This engine build is for a 1976 3.0 Turbo Carrera that was previously modified to a 3.2 twin plug. We converted the engine back to single plug and its original 3.0L displacement. In addition to the build, the engine tin was also in need of a great deal of repair, which we restored in house, along with the alternator fan and housing.
We first evaluated and disassembled the engine; this evaluation helps us to determine the extent of build needed. All components were cleaned, then fully evaluated, tested and measured. The camshafts, rockers and connecting rods were all in need of reconditioning. All crankcase and crankshaft oil passage plugs were removed for proper cleaning of the oil passages. We then installed new plugs and micro polished the crankshaft. The intermediate shaft was replaced, as well as the timing chains, ramps, and tensioners. New 3.0 Turbo Carrera Mahle pistons and cylinders were special ordered from Mahle. ARP cylinder head studs and rod bolts were installed. The pistons were balanced, as well as the connecting rods end to end. The cylinder heads were original, so we fabricated and welded in plugs to convert them back to single plug. We then resurfaced the heads, CC’d the combustion chambers and installed new valve guides. All valve seats were cut on our Mira precision valve seat cutting machine from Switzerland. New performance valves were installed and valve lengths were set. New valve springs were pressure tested and spring heights were set. Deck height and compression ratio were checked and adjusted. All bearing specifications were checked and recorded.
Upon assembly, we measured and recorded all fitment and clearance specifications. The fuel distributor, warm up regulator, ignition distributor, CDI box, turbo, waste gate, turbo oil pump, intake and recirculating valve housing, alternator, alternator fan and housing, were all rebuilt. The wiring harness was fully gone through and repaired; all connectors and contacts were cleaned or replaced. We fully restored the original muffler due to pin holes in the outer cover and erosion of the internal baffle material. We re-skinned the muffler completely, welded the original factory part number, production date and manufacturer’s name back into the newly fabricated outer skin and re-packed the internal parts of the muffler as original. The hardware was re-plated and engine tin was repaired and powder coated.
After the build was completed, we properly broke in and set up the engine. Once we had 100 miles on the engine, we changed the oil and filter, took an oil sample, cut open the oil filter (to check for debris), re-torqued the cylinder heads, adjusted the valves and went over the final engine set up. The owner was given a maintenance interval protocol to follow for proper care of the engine during the remainder of the break-in period.
