JT's 2001 Maserati 3200GT Rebuild! Story, Parts and Advice

The Magneti Marelli throttle bodies are still available new if you know the right people. They are,of course,expensive.
I had mine converted cheaply & within 1 week by a firm who specialise in contactless conversions in Canada. They backed up their conversion with a test graph to show it conformed with Maserati specification. I also bought a Chinese contactless conversion kit which is still in the spares box.
The Bosch throttle pedal potentiometers are no longer available but a contactless substitute is readily available on this forum.
The Volvo throttle bodies can be adapted to work on the Maserati,also available on this forum.
The basic problem with both these items is long term wear of sliding components.
 
It only gets better from here :)
I think..

Wickedly enough, as soon as I arrived home I had access to a mate's brand new hydraulic press to swap the bearings out of their metal guide shells.
I attempted to do this prior to leaving for my trip, in a vice and that was to no avail. The press however, after a dozen pumps abruptly gave way and there I knew I had false hope of magically removing it with the vice or with any other piece of equipment haha
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These Explorer bearings were cheaper to attain from Europe than anywhere locally in Australia, and I spent more than enough time hunting for the original SKF 633186A part just for the over extreme Dynamic capacity(C) that these are rated for. Again my understanding only contributes to the theoretical rotational life of the bearing. So a larger number would benefit to live a longer lifespan. But nobody has them sooooooooooooo
Bit of lithium grease and new ones pressed in for both housings. Might as well :p

July ->
Spent the month repairing my VW and bought another(as a quick project) as I've left it neglected for a little bit too long... This month was conclusion month for the engine shop too
Frank had stuck into getting everything ready for me and it definitely has gotten there. Block was cleaned and back to its former glory. Here he also finished up with the heads and had everything package up for me ready to go!

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Crank was hot tanked and journals were polished and all dimensioned checked for wear(as good as out of factory! Checked this myself too, prior to handing it(might not have been worth doing anything if it wasn't) over and after getting it back from the shop check the clearance for the brand new bearings.)
Oil galleries were drilled out, and all hardened carbon grit was cleaned up(I posted a photo earlier of the camera view of this gunk) and new plugs installed via the "Ferrari" method.
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Block was jet washed, degreased, cold tanked and bead blasted; unsure of Frank's specific order of these tasks
De-carboned all pistons and cleaning all ring landings - preparation for ceramic and teflon coatings.
Liners all prepped and set for power honing for new piston clearances
All pistons and rods then fully assembled, with a reset on piston rings (got brand new Nissan VQ25 rings that were a spot on match to the originals as some were already broken or snapped when trying to be removed)
Re-tapped all holes except head bolts, I ended up doing this.

Heads were stripped, cleaned with intake and exhaust ports bead blasted. Then passed through the sergi jig, corrosion welded and passed through the jig again
Then cleaned, both valve seats and valves refaced. Power honed the valve guides, reset the valve stem protrusion.
New valve stem seals(I got through Maserati, but they are just Elring seals... nothing fancy) Spring rates checked.
Finally re-shimmed to match specifications and finally doing a vacuum check to be sure the valves are not leaking!

The only thing that Frank was afraid of bead blasting, was the cam box, and I agree with him. Any beads damaging the cam surface and it's trouble. I would need to seal these tight and let Greg blast the exterior (another job to be done another day!) Or to leave it as evidence to the history of it :|

Next day; after a months worth of work! All the Hydroblasted bits were complete and ready for their next journey
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Greg had some trouble with dismantling the brake master cylinder and mentioned if I can dismantle it, he'll gladly get it done. It was as simple as pushing the spring in and turning it upside down for the pin to fall out of the exchange ports. And back it went along with the throttle body(and few other smaller bits I forgot about). This. was a disgusting mess(which I still haven't finished, ugh) I'll explain this in the next post
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Anyway; here are some one pretty pictures of perfect looking parts :)
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Photo Maximum; I'll continue seeing as I'm a tad bored today, lol
Throttle body is not a simple clean up job be careful there. If you get into trouble i can help out.
 
