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− | == ST215 Caldina Engine Rebuild == | + | [[Category: User projects]] |
− | OK, here's the plan
| + | == Brake Rebuild == |
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− | The engine in Black Beauty is tired and suffering big end rattle | + | The car has been off the road for so long that the brake calipers have seized |
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− | I want to go aftermarket ECU with coil on plug in Hannibal with a sidefeed manifold | + | Here's how I went about rebuilding them |
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| + | [[ST205 brake caliper rebuild]] |
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| + | == Project Engine Swap == |
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− | The solution is obvious to me
| + | Having rebuilt the engine it's time to fit it |
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− | First buy one of these. It's apparently a low mileage ST215 caldina engine bought og fLeabay. Hmmmmmmmm
| + | [[ST205 engine swap]] |
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− | http://media.share.ovi.com/m1/s/1747/464115df7cd043bfb805315c2b55d64a.jpg
| + | == Rebuilding My Engine == |
| + | When the engine in my daily smoker started rattling I decided to rebuild it. Details of the process can be found here |
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− | The idea is to refresh this bottom end with new bearings, pumps, pressure relief valves etc etc.
| + | [[ST215 engine rebuild]] |
− | It will then go into Black Beauty which will revert to standard ECU running notionally stock power as my reliable daily driver
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− | The good bits will then be transferred onto my current forged block
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− | Along the way I'll try to detail a few things and probably bore everyone to photographic death :lol:
| + | == Refurbishing My Rear End == |
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| + | I have issues with a whiney rear diff |
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− | An interesting feature. The ST215 uses a turbo that looks similar on the compressor side to a CT20 ST205 turbo. The hotside is obviously a little different! It's an integrated hotside/manifold setup
| + | Since the diff has to be removed for a refurb I took the opportunity to give the whole rear subframe some loving |
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− | http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1196.jpg
| + | Details here |
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− | | + | [[ST205 Rear Subframe Refurbish]] |
− | For reference, a 205 WRC manifold plonked on top. You can see that the lineup is about the same as the 205 setup position wise
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1195.jpg[/img] | + | |
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− | Mmmmmm sidefeed manifold and coil on plug goodness :D :D
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1197.jpg[/img]
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− | There's two things to note here. There's a distinct lack of even a vestigial dizzy. Ant the water elbow only has one sensor. No more ECU + dash sensor setup
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1198.jpg[/img]
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− | Round the back it's immediately obvious the knock sensor has moved
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− | Also note the shiney bolt middle left. This goes directly into the water jacket. I can't remember if the 205 block has such a drain or not
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1199.jpg[/img]
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− | Top mount intercooler. Significantly better than the 185 setup, bigger and thicker. Also equipped with plastic tanks
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1200.jpg[/img]
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− | Front of the engine looks familiar. Note that the cambelt tensioner pulley is different with a 1/2" square drive in the centre for some reason
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1201.jpg[/img]
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− | Turbo support bracket is a much more sensible steel affair compared to the ST205 braacket which is hewn from solid heavy
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1202.jpg[/img]
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− | Doughnut oil cooler is redesigned but still present on the 215. On the ST245 caldina it's gone!
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1203.jpg[/img]
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− | The sensor in the middle is the TPS (Turbo Pressure sensor) which is now directly bolted to the manifold not the firewall
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1204.jpg[/img]
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− | Where the dizzy would normally be is now the location for the turbo VSV control unit
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1205.jpg[/img]
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− | Which is also attached to this resevoir on the rear of the manifold. Presumably this provides a smooth pressure despite the PWM action of the VSV controller
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1206.jpg[/img]
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− | Front of the throttle body. Note the ISC attached to the bottom. It appears to be the same as that used on the 205 complete with throttlebody heating circuit
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1207.jpg[/img]
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− | Rear of the throttlebody. Not dissimilat to the 205 unit | + | |
− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1208.jpg[/img]
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− | Disassembled IAC control block. You can see the barrel "throttle" of the ISC and you can also see that the manifold heater is just a very short direct connection channel. It does not go round the TB in any way
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1209.jpg[/img]
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− | 4 layer exhaust manifold gasket is made up of 4 single identical steel gaskets
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1210.jpg[/img]
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− | Head exhaust ports and stud pattern appear identical to a st205 head
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1215.jpg[/img]
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− | Note the change to a "log" manifold. On the 205 manifold there's some separation of exhaust to make the twin scroll turbo work. On the 215 all the exhaust ports are conected into a single pipe. I'm certain this means no twin scroll
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1216.jpg[/img]
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When the engine in my daily smoker started rattling I decided to rebuild it. Details of the process can be found here
Since the diff has to be removed for a refurb I took the opportunity to give the whole rear subframe some loving