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

JTop

Junior Member
Messages
47
Hi All!
Some of you might have seen foibles post regarding the damaged 3200GT at auction..
Yeah I'm the silly 21yr old who bought it :| the house deposit can wait :oops:
Guess who was more excited about it than I was? My father; Who legitimately picked it up the day we won the auction, and placed the winning bid on it on my behalf, and seen it on Manheim auction site the week prior and as to now, been attempting to be of some help(ONLY WHEN REQUESTED..) with this entire process :saifi4:
Anyway, my background is VW and Bosch systems as I work on 06-09 Polo GTI's, up to #7 and know the ins and outs quite well pretty much to the stage of waiting for parts to arrive from the US to start building an engine for a big turbo build. I frequent the VWWatercooled forum with the occasional build post. Located in South East Melbourne who anyway have another lockdown to endure. Luckily I have work most of the week and my final semester of my engineering degree, so lots to do and not a lot of time!

I'll do a quick catchup on the progress, I've been documenting and recording videos with this car because there are so many parts, and lord knows if they are even the correct or original fittings/fixtures as I have noticed it has been molested by someone silly... Anyway the manual I've bought off ebay is as good as my ability to do and see as it comes(and not break ****, pretty good at that). Other than the engine specifics, part numbers and the electronic mumbo jumbo, missing a lot of assembly information which is quite useful when you're unsure how to disassemble something
but anyway.. I saw this and thought to myself, it couldn't be that bad... Could it?

This is the car, day we got it; bit of a mess but it looks worse than it is(kind of.. will get to that later)
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Would anyone like to guess the cause of this mess? Look closely and you will see :)
Where to start.... Well firstly it was evident to get rid of the soundproofing and the bonnet vents as they were goners and give a quick vacuum of all the big parts. I took the windscreen wipers off, along with the weather plastic cover to reveal the tone of powder sitting on the sill. As well as the dodgy fixup of one tab by someone. We realised vacuuming is practically useless to do this as this fire retardant is a little like glue. Sticks to the surface until agitated. We took as sample and brought it in to our local fire department and asked for someone a bit more experienced to help us out. The gentleman only mentioned that it's "toxic" to breathe in but had ABSOLUTELY NO IDEA HOW TO CLEAN IT.. bit ironic asking an experienced firefighter this... Mustn't be a chemist and we let that slide. Anyway :oops:

Masks on and off we went to cleaning it up as much as possible, whilst removing any damaged debris
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As evident here, lot of this stuff got everywhere and soiled the BMC air filter on one side :too_sad: There is a lot going on and lots to learn for each system has its functions, lines and electronics going to and from. The fuel shot about the engine bay cooking lots of things, Relay cover, coolant tank, brake fluid reservoir, wiring, piping and the lot. Didn't go for long, but long enough to do the damage.
But because it was absolutely full of this powder, did the undesirable and took an air compressor to it as water doesn't really help with cleaning it off. Makes it thick and gunky, worse than if it's a powder. IPA, methanol, and I forget what else we tried, and it's all practically useless
Had its bit of glory and final sunshine before heading back into the garage for the process of complete dismantlement.

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So same day we took all the easily accessible piping and parts off. What I read being the notorious throttle body, the intake manifold and few other bits and pieces around the bay.

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At a closer look the LHS lambda probe wiring was cooked, custom job to rectify that coming soon. Engine wiring harness was way beyond gone, so that was to be ordered. Parts list had started growing by the hour.

Backtracking a little, second day when I was bored I started to deal with the interior, due to the fact it had a broken pioneer flip up head unit a saggy headliner and few other trims that I wanted re-glued and refinished. So started the dreaded journey of the dash... It was in a million pieces until I finally found the two hidden screws on the upper section holding it in!!! Absolute nightmare.. I've still got the seats in, although I would like to take them out so I can vacuum, wet vac the carpet and get everything nice and tidy before putting it back in. Any advice here to get them to actuate forward+back without power would be appreciated!
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I've only got videos of the interior disassembly as I discovered a lot of hidden gems which I'm really ashamed to even mention that someone could do to such a beautiful vehicle like... some smart-head had bits apart and missed so many screws and... I just can't
Not to even mention the radio wiring job, absolute disaster... Like it seemed like it worked? But it's not even close to my standards of neatness and tidiness that it must be. Anyway, had the pioneer unit checked, rebuilt and tested by my good friend(who also convinced me to get the car hahaha) Have it ready to just plug in once the dash is back together! Anyway, door trims, headliner and rear quarter trims off and to Blackmans restoration, yet to hear back from them if they've got it done or not, will see this week.. Not much else to the interior other than the botched mounted JBL speakers in the rear sides. Also need to figure something out there. Stock for the moment will do, albeit they do be $100 a piece so... maybe not, but something proper to suit the elliptically shaped holes.