As ever a Great read with aperitifs.
Cheers Phil ;)

The Magneti Marelli throttle bodies are still available new if you know the right people. They are,of course,expensive.
I had mine converted cheaply & within 1 week by a firm who specialise in contactless conversions in Canada. They backed up their conversion with a test graph to show it conformed with Maserati specification. I also bought a Chinese contactless conversion kit which is still in the spares box.
The Bosch throttle pedal potentiometers are no longer available but a contactless substitute is readily available on this forum.
The Volvo throttle bodies can be adapted to work on the Maserati,also available on this forum.
The basic problem with both these items is long term wear of sliding components.
I don't see anything wrong with mine, apart from a few bits that I'd personally wish to get sorted. Why I'm not hunting for new, no point really.
My one has the Sacer Chinese conversion, which someone has done prior. As to why I mentioned I was not the first one to open mine!
Will see once the electronics and all parts are plugged in. If there is anything else that's uh. broken haha

Throttle body is not a simple clean up job be careful there. If you get into trouble i can help out.
Cheers, once I'm up to it and can't get it right. Will do!

AH, a week has passed and my *** hasn't had a good opportunity to sit down behind any PC... Jetlag sucks, and I'm still not affixed to the right timezone

So August was a busy month as we had a new Merc to sort out and get on the road asap. So I had some time to sit and clean the engine harness that I received earlier in the year, and progressively replace all the rubber boots, connector by connector. I'm still a long way off!, hopefully after the motor is assembled, I can mount it all onto the motor and tesa-tape and corrugate conduit everything perfectly.

September arrives and well.. I had the immediate urge to get it all finished! So away we go, from almost a perfect beginning that last occurred 21-22 years ago
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Loctite 242E was a fun experience to attain as nothing explains what the E is. Loctite Australia had to ask the USA branch for what E is, and to conclude. "E = Europe" so 242 it was!

Got all the studs in about the same amount by hand, some required a little bit more persuasion than others with a double nut trick. But they're back in.
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Mains then Head, then the coolant ports on the sides.
Which I uh, forgot to get plated at the moment of the photos.
This anyway prompted me to sort all the hardware, and get it all cleaned up and zinc plated once again!
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Fitting the most crucial waterpump parts; the dowels!
They were non existent, causing the bolts to rust and that was a nightmare! Never lose these when swapping a waterpump.
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Rebuilt the entire Wiper mechanism, and reattached the motor to it. Need to find a photo of how it originally looked; white as powdered snow.

Next few days were all hardware related. Sorting. Organising and plating everything I needed for the next set of stages!
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Loctite 971 not being available in Australia(legal reasons), prompted another question of what's next best. Loctite's response being, 577 compound.
Here all the threads were cleaned and all the coolant port fittings installed (with some fresh copper washers)
Brand new bearings in, fresh with no oil yet. ready for the important clearance checks

Photo MAX; I will continue tomorrow, public holiday gives me time to maybe sort out the rest of the wiring harness
And I find out today, turbos are not finished. main shaft sealing ring order gone wrong lmaooooo. he can finish one, but not the second. it has been an entire year!
 
Just a thought was it worth running a tap down the threads first to ensure totally clean and blowing the debris out with a air line ?
Possible old loctite in the threads.
 
Just a thought was it worth running a tap down the threads first to ensure totally clean and blowing the debris out with a air line ?
Possible old loctite in the threads.
oh yes, forgot to mention it!
Frank done the mains, but I ran it through once again to be sure they were clear
Frank couldn't do the heads, as he couldn't figure out the thread pitch. I managed to get only halfway down (not to damage the head surface), cleared up and blown out.
Took a solid 4-5hours of fenagling to get that sorted, and studs secured in properly.
 
I say public holiday; and then I end up doing a full 12hour work day, YAY

OK so, I been doing Masa things. Sat in the engine bay for a silly few hours playing the fun game of, why the **** won't this come out.
TRW say they are clueless about their own product.
Which product am I talking about; well it's the steering rack! (yes, I fought hard removing one of the ends, using the correct tool sadface too )
I did sit for a couple hours searching for alternatives to the original TRW parts to get them ordered and on the way.
-> Hyundai Accent 2 is a doable method(I'll make my own inserts, except I need to take the hub off and press the existing ones out.. EVEN MORE WORK)
-> Fiat Stilo(which in a photograph, look to be identically close but anyone tried these?)
My method to check is insufficient as I can't get any technical data of these products anywhere. They either fit or don't and that's what's killer.

