I had the same problem after putting a bit of rubber grease on a hose to get it to slide on all the way. A bit too much grease! Pictures are a bit on the small side, but well done with the installation. The only bit that makes me nervous is that gap between the radiator and fan - it does seem...

Have a luvverly time in France Benneh.

Any chance of a few photos? Particularly showing where and how you had to modify stuff. A photo of the intercooler itself would be nice too. Also, how long did the work take you? I just lashed out about £350 for a Serck from Paddock. The best deal around at the moment for a dedicated Disco 2...

As a suggestion, run it for a few more days and if there is still a problem, strip out the pro-vent completely, then see if the problem persists.

Not so much the most rust I've seen on a Disco chassis than the least chassis I've seen on a Disco chassis. Mine spent 9 years on a farm in Fife and is almost glistening in comparison. Good luck with the MOT.

You probably get to keep your GF too.:D

Can't speak for V8's, but a well looked after TD5 should be good for 250,000 miles. Service history quite important here. Mine has 154,000 (bought a year ago at 147,000) and I hope to still have it in 10 years time. It gets used every day. Whatever you get, service it regularly and use good...

See what your garage says. If the engine is damaged/scrapped, get the garage to write a report, then take the car back to the vendor and get a full refund of your money.

My gut advice would be to go with your heart and get a Defender. But what if your GF is as unhappy with a 300tdi as she was with the series? See if you can blag one for a few days to see how she likes it before parting with the Disco.

I like it when these threads appear. They remind me of what I have to come, hopefully by the end of the year.

I will give you the details of my tester next time we meet Benneh. You'll get none of that sort of nonsense from him. If something is unsafe he will fail. If it is not, he may give an advisory. I got an advisory on one tyre, now changed.

I got a set of silicones down the net from Derby Performance Hose. Available in several colours for £60. Another £12 gets you some rather nice wide stainless hose clips that are much better than either the standard ones or jubilees. I found that the one that fits to the turbo needed about 2cm...

Erm. My D2 has a steering box, not a rack.

Good luck wth the MOT Benneh. Mine is also tomorrow, but doing it a month early as I'm expecting it to fail on a couple of things. Will be hanging around while it's done so I can pick the testers brains and get to know the car a bit better.

Yup. Copper washers. Copper does work harden over time, so if they have been on and off a few times prior to your ownership, you may well get a problem. As an aside to Blimps comment about starting. My own Disco will not unlock with the remote if I park near the far corner of our local...

Never understood why they never made them full length, then decided to sell rear extensions as an extra. Could've been to make a bit more money. I could really do with the rear extensions so I can fit some properly spaced ladder racks instead of the huge tall unsightly things that fix to the...

Thanks for a great re-build guide Benneh as well as a "music" video to go with it - sounds lovely. I think there would be a good case for extracting the engine build from the rest of the thread and using it as a "sticky". A great source of reference for anyone wanting to re-build their TD5...

Tis a thing of true beauty Benneh. Why are you slinging it in an old Disco? It should be in an art gallery somewhere, or a posh blokes front room. Others may disagree here, but I would be tempted to put the inlet manifold on the head before fitting it, as I don't have hands like Jimmy Savile.

Did most of intercooler fitting today. Laid them side by side and had a bit of a measure. They are same width, but the Serck (with "Serck Racing" stickers alll over it and sprayed on the front) is almost 3" taller and 3/4" thicker. Tubes look to be about 30% wider although fin density is about...

Even if you got the seats re-cut and used new valves, it's still best practice to lap them in with a dab of fine paste. Just a minute or so per valve would do it.