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Took a trip to Maserati in Richmond, with a whole sheet of parts to ask for prices, like any normal person would do given they have a broken vehicle. Whilst waiting to be served we asked one gentleman who was working about a few things. What's a basic service set us back. "Anything from $1500-50,000" jaw drop and where can we get a car painted who is Maserati approved. Either Luxury Auto Body in Cliffton hill or Zagame Tullamarine. longish story, anyway.
The lady managing the parts department was awesome as she got to the point right away. No Maserati do not supply parts anymore, look at Eurospares or Scudaria, BUT I will photocopy your list and check anyway, maybe there is something. Called me back later and yeah, nothing...
So have ordered from Germany: Engine wiring loom, coolant bottle, brake fluid bottle, both air filter housings and there goes $500... Which is not bad considering we had it all sent to our wonderful family friend in the town next to the sellers, and had him ship all of it to us (to avoid $150 per item shipping costs)! It's sadly delayed for the past 9 days, cleared and awaiting a flight to Australia, but can't do anything there...

After that, I made a big 1500£ order with Eurospares, as they seemed to have the majority of the items available that I needed. This is still in the process and I will post a list of parts if anyone knows/has or can acquire them, I am more than happy to pay for the part and postage via Paypal, given it's a reasonable amount for the item/items.
TBC in a few minutes lol, can only attach 10 photos per post :p
 
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Oneball

Member
Messages
11,141
Good luck, proper effort so far.
The factory maintenance manual is in 3 or 4 parts which might explain why yours doesn’t cover everything.
 

Oneball

Member
Messages
11,141
PS there’s a really dodgy Dutch bloke who sells used parts on eBay. Avoid like the plague. Can’t remember his name at the moment. I’m sure someone will chip in.
 

JTop

Junior Member
Messages
47
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Exhaust is legit just the rear mufflers, rest is stock original. I've read Larini make some decent pipes hahahaha, I will be murdered if I mod this thing, even though I'm sitting here like... Hybrid turbos, full Larini exhaust, KW coilovers(even though I prefer Bilstein and Eibach more which the car currently has given the dampening system is nowhere to be found!!!! Yeah.. I had a shock once I realised this), Ultraracing rear braces, Powerflex bushes and get the car tuned at Underground Performance. Oh I've thought of it alright ;):saifi: Anything else available that might be unspoken of?
Timing belt/waterpump to be done again? At 142k kms and it hasn't been driven at all for 9 years... Highway Kms because the body is fairly clean
Oil, Selenia Racing 10W-60 the go to? Everyone says to find and use it, I found this website; Foley Auto who seem to have it. I've ordered a new filter and O-rings for the sump plug given the sump plugs are no longer stocked... I'm a VW dude who replaces every two oil services...
Power steering? Coolant? Anything special here or just the generic what the manual states. (I need to go through it, honestly missed the info on these)

I can't get in contact with Whootman, as he is called on ebay due to him not having any listings up, so if anyone knows this gent, would be appreciated to if they have the spare key+all the service manuals, more than happy to pay for the few things! even the wheels probably :p
 

JTop

Junior Member
Messages
47
Good luck, proper effort so far.
The factory maintenance manual is in 3 or 4 parts which might explain why yours doesn’t cover everything.
Thank you! Always hope that some enjoy the read or there is some new insight/thought for something better :)
This is what I've finally collated, might help someone else too
https://drive.google.com/drive/folders/12ROzaxoRdZSTHti9bNN7Gp9Ki9t2NCrh?usp=sharing
Hope this is all, would appreciate feedback on it :p

Ok... Great to know, even though he does have some bits I'd be after hahaha. Will stay away! Thank you for that

I'll do a full parts list post tomorrow and where I'm currently at with it (engine out Monday morning).
Still chasing like the RHS bonnet vent, the large black plastic dash aircon piece which was cracked(and I made it a tad worse...(worst case, glue it together and call it a day really :saifi4:)) and swaybar/stabiliser links for both sides, eurospares says they're MAYBE available 12th week of next year so... Nope can do
 