So Question to all; what's doable in 2022 for both Tie-Ends and Gaiter boots! I know TenCAR sell this stuff, but $120 for each Tie-End is well. a bit much for a $10 piece of steel. And really, a $5 piece of rubber. (says the idiot who paid 990 euro for 3 headgaskets (fun story which I'm yet to get to)) :) ANYWAY

And where I left off! Mid-September
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Knock sensors; down and torqued to 20nm("2.0 to 2.5 kgf.m") as specified by NTK, or the internet. same same at this point
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New bearings in dry, as well as the three drain plugs underneath! Loctite + copper washer(for the central duct only) and sealed. Tight!
And then we play important measurements!
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Bottom on and all nuts torqued to spec, to make sure we've got enough oil clearance. Which on paper added up perfectly (I'll put all the data in a later post when I can be bothered typing lots of numbers :)
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It was around 9pm and I think I called it a day by putting the sump cover on and towel over it all. NEXT DAY!
Bottom off, gloves on, oil out and 180degrees we go! followed by precarious surface preparations hehe
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O-Ring onto the liner and no lubrication on the liner itself. Carefully oiled the cylinders and made sure to not get any on the chamfer or it would be game over dictated by the manual!!!!
I made fun videos of just sliding these in; might put it on YT or something, if people would like to see that?

Installed everything; redone all the piston ring orientations so that they were perfect. Made sure the crown markings were facing the correct way both sides, conrod chamfer facing the correct way too and ta-da!

Soooo. I then realised a big problem. If I turn the block 180 degrees for the next step, I will lose my pistons and liners haha.........
Stepped out for a good two hours on break, for any excess oil to settle and run down and made cardboard plates to hold the liners in position so they would not fall out.
A treat that was!
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Caps off! Brand new bearings in. Caps On.?. and check the CLEARANCE because I was a little silly to do it earlier :as001 (2):
Caps off!! Lube on and crank time! END BEARINGS IN, with a little bit of grease(as seen in the photo above). Oil Seal on!
And then, only then. Finally laying the crank in, as demonstrated in Fig. 176, and then pushing all the pistons up, allowing the connecting rods to mate with the crank.
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Conrod side gaps checked; and all passed their test!
Surfaces cleaned and prepped for application
And then I realised... New O-Ring seals, laying the gasket into the track and hang on...
It terminates into the oil seal. Off it comes for a perfect cut :|
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Photo limit again... I'd love 15 photos a post; would be phenomenal. or well.. I can just post and keep going :P
Hope I didn't miss anything
 
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And a bit of end floating, and I called it a night at 3am :) (Monday morning, where I got up and went to work)
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Monday Night, Fat Dabs of Silicone, following Fig. 183
Oil on each bearing and on goes the bottom end! With its half bearing washers of course.
Tightening process as illustrated in the manual, nuts and bolts. I kept everything the same position and orientation that I had when I pulled it all apart
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New O-Ring for the pickup and installed! Bottom end complete?
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Sump cover on for the minute and I called it a midnight Monday! To work, today.... Tuesday haha
And to sort all the hardware for the next stage. Bags and bags of labelled nuts and bolts that were corroded or eaten or rusted(replaced).


I'm done for tonight. Cheerio
 
So Question to all; what's doable in 2022 for both Tie-Ends and Gaiter boots! I know TenCAR sell this stuff, but $120 for each Tie-End is well. a bit much for a $10 piece of steel. And really, a $5 piece of rubber. (says the idiot who paid 990 euro for 3 headgaskets (fun story which I'm yet to get to)) :) ANYWAY

JTop - Hmm, our current Ebay auction show some like 65 USD (not 120) + delivery / each a piece of steel and a piece of rubber 3200/4200 ;-)
 
Whaou I just caught up with this story. What a project! I almost envy you (almost... :rolleyes:).
Could you tell us where you managed to source the bearings (main, big and end float schims) ? All in Italy as I understand but from whom? As they are quite scarce at the moment..
Finally no turbos refurbishing? You didn't managed to source the chras? I thought we could source some from the Subaru gt that also have the rhb turbocharger.
Congrats and thank you for sharing with photos!!
 
