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ST205 Engine Rebuild
http://gt4dc.co.uk/forum/viewtopic.php?f=2&t=3505
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Author:  two_OH_five [ Tue Mar 16, 2010 8:06 pm ]
Post subject:  ST205 Engine Rebuild

This will take a long time as I'm in no hurry to get on with it

However, I need the sump for the ST215 engine so today I removed it to be greeted by this. Of all the things that could be causing a bottom end rattle I never ever even considered this :shock:

It's possible that this lead to the demise of the engine as the baffling in the sump is obviously not right. When the baffle detached it dropped to the bottom of the lower pan and might have cut off/hindered oil flow into the lower section where the oil pickup is
Throw in some track action and maybe surge/starvation ensues. I can already see that for sure #2 big end is shot and #3 is not far behind :(


Compare this with the scraper/baffle plate from the Caldina. It should be one piece
Image

The mounting tag one side has cracked. The other two connection points have failed spot welds allowing complete separation of the baffle
Image
Image
Image

This is what it should look like
Image

Author:  TrackToyFour [ Tue Mar 16, 2010 11:22 pm ]
Post subject: 

The pics appear to show that the ST205 scraper plate is a two piece affair albeit sport welded together whereas the ST215 scraper is a single piece part?

Seems strange that this should have failed. Presumably its some sort of fatigue failure due to vibration?

Author:  two_OH_five [ Wed Mar 17, 2010 12:32 am ]
Post subject: 

The two scraper plates are pretty much the same design. TBH it looks a bit rubbish. It's flimsy when you look at it knowing that there's been a failure

However, it's an extremely uncommon failure - I've not seen another in my years of four ownership.

It might be worth Jon adding a couple of additional tabs to yours given that it's likely to see lots of high RPM ;)

Author:  TrackToyFour [ Wed Mar 17, 2010 12:45 am ]
Post subject: 

two_OH_five wrote:
It might be worth Jon adding a couple of additional tabs to yours given that it's likely to see lots of high RPM ;)

Fair point, I'll mention it to him next time we speak.

Author:  vindz [ Mon Mar 22, 2010 5:52 pm ]
Post subject: 

Ill see if i can steal one of these today for you steve.

The caldina block has arrived apparantly!

Author:  two_OH_five [ Mon Mar 22, 2010 7:15 pm ]
Post subject: 

Cheers Chris



Out of interests, I actually gave this a good examination today as I fitted the correct sump. The Caldina version is the same but mine looks fine. I think it's a 1 off failure in the 205 but I'd still look to beef up one fitted to a high spec engine

Author:  vindz [ Mon Mar 22, 2010 10:04 pm ]
Post subject: 

Ive got it, now its how u wanna get get it from me to you.

Author:  two_OH_five [ Mon Mar 22, 2010 10:15 pm ]
Post subject: 

Ta very much!

I'll grab it next time we meet somewhere. No great hurry for it at the moment as the 205 engine rebuild will take a while

Or if you happen to see any of the crowd up that way drop it off and I'll grab it

Author:  vindz [ Mon Mar 22, 2010 10:48 pm ]
Post subject: 

Ok no problem.

Whilst on the subject of bits, Could you detail what gaskets you actually need when putting this lot back together (caldina block/ 205 head)? Really dont want to have to buy a whole gasket set from TCBparts at just shy of £150 to have lots of bits i dont use and for the kit to have bits missing that i do actually need!

Edit: feel free to answer in the 215 thread if thats where this question should actually have gone :oops:

Author:  two_OH_five [ Mon Mar 22, 2010 10:58 pm ]
Post subject: 

I didn't use any odd gaskets, it's all ST205 rebuild stuff

Mostly because I bolted a lot of 205 gear onto the 215

I've ended up with
205 head and rocker cover
205 inlet mani and TB
205 water pump and housing but 215 water bypass and oil cooler as the 205 cooler setup doesn't fit the 215 block
205 oil pump
205 sump


If you're going to actually use the 215 as is with the coil on plug setup then I think the same gasket setup will fit anyway. I'd recomend going with your old 205 water pump and housing though ;)

Author:  two_OH_five [ Tue Mar 23, 2010 2:41 pm ]
Post subject: 

Chris,

I assume you'le have then 215 engine completely stripped to use uprated internals?

If you do can you please take photos of the con rods.

The EPC tells me they're different to the 205/rev 3 3s-GT versions but I don't know what the difference is

Cheers :D

Author:  vindz [ Sun Mar 28, 2010 6:27 pm ]
Post subject: 

Image

I believe its meant to look like this lol!

Author:  two_OH_five [ Sun Mar 28, 2010 6:36 pm ]
Post subject: 

Yes it is :lol:


Cheers Chris, you're a star. Are you going to the virtual carting/AGM meet in a couple of weeks?

Author:  vindz [ Sun Mar 28, 2010 6:46 pm ]
Post subject: 

egh a double post how did that happen!

Yes i plan to be, most likely by TDI power at this rate :(

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