Hammer ..............................................................................................................................................................................................................................613, 614
Hot air gun..........................................................................................................................................................................................................................613, 614
jigsaw with 70 mm blade ........................................................................................................................................................................................................613
Mallet...................................................................................................................................................................................................................................614, 615
Pin punch......................................................................................................................................................................................................................................613
Rivet gun for high-strength rivets...............................................................................................................................................................................616, 618
Screw clamp......................................................................................................................................................................................................................617, 618
Torx 25..........................................................................................................................................................................................................................................612
Tyre lever......................................................................................................................................................................................................................................614
Wire brush....................................................................................................................................................................................................................................612
Wooden block ...................................................................................................................................................................................................................614, 615

V7,12/2022 911 GT3 Cup (2021–2023) 1071

 TOOLS

MAIN GROUP
Component Tool Page

Rear quarter panel.......................................................................... 4.2 mm drill bit ....................................................................................................................................................................................................... 568, 571, 572
5.0 mm drill bit ....................................................................................................................................................................................................... 567, 568, 574
6.0 mm drill bit ............................................................................................................................................................................................. 552, 553, 554, 555
6.7 mm drill bit ................................................................................................................................................................................... 564, 566, 567, 572, 573
Angle grinder with serrated disc..................................................................................................................................................................................553, 562
Belt grinder ...............................................................................552, 553, 555, 557, 559, 561, 562, 563, 564, 565, 566, 568, 569, 570, 571, 574
Flat chisel ...........................................................................................................................................................................................................................557, 562
Hammer ................................................................................................................................................552, 553, 555, 557, 559, 561, 562, 566, 569, 570
Hand anvil (dolly)........................................................................................................................................................................................................................573
Hot air gun.........................................................................................................................................................................553, 555, 557, 561, 562, 569, 570
Jigsaw with 70 mm blade............................................................................................554, 555, 556, 560, 561, 563, 564, 565, 568, 569, 570, 571
Marker pen ...................................................................................................................................................................................................................................551
Mortise chisel...................................................................................................................................................................552, 553, 555, 561, 566, 569, 570
Pin punch........................................................................................................................................................................................................ 557, 559, 561, 562
Plastic hammer...........................................................................................................................................................................................................................573
Rivet gun for high-strength rivets..............................................................................................................................564, 567, 568, 571, 572, 573, 574
Screw clamps..............................................................................................................................................................................................................................564
Scriber ............................................................................................................................................................................................................. 555, 556, 568, 574
Torx 25..........................................................................................................................................................................................................................................560
Vice grips.................................................................................................................................................................................................................. 564, 566, 571
Wire brush..........................................................................................................................................................................................................................553, 558
Rear window .................................................................................... Adhesive tape..............................................................................................................................................................................................................................651
Awl from VAS 861 001A .........................................................................................................................................................................................................649
Cup suction tools .............................................................................................................................................................................................................649, 654
Cutting cord for VAS 861 001A............................................................................................................................................................................................649
Cutting device from VAS 861 001A ....................................................................................................................................................................................649
Dual-cartridge gun ....................................................................................................................................................................................................................655
Electric special cutter .....................................................................................................................................................................................................650, 653
U-shaped scraper blade for electric special cutter ................................................................................................................................................650, 653
Window removal set VAS 861 001A ...................................................................................................................................................................................648
Rear wing.......................................................................................... AF 10 .............................................................................................................................................................................................................................................476
AF 13 .............................................................................................................................................................................................................................................475
Torx 25................................................................................................................................................................................................................................476, 477

V7,12/2022 911 GT3 Cup (2021–2023) 1072

 TOOLS

MAIN GROUP
Component Tool Page

Rear wing mounting ...................................................................... 13 mm AF socket................................................................................................................................................................................................... 621, 627, 628

