Banana engine replaces 100td engine 1999 Smiley

[ob1cnoby]

Hi all- I just blew my engine coming back from france, (100td) and had to have a replacement engine fitted,and at £350 fitted inc engine, who am I to grumble, although i do have a few small problems

1- Temperature guage doesnt work ,
On the banana, there seems to be 2 plugs for the gauge, one is brown and just below the thermostat housing, and this appears to be the correct temp gauge point, as in brown plug, and brown socket (in head) fits perfect. But it doesnt wortk.
To Check, I have shorted out the 2 pins, and this throws the temp gauge (in cab) right over, so recon at least I have the gauge wiring, however, the sensor in the cylinder head- either doesnt seem to work, or has a different impedance to the 100td or

2 There is another fixed plug in point just above the brown one, (dirty white or grey) at the top side of the top hose / thermostat housing, maybe it should fit in here, but the brown plug I have wont go in without cutting it off, and getting a white/grey plug baring in mind, the old socket that was on my 100td, is brown and fits straight into the lower (brown) socket, with no bother ( think sensor is US but will head advice

3- starting first thing on a morningis a sod, my 100TD used to have glows plugs ( I think) and was no problem, I have been adviced that the banana doesnt have glow pluges ( it doesnt I have looked) , but works on EGR (exhaust Gas Return) to heat ignition,( or is there something I am missing) also suspect- back syphoning, as i crank it over till battery goes flat, but saying this, the battery is no great shakes, and neither is spare, once started its fine
last point, it smokes a bit on start up, although it could be remnants from intial engine blow, as i had water, and oil in my exhaust.
I have also set back the Bosch pump ( leaned out) by turning regulator anti clockwise 2 turns, as the exhaust is very black and sutty, but still to road test, before this , I did come up to Leeds from London and mpg was about 28 to 30 with no great pull, whereas my old TD did around 32 to 35mpg and pulled a lot better (less noisey too.
Any comments wellcome, it might come to new engine, so anyone with a half decent 100td, let me know
cheers Dave

[GBBiker]

1- Temperature guage doesnt work ,
On the banana, there seems to be 2 plugs for the gauge, one is brown and just below the thermostat housing, and this appears to be the correct temp gauge point, as in brown plug, and brown socket (in head) fits perfect. But it doesnt wortk.
To Check, I have shorted out the 2 pins, and this throws the temp gauge (in cab) right over, so recon at least I have the gauge wiring, however, the sensor in the cylinder head- either doesnt seem to work, or has a different impedance to the 100td or

The sensors are different and not interchangable.

2 There is another fixed plug in point just above the brown one, (dirty white or grey) at the top side of the top hose / thermostat housing, maybe it should fit in here, but the brown plug I have wont go in without cutting it off, and getting a white/grey plug baring in mind, the old socket that was on my 100td, is brown and fits straight into the lower (brown) socket, with no bother ( think sensor is US but will head advice

Must admit I don't know what the greyish socket is for

3- starting first thing on a morningis a sod, my 100TD used to have glows plugs ( I think) and was no problem, I have been adviced that the banana doesnt have glow pluges ( it doesnt I have looked) , but works on EGR (exhaust Gas Return) to heat ignition,( or is there something I am missing) also suspect- back syphoning, as i crank it over till battery goes flat, but saying this, the battery is no great shakes, and neither is spare, once started its fine
last point, it smokes a bit on start up, although it could be remnants from intial engine blow, as i had water, and oil in my exhaust.
I have also set back the Bosch pump ( leaned out) by turning regulator anti clockwise 2 turns, as the exhaust is very black and sutty, but still to road test, before this , I did come up to Leeds from London and mpg was about 28 to 30 with no great pull, whereas my old TD did around 32 to 35mpg and pulled a lot better (less noisey too.

Your 100TDi wouldn't have had glow plugs either

My advice would be to replace the battery with one of at least 680CC and 72Ah, such as the Bosch S3 or S4, type 096 (the correct model for a Di). Then I would replace the main battery leads (the + direct to the starter and the earth direct the the alternator mounting), increasing the conductor size from the OE 16mm to at least 25mm, preferably 40mm. You will need to leave a few inches of slack as the Di engines vibrate a bit when running. I would make sure that all earth connections, battery connections and the main starter + feed are clean and smeared in copperslip. You may want to consider fitting twin batteries as a permanent setup.

I would also give the engine a complete service. New filters all round and new oil. I would recommend semi-synthetic for a Di. You will find that using 5w30 will benefit starting as it is a bit thinner than 10w40 but either can be used quite safely and with no adverse effects.

The engine would also benefit from the EGR and leak off mods. They are covered in quite some depth with step by step instructions on here somewhere - just do a quick search.

Best of luck and keep us updated of your progress

[jay]

wel the banana engine is 76ps and the TDi is 100ps you will notice a diffrence in a drop of power..The TDi is ecu controlled and the fuel is metered much better than the mechanical pump in a N/A Di thats why the TDi is much quieter....You could get the banana block converted to turbo power with no problems.