info needed for installing ST185 chargecooler

[tilma800]

Is there a write up somewhere about installing the ST185 chargecooler on a 1991 MR2 US turbo?
It's supposed to be plug &play, but there are some clearance issues and I want to know how it's done before.

Some issues:
- support chargecooler hits watercooling elbow
- Water connection of chargecooler hits same elbow
- other water connection blocks some existing airpressure hoses.
- there's no connection for the stock MR2 BPV

How to solve this and are there pictures of it? (I like pictures )

[BenGTS]

There are no write ups at the moment as far as I am aware. I beleive the ST185 CC should fit straight on a rev 1/2 and the ST205 CC fits straight on a rev 3 onwards.

I have fitted a ST205 CC on my rev 3 and it was fairly staright foward.
The only thing that stopped the actual CC bolting staright on was the engine lifting bracket (had to be bent out the way).

I also had to make up a bracket to support the throttle.

The ST205 CC...


Fiat Cinqueciento rad...



Any questions let me know

[tilma800]

These are my current problems:

Left red circle, no BPV connection, how did other people do that?

Midle red circle, water connection touches engine cooling part, just shorten it?

Right red circle, path ofhose connected to that pipe goes through the other water connection, but the bracket on the engine can be relocated a bit.

[BenGTS]

Left circle - The only person I know who has fitted a ST185 CC is Brook and I believe he is running his CC with out a dump valve. Unless you modify the CC (i.e cut a section out and weld a dump valve 'take off' onto it) i can't think of another alternative.

Middle circle - This was very tight. I had to cut the bracket off (the one that attaches the actual CC to the cam cover) and then move the CC around until it fitted into place. It was tight but it did go (I do have rev 3/ST205 though).

Right circle - Are you sure this is a water hose? It looks like the vacuun hose that connects to the dump valve. If it is the vacuun hose, I did have to remove the metal bit and replace with new rubber hose (another route).

Hope this helps.

Ben

[tilma800]

Right circle - Are you sure this is a water hose? It looks like the vacuun hose that connects to the dump valve. If it is the vacuun hose, I did have to remove the metal bit and replace with new rubber hose (another route).

Hope this helps.

Ben

It's a vacuum line that routes right through the waterconnection of the CC. The line goes to the intake I believe and a smaller one behind it on the same bracket goes to the BPV.
The bracket can be mounted with a spacer to clear it (I hope).

[Rory]

Tilma800 - Check out this link http://935motorsports.com/catalog/produ ... e829f2145c

I think someoe reccomended this link to you on mr2oc.com. Why done you get one of these?

Rory

[MR2Mania]

BenGTS has pretty much covered it well for ya, but here goes...

These are my current problems:
Left red circle, no BPV connection, how did other people do that?

You don't need a BOV, to be honest. This is one thing I'm actually going to try with my own CC kit, and see how it feels. As long as you're not running BIG boost, then it should be OK.

I'd just block the return for the BOV in the intake pipe, job done!

Midle red circle, water connection touches engine cooling part, just shorten it?

Get a nice long (preferably round) rod (something like mandrel), and then heat up the water connection tube for a bit and insert the rod into the tube and slowly but smoothly bend the tube towards the back of the car. If you bend the tube by about 10-15%, it should clear no probs. Just be gentle and it should be OK.

Right red circle, path ofhose connected to that pipe goes through the other water connection, but the bracket on the engine can be relocated a bit.

I can't quite see from the pic what the problem is here, so can't help.

[tilma800]

Tilma800 - Check out this link http://935motorsports.com/catalog/produ ... e829f2145c

I think someoe reccomended this link to you on mr2oc.com. Why done you get one of these?

Rory

Fensport has something simular, I mailed them already I have a solution for it also if that is to expensive. I can make a T-piece consisting of a halve tube with a pipe on it. Al I have to do to mount it is cutting a hole in the CC intake pipe and attach the T-piece with 2 pipe-clamps and some sealant.

[Rogue]

You might want to have a look at one of our customer's cars:

http://www.imoc.co.uk/forums/garage.php ... le&CID=124

Brook is running an ST185 chargecooler on a revision2 MR2 turbo. I remember that there was an amount of custom fabrication work required for mounting brackets, and to the chargecooler itself. If you want to drop us an email direct (prefereably to [email protected]) then we should be able to point you in the right direction.

Best regards,

Patrick Mortell
Rogue Systems Limited
01676 530222

[tilma800]

Get a nice long (preferably round) rod (something like mandrel), and then heat up the water connection tube for a bit and insert the rod into the tube and slowly but smoothly bend the tube towards the back of the car. If you bend the tube by about 10-15%, it should clear no probs. Just be gentle and it should be OK.

Thanks, I did that! Should be ok now, but that I'll see next weekend.

I can always try the car without a the BPV, but I think in the end it's better to fit it.

@Rogue: I have the general idea now of how to mount the CC, but thanks for your offer to help me out. I might need it later