4.2 mm drill bit ............................................................................................................................................................................................. 620, 622, 624, 630
5.0 mm drill bit ...........................................................................................................................................................................................................................622
Belt grinder .................................................................................................................................................................................620, 622, 624, 627, 628, 630
Flat chisel ....................................................................................................................................................................................................... 620, 621, 622, 623
Hammer ................................................................................................................................................................................................ 620, 621, 622, 623, 624
Hot air gun...................................................................................................................................................................................................... 620, 621, 622, 623
Pin punch............................................................................................................................................................................................................................620, 622
Rear wing jig ................................................................................................................................................................................................................................624
Rivet gun for high-strength rivets...............................................................................................................................................................................628, 630
Torx 25................................................................................................................................................................................................................................620, 630
Wire brush....................................................................................................................................................................................................................................620
Roof hatch ........................................................................................ 4 mm Allen key with ball head ...............................................................................................................................................................................................479
Roof module..................................................................................... 25mm blade for electric special cutter .....................................................................................................................................................................534, 535
80-grit sanding paper...............................................................................................................................................................................................................547
Adhesive tape..............................................................................................................................................................................................................................545
Awl from VAS 861 001A ........................................................................................................................................................................... 535, 538, 540, 542
Cutting cord for VAS 861 001A..................................................................................................................................................................................535, 539
Cutting device from VAS 861 001A ..........................................................................................................................................................................539, 543
Dual-cartridge gun ....................................................................................................................................................................................................................548
Electric special cutter ................................................................................................................................................................................. 534, 535, 544, 547
Hook from VAS 861 001A ......................................................................................................................................................................................................538
U-shaped scraper blade for electric special cutter ................................................................................................................................................544, 547
Window removal set VAS 861 001A .........................................................................................................................................................................532, 533
Underbody panel, rear................................................................... AF 10 .............................................................................................................................................................................................................................................457
Underbody panels .......................................................................... AF 10 ...................................................................................................................................................................................................................................454, 455
Torx 25...................................................................................................................................................................................................................... 454, 455, 457
Torx 30..........................................................................................................................................................................................................................................456

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 TOOLS

MAIN GROUP
Component Tool Page

Windscreen...................................................................................... Adhesive tape....................................................................................................................................................................................................................642, 647

Awl from VAS 861 001A .........................................................................................................................................................................................................639
Cup suction tool .........................................................................................................................................................................................................................638
Cup suction tools .......................................................................................................................................................................................................................645
Cutting cord for VAS 861 001A............................................................................................................................................................................................638
Cutting device from VAS 861 001A ....................................................................................................................................................................................639
Dual-cartridge gun ..........................................................................................................................................................................................................646, 647
Electric special cutter .....................................................................................................................................................................................................641, 644
U-shaped scraper blade for electric special cutter ................................................................................................................................................641, 644
Window removal set VAS 861 001A ...................................................................................................................................................................................637
Wishbone mounting...................................................................... 13 mm AF socket......................................................................................................................................................................................... 508, 510, 511, 513
6.7 mm drill bit .................................................................................................................................................................................................................512, 513
Belt grinder ........................................................................................................................................................................................................................507, 510
Flat chisel ...........................................................................................................................................................................................................................508, 509
Hammer ..............................................................................................................................................................................................................................508, 509
Hot air gun..........................................................................................................................................................................................................................508, 509
Marker pen ...................................................................................................................................................................................................................................509
Pry bar ...........................................................................................................................................................................................................................................509
Rivet gun for high-strength rivets..................................................................................................................................................................... 511, 512, 513
Torx 25...................................................................................................................................................................................................................... 507, 508, 509
Wire brush..........................................................................................................................................................................................................................507, 508

BODY INTERIOR
Additional weights ......................................................................... Impact wrench............................................................................................................................................................................................................................701
Passenger seat................................................................................ Impact wrench............................................................................................................................................................................................................................689
Safety net ......................................................................................... Spirit level with calibration function...........................................................................................................................................................................695, 699
Tape measure....................................................................................................................................................................................................................695, 699
Seat riser........................................................................................... 3 mm Allen key ....................................................................................................................................................................................................... 686, 687, 688
Screwdriver 8 mm .....................................................................................................................................................................................................................686

ELECTRIC SYSTEM
Video system................................................................................... Helicopter tape ........................................................................................................................................................................................................................1020
Voltage supply ................................................................................ VAS 5908.....................................................................................................................................................................................................................................719
Wiper ................................................................................................. AF 13 .............................................................................................................................................................................................................................................778
Puller..............................................................................................................................................................................................................................................778

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OPERATING MATERIALS
MAIN GROUP
Component Type Designation Page

ENGINE
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning agent . . . . . . BMC - Cleaning kit Nr. WA 250-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . .Anti-freeze . . . . . . . . . Glysantin G40-91 EF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Coolant. . . . . . . . . . . . . Glysantin G40-91 EF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Greases . . . . . . . . . . . . Klüberplus Gel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 103
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oils . . . . . . . . . . . . . . . . Mobil 1 ESP X3 0W-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oils . . . . . . . . . . . . . . . . Mobil 1 ESP X3 0W-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . micro GLEIT LP475 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112, 113, 115
Oxygen sensors. . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Microgleit LP 475. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

