[Mk2] [Turbo] ST205 Chargecooler Installation Guide (non 56k friendly)

[Marf]

lol, ok I'll double check my pump and order up whats needed. I also need to check if my pump has the bracket on it, I cant remember, when I picked up the chargecooler and pump it just went in the shed as soon as I got home.

[Marf]

Yep, the pump and CC water inlet/outlets are 22mm, and neither samco, siliconhoses.com nor any eBay shops sell 32mm-22mm reducers. Looks like we'll have to fit reducers to the pump and core itself.

[toxo]

Did you get 32mm from the fiat rad? I used 32mm -> 19mm then ran 19mm hose under the car, 22mm hose is a right pain to get IME.

[Marf]

Yeah got the 32mm from the Fiat rad.

I managed to find some 22mm coolant pipe, but as I say unfortunately nowhere I can find sells 32-22 reducers, so theres not much point using it.

I'll go with 19mm pipe as you have.

How are you going to attach the 19mm pipe to the pump/core? more reducers?

[toxo]

Ideally I'd like to use reducers and alloy couplers as I have elsewhere but they are so ridiculously expensive. Luke gave me a few tips on fitting tight hoses last time I was down at Pacific Works so I'll give them a try and let you know

[raptor95GTS]

search ebay for item 110320534178 but I think it's not quite perfect. I managed to get 19mmID pipework onto the core and pump. Plenty of hot water (i used a kettle) and it will literally just slip on.

[toxo]

Boiling water didn't work for me...

[RST]

Are you guys talking about the little white pot which plumbs in at the CC core filling cap?

I might be wrong -but there's a little black pot in Halfrauds which I think they call a "oil filler pot" which looks like it might be suitable. I can't find it on-line, maybe check it out next time you're passing. It's in the generic oil cap and sump plug section. Little black pot about 3" diameter with a couple of lines coming out from it, I think the top of it is slightly cone shaped. Dunno if that's any use to you -I'm sure I saw it mentioned in an ST185 thread somewhere at some point as an alternative.

Edit -found a pic -they're actually using it on the PCV line though. Maybe it's no good.

http://www.gtfours.co.uk/how_to/catch_can/catch_can.jpg

[>PETE<]

Hey Toxo,

Did you find that when running the ST205 ECU you lost your power steering?

I'm running the ST205 ECU on my MR2 at the moment with the chargecooler but I've lost my Power Steering. Curious to see if you've encountered the same issue...

Also, I believe you should get a little more hp out of the ST205 ECU compared to the MR2 one.

[toxo]

Hey Toxo,

Did you find that when running the ST205 ECU you lost your power steering?

I'm running the ST205 ECU on my MR2 at the moment with the chargecooler but I've lost my Power Steering. Curious to see if you've encountered the same issue...

I've not run on it for very long, because I've not got the CC core installed yet so the ECU just went into safe mode straight away as it couldn't detect coolant level. However from my notes & wiring diagrams I don't think the power steering is connected to the ECU at all, so what you've said doesn't make sense.

Also, I believe you should get a little more hp out of the ST205 ECU compared to the MR2 one.

What makes you think that?

[Driftlimits Performance]

Oh i can get hold of some super awesome piping, completely uncrushable. You could stand on this stuff and it wouldn't kink. Very expensive though.

Also I might be-able to get special reducers if people need

[>PETE<]

Hey Toxo,

Did you find that when running the ST205 ECU you lost your power steering?

I'm running the ST205 ECU on my MR2 at the moment with the chargecooler but I've lost my Power Steering. Curious to see if you've encountered the same issue...

I've not run on it for very long, because I've not got the CC core installed yet so the ECU just went into safe mode straight away as it couldn't detect coolant level. However from my notes & wiring diagrams I don't think the power steering is connected to the ECU at all, so what you've said doesn't make sense.

The power steering does connect to the ECU. It has two pinouts (PSCT + PS from the Gen II) When I connect my Gen III MR2 ECU to the car my power steering starts working, whereas when I connect the ST205 ECU to power steering stops. Remember that the power steering on the ST205 ran via the engine rather then an electric pump.

Also, I believe you should get a little more hp out of the ST205 ECU compared to the MR2 one.

