1.6 Connecting Rods

[SteveG]

Having a continuing battle with the 1.6 engine I got to rebuild. The block has now been re-bored to suit the pistons I found but when the engine place went to fit the pistons the gap between the bosses in the pistons was too narrow for the rods. Unsure if the pistons are just wrong or if the rods just don't match them.
Does anyone know what the difference is between TU5JP rods and pretty much any other 1.6 8 valve engine fitted in a Saxo/106 ? I need to know the width of the small end in particular as I think they must be different. If anyone has a set and they are different I might be interested in buying them.
Thanks.

[SteveG]

Having had another look at the numbers I think the only different 8 valve rods were fitted on late Saxo's. Got a feeling the pistons I was sold are not the right ones.

[SteveG]

I got all the parts back today and the only way I am going to get it all to fit is to machine the rods and pistons. Wish there was some way to add some pictures.
Bit annoyed with the guy who sold me the pistons as he said they would fit so if you see some oversize pistons for sale ask some questions first.

[MartinObviously]

I got all the parts back today and the only way I am going to get it all to fit is to machine the rods and pistons. Wish there was some way to add some pictures.
Bit annoyed with the guy who sold me the pistons as he said they would fit so if you see some oversize pistons for sale ask some questions first.

So are the rods correct, but you've been sent the incorrect pistons?

From what I know, all the 8v rods are the same width and they of course have a bit of slack side to side on the little end pin. The only different 8v rod is the 1.4/1.5d conrod, which is the same as the 8v petrol except the little end is 24mm pin! It's still the same width though.

Is it not easier to take a little bit of material away from the pistons? If you're needing to machine the rod and the piston, sounds to me like the piston is just totally wrong.

Might want to check the height between OEM piston pin to top of crown and compare. Make sure it'll actually come up to the deck.

[SteveG]

Got the chance to update this.

I still haven't put the engine together but am getting closer. Turns out the pistons I was sold are later ones found normally in a 206. These are 16 valves but don't have cut outs for the valves and have shallow skirts and are similar to slipper pistons. The rods used with them are exactly the same castings as the early press fit ones but are machined narrower at the top. A few pictures would explain if I could put some on.

I've made up a tool to hold the pistons still so I can fit the gudgeon pins just need to finish a few bits off.

[SteveG]

https://img.retro-rides.org/i/v/steveg/29a8d669b82c.jpg

[SteveG]

Not sure if the picture is available to everyone. Piston on left is the original TU5JP one and the one on the right is from the later 206 engine. The rods aren't exactly the same casting but share the same number.

This is the tool for fitting the gudgeon pins, if it shows up !

https://img.retro-rides.org/i/v/steveg/eb8d08872709.jpg

[MartinObviously]

Looks good, it all makes sense now though!