GEARBOX
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185, 187
Assembly opening cap . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Bearings/sleeves . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 638 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Clutch release bearing . . . . . . . . . . . . . . . . . . .Cleaner. . . . . . . . . . . . . Bonderite C-NE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145, 238
Clutch release bearing hydraulic lines . . . . .Pastes. . . . . . . . . . . . . . Aluminium paste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Coolant connections . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 574 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Counterbearing . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Cross shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Cross shaft cover cap . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Cross shaft needle roller bearing . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269, 270, 275
Differential cover . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 574 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Loctite 638 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Pastes. . . . . . . . . . . . . . Optimol Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Driveshaft output flanges . . . . . . . . . . . . . . . .Pastes. . . . . . . . . . . . . . Castrol Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Electronic shift barrel . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oils . . . . . . . . . . . . . . . . Mobilube 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216, 221, 222, 223, 224, 225, 226, 228, 229, 233, 247, 248, 249
Heat exchanger. . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

V7,12/2022 911 GT3 Cup (2021–2023) 1075

 OPERATING MATERIALS

MAIN GROUP
Component Type Designation Page

Pastes. . . . . . . . . . . . . . Optimol Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Oil spray pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Oil suction pipe . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Pinion shaft bearing. . . . . . . . . . . . . . . . . . . . . .Oils . . . . . . . . . . . . . . . . Mobilube 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Pinion shaft retaining cage . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Removing/attaching the gearbox . . . . . . . . .Pastes. . . . . . . . . . . . . . Copper paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Selector rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optipit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . .Oils . . . . . . . . . . . . . . . . Mobilube 75W90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198, 207, 210
Pastes. . . . . . . . . . . . . . Optimol Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198, 207
Shift barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Sleeves/cylinder pins . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 638 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194, 195
Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 184, 185, 186, 187, 188, 200, 201, 202
Threaded plugs . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 574 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196, 197, 205
Pastes. . . . . . . . . . . . . . Aluminium paste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

CHASSIS
Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309, 350
Greases . . . . . . . . . . . . Autol TOP 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309, 350
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .378, 381
Brake fluid . . . . . . . . . . Brake fluid DOT 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Cleaning agent . . . . . . Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386, 387
Isopropanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386, 387
Driveshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite high strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Pastes. . . . . . . . . . . . . . Molub Alloy Paste TA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Self-locking nuts . . . . . . . . . . . . . . . . . . . . . . . .Pastes. . . . . . . . . . . . . . Copper paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Track rod end to Track rod. . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Klüberplex BEM 34-132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greases . . . . . . . . . . . . Optimol HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Wheel nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning agent . . . . . . Brake cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Pastes. . . . . . . . . . . . . . Molub Alloy Paste TA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368, 369

BODY EXTERIOR
Front chassis section. . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . 3M DP 490. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
3M DP490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
Cleaning agent . . . . . . Acetone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587, 591

V7,12/2022 911 GT3 Cup (2021–2023) 1076

 OPERATING MATERIALS

MAIN GROUP
Component Type Designation Page

Front chassis section-subframe repair. . . . .Adhesives . . . . . . . . . . 3M DP490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .604, 607

Cleaning agent . . . . . . Acetone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .604, 607
Rivet gun for high-strength rivets606Rear chassis sectionAdhesives3M DP490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615, 617, 618
Cleaning agent . . . . . . Acetone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615, 617, 618
Rear quarter panel . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . 3M DP490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564, 566, 568, 571, 574
Cleaning agent . . . . . . Acetone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564, 566, 568, 571, 574
Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . 2K adhesive set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651, 652, 653, 655
Cleaning agent . . . . . . Isopropanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650, 653
Varnish . . . . . . . . . . . . . Automotive varnish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
Rear wing edge (Gurney) . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . 3M PT110 adhesive tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Rear wing mounting . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . 3M DP490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625, 627, 628, 630
Loctite 270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
Cleaning agent . . . . . . Acetone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624, 625, 627, 628, 630
Sealants . . . . . . . . . . . . Teroson 9320 SF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
Roof module . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . 2K adhesive set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545, 546, 547, 548
Cleaning agent . . . . . . Isopropanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .544, 547
Varnish . . . . . . . . . . . . . Automotive varnish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
Strut mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Sika Power 477R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503, 504
Cleaning agent . . . . . . Aceton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501, 502
Isopropanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501, 502
Wheel trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . 3M Acylic Plus Tape PX5011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Cleaner. . . . . . . . . . . . . Isopropyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . 2K adhesive set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642, 643, 644, 645, 646
Cleaning agent . . . . . . Isopropanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
Isopropyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
Varnish . . . . . . . . . . . . . Automotive varnish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
Wishbone mounting . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Sika Power 477R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510, 512, 513
Cleaning agent . . . . . . Acetone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510, 512, 513