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And a bit of end floating, and I called it a night at 3am :) (Monday morning, where I got up and went to work)
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Monday Night, Fat Dabs of Silicone, following Fig. 183
Oil on each bearing and on goes the bottom end! With its half bearing washers of course.
Tightening process as illustrated in the manual, nuts and bolts. I kept everything the same position and orientation that I had when I pulled it all apart
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New O-Ring for the pickup and installed! Bottom end complete?
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Sump cover on for the minute and I called it a midnight Monday! To work, today.... Tuesday haha
And to sort all the hardware for the next stage. Bags and bags of labelled nuts and bolts that were corroded or eaten or rusted(replaced).


I'm done for tonight. Cheerio
Lovley work and documunation! :) One question about the gasket and oilsump. In the workshop manual it say that you sould use loctite black seal in the connection points. What do they mean about that? did you use Loctite one your engine?
 
wow. last post - November 10th 2022...

I sit and wonder to myself.
Why did I stop.
The writing.
The little space of brain ventilation.
The fluidic passion of questions outlining inevitable problems; answered with scientific and logical reasoning.
And oh, the part numbers -> can never get enough of.
Where did it suddenly disappear to in my life.
I don't believe in my brain that it did. Definitely for the audience reading this message. An empty thread is of unimportance. Nothing to see here...

I was the kid in school who got an A Grade in Philosophy class and a D grade in English.
To question everything from every side rather than justify the significance of "********". As fact, the world runs on the latter.
I never believed in the inability of my coherence from a standardised grade; rather that time would come and improve my abilities. If I actively persisted, of course.

Day in - Day out. Work. Personal Work. Training. Sleep.
Started as everyone else with a 5 day working week; mixing university with engineering work-life. Quickly realised it's not enough. Turned to longer hours, extended to 6 days. Turned to 7 and it's been like that fairly consistently for the last 3 years. Maybe some days off to recover. Sick or simply mentally drained from the day job. Worst type of tired and after a 12-16hr day.
Ending each day with the worst type of cooldown:
Brain-dead brain-rot internet.
Hard dopamine addiction for the lack of; in general life. It's so easy to laugh at your phone than to laugh with others. But also drown in information overload. For we no longer can think for ourselves, life started becoming heavily reliant on outsourcing brain activity.

I feel like I've mentally recovered by now, 9 months out of the job that sucked the life out of me; but respectively taught me everything I know in the professional world.
But don't think I ever stopped. I'm 2 businesses in and finalising a 3rd to launch before my 26th. I'm just running out of time.

They say every great writer has his ups and downs.
Vanishing for long periods, then back in the limelight with something new again.
It's all stems back into the art of 'trying'. Or what I like to call, working my *** off!
Energy. Effort. Persistency. Perseverance. Achievement.

Or in this immediate case; monologue.
Lots of stress of course. You don't even realise it until the day ends and the fatigue hits.

Right now I'm trying to practice my theory of "Closing the Loop".
Any and all ideas that I've had in my adult life. Make them all happen. One way or another. Like my forum posts!
No matter what it is. Shia LaBeouf said it best. Just do it. Or Nike. Or yeah...

I'll stop my crazy foolish blabber that most won't regard and continue to the point of this thread.
That was a build; a personal and physical journey of my beloved Quarzo Dolomite 3200GT. Only 3200GT of its colour known in Australia. And that's from me having my own vinwiki of this model; which I'd like to share, but only to other 3200GT owners in Australia because some things are best kept behind lock and key.
Oh and I've bought a Quarzo Dolomite 4200GT too. Just collecting parts for it slowly before I do a rebuild series.

I sat in my apartment in Croatia in 2023, writing the next lot of gargle that I think most would end up reading as they are building their own motors.
That was until all the monologue felt very flat. Like I didn't know how to continue and emphasise on sections, albeit I was just recycling memory.
TLDR as the reddit community would define - Too-Long-Didn't-Read:
For I built this motor, dropped it into the engine bay, forgot about the black immo chip in the key, got it running but poorly, couldn't figure why it wasn't running right for ages. Took it from Melb to Canberra and back, maybe two drives after that and then dead again... One person to blame(myself for the fellow I trusted to rebuild two critical parts(simply don't have the tooling to do it myself)) BUT I'll get to that.
Up to now.
Dead car manually lifted 2m up on a dead hoist with a dead motor. At my workshop. Oh yeah, lots of ups and downs.