What makes you think that?

The Jap St205 was advertised to put out 255Hp Compared with a Jap Gen III Mr2 being only 245hp. The only real difference between the two was the intercooler, so I can only guess they advanced the timing slightly between the ECU's.

[toxo]

Hey Toxo,

Did you find that when running the ST205 ECU you lost your power steering?

I'm running the ST205 ECU on my MR2 at the moment with the chargecooler but I've lost my Power Steering. Curious to see if you've encountered the same issue...

I've not run on it for very long, because I've not got the CC core installed yet so the ECU just went into safe mode straight away as it couldn't detect coolant level. However from my notes & wiring diagrams I don't think the power steering is connected to the ECU at all, so what you've said doesn't make sense.

The power steering does connect to the ECU. It has two pinouts (PSCT + PS from the Gen II) When I connect my Gen III MR2 ECU to the car my power steering starts working, whereas when I connect the ST205 ECU to power steering stops. Remember that the power steering on the ST205 ran via the engine rather then an electric pump.

Ah well, that can't be that hard to fix Also I've got a rev3 so there should be fewer differences between the ECUs (if there are any other than MAP vs AFM rev2 -> rev3 anyway).

Also, I believe you should get a little more hp out of the ST205 ECU compared to the MR2 one.

What makes you think that?

The Jap St205 was advertised to put out 255Hp Compared with a Jap Gen III Mr2 being only 245hp. The only real difference between the two was the intercooler, so I can only guess they advanced the timing slightly between the ECU's.

Hm interesting. I can't remember whether my ECU is from a UKDM ST205 or a JDM ST205, I did look when I got it but that was months ago...

[toxo]

Good news people - this lot turned up today Looks like I have an eventful easter weekend coming up lol



Luke> Cheers for pointing me at SFS, they were a lot cheaper than the alternatives.

PS No comments on the colour choice! I have a scheme up my sleeve

[Marf]

cool man keep us posted

My MOT is next week, once thats out of the way I'm booking the car in to have the decat and CC fitted

[toxo]

OK, got it installed. Once I got bleeding it right it makes a sizeable difference.

As everyone who's done this mod will testify, the first thing you notice is the increase in throttle response. With the stock intercooler, when you put your foot down the turbo has to pressurize the send and return pipes to the intercooler and the inlet manifold itself, while all the time the valves are opening and closing to consume air, which drops the pressure a little each time. As a result it can take a while! With the chargecooler core in place there's far less to pressurize, so you feel the effect of slamming your foot to the floor in maybe 1/8th of a second, instead of 3/4 which was closer to what I felt before! Hope that makes sense.

It also seems to have lengthened the power band a little. I'm certainly getting to the rev limiter in 3rd now, whereas I used to have naturally changed up to 4th before then. I can't really explain that unless the intercooler was heatsoaking at a greater rate than it was cooling (I don't know how to work it out, but it would be the heat generated from 1bar of boost vs the cooling capacity of the air intake at say 40mph -> 80mph).So it certainly feels faster at full boost. I've not rigged up a gauge yet to see if there's a boost increase due to denser air.

I've still not done the ST205 ECU as despite wiring up all the sensors I couldn't work out how to get the extra pins into the existing ECU plug So I have wired the pump running on ignition (this aided bleeding also). I don't drive the car often and will resolve this soon so am not too concerned with the pump wearing out.

[Marf]

Sounds great

I had hoped to fit mine this month, but after some unexpected costs from my MOT and the washing machine going kaput I've had to put it off till middle of next month.

How did you sort out the issue with the coolant pipe being too small for the inlet/outlet on the pump??

[toxo]

Have just updated the guide on page 1 (feels like I've written a sodding essay!!!) it's all detailed there. I used silicon reducers anywhere there was a hose size difference - expensive, but robust.

[Marf]

Cool thanks, where did you get the reducers from in the end? When I was searching I couldnt find anyone who sold 22->19 reducers, straight or elbowed.

[toxo]

The first lot came from forge motorsport who in turn use http://www.siliconhoses.com/ - the 2nd lot came from sfsperformance who are at http://www.siliconhose.com/

The two urls are very similar and easily confused They both sell straight and elbowed reducers.