BODY EXTERIORWINDSCREEN
Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2K adhesive set . . . . . 647BODY INTERIOR
Seat riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688

V7,12/2022 911 GT3 Cup (2021–2023) 1077

 OPERATING MATERIALS

MAIN GROUP
Component Type Designation Page

ELECTRIC SYSTEM
Break light switch . . . . . . . . . . . . . . . . . . . . . . .Adhesives . . . . . . . . . . Loctite 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 769

V7,12/2022 911 GT3 Cup (2021–2023) 1078

INDEX
A Assembly of differential, general overview........255 Bottom wishbone ........................................... 318, 345 LIN......................................................................... 748
ABS hydraulic unit ....................................................395 Assembly opening cap, installation .....................278 Brake cooling Vehicle network................................................. 745
Accelerator pedal Air hose ................................................................ 365 Cap of assembly opening, installation ................ 278
B Installing ..............................................................343 Cap of cross shaft cover, installation.................. 278
Installing ..............................................................414
Backlash of angle drive, check ..............................252 Brake fluid...................................................................389 Cap, removal from gearbox housing ................... 152
Additional weights....................................................701
Balance bar Replacing.............................................................390 Catch tank .................................................................. 665
Mounting .............................................................702
Basic setting.......................................................404 Brake force Centre console .......................................................... 785
Prepairing ............................................................701
Repair kit..............................................................407 Calculation .......................................................... 406 Overview of buttons and switches............... 785
Adjustment shim H2, determination of thickness...
Replacing.............................................................409 Brake force distribution ..........................................403 Overview of instrument panel ....................... 789
212
Balance bar system ..................................................402 Brake hydraulics........................................................394 Clutch........................................................................... 133
Adjustment shim Q1 of cross shaft bearing,
Installing ..............................................................413 Brake line....................................... 397, 398, 400, 401 Assembly............................................................. 139
determination.............................................................245
Installing and removing ...................................410 Brake master cylinder Cleaning............................................................... 136
Aerodynamics ............................................................631
Basic locking torque, check ...................................274 Installing and removing ...................................410 Clutch fluid, changing/bleeding ................... 141
Air deflector
Battery .........................................................................710 Brake piston seal.......................................................385 Clutch pedal, adjustment ............................... 144
Attaching ...................................................458, 461
Battery charger..........................................................718 Brake pressure sensor.............................................399 Clutch system, bleeding ................................. 142
Air duct ..............................................................344, 363
Battery disconnect switch .....................................714 Brake system .............................................................374 Scope of inspection.......................................... 136
Air filter .......................................................................... 80
Actuation inside vehicle ..................................716 Bleeding...............................................................391 Spring finger wear – determination ............ 137
Removal/installation .......................................... 80
Actuation outside vehicle ...............................716 Brake pad, changing.........................................386 System leaking .................................................. 143
Air jack system ..........................................................631
Preassembly .......................................................714 Brake pistons/piston seal, replacing ...........387 Clutch discs and pressure plates, arrangement ......
Installing ..............................................................633
Bearing of cross shaft cover, removal.................178 Front axle.............................................................377 264
Air scoop......................................................................325
Bearing of gearbox cover, removal.......................179 Rear axle ..............................................................380 Clutch fluid, changing/bleeding........................... 141
Alarm signals..............................................................812
Bearing of pinion shaft, installation ...........168, 211 Building up Clutch hydraulics ...................................................... 415
Aluminium components..........................................480
Bearings and sleeves, installation ........................203 Engine oil pressure ..............................................59 Clutch line
Angle drive backlash, check...................................252
Bearings of gear housing, removal.......................180 Bumper, front Installing .............................................................. 417
Antilock brake system (ABS).................................997
Bearings of gearbox housing, removal................174 Removing/installing.........................................439 Clutch pedal, adjustment ....................................... 144
Anti-roll bar.......................................................305, 348
Bearings, installation................................................189 Bumper, rear Clutch release bearing
Adjustment ...............................................312, 353
Bedding brakes..........................................................393 Removing/installing.........................................469 Installation .......................................................... 238
Assembly
Belt...................................................................................63 Removal ............................................................... 152
Assembly opening cap.....................................278
Installing .................................................................66 C
Bearing of pinion shaft, installation ...168, 211
Removing................................................................63 Cage padding.............................................................700
Cap of assembly opening, installation.........278
Replacing................................................................63 Calibrating the
Clutch ...................................................................139
Body sensory system.................................................. 767
Pinion shaft, installation bearing.........168, 211
Addon parts ........................................................430 CAN Bus
Subassembly of gearbox housing.................182
Body repair..................................................................496 Ethernet network ..............................................747
Subassembly of shift barrel............................228
Bodyshell.....................................................................480 FlexRay network ................................................749
Assembly carrier
Addon parts ........................................................480 CAN bus....................................................................... 745
Installing ..............................................................474
Material overview..............................................480 CAN....................................................................... 746
Removing.............................................................473
Description of bus devices ............................. 750