BL330

Member
Messages
1,123
Welcome to the wonderful world of older Maserati ownership in Australia. When it's done you should bring it up to Canberra for the Auto Italia gathering each March.
Some contacts for you. Join MOCA - Maserati Owners Club of Australia based in Melbourne. John the president is a really helpful guy.
There are specialty repairers outside the dealer Zagame in Melbourne he can point you to. Others on this forum from Melbourne will have opinions as well.
There are 2 wreckers in Australia who carry Maserati's. Both sell on eBay, GT Spares in Adelaide and MW Wreckers in Sydney. I have visited both and used them for all sorts of things for my Gransport. PM me for their contacts if you can't find them through searches.
Also speak to my suspension guy in Canberra - Capital Steering & Suspension as he has 2 x 3200GT's. Andrew is super knowledgeable about setting up suspension on these, as he has done mine and races his second car. He'll know a thing or two about 3200GT issues.
Hope this helps. You are not alone.
 

MRichards

Member
Messages
283
I admire your enthusiasm. I get badly depressed just looking at that mess. Best of British luck.
 

JTop

Junior Member
Messages
47
Welcome to the wonderful world of older Maserati ownership in Australia. When it's done you should bring it up to Canberra for the Auto Italia gathering each March.
Some contacts for you. Join MOCA - Maserati Owners Club of Australia based in Melbourne. John the president is a really helpful guy.
There are specialty repairers outside the dealer Zagame in Melbourne he can point you to. Others on this forum from Melbourne will have opinions as well.
There are 2 wreckers in Australia who carry Maserati's. Both sell on eBay, GT Spares in Adelaide and MW Wreckers in Sydney. I have visited both and used them for all sorts of things for my Gransport. PM me for their contacts if you can't find them through searches.
Also speak to my suspension guy in Canberra - Capital Steering & Suspension as he has 2 x 3200GT's. Andrew is super knowledgeable about setting up suspension on these, as he has done mine and races his second car. He'll know a thing or two about 3200GT issues.
Hope this helps. You are not alone.
Thank you! Definitely an event to put in the calendar then, plenty of time before then to have everything ready
I will get in contact with John soon and join the club as it might be a better idea to get a few quotes in before picking who will respray the car, will probably just trailer the rolling shell to a shop. Pity Zagame has a bad rep according to you all although I can ask the family almost directly to look after me if need be.

I've seen both GT spares and New Motor Wreckers in Sydney(that correct? can't find MW?) prior, and they unfortunately don't have anything I'm after other than the injectors, even though I just need 2x as they got a little bit melty. The Eurospares order will probably come in within the next two months so have quite a bit of time to organise other things around this.

As for suspension, will address it as it comes, a little later on. Not an immediate concern given the engine will be out shortly
I admire your enthusiasm. I get badly depressed just looking at that mess. Best of British luck.
Thank you! I've always been like this, my recent daily has been completely apart just to get everything how I like it.. Floods my weekend with work but it's hella satisfying. It will be back to its former glory soon enough!



Whilst here, I'll get to where I'm at;
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Took the entire front end off in a day, I took the time to be extra careful with it not to break anything, which was a success.
Found out the process and it's a fun one actually when you start to think of how to remove the accessories. Like the headlights, they have to come out from the wheel arch which for me was something different.
Anyway, the plan is to drop the engine with the subframe and trolley it out rather than to lift it out and risk hitting something, less stress this way although the car will be on jackstands for a little while, which will be fine when cleaning up, testing and rewiring the accessories loom and prepping the new engine wiring loom.

I've got the power steering disconnected, aircon disconnected too(no gas was present so must have a hole up the back). Steering rack disconnected, driveshaft too(marking all the nuts and bolts as I understand these are to help with balancing). Earthing wires, the empty clutch line and thermocouples are off along with splitting the rear exhaust section apart. Found that the rubber bushings for the transmission are completely gone, lucky eurospares has them! Not sure what else to do other than to wait tomorrow for the trolley to arrive. and unbolt the last 6 bolts, lowering the subframe away from the car completely. Maybe disconnect the shifter from the gearbox if that doesn't come with. otherwise looks like it's all good to go!

Cheers everyone!
 

Oneball

Member
Messages
11,141
You will need to disconnect the shifter. If there’s any play in it you want to sort bushes are much easier to do out of the car. Got mine from BMW as it’s a Getrag box.
 

lifes2short

Member
Messages
5,867
i take my hat off to you, well done for taking it on board, i remember similar enthusiasm when i was late teens and early twenties many moons ago when re-building motors
 

madmanmart

Member
Messages
377
Excellent project I will look forward to your progress.
Drop me a message with a list of parts you need and I will help where I can.
 

