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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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− | Once the turbo VSV resevoir has been removed another VSV is immediately visible....more later
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1221.jpg[/img]
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1224.jpg[/img]
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− | Off with the inlet manifold then. You can clearly see that the 215 has switched back to top feed injectors a la ST165
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1228.jpg[/img]
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− | Fuel return and FPR
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1229.jpg[/img]
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− | Fuel feed
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1230.jpg[/img]
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− | The rail is perfectly set up for a fuel pressure gauge. The large nut undet the FPR is removable and directly accesses the fuel rail :D
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1232.jpg[/img]
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− | With everything out of the way you can now see that the FPR is connected to the VSV that was on the back of the inlet manifold. I assume this does away with the fuel pump resistor but I don't know for sure
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1233.jpg[/img]
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− | It's a bit of a poor photo but you can actually see right through the fuel rail if you look hard. Internal Diam of the fuel rail is ~10mm. It's a pretty good looking rail for high power
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1235.jpg[/img]
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− | Coil on plug packs :D :D
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1236.jpg[/img]
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− | A vital part of the coil on plug setup. With no dizzy you need another cam position sensor. This is it and it's great news for me :D. The "trigger wheel" is attached to the end of the inlet camshaft. You can also see the sensor in the background
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1241.jpg[/img]
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− | The cam sensor is simply bolted on in place of the dizzy. This means the nice 264 cams in Hannibal should work fine with the system (they might need a bolt hole drilling but that's apparently it)
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− | You can also see the blank used to dispense with the dizzy shaft. This one is clearly well sealed then :roll:
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1246.jpg[/img]
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− | The buckets show no visible wear. I think this might be a genuine low mileage engine :shock:
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1245.jpg[/img]
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− | Nothing unusual here except....The cam cover has an inbuilt catch can type setup. The baffle plate should condense any oil out
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1248.jpg[/img]
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− | And the view from abovu. Note lugs to secure the COP units and a return to a 185 style breather position
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1249.jpg[/img]
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− | Better view of the distributor replacement plug with several feet of leaky crud removed
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1250.jpg[/img]
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− | Gratuitous photo of things to come for Hannibal. GT3071 with (eventually) external remote wastegate :twisted:
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− | I'd really really like to turn the turbo the other way up though ;)
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1251.jpg[/img]
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− | A few closeups of the combined mani/turbo setup. Note the hulking great single wastegate. Boost creep should not be an issue on the Caldina :D
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1253.jpg[/img]
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1254.jpg[/img]
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1255.jpg[/img]
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− | And over we go :lol:
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− | After an hour of unsuccessful panning for gold in the metal sump, off with the main sump section. Nothing bad looking here. The usual 3S-GTE varnishing but nowt unusual. This really might be a low miler. Time will tell
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− | I wonder if my warranty is still valid :lol:
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1256.jpg[/img]
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− | Scraper plate removed and block face cleaned ready for a nice new bead of sealant. Nothing looks out of place or different here
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1257.jpg[/img]
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− | A poor picture but you can just about make out the oil squirter underneath the counterweight
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1258.jpg[/img]
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− | :lol:I hope you're reading this Don :lol:
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− | Part 2 of the COP setup. You can see a crank trigger wheel built into the cambelt drive puley
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1259.jpg[/img]
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− | And here's the sensor that actually picks up on that trigger wheel giving a high resolution crank angle sensor unlike the 12 tooth version in the stock ST205 distributor setup
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− | [img]http://i21.photobucket.com/albums/b277/Stevo_st205/Caldina%20Engine%20Rebuild/IMG_1260.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