V7,12/2022 911 GT3 Cup (2021–2023) 1079

 INDEX

Clutch release bearing hydraulic lines, installation . Dashboard...................................................................704 Driveshaft output flanges, installation ............... 279 Brake hose, installing ....................................... 380
281 De-fuelling..................................................................672 Cross member.................................................... 322
Clutch system leaking .............................................143 Design of the fire extinguisher system...............772 E Cross member reinforcement ....................... 321
Clutch system, bleeding .........................................142 Diagnostics connection...........................................742 Electric contactor Single brake disc, replacing ........................... 379
Colour code body exterior ......................................428 Diagonal strut ............................................................364 Closing of ............................................................720 Front chassis section
Colour code body interior .......................................677 Differential..................................................................127 Electric shift barrel Diagnosis............................................................. 575
Colour code rims .......................................................367 Assembly .............................................................267 Installation .......................................................... 280 Repair ................................................................... 575
Connections, threaded plugs and sensors, Assembly, general overview...........................255 Overview..............................................................129 Front chassis section-luggage compartment
installation ..................................................................196 Cross pin III (ramps) .........................................261 Removal ...............................................................150 Remove ................................................................ 577
Control units...............................................................724 Differential housing i+II...................................259 Engine and gearbox.....................................................70 Replacing............................................................. 586
Installation...........................................................743 Function...............................................................127 Removal/installation...........................................70 Front lid
Cooling system............................................................ 97 General overview, assembly...........................255 Engine control unit (Bosch MS 6.6) ....................734 Removing/installing......................................... 431
Checking the coolant level..............................101 Installation...........................................................275 Engine cooling ........................................................... 320 Front section
Draining the coolant .........................................102 Magnetic disc VI................................................258 Engine cover Removing/installing......................................... 437
Filling ....................................................................104 Measurement procedure.................................257 Installing ..............................................................447 Fuel cut-off valve (FCOV)....................................... 663
Mixing ratio ........................................................... 99 Plate set Va + Vb, calculating ........................263 Removing ............................................................446 Fuel pump................................................................... 666
Total volume including engine......................... 99 Plate sets Va + Vb.............................................265 Engine mount.............................................................421 Fuel pump control unit............................................ 664
Total volume of vehicle without engine........ 99 Ramps and friction surfaces ..........................128 Engine oil........................................................................57 Installation .......................................................... 744
Counterbearing Ramps including cross pin III .........................261 Change ....................................................................57 Fuel supply ....................................................................92
Installation...........................................................230 Removal ...............................................................154 Mobil 1 ESP X3 0W – 40...................................57 Low-pressure side...............................................92
Removal ...............................................................171 Thrust ring IVa....................................................262 Engine oil level..............................................................61 Fuel system ...................................................................92
Coupling rod ...............................................................317 Thrust ring IVb ...................................................262 Measuring ..............................................................61 High-pressure side ..............................................93
Cross member..................................................305, 343 Differential bearing, installation ...........................209 Engine oil pressure ......................................................59 Fuel tank...................................................................... 657
Cross pin III (ramps).................................................261 Differential cover subassembly ............................210 Exhaust system......................................................... 109 Design and components ................................. 660
Cross shaft Differential housing I+II ..........................................259 Loud ......................................................................113 Other tightening torques ................................ 675
Assembly .............................................................247 Differential package, removal................................155 Silenced ...............................................................114 Removing/installing......................................... 667
Installation...........................................................247 Diffuser Standard ..............................................................112 Vent pipe ............................................................. 670
removal.................................................................159 Removing/installing .........................................464 F Full Course Yellow (FCY) ........................................ 808
Setting values.....................................................285 Disassembly Fender
Cross shaft bearing adjustment shim Q1, Gearbox................................................................146 G
Removing/installing.........................................450 Gear housing
determination.............................................................245 Display .........................................................................791 Fire extinguisher cylinder .......................................774
Cross shaft cover bearing, removal .....................178 Function description LEDs .............................848 Installation .......................................................... 276
Fire extinguisher system ........................................770 Subassembly...................................................... 199
Cross shaft cover cap, installation .......................278 Pages ....................................................................791 Actuation from exterior ...................................771
Cylinder pins and sleeves, installation ................194 Door Gear housing and gear set, removal .................... 163
Actuation from interior .................................... 771 Gear housing bearings, removal ........................... 180
Adjusting .............................................................442 Contact ................................................................ 776
D Removing/installing .........................................441 Gear set
Damper strut ....................................................318, 358 Trigger unit ......................................................... 775 Installation .......................................................... 221
Driver seat Flywheel .........................................................................69
Damper strut support Removal/installation........................................681 Overview.............................................................. 221
Installing ..............................................................503 Assembly instructions ........................................69 Gear set and gear housing, removal .................... 163
Driveshaft..........................................................358, 362 Front axle ....................................................................300
Preparing .............................................................501 Driveshaft output flanges Gearbox
Removing.............................................................499 Assembly .............................................................305 Assembly............................................................. 182
Removal ...............................................................153 Axle design.......................................................... 300
Replacing .............................................................498 Clutch................................................................... 133
Brake caliper, installing ...................................378 Differential .......................................................... 127
Brake disc, installing ........................................378 Disassembly ....................................................... 146

