Peugeot 106 Rallye white and Kenwood black

[evsp]

I got it, but what is the difference between XSI (K6B ?) and non XSI (KDX, KDY KFZ )1360cc engines piston? I did not find relevant info..

[AgAdOu]

They have flat pistons compared to XSi.

[evsp]

Probably XSI piston than, because there is a hole on the top...
We made further investigation on the motor. Here are the coclusions:
The cylinder head is original. We measured the volume of the combustion chamber in cylinder head, it is ~30ccm. According to the homologation form of group N Rallye 1.3 the volume is 30.1ccm. We also measured the volume of the hole on the top of piston, it is ~5ccm. The distance between top of piston and gudgeon pin center line is 40.5mm.

From this data I calculated the compression ratio of the motor, and it is very far from original. ~8.6 instead of 10.6.

So I am not willing to repair it in this condition, we need to change something. There are a few options:
-Convert it back to original condition, than I should find crankshaft, connecting rods and pistons.
-Find other connecting rod - piston combination with 1.4 crankshaft. 1.4 parts can be found easily.
-Put a 1.6 crankshaft with actual piston and connecting rod. By calculation the capacity would be 1445ccm, and the compression ratio would be 11.5:1
Well, it is higher than the original Rallye, but we can use 100 octane number gasoline. And in amateur slalom race any modification is allowed.

What is your opinion? Can the TU5 1.6 crankshaft be fitted into Rallye block? Does anyone have experience?

[AgAdOu]

Xsi piston looks like that :

e051a8e6fc71800f961fce9ba9542cba.jpg (41.89 Kio) Vu 766 fois

[AgAdOu]

Can you share pics of the head ? Exhaust side with center references (middle and right).

[evsp]

I have one, see below. At the moment I am ~2000km away from it, therefore I cannot make new pictures.

[AgAdOu]

Definitely not rallye/XSi piston.
J cam is TU2J2/TU5J2 cam

[evsp]

"What is your opinion? Can the TU5 1.6 crankshaft be fitted into S1 Rallye block? Does anyone have experience?"

Noone?

[evsp]

Finally we managed to repair the engine. The 1.6 crankshaft fits in, so the repair cost was quite low. ( crankshaft, sealings, connecting rod, bearings etc.). The result is ~1450ccm and ~11 compression ratio. After a few hours of low speed running-in, last week we went to a trackday. Here is the result:

best lap.png (208.05 Kio) Vu 329 fois

[AgAdOu]

Never seen an engine built like yours.

alloy bottom + TU5 crankshaft + 126 rods + hollow piston = it works well ?

[evsp]

It works better than before. The problem I have is that I have never driven an S1 Rallye with 1.3l engine. So I don't know if it is better than it could be with it's original engine condition or not. Very probably yes! It can still revs up to limit at 7400rpm. And I do believe it has more torque at lower rpm than before.

[tour2babel]

very interesting!

does this assembly work with the original tu2j2 ecu?

[Bracam]

I'm curious to see the "KERS" system in the car? Do you have any pics or maybe some explaination on how dit it work with the 106 transmision?

[evsp]

Well, there is nothing special. The original alternator is replaced to a newly developed motor-generator unit. It is not externally excited, but has permanent magnets on rotor. We replaced the original v-belt to 6pk micro V belt. The system gives ~extra 20-25 HP between 5000 and 7000 engine RPM. (The motor-generator unit rotates 15000-21000 rpm) That is the difference between our system compared to mild hybrids in new cars nowadays: we did not care low rpm operation. There is a 48V ~1.5kWh Li-ion battery, a 400A inverter and a 90A DC-DC in the "black box". The system operates in S3 10% 100s duty cycle.

[evsp]

"does this assembly work with the original tu2j2 ecu?"
Yes, we did not change anything else. By the way is there any difference between S2 Rallye ecu and S1 Rallye ecu?