Ghibli II winter works

Wally

Member
Messages
244
Good company!! Well done. Enjoy the car before winter falls. For the shoelace: use some VAG-gasket-cream: remains creamy but seals small irregularities. Partnumber : D 454 300 A2. (or next time: use silicone, but this is more work to remove)
 
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spacecadet

Member
Messages
378
There were definitely ups and downs, and a lot of learning during the past 3 years. Fortunately I didn't count the hours but took a lot more effort than initially expected.

Thanks everybody for encouragement and tips they helped a lot.

Winter is unfortunately pretty much here again, but at least it's time for some minor updates :D (hint: brake system upgrade, in a new thread)

I've used Hylomar non setting compound on the shoelaces, not sure yet why one side is weeping.
 

Oneball

Member
Messages
11,075
There were definitely ups and downs, and a lot of learning during the past 3 years. Fortunately I didn't count the hours but took a lot more effort than initially expected.

Thanks everybody for encouragement and tips they helped a lot.

Winter is unfortunately pretty much here again, but at least it's time for some minor updates :D (hint: brake system upgrade, in a new thread)

I've used Hylomar non setting compound on the shoelaces, not sure yet why one side is weeping.

If there was any oil on the mating surface the Hylomar won’t have sealed.
 

spacecadet

Member
Messages
378
If there was any oil on the mating surface the Hylomar won’t have sealed.

I've cleaned and degreased everything, at least as I remember. I think the problem is that I've run out of the factory one, and used a different one. It was also viton, but maybe 0.1mm smaller in diameter. Looked up my notes, everything is there, except this, so not sure.
 
Messages
388
Just been rereading this fascinating thread and catching up on developments. What an epic undertaking!

I hope your Ghibli is now running really well spacecadet, and you're getting the benefits of all that hard work.
 

spacecadet

Member
Messages
378
Thanks for the question, but unfortunately it's not perfect yet.

From the remaining list I've crossed two items: idle setup (that was an easy one) and A/C (again easy, because it's actually working). But the remaining two did cause me headaches.

Regarding clutch / drivetrain noise I removed the gearbox again, after I've realized that the root cause for the big clunk during shifting was the prop shaft hitting the chassis above and the exhaust heat shield below. This was caused by a broken gearbox mount for which I couldn't find a replacement. For now swapped it with the center exhaust mounts which do have the same part number.

86023

While there I've also replaced the prop shaft central support (Maserati 316020103) which is the same as in a Volvo 700 and 900 series models (for example Meyle 514 134 0501).

86024

86025

86026

After reassembling everything I still have some noise coming from the clutch while it's depressed o_O I'm quite clueless at this point.
 

spacecadet

Member
Messages
378
Finally also found the source of the oil leak today. As I feared it's coming from behind the cylinder front cover, the dreaded shoelace gasket popped out during assembly. Previously though I'll just leave as is whatever the cause, but now I do have to fix it, meaning a full timing belt change procedure.

Would you reuse the timing belt in this situation, or should I get a new one? I'll probably get a new one to save me an additional year.

86027
 
Messages
388
Thanks for the update. As much as these final niggles are a royal pain in the backside, just think when finished she’ll be virtually perfect!
 

spacecadet

Member
Messages
378
Better to be :) But this was a stupid mistake from my side, the slips should be on the top to avoid such an issue and other possible leaks. On the other side it's fine, not sure why I inverted here.

Anyway at least I know what to do for this, and already ordered a new belt as well.
 

alpa

Member
Messages
169
Hey spacecadet,
Just saw this old post. You won most of the common gifts :) .

Cracks have been repaired. Turned out that on the L.H. side outside in the wheel well the lip was cracked the same way as on the R.H. side. The cut in R.H. rail and the quality of the weld done in the factory was a joke. Besides these front rails are like rubber, made from thin sheet metal without necessary strengthening. No wonder they crack. They can mainly move in the vertical direction. Strengthening them partially is not possible because the forces will cause cracks further down. The only possible solution is rebuilding them from thicker sheets all they way until they join the main structure.

What I don't understand, they didn't learn from the earlier Biturbos?

...

index.php

No they did not even on QP4. The design is a disaster: the front part of the rail that holds the engine frame is made of one or two 1.5mm metal sheets + the 0.9mm body layer. And then in the junction with the rail that goes under the body it's suddenly just one 0.9mm layer. Needless to say it cracks there. The 1.5mm layers are inside and outside of the rail and they rust in between up to reaching outside on the wheels side.
All this area is essential hold by the walls of the V, the strut's tower and a strong rail that starts under the windshield and goes toward the top of the wheel arch.

I found a radical solution :)

Left side in the turn.

20170710-213257.jpg


This on the left side inside the rail. It was not finished here, just to show where tubes go.

20170712-210622.jpg
 
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spacecadet

Member
Messages
378
Hi!

Sorry for disappearing, got into unrelated projects this year, had less time with the Ghibli.

Anyhow I did fix the oil leak, along with redoing the timing. Already put 500km into the car (not a big number but still) and drives well. Wanted to test on the rolling road to have proper data but still couldn't get rid of the drivetrain / clutch noise. I either suspect the replacement gearbox or the new clutch lever. Will have to put back my old gearbox but after doing the process three times in total I just can't forget what a pain it is doing it on jack stands.

Alpa, nice to see you! That's radical indeed. Where do you attach the end of the tubes?

There was also an article about Biturbos in a major online magazine here and my Ghibli also took part in it. It's in Hungarian, but there is a nice gallery if you are interested (scroll down to the "Maserati Ghibli II - 1994" section): https://totalcar.hu/magazin/szerele...9-ghibli-ii-1994-quattroporte-iv-v6-evo-1999/
 

Wally

Member
Messages
244
Even an Hungarian Shamal!! Great that at least the engine is fine now. Pity that the gearbox is still causing headaches.... Hope you find the courage to fix that as well.
 

del mar 2

Member
Messages
212
Clutch / Gearbox noise.

The 6 speed Getrag box does have a noisy lay shaft bearing, mine has done it for years. Noise goes away when clutch pedal is pressed down.

If you look on the internet it is a known issue and even rebuilding the box doesn't always fix the problem, it causes no mechanical problems just an annoying noise.
 

alpa

Member
Messages
169
Clutch / Gearbox noise.

The 6 speed Getrag box does have a noisy lay shaft bearing, mine has done it for years. Noise goes away when clutch pedal is pressed down.

If you look on the internet it is a known issue and even rebuilding the box doesn't always fix the problem, it causes no mechanical problems just an annoying noise.

Same on the ZF5