V7,12/2022 911 GT3 Cup (2021–2023) 1080

 INDEX

Oil, draining .........................................................148 Cross shaft cover cap.......................................278 Lighting........................................................................ 777 Pinion shaft and mainshaft, tightening .............. 240
Overview ..............................................................123 Cylinder pins and sleeves................................194 Pinion shaft position, adjustment ........................ 218
Power flow ..........................................................126 Differential ..........................................................275 M Plate set Va + Vb, calculating ............................... 263
Service intervals ................................................120 Differential bearing...........................................209 Magnetic disc VI .......................................................258 Plate sets Va + Vb .................................................... 265
Setting values.....................................................285 Driveshaft output flanges ...............................279 Mainshaft ....................................................................169 Plate sets, stacking .................................................. 264
Technical data....................................................123 Electric shift barrel............................................280 Installation .......................................................... 221 Porsche Powerbox.................................................... 725
Transmission ratios ..........................................124 Gear housing.......................................................276 Removal ...............................................................169 Pin assignment .................................................. 725
Gearbox cover bearing, removal ...........................179 Gear set................................................................221 Mainshaft and pinion shaft, tightening ..............240 Porsche Toolbox ....................................................... 876
Gearbox housing Heat exchanger..................................................282 Measurement procedure of differential .............257 Porsche Toolset ........................................................ 931
Bearings, removal..............................................174 Hydraulic lines of clutch release bearing....281 O Power unit mount..................................................... 419
Removal of cap...................................................152 Input shaft...........................................................236 Oil filter Pressure plates and clutch discs, arrangement264
Subassembly ......................................................182 mainshaft ............................................................221 Installation .......................................................... 235
Gearbox mount ..........................................................419 Oil filter.................................................................235 Q
Removal ...............................................................149 Quarter panel
Gearbox oil Oil pump ..............................................................231 Oil level, measuring .................................................. 130
Mobilube 1SHC 75W90 .................................123 Oil spray pipe......................................................282 Replacing............................................................. 563
Oil pump
Gearbox oil, draining.................................................148 Oil suction pipe ..................................................234 Installation .......................................................... 231 R
Pinion shaft.........................................................214 Removal ...............................................................170 Ramps including cross pin III ................................ 261
H Reverse idler gear..............................................229
Headlight Oil spray pipe Rear apron
Selector forks and selector rod .....................233 Installation .......................................................... 282 Removing/installing......................................... 466
Removing/installing .........................................445 Selector rods and selector forks ...................233
Heat exchanger Removal ...............................................................157 Rear axle...................................................................... 339
Sensors, threaded plugs and connections .196 Oil suction pipe Assembly............................................................. 343
Installation...........................................................282 Shaft sealing ring ....................................198, 207
Removal ...............................................................151 Installation .......................................................... 234 Axle design.......................................................... 339
Sleeves and cylinder pins................................194 Removal ...............................................................170 Brake caliper, installing ................................... 381
Hydraulic lines of clutch release bearing, Speed sensor......................................................283
installation ..................................................................281 Option separating points ........................................753 Brake disc, installing ........................................ 381
Studs...........................................................183, 199 Outer safety net Brake hose, installing ....................................... 383
Hydraulic lines, removal ..........................................150 Subassembly of differential cover................210 Installation/adjustment ..................................693 Single brake disc, replacing ........................... 382
I Threaded plugs ..................................................205 Outside mirror Rear chassis section
Ignition coils ................................................................. 94 Threaded plugs, connections and sensors.196 Removing/installing.........................................444 Diagnosis............................................................. 610
Ignition sequence........................................................ 50 Wiring loom ........................................................284 Oxygen sensor Removing rear chassis section-rear frame 611
Ignition system............................................................ 94 Intake system Removing/installing.........................................116 Repair ................................................................... 610
Inner safety net Restrictor aperture...............................................83 Oxygen sensors ......................................................... 116 Replacing rear chassis section-rear frame 615
Installation/adjustment...................................696 Interior ventilation ....................................................704 Rear quarter panel
Input shaft Intermediate steering shaft ...................................337 P Cutting--Out ...................................................... 551
Installation...........................................................236 IPS outputs.................................................................732 Passenger seat Replacing............................................................. 563
Removal ...............................................................169 Installation/removal.........................................685 Rear quarter qanel
L Pedals...........................................................................412
Installation Leg protection ...........................................................700 Repair ................................................................... 549
Bearings ...............................................................189 Installing ..............................................................412 Rear side window
Lenkgetriebe ..............................................................313 PFC RH665 Racing DOT4 ......................................416
Bearings and sleeves........................................203 Light panel Installing .............................................................. 472
Cap of cross shaft cover..................................278 Pinion shaft Removing ............................................................ 471
Removing/installing .........................................448 Adjustment of position.................................... 218
Clutch release bearing .....................................238 Rear window
Clutch release bearing hydraulic lines.........281 Bearing installation........................................... 211 Installing .............................................................. 654
Connections, threaded plugs and sensors .196 Bearing, assembly.............................................168 Preparatory work before installation ........... 650
Counterbearing ..................................................230 Installation .......................................................... 214 Removing ............................................................ 649
Setting values .................................................... 285