Jumping back in time:
 
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*written in August 2023.*
TLDR: In hindsight, dipping toes in every avenue is great to start, but mentally exhausting in the long run. Do as you think is best for the situation that is your own.


Where to begin… For it has been a year since I have had the opportunity to express the journey I have begun; now be but a quick two years from the beginning.
I really hate writing; making documents, yet I challenge myself to simply do it, for I fear if I do not, I will never use it as the skill I enjoy. As my boss keeps telling me. Short and sweet, convey the message in as little words as possible. Something that doesn’t work in my ‘overthinking’ style mind. He’s like Kevin from the Office;
“Why waste time say lot word when few word do trick?” haha, boy, you’re all in for a regurgitation treat!

My last opportunity I was writing in the hotel in Seville Spain, on holiday. Bored out of my head, I had time to catchup but also prepare all the mental planning for the next few months, given I wished to have the car completed by January 2023.

A goal I had achieved, partially(car was driving); but you may ask. Why the silence? A few things:

After my last post, back in Melbourne, I was deep in getting everything going. I just redone my Polo’s steering rack as it was leaking. And with that replaced the original 5-speed to a custom 6-speed gearbox that I had sitting for a long time, cleaned everything. Did it all given the weekend after was ‘Day of the Volkswagen’ a show that everyone was looking forward to, as it is the biggest. It then was cancelled two days prior due to the heavy rains; yet the guys at the workshop were keen on having an event, so we hosted our own. I spent the entire Saturday sorting and cleaning my car to then be in an unfortunate freak car accident that was not my fault. This crippled my spirit entirely. Fast forward--->

Even though I had this Maserati running, it was not perfect. And I had spent countless weekends Jan-March trying to fix an issue after another. To complete it all; I am a perfectionist in this regard. My freedom would have in-turn give me the time to write.

But then I bought another project, one that I could not turn down… Another 3200GT

This spiralled itself towards self-destruction.
Personal self-neglect. Depleted energy. Mental exhaustion. ~Tiredness if that ever can be an excuse
I slowly began arriving late to work, and it would trickle into the rest of the week, month.
All problems which I have been working at resolving. Fixing temporarily before it launches me back.
Having travelled out of the country; seemed to kick the reset button for me. It let me know the sweet spot of just stopping for a minute and allowing myself to enjoy a bit, for life goes by too quickly. When there is comfort, we just cruise on by. Which I don’t like at all.


I am told consistently that I am fortunate to be where I am and have my kind of job, traveling the world a few different places at a time. But inside I feel a bit hollow and empty, an NPC because I am braindead from overload. Paired with the inability to combine my external endeavours into a consistent workflow, to readily achieve everything; this reflected on my character.
Situating all my ideas that revolve on my notepads, never having the time to begin has me drowning, for I know that if I do not start them now, they will never come to be and that is scary for me.

I failed to write this year.
I needed ‘off time’, which I could never really get. This is my own doing; for I am part of 5 families. My folks and my few friends that have come along the way, Engineering work(Mon-Thursday. 40hrs minimum and I’m the idiot doing overtime to make up for the lack of employees...), Mechanic-Workshop Work (volunteering every Friday-Saturday). The VW Polo Facebook community that I manage but fail to run it as I think I should and finally my friend Boris(I will get to this at some point). Dipping my toes into every avenue to have the best mentors and people around me, to be that knowledgeable mentor for those who come to me.
You can only become what you say you want to become.

I am now on a mental break holiday in Croatia, away from everyone and everything. Yet my mind still churns, and stresses over all the things I have left behind. Pursuing all my broken ends and endeavours as I simply have to. For the sake of everything I have started, I mentally must finish these journeys and get to the next ones.



So here I am.



A continuation from the bottom and front-end construction, which I completed in the last post.
(Give me a day. Hunting for photos and dealing with upload dilemmas where it just goes. 'OOPS. IT AIN'T HAPPENING!')

