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Progress report. I welded in the outer sill first. I found it impossible to then fit the inner sill complete with the body mounts. I ended up drilling out the spot welds on the rear mount. It should be easier to put it in place and weld it up. My welding isn't especially pretty but it is strong.

I've now got all the cutting out done. I had to use the hole saw to get the rear sill mount bolt out. It will make it easier to put it back.

Thanks for that. I've wire brushed the threads and soaked them in WD40, hopefully by morning they'll be good to go.

'95 300tdi four door I should rephrase the title. I've cut out the floor section just leaving what remains of the outer sill to maintain the door gaps. I bought some replacement inner and outer sills from GDI Products on ebay. Before I do the final cuts I have a couple of questions. When I...

Give that man a coconut. I disconnected the resistor behind the washer bottle, the dim lights went out and they work properly again with the switch. Many thanks.

That's a great help, thanks. I didn't notice the yellow relay clicking when I switched it on and off. I think water may have leaked into it. I saw some water on the floor mat.

I've checked the earths and cleaned them up. I fixed the dodgy connector on the RHS lamp and it too still glows when the lights are all switched off. I want to eliminate the relay, but I can't find it's location in either the Haynes manual or the handbook. Can anyone help me find it?

I have a strange wiring issue on my 300 Tdi Discovery. The left hand side headlamp is dimly illuminated even when the the light switch on the steering column is switched off. The right hand side has a slightly dodgy connector which I need to sort too. I can't figure out how power could...

I just changed the engine over on my 300tdi Discovery. The new engine had a different alternator. I swapped the old one back over but failed to record the locations of each wire as I removed them. The large feed wire is obvious. the second wire with the strange captivated nut is...

It went back in after a bit of faffage ensuring everything was level and aligned. I took the engine mounts off completely including the big metal plates. That helped a lot. Just need to fill it with coolant and antifreeze in the morning.

I pulled the old engine out today. It was fairly straightforward. the only problem was lifting the engine clear of the chassis engine mounts. I anticipate that may be a problem putting the new engine back in. Are there any tips that I should follow for the installation? Thanks, Peter

Thanks for the input folks. I have a epco engine hoist and a pit, so hopefully I should be able to to get to everything. I've been down the engine swap many times before with an old series IIA, so I'm not going in blind. Not being able to remove te wings and front panel will make access a bit...

I've completed another 500 miles or so since I replaced the head gasket. No cooling woes, but the engine still feels down on power. I noticed when the head was off there were some scores in a couple of the bores, deep enough that I could feel them with my finger nail. So, I found a...

Thanks for that RichP. I just had a look at it, it doesnt look as if its been serviced for a while. I think I'll just take the whole thing off and clean it on the bench. Previous experience with anything plastic on a Land Rover says that it will break! EDIT the fuel cut out connection was...

I've never checked the sedimentor.

I replaced the head gasket and sorted a cooling problem. A couple of hundred miles of heavy towing down the road with no cooling issues but another problem. Starting from cold this morning the engine just cut out. It happened a couple of times when on the road, but it sprung back into life, I...

I think I may have found the source of my problem. When going through each of the hoses to check for sediment etc I removed the expansion tank to flush it out too. Once removed I heard a rattle from inside. It was a pebble!!!!! So I think it had been blocking the return side of the...

I cant see any evidence of a leak there unless its so slight that it evaporates before reaching te ground, but when its been sitting in a spot for a while there are no leaks underneath the car at all. I must try and get the radiator and bottom hoses out and flushed.

The poor circulation and inability to expel the air from the coolant has led me to suspect the water pump. I have heard tales of the impeller parting from the spindle. Once removed it seemed ok. It has a metal impeller. The bearing feels sound. While looking on ebay I noticed pumps being...

Update update. I checked the thermostat and it was fine. I filled the heater matrix by disconnecting the feed hose from the rear of the head. I couldnt get access to the jubilee clip that held the bottom radiator hose on because of the fan shroud. I've ordered a viscous fan spanner to get it...