V7,12/2022 911 GT3 Cup (2021–2023) 1081

 INDEX

Rear wing Removing/installing front wheel arch liners .....433 Sleeves and cylinder pins, installation ................ 194 Technical data ........................................................... 123
Adjustment .........................................................476 Returnless fuel system...............................................92 Spark plugs....................................................................96 Thread repair.............................................................. 515
Removing/installing .........................................475 Reverse idler gear Speed sensor Threaded plugs, connections and sensors,
Rear wing end plates Installation...........................................................229 Installation .......................................................... 283 installation .................................................................. 196
Removing/installing .........................................477 Removal ...............................................................171 Installing .................................................... 303, 342 Threaded plugs, installation .................................. 205
Rear wing mounting Ride height Removal ...............................................................158 Thrust ring IVa ........................................................... 262
Fitting ...................................................................624 Measuring and adjusting.................................298 Spring finger wear, determining...........................137 Thrust ring IVb........................................................... 262
Removing.............................................................619 Roll cage ......................................................................482 Spring finger, determining wear...........................137 Tightening of pinion shaft and mainshaft.......... 240
Repair....................................................................619 Roll-over valve ...........................................................662 Spring leaf......................................................... 309, 350 Top trailing arm......................................................... 347
Recovery fixtures ......................................................483 Roof Steel parts...................................................................481 Top wishbone ............................................................ 317
Recovery bar .......................................................484 Installing ..............................................................548 Steering ....................................................................... 326 Torque.............................................................................50
Recovery loops...................................................483 Removing.............................................................533 Steering column........................................................334 Track rod ..................................................................... 345
Removal Roof opening, preparing..................................543 Bracket................................................................. 335 Traction control (TC) ............................................ 1011
Bearing of cross shaft cover...........................178 Roof hatch Electronics unit.................................................. 334 Trailing arm ................................................................ 313
Bearing of gearbox cover ................................179 Removing/installing .........................................479 Steering angle sensor ......................................335 Trailing arm mount................................................... 361
Bearings of gear housing ................................180 Steering rack..............................................................328 Transport nut ............................................................. 371
Cap of gearbox housing...................................152 S Steering system Trigger system
Clutch release bearing .....................................152 Safety foam ................................................................664 Assembly .............................................................334 Testing/activating the system...................... 775
Counterbearing ..................................................171 Safety nets..................................................................691 Steering wheel................................................. 338, 779 Trigger unit................................................................. 775
Cross shaft ..........................................................159 Seat belt ......................................................................678 Function description of buttons/switches 781 Battery change .................................................. 776
Cross shaft cover bearing ...............................178 Seat pads ....................................................................684 Overview of buttons and switches............... 780 Tyre pressure monitoring system (TPMS) ........ 372
Differential ..........................................................154 Seat system................................................................680 Stiffening plate.......................................................... 363 Assembly............................................................. 373
Differential package .........................................155 Selector forks and selector rod, installation......233 Studs Tyres............................................................................. 366