JTop

Junior Member
Messages
47
Good effort and looking forward to seeing your progress too.
i take my hat off to you, well done for taking it on board, i remember similar enthusiasm when i was late teens and early twenties many moons ago when re-building motors
Oh. My. Word. Good luck, sir!

C

Thank you all! Didn't expect this many people interested this quickly... truly! Thought I'd catch a few prying eyes :D

You will need to disconnect the shifter. If there’s any play in it you want to sort bushes are much easier to do out of the car. Got mine from BMW as it’s a Getrag box.
You are right! Just the two circlips and should pull out. As for the shifter, it's fairly rigid, has minimal play left-right and feels VERY Very Nice... I'll see tomorrow if those bushes are ok, and honestly I'll see what I can find to maybe stiffen them up/replace the circlip setup entirely.

Excellent project I will look forward to your progress.
Drop me a message with a list of parts you need and I will help where I can.
Thank you too! I'm just about to write up a long list of parts, what I've ordered and gotten and what I'm after/need! If you have any of the items, feel free to let me know!
Doing this all so if there is anyone else who endures a task like this, might understand what they're getting themselves into ;)
 

BL330

Member
Messages
1,123
Did you order the coolant bottle yet?
I think I've got one as it was a wrong supply from Eurospares.
If I can find it amongst my Maserati boxes you can have it.
 

JTop

Junior Member
Messages
47
Ok, so I'll break down the parts list into sections of each subsystem. Happy to learn/be advised anything different, or even add/contribute to this if there are more pieces. Not too hard to edit and change up, so will keep this here!
Actually.. I'll borrow some diagrams

SO.. Let's start with the Body and Accessories, as there's not much really.. just the 15 or so items here

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ORDERED #11 - 254569 , this wasn't even in the car... Wanted just the tow hook, but why not have all the tools in the car in its bag!
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ORDERED #9 - 980000973, washer filter. Melted and gone, so have to swap on a new one.
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ORDERED #9 - 7560860, fixing buttons as lots melted and were not saveable. ordered 24 of them
ORDERED #11 - 384300362, used so will see how good it will be... looks OK with its photo.
UNAVAILABLE #19 - 386100515, rubber button cap. Missing just the 1... oh well
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UNAVAILABLE ORDERED #7 - 384310020 even though they have a used one in stock? Mine is just melted on one lead, might do a repair job on it as it's just a short section that's melted.
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UNAVAILABLE #16 980000920 RHS bonnet scoop
ORDERED #16 980000919 LHS bonnet scoop. both were melted as the fire escaped consuming that beautiful fresh air
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forgot oops, will add to order ORDERED #4 - 012638177 washers as I'm missing like 5-6
forgot oops, will add to order ORDERED #5 - 010977687 screws as they are all assorted for some fun reason. Yet to check the rear...
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UNAVAILABLE ORDERED #10 - 386600139, swaybar links as both of mine are torn/damaged.
Will see how the car handles before tightening it up with powerflex bushes and ultraracing braces
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UNAVAILABLE CANCLED #19 - 386100025 for LHS. I have the right hand side one, for some reason missing the left? I don't get having one and not the other? Or is that how it's supposed to be. Can't make my mind up about this really... anyone? I'll order 20 if needbe
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ORDERED #19 - 385500500 AC sheath protection, which melted for me, and possibly damaged the copped pipe, will see tomorrow
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ORDERED #4 - 323850305 the ABS Clips. Will be redoing the wiring for the rhs wheel as that got fried running across the engine bay. ALSO, those two wall clips... Anyone know a part number for those, I've either missed them whilst going over every page or just they aren't available... :(

Don't think there is any more for this set. Next post, 20 more diagrams to go... :oops:
 
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JTop

Junior Member
Messages
47
Did you order the coolant bottle yet?
I think I've got one as it was a wrong supply from Eurospares.
If I can find it amongst my Maserati boxes you can have it.
I've got the engine wiring harness
Coolant bottle
Brake fluid bottle and
Both Air filter housings coming from Germany.. I hope soon!

Thank you anyway! Will see the condition of it and if it's rubbish will take you up on that
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Lozzer

Member
Messages
2,287
UNAVAILABLE #10 - 386600139, swaybar links as both of mine are torn/damaged.
Will see how the car handles before tightening it up with powerflex bushes and ultraracing braces

 

JTop

Junior Member
Messages
47
UNAVAILABLE #10 - 386600139, swaybar links as both of mine are torn/damaged.
Will see how the car handles before tightening it up with powerflex bushes and ultraracing braces

Have not come across this website yet! Thank you, will take those up then :)