User talk:Two OH five

ST215 Caldina Engine Rebuild

OK, here's the plan

The engine in Black Beauty is tired and suffering big end rattle

I want to go aftermarket ECU with coil on plug in Hannibal with a sidefeed manifold

The solution is obvious to me

First buy one of these. It's apparently a low mileage ST215 caldina engine bought og fLeabay. Hmmmmmmmm

The idea is to refresh this bottom end with new bearings, pumps, pressure relief valves etc etc. It will then go into Black Beauty which will revert to standard ECU running notionally stock power as my reliable daily driver The good bits will then be transferred onto my current forged block

Along the way I'll try to detail a few things and probably bore everyone to photographic death :lol:

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

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 [img][/img]

Mmmmmm sidefeed manifold and coil on plug goodness :D :D [img][/img]

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 [img][/img]

Round the back it's immediately obvious the knock sensor has moved 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 [img][/img]

Top mount intercooler. Significantly better than the 185 setup, bigger and thicker. Also equipped with plastic tanks [img][/img]

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 [img][/img]

Turbo support bracket is a much more sensible steel affair compared to the ST205 braacket which is hewn from solid heavy [img][/img]

Doughnut oil cooler is redesigned but still present on the 215. On the ST245 caldina it's gone! [img][/img]

The sensor in the middle is the TPS (Turbo Pressure sensor) which is now directly bolted to the manifold not the firewall [img][/img]

Where the dizzy would normally be is now the location for the turbo VSV control unit [img][/img]

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 [img][/img]

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 [img][/img]

Rear of the throttlebody. Not dissimilat to the 205 unit [img][/img]

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 [img][/img]

4 layer exhaust manifold gasket is made up of 4 single identical steel gaskets [img][/img]

Head exhaust ports and stud pattern appear identical to a st205 head [img][/img]

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 [img][/img]