Driveshaft output flanges ...............................153 Selector rod and selector forks, installation......233 Installation .......................................................... 199 Michelin Rain...................................................... 367
Electric shift barrel............................................150 Sensors, threaded plugs and connections, Studs, installation.....................................................183 Michelin Slick ..................................................... 367
Gear housing and gear set ..............................163 installation ..................................................................196 Subassembly
Gear housing bearings .....................................180 Sensory system .........................................................765 Differential cover...............................................210 U
Gear set and gear housing ..............................163 Service intervals........................................................120 Gear housing.......................................................199 Underbody panel, rear
Gearbox cover bearing .....................................179 Body exterior ......................................................427 Gearbox housing................................................182 Removing/installing......................................... 456
Gearbox housing cap........................................152 Body Interior .......................................................677 Shift barrel .......................................................... 228 Upright............................................................... 301, 340
Heat exchanger..................................................151 Engine......................................................................48 Support bearing .............................................. 324, 365
Suspension..........................................................291 V
Hydraulic lines....................................................150 Vehicle views ............................................................. 428
Input shaft...........................................................169 Shaft sealing ring T
Installation.................................................198, 207 Tail lights Voltage supply........................................................... 710
mainshaft.............................................................169
Oil filter.................................................................149 Removal ...............................................................173 Removing/installing.........................................449 W
Oil pump...............................................................170 Shift barrel Wear limits ................................................................. 384
Oil spray pipe ......................................................157 Removal ...............................................................172 Brake discs.......................................................... 384
Oil suction pipe ..................................................170 Subassembly ......................................................228 Brake pad ............................................................ 385
Reverse idler gear..............................................171 Shift barrel, electric..................................................129 Wheel alignment....................................................... 297
Shaft sealing ring ..............................................173 Shift play, check........................................................244 Wheel arch liners, rear
Shift barrel...........................................................172 Side section................................................................343 Removing/installing......................................... 435
Speed sensor ......................................................158 Sill trim Wheel bearing ................................................. 301, 340
Wiring loom, removal .......................................149 Removing/installing .........................................463 Installing .............................................................. 301

V7,12/2022 911 GT3 Cup (2021–2023) 1082

 INDEX

Wheel hub.........................................................301, 340

Wheel lock ..................................................................370
Wheel nut....................................................................368
Handling and maintenance.............................368
Wheel trim
Installing ..............................................................452
Wheel/tyre
Combination .......................................................367
Wheels .........................................................................366
Nominal width ....................................................367
Rim diameter ......................................................367
Windscreen.................................................................637
Installing ..............................................................645
Preparatory work before installation ...........641
Removing.............................................................637
Windscreen wiper unit
Removing/installing .........................................778
Wiring loom ................................................................149
Installation...........................................................284
Wiring looms ..............................................................752
Wishbone ................................................313, 328, 344
Wishbone Mounting
Replacing .............................................................506
Wishbone mounting
Installing ..............................................................510
Removing.............................................................507

V7,12/2022 911 GT3 Cup (2021–2023) 1083