I've just painted my new bulkhead, which is my first time using a compressor and spray gun in anger, and I've been having problems. I've got a Clarke AP14GF gravity feed HVLP gun and whatever I try the maximum fan pattern is pretty small and it doesn't seem to be putting enough paint on at once...

Any idea what this second small pipe is for on the 200Tdi air filter box? The photo shows both my old knackered one and the replacement one, which has an additional sticky-outy bit.

I have a new alternator that I bought from Craddock's a couple of years ago which had the correct part number for a 200Tdi. The only screw connectors on the back are marked B+ and W. As far as my limited knowledge of alternators goes these are the battery connection and a connection for a...

The Defender 200Tdi I'm rebuilding (very slowly) has been leaking oil over the garage floor despite not having even been run yet. I've tracked down the oil leak to the sump, which I took off and reassembled some time ago, and clearly made a pig's ear of it. I can see that the official guidance...

Looking for an air filter housing for a 200Tdi Defender in reasonable condition

Another day, another photo with pointy arrows. What are these bits on my new galvanised bulkhead for? It's supposed to be a 200Tdi LT77 bulkhead but these brackets aren't on my old rusty one (unless they'd fallen off which is quite possible). There's another one on top of the passenger side...

I'm busy repainting all the rusty bits from the engine compartment and have got to this intercooler pipe (archive photo from before I dismantled everything and scattered it around my garage) How hot does this get in use? Should I be using a high temperature paint, and if so, will engine paint...

I've just replaced a couple of glow plugs on my 200Tdi as the threaded end sheared off when I attempted to undo the nuts. For some inexplicable reason Beru can't see their way to including the tiny nut that clamps the ring connector to the glow plug and as the originals are seized onto the old...

I've just started looking at getting the gearbox ready for fitting to the new chassis and to say it needs a good clean is a bit of an understatement! But why is it so badly covered in oil/grease? Anywhere I should be looking to track down the source? It's an LT77.

I've been tidying up my 200Tdi as part of a rebuild and I was wondering about a few things. I've labelled the photos with the bits I'm talking about. 1. Someone had used RTV to plug these small holes that look like the end of bolts coming through from inside the block (before they were pulled...

I'm about to replace the timing belt in my 200Tdi. Should I replace the camshaft oil seal, crankshaft oil seal and the one in the timing cover while I'm at it? There's no obvious oil leakage from them, except maybe a small amount around the crankshaft seal. The engine has only done around...

Has anyone ever found anything like this horrible looking slime and crystals lurking in their cooling system? Hopefully it's not a sign of anything more serious. It's only ever had proper coolant in the system, so I'm a bit surprised it's so bad. I'm going to replace the pump as the impeller is...

The vacuum pump on my 200Tdi seems to have some sort of oil leak around it (see photo). Is it likely to just be the gasket where it meets the block or are they prone to leaking elsewhere? Also, the parts diagram seems to show two gaskets sandwiched between the pump and block, separated by an...

I'm trying to fit a new oil seal to the flywheel housing of my 200Tdi but because I'm lacking special tool 18G.134-11 or anything large and solid enough to drift the seal in properly I've managed to deform it and now need to order another one. As they're not exactly cheap I'm keen to avoid this...

I'm rebuilding the swivels on my 1993 Defender 90 and the stub axle won't go back onto the swivel once the halfshaft and CV are in position. There's a 2mm gap all the way around where the stub axle should meet the swivel. If I tighten it up everything locks solid and the swivel won't turn. I've...

I'm now at the stage in my rebuild where I can fit new brake pipes to the rear axle of my 1993 Defender 90 (with drum brakes), but the previous fixing clips have disintegrated and I'm not sure how best to fix the new pipe. The parts diagrams show two items - 577873 and 11820L, but these are...

I've been refurbishing my seats as part of my Defender 90 rebuild and have run into a small issue. The metal pans in the bottom of both front seat bases have cracked where they were welded to the frame (you can see in the photo below where I've scoured the paint off fully in preparation for some...

I've just spent a frustrating evening reassembling a swivel. First I forgot to put the seal on before bolting the swivel to the axle, then got the seal plate the wrong way around so had to take it off a second time, then destroyed the swivel to axle gasket by misaligning the holes. Finally I...

I'm just refitting a new inner hub oil seal and even though it's at the required 4mm depth the lip protrudes slightly beyond the top of the hub whereas the old seal has a shorter lip. Is this correct? It's an OEM part FTC4785 (the same code is on the old seal) going into a K-reg Defender 90 rear...

I'm getting the rear axle ready for painting and after a whole evening spent getting the seized brake drums off I've discovered one of them was full of grease. I stripped down the hub expecting to find a shredded oil seal but there's nothing obvious. The only thing that was damaged was the...