122-M2R2G-10

Service
Technical Information
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Misfiring at High RPM (59/15)
Information
This Technical Information replaces the previous Technical Information dated September 2, 2015.
•
Reason: Different repair concept used if there are visible signs of wear on camshaft
and/or valve levers
If visible signs of wear are found on the camshaft and/or valve levers during the fault finding steps
described in this Technical Information, the engine must always be replaced.
This means that the various repair stages used previously depending on the date of manufacture of the
respective engine will no longer be used.
Please note that although the various repair stages are no longer used, the issue must still be investigated first by Technical Support in order to obtain approval for the repair work and allocate
the required replacement engine before carrying out repairs.
You will find details of the procedure in the description below.
Vehicle Type:
911 GT3 (991)
Model Year:
As of 2014
Concerns:
Engine malfunction (Misfiring at high rpm)
Situation:
•
•
Diagnostic path for fault finding in the event of the complaint "Engine malfunction"
Required repair measures
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Diagnostic path for systematic fault finding
Action
Required:
Information
The following diagnostic path will assist you to quickly and effectively diagnose "Misfires at high rpm (>
7,000 rpm)".
In particular, this involves identifying possible wear on the valve levers which usually occurs at high engine
speeds.
If misfires occur even at considerably lower engine speeds or over the entire rpm range and
depending on the fault memory entries stored in the DME control unit fault memory, the components
that are usually affected by this type of fault (spark plugs, ignition coils. injectors, etc.) must always
be checked first in accordance with the instructions provided under Guided Fault Finding in the PIWIS
Tester.
The recommended procedure for systematic fault finding in the event of the complaint "Misfires at high
rpm (> 7,000 rpm)" is described here. For greater clarity, the detailed description includes a condensed
overview of the information in the form of a table.
Customer complaint:
•
Engine malfunctions occur during full-load acceleration at high rpm (> 7,000 rpm).
•
The yellow warning message "Reduced power Driving permitted Consult a garage" is displayed on
the multi-function display in the instrument cluster.
•
The engine warning light ("Check Engine" symbol) also comes on in the instrument cluster.
•
Engine running in limp-home mode.
•
The engine warning light and warning message disappear after switching off the ignition and then
switching it back on again (ignition reset). The engine is running normally again.
Fault verification:
If these symptoms are present, the fault must be verified using the procedure described below.
Information
If misfires occur even at considerably lower engine speeds or over the entire rpm range and
depending on the fault memory entries stored in the DME control unit fault memory, the components
that are usually affected by this type of fault (spark plugs, ignition coils. injectors, etc.) must always
be checked first in accordance with the instructions provided under Guided Fault Finding in the PIWIS
Tester.
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Read out the fault memory using the PIWIS Tester: The fault entry P0300 – Misfire totals
error together with a fault entry P0301 ... P0306 (Misfire cylinder 1 ... 6) is set in the DME
control unit fault memory.
•
Create Vehicle Analysis Log (VAL) using the PIWIS Tester.
•
Test-drive the vehicle until the fault occurs: Drive with full-load acceleration in 3rd gear (manual
gate) over a rev range of 4,000 – 8,500 rpm
•
Reproduce the fault: The fault can be reproduced again - always in the same rpm range (+/- 300
rpm) - as described above.
Action Required:
1
2
The fault cannot be reproduced:
•
There is a high probability that the malfunction is not caused by wear on a valve lever. Another
component must be checked in order to determine the cause.
•
If necessary, contact Technical Support in order to decide what to do next.
The fault can be reproduced:
2.1
Swap the ignition coil and spark plug from the "suspect" cylinder with the ignition coil and
spark plug from a cylinder that is working perfectly.
For instructions, see  Workshop Manual '282020 Removing and installing ignition coils'
and  Workshop Manual '287020 Removing and installing spark plugs'.
2.2
Test-drive the vehicle and try to reproduce the fault again under the conditions specified
above.
2.3
Then read out the fault memory of the DME control unit using the PIWIS Tester and check
whether the same fault memory entry is stored again, i.e. after swapping the ignition coil
and spark plug, the previously suspect cylinder is now working perfectly and the fault occurs
instead on the cylinder into which you installed the ignition coil and spark plug from the
cylinder that was originally suspect.
•
If YES (The same fault is stored again): Remove the ignition coil from the cylinder that is
now suspect and install it again in the cylinder that was originally suspect. Leave the
spark plug in the cylinder that is now suspect. Then test-drive the vehicle again and
reproduce the fault again in order to clearly identify the component that is causing the
fault.
