First we discovered a former severe engine damage. One valve was obviously broken and had damaged the head. Also two pistons were different from the other side. In the middle of both heads water had corroded the head because of a rotten head gasket and lack of antifreeze. Deep wholes had to be welded before polishing the heads. We had to take 1mm off which will rise compression to ~ 10 The intake and outlet channels are very rough and will be polished.
the gaskets down on the block were partially destroyed and the surface scratched - the reason for the water/oil "cream" in the oil filler tube. We will polish and coat this surface to get a perfect base.
the cams and the rockers were heavily worn - about 2 mm and will be replaced same as the main bearings, which were worn till the ground.
The pistons showed bad gasoline burnt. They will be redone and coated by MAHLE and the shafts will be fine- balanced.
When we got all parts new from Jack Roman - thanks so much - we started the reassembling. Left You see the mounted, finebalanced and coated crankshaft and the ported and polished heads, watch the the wholes for the finebalancing and the even polished and optimized valveshafts.
Right You see the new cam compared to the old one which had a slightly different timimg. The new cams end were slightly corroded as You mway see on the picture. We tried to remove the rust polishing and hoped, we will not get problems as to the play of ~1mm. The valves are the old ones but optimized. Now we wait to get back the redone pistons from MAHLE.
While assembling the engine the mechanic discovered worn gaskets at the transmission main bearing, worn sleeves at the front half axles, substituted all water lines in rubber and cupper and installed new wishbones with new bearings. Great problems rised, when the electric gas pump did not start. The circuit runs through three relays and there is no description in the carburator - only - diagramm. We managed it, got the car running. The first check was to the play of the cams and there was oil to be seen leaving at the servopump bearing outlet. Sh..t happens. I ordered a new set of cams from M.A.R.A in Milano.
The most important thing was the new adjustment of the engine. The specialist, with 4000 hours engine testing experience, modified the setting especially of the O2 box and the ignition point advance .The result is as expected an engine with competition character. Fully directional developpment of torque and HP til 6000 RPM. An engine power test will soon show the truth.
interesting detail:
CO before the tuning was 3,46%
CO after the tuning is 1,82%
The Gamma ignition problem: New engine installed and ready to drive the race experts found a bad idling engine resulting from a severe lack of current, just 7 volt. First we substituted the coil with a RED BOSCH one with resistor (Bosch # 0221 102 081), what I always do on classic Italians, plugged a resistor an a starter current raising relay and got better results but not what we want. Than we rebuilt the complete ignition current lines and joined a diode to get a stabile high voltage current. (Check the new design here)
The result is great: The engine starts at first key turn, idels very calm, no vibration, no shimmy, performance is excellent at low RPM. I use first, fourth and fivth gear. Fivth range is from 30 to - supposed - 200, I did not try yet top speed, but with 140kph the car geers to go faster. There is no more rrrrmmmm at 120 -130. Great engine. Torque monster.
Oil pressure is 4 while driving, even warm. No Cream in the oil filler tube. Mechanical noise of the valves has raised, they are correct adjusted at 3.0 and 3.5.
To me the most severe problem of the Gamma is CURRENT: bad contact technic, bad lines, weak relays, weak fuses, weak coil. After 300 km I say - was worth doing - and investing
