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I didn't, they are the standard lighter socket sized holes, it's just that the switches are slightly too small so they can move around slightly in the holes. I have since straightened them out ;)

Got them all on ebay :)

No :( :o

So my boy was in the back and said 'Dad, that noise sounds really loud back here!'. Turns out I had been barking up wrong tree the whole time: Ooops......

None that are obvious without removing it.

All the intercooler pipes are new. I'll check all the exhaust joints.

I eliminated anything on the intake side when I briefly ran it with the intake hose completely disconnected, thus bypassing the fiter all together. Still made the noise.

EGR is blanked, I don't think it's blowing from the blanking plate but it's something I can check. Only other places for potential leaks I can think of on the exhaust side are the head to manifold gasket (already replaced), 'bull horn' joints which I haven't really looked at yet, or turbo to...

There is no manifold to turbo gasket, the exhaust manifold is part of the turbo exhaust housing. I don't have a viscous fan. It really has got me puzzled :/

I have a 110 fitted with a 300tdi (disco lump). A few months ago I started getting what sounds like a boost leak. This has got progressively worse and now sounds like a tornado at full boost. I replaced all intercooler piping, no change, fitted a new intercooler, still no change, and just...

A day, maybe two at the most..... ;)

Been up there a couple of times myself, nice little site :)

Yes, in front of the rad. I drilled two extra holes in the radiator frame so I could move the radiator over to allow the intercooler hose connections to come through. It's tight, and I'm probably going to redo it as I'm not entirely happy with how it's sitting at the moment. I'll likely make...

Bought it from the same seller as me then :)

My 300 doesn't need the fan either TBH, I can't actually remember the last time I actually needed to switch it on lol. I keep meaning to connect it up to a temperature controlled switch but I haven't bothered as I don't think it would ever get hot enough to trigger it.....

Yeah, the noisy fan pulley bearing was the main reason I did it really, a shorter belt was cheaper than an new timing chest ;) I actually tried a couple of length belts before I settled on this one, can't remember the length off hand but the tension is perfect. Only downside is lack of auto...

I removed the viscous fan, fan pulley and tensioner and bypassed it all with a shorter aux belt. I did it because A: I had no use for the viscous fan as I'm running an electric fan, and B: I couldn't shut the chirping noise from the tensioner up, even after trying the 'penny trick' and replacing...

Yeah I used reducers, Defender pipework is 2" OD. It wasn't a kit, I just worked out what I'd need and got it all from this seller: autosiliconehoses_outlet on eBay

Looks worse in the pics but yeah it is a little bit wonky, need to bring the right side up a tad. I didn't go mad with the pump as I don't have an EGT gauge.

So, the old girl was making all the noises typical of a boost leak, I checked all the hoses and couldn't find an obvious split so I put it down to a crack on the intercooler itself. Anyway, I took the opportunity as an excuse for bit an upgrade ;) Ordered an RS500 intercooler as I've seen...