•
If NO (The cylinder that was originally suspect is still suspect): Remove the cylinder
head cover on the suspect cylinder bank and check the camshafts and valve levers for
visible signs of wear. For instructions, see section  Technical Information '1X0000
Checking camshafts and valve levers for wear'.
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Summary:
Customer complaint
•
Engine malfunctions occur during full-load acceleration at high rpm (> 7,000 rpm).
•
The yellow warning message "Reduced power Driving permitted Consult a garage" is displayed on
the multi-function display in the instrument cluster.
•
The engine warning light ("Check Engine" symbol) also comes on in the instrument cluster.
•
Engine running in limp-home mode.
•
The engine warning light and warning message disappear after switching off the ignition and then
switching it back on again (ignition reset). The engine is running normally again.
Fault verification
•
Read out the fault memory using the PIWIS Tester: The fault entry P0300 – Misfire totals
error together with a fault entry P0301 ... P0306 (Misfire cylinder 1 ... 6) is set in the DME
control unit fault memory.
•
Create Vehicle Analysis Log (VAL) using the PIWIS Tester.
•
Test-drive the vehicle until the fault occurs: Drive with full-load acceleration in 3rd gear
(manual gate) over a rev range of 4,000 – 8,500 rpm.
•
Reproduce the fault: The fault can be reproduced again - always in the same rev range (+/- 300
rpm) - as described above.
Fault can be reproduced
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Fault cannot be reproduced
•
Swap the ignition coil and spark plug from
the "suspect" cylinder with the ignition coil
and spark plug from a cylinder that is working
perfectly.
•
There is a high probability that the
malfunction is not caused by wear on a valve
lever. Another component must be checked
in order to determine the cause.
•
Test-drive the vehicle and try to reproduce
the fault again under the conditions specified
above.
•
If necessary, talk to your contact person for
technical enquiries at your importer's office
in order to decide what to do next.
•
Check whether the same fault memory entry
is stored again.
•
If YES: Remove the ignition coil from the
cylinder that is now suspect and install it
again in the cylinder that was originally
suspect. Leave the spark plug in the cylinder
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that is now suspect. Then test-drive the
vehicle again and reproduce the fault again
in order to clearly identify the component that
is causing the fault.
If NO: Remove the cylinder head cover on
the suspect cylinder bank and check the
camshafts and valve levers for visible signs
of wear. For instructions, see section 
Technical Information '1X0000 Checking
camshafts and valve levers for wear'.
•
Checking camshafts and valve levers for wear
Work Procedure: 1
2
Remove cylinder head cover on the affected cylinder bank  Workshop Manual '158219 Removing
and installing cylinder head cover'.
Remove camshafts and valve levers, inspect for visible signs of wear.
The following problems indicate a worn valve
lever:
3
•
Rough surface on the cams of the cylinder in
question. If there is a significant amount of wear,
the contour of the tip of the cam will be "square"
and will show significant tempering colors
(blue/brown discoloration of the material caused
by high temperatures).
•
The valve lever shows significant signs of linear
Wear on valve lever
wear on the contact surface to the cam  Wear
on valve lever -arrow- at the edge of the hydraulic valve clearance compensating element 
Wear on valve lever -inset-. The black coating is worn down and the silver base material can be
seen.
Take a photo of the relevant damaged areas of the valve lever  Wear on valve lever -arrow- for
documentation purposes. Make sure that the photos clearly show the installation position of the
valve levers in question.
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Also indicate the installation position of the valve
levers in question (e.g. cylinder 6 – intake) or identify
the components by labelling them  Marking valve
levers.
Marking valve levers
4
Send the photos together with the Vehicle Analysis Log to Technical Support via PTEC -> Techline
Assistance Request and specify the vehicle identification number (VIN) and engine number of
the relevant vehicle.
The information must then be sent via PRMS ticket to Technical Support in order to investigate the issue and obtain approval for the replacement engine.
References:
 Workshop Manual '158219 Removing and installing cylinder head cover'
 Workshop Manual '282020 Removing and installing ignition coils'
 Workshop Manual '287020 Removing and installing spark plugs'
Repair measures
Work Procedure: 1
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Following feedback and approval from Technical Support, replace the engine. For
instructions, see Workshop Manual '100119 Removing and installing engine'.
2
After you have replaced the engine, re-program the DME control unit using the PIWIS
Tester with PIWIS Tester software version 32.000 (or higher) installed: DME control unit > 
'Programming' menu >> 'Automatic programming' function.
3
After completing the work, carry out a test drive until the engine reaches operating
temperature.