I don’t think I ever mentioned the interior; for this was the simple part of all the work. Other than removing all the AC components, back to bare shell status, in order to replace O-Rings, seals and tubing. Cleaning up the wiring mess that the previous owner left, and making sure it is taped up correctly again(I hate PVC electrical tape)
Carpets, but why?
I sorted the carpets for the interior as they were looking horrendous. I bought some thick black cloth and glued it down to all the noise dampening pads because they had this tacky state...
Also ordered interior removable carpets as they were on offer from a local company. Never got any with the car so why not eyy?
This allowed me to put the carpet back in and get the roof liner in and rear seats done.
Comfy once again.
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Professional Quality:
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Hi Jan,
I was thinking you have been keeping a low profile. You seem like a normal 26 y.o. questioning everything & expecting too much.
 
One thing I've learned in my own life is taking on too much in life can certainly not be well for your own well being and sometimes you just have to say no stop and take time out.
For myself when I stopped doing the automotive work all over Europe that paid me well and I enjoyed the places I worked in it wasn't doing me any good in the end.
Not been on a flight for over two years now.
Just take care of yourself and enjoy your projects.
 
Hi Jan,
I was thinking you have been keeping a low profile. You seem like a normal 26 y.o. questioning everything & expecting too much.
Hey Mike!
Always held highest of hopes. Lowest expectations. Just getting on by one step at a time. Too much to do, so little time...

One thing I've learned in my own life is taking on too much in life can certainly not be well for your own well being and sometimes you just have to say no stop and take time out.
For myself when I stopped doing the automotive work all over Europe that paid me well and I enjoyed the places I worked in it wasn't doing me any good in the end.
Not been on a flight for over two years now.
Just take care of yourself and enjoy your projects.
Hey Phil!
It's in the ability to recover. Next day stronger and wiser.
Balancing Yes-No's responses based on potential extended time based dilemmas. Foresight is only learned not taught. You only suffer a couple times.
-> The boomerang effect is certainly my favourite.
E.G. Customers returning for 1 coilpack/sparkplug during each visit(because they refuse to pay for more than 1).
Unhappy each time instead of accepting the true reality of the situation.

Funnily enough, travelling became my reset. Time off with less stress and demand. Everyone is different in how this affects them. Gave me some time to think and write.
Started looking after myself again and definitely doing better right now, I'll continue the catchup posts!

I've started the habit to sit with my laptop every evening instead of my phone.
Bit bored, but continue with something new(ie. procrastinating 3x big jobs coming up).
 
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*in continuation from last post*
Meanwhile I had started on organising all the hardware to be cleaned from the corrosive fire retardant, and yellow zinc plated again.
This stage was critical for I now knew how well I organised all of it in the correct categories in baggies. I had zero spares. So, I was pleased
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Fun story!
I was chasing the powder coating guy as he had my parts for an entire year and had not finished the job. Like it really made me angry as I spent week on week, my Friday morning driving 60km to see him and then back getting nothing. Him finally completing most things; forgetting my fuel flap latch and not getting the throttle body cover done perfectly as he liked(holding onto it for another few weeks). He did spend a wicked amount of time on the covers, so I do appreciate all that. For what it was worth, it took too long. *will see the results later*

*I seemingly missed writing this entire section. So I'll just add the photos I took with some notes*
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*the block as it stood before the next job lot*
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All prior to 24x bolts to their 10.8nm torque. Oh. and put sealant on the entire outer edge. Don't ask how I know...

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*Front oil pump preparation* Cover. Dowel. Gear. O-Ring.
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"Well greased O-Rings" I didn't read
And
"Centre the driven gear on the oil pump body so that a tooth gap is facing the dowel hole".
If in doubt, read the manual!
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Max photos for this one. one more post tonight and I'll see if I can do some more this week. I got plenty more!
 
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A now nice and shiny front engine. I did want the block to be blasted. But Gregg and Frank both told me. NO! Too risky potentially damaging journals.

New note. I have my own replica oil fittings as they are still NLA and nobody else had any. So why not make some!
I'll be back tomorrow to replace my CAD drawings with some live photos -> Stock if anyone needs these fittings. Brand new off oil filter housing to oil cooler.
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*these were broken from a crashed 3200GT that's now my personal parts car because I've given up on attempting to save it, one day someone will hate me*

Waterpump on next.
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The gasket was designed for a different engine(there is no different engine), it just doesn't line up whatsoever. All wonky.

And fin. Installed the pulleys and balancer too!
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