4
After carrying out the test drive, use the PIWIS Tester to create a Vehicle Analysis Log (VAL)
and select the function  ‘Data management’ > ‘VAL data return’ using the PIWIS Tester to send
it to Porsche AG.
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Parts Info:
Information
To simplify the ordering process, the additional parts required for replacing the engine have
been grouped together as a repair kit under one part number.
Overview of the parts to be ordered for replacing the engine:
Part No.
Designation
– Use
Qty.
9A1 100 975 EX
 Replacement engine
1 ea.
000 043 303 61
 Engine repair kit
1 ea.
The parts included in the repair kit and details of where they are used are listed here for your information.
There is no need to order the parts individually unless additional individual parts are required.
Part No.
Designation
– Use
Qty.
000 043 303 61
Engine repair kit
1 ea.
Includes:
•
999 073 443 01
Combination screw, M12 x 1.5 x 40
– Threaded joint for diagonal brace
2 ea.
•
999 072 869 01
Hexagon-head bolt, M12 x 1.5 x 45
– Threaded joint for diagonal brace
2 ea.
•
999 084 123 09
Hexagon nut, M10
– Threaded joint securing anti-roll bar to
connecting link
2 ea.
•
900 076 064 02
Hexagon nut, M8
– Threaded joint securing anti-roll bar to body
4 ea.
•
999 072 868 01
Hexagon-head bolt, M12 x 1.5 x 80
– Threaded joint for rear axle cross member
2 ea.
•
999 072 859 01
Hexagon-head bolt, M12 x 1.5 x 58
– Threaded joint for rear axle cross member
2 ea.
•
999 084 445 01
Hexagon nut, M12 x 1.5
– Threaded joint for rear axle cross member
4 ea.
•
999 076 053 01
Hexagon nut, M10
– Threaded joint for transmission support
2 ea.
•
999 086 009 02
Hexagon nut, M12
– Threaded joint for transmission mount
1 ea.
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Materials:
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N 908 484 05
Hexagon nut, M12 x 1.5
– Threaded joint for engine carrier
2 ea.
•
996 106 801 03
O-ring
– Coolant lines
3 ea.
•
999 707 660 40
O-ring
– Desiccator
2 ea.
•
944 573 143 01
Desiccator
1 ea.
•
N 906 651 01
Cheese head bolt, M10 x 1 x 29
– Threaded joint securing flywheel to crankshaft
10 ea.
•
999 385 009 01
Hexagon round-head bolt, M12 x 1.5 x 55
– Threaded joint securing transmission to
engine
6 ea.
•
999 073 517 01
Cheese head bolt, M10 x 1 x 46.5
– Threaded joint securing drive shaft to transmission
12 ea.
•
997 111 336 90
Clamp
– For securing front silencer to catalytic
converter flange
2 ea.
•
900 380 005 01
Hexagon nut, M8
– For securing front silencer holder
4 ea.
•
900 067 362 01
Cheese head bolt, M8 x 50
– Threaded joint for restraining straps for rear
silencer
2 ea.
•
999 651 401 01
Line bracket
– For securing control line for exhaust flaps to
engine carrier
4 ea.
•
999 512 707 00
Hose clamp
– For securing control line for exhaust flaps to
vacuum unit
2 ea.
•
N 100 988 11
Hexagon-head bolt, M6 x 16
– Threaded joint for heat shield on engine carrier
3 ea.
•
980 111 561 00
Seal
– Exhaust manifold
2 ea.
Required materials (usually already available in the Porsche dealership, only order if additional
materials are required):
Part No.
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Designation
– Use
AfterSales
Qty.
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Technical Information
Tools:
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•
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000 043 020 00
Optimoly TA mounting paste
– Wheel centering surface on wheel hub
100g tube
(approx. 5–10 grams
required per vehicle)
000 043 205 93
Klüberplus Gel grease
– For coating O-rings and coolant hoses
100g tube
(approx. 5 grams required
per vehicle)
000 043 305 16
Antifreeze
20-liter container
(approx. 5 liters required per
vehicle)
000 043 004 00
Optimoly HT mounting grease
– For greasing clamp securing front muffler
to catalytic converter flange
90g tube
(approx. 10 grams required
per vehicle)
Part No.
Designation
– Use
Qty.
9A1 101 213 00
Transport eyebolt
– For lifting engine
1 for every Porsche
dealership
(only if not already available)
Auxiliary tool:
Special tools:
Designation/Comment
Use
9900 - PIWIS Tester 3
Creating VAL/On-board diagnosis
Battery Charger/Power Supply - Suitable
for AGM Type batteries, recommended current
rating of 70A fixed voltage 13.5V to 14.5V.
9453 - Access ramps
Moving the vehicle onto the lifting platform
Only if required (depending on type of lifting
platform)
9794 - Assembly aid
Removing and fitting rear wheels
9796 - Socket wrench
Torque wrench, 150 – 800 Nm (111 – 592 ftlb.),
e.g. V.A.G 1601 - Torque wrench, 150 - 800
Nm (111 - 592 ftlb.)
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Suitable air-conditioning service unit, e.g. VAS
6456A - A/C service station with rinsing
device
Draining and filling refrigerant in the air conditioning
system
Disassembly tool, e.g. VAS 6933 - Disassembly tool
Disconnecting parking lock cable from PDK transmission
9822 - Assembly tool
Opening and fitting air conditioning lines
9443 - Oil filter wrench
Removing oil filter
Oil collection container
Assembly pliers for spring band clamps, e.g.
VAS 6856 - Spring band clamp pliers
Removing and installing engine
VAS 6832 - Master Gear unit elevating
platform
9769 - Retainer plate
9769/1 - Support
Suitable tension strap for securing the engine on
the lifting platform during removal, e.g. 9454 strapping belts
Workshop crane, e.g. VAS 6100 - Workshop
crane
Lifting the engine
Suitable lifting equipment, e.g. cross member
with carabiner hook and lifting straps
VAS 6766 - Counter-hold tool
Removing and installing flywheel
9321 - Centring pins
Torque angle torque wrench for tightening the
fastening screws for the flywheel to a tightening
torque of 25 Nm (19 ftlb.) and torque angle of
120°, e.g. VAS 6942 - Torque/torque angle
screw tool
•
VAS 6199 - Pliers for hose clamp with side
cutters
Removing and fitting hose clamps on the control
line for exhaust flaps
Coolant collection container
Draining coolant
9696 - Filling device
Filling coolant and bleeding the cooling system
Other tools:
Torque screwdriver, 1.5 – 3 Nm (1 – 2 ftlb.), e.g. VAS 6494 - Torque screwdriver
Torque wrench, 4 – 20 Nm (3 – 15 ftlb.), e.g. WE1052 - Torque wrench V.A.G. 1410/1576
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Torque wrench, 6 – 50 Nm (4.5 – 37 ftlb.), e.g. V.A.G 1331 - Torque wrench, 6-50 Nm (4.5-37 ftlb.)
Torque wrench, 40 – 200 Nm (30 – 148 ftlb.), e.g. V.A.G 1332 - Torque wrench, 40-200 Nm
(30-148 ftlb.)
Torque angle torque wrench, 4 – 400 Nm (3 – 296 ftlb.), e.g. VAS 6942 - Torque/torque angle screw
tool
Insert for torque wrench, Torx E18
Ring insert for torque wrench, a/f 18
References:
 Workshop Manual '100119 Removing and installing engine'
 Workshop Manual '373427 Removing and mounting Porsche Doppelkupplung (PDK)'
For invoicing and documentation using PQIS, enter the following coding:
Location (FES5)
15050
Camshaft
Damage type (SA4)
1824
severe wear
Important Notice: Technical Bulletins issued by Porsche Cars North America, Inc. are intended only for use by professional automotive technicians who have attended Porsche service training
courses. They are written to inform those technicians of conditions that may occur on some Porsche vehicles, or to provide information that could assist in the proper servicing of a vehicle. Porsche special
tools may be necessary in order to perform certain operations identified in these bulletins. Use of tools and procedures other than those Porsche recommends in these bulletins may be detrimental to the
safe operation of your vehicle, and may endanger the people working on it. Properly trained Porsche technicians have the equipment, tools, safety instructions, and know-how to do the job properly and
safely. If a particular condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your authorized Porsche Dealer for the latest information
about whether a particular technical bulletin applies to your vehicle. Part numbers listed in these bulletins are for reference only. Always check with your authorized Porsche dealer to verify the current and
correct part numbers. The work procedures updated electronically in the Porsche PIWIS diagnostic and testing device take precedence and, in the event of a discrepancy, the work procedures in the PIWIS
Tester are the ones that must be followed.
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Porsche Cars North America, Inc. believes the specifications to be correct at the time of printing. However, specifications, standard equipment and options are subject to change without notice. Some
options may be unavailable when a car is built. Some vehicles may be shown with non-U.S. equipment. Please ask your authorized Porsche dealer for advice concerning the current availability of options
and verify the optional equipment that you ordered. Porsche recommends seat belt usage and observance of traffic laws at all times.
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