Hello, Jake here - Ashley, you're right, I didn't respond very quickly but I thought I'd share the conversation at it seems a little miss represented here. (of course confidential details hidden)

Spoke too soon... leak from the rear main seal, I assume. Engine oil from the flywheel housing, only a slow drip so too concerned at the moment. Obviously a new seal went on during the rebuilt, but it wasn't one of those fancy Teflon ones...

Gotcha, thanks. Ive got my electric fan on the outside of the radiator which limits my options somewhat.

Series rad in the standard place. Spal fan and flat shroud between rad and engine. Similar to this, with some minor trimming. Intercooler in front of the rad with some not great brackets holding it. Both cooler hoses under the expansion bottle...

They never were, technically. My family name is Thomas, it's been in the family since new being used by my grandfather and his father as a recovery truck for their workshop in the village. So getting the sign-writing was just a throwback to them.

Yes, whipped out the thermostat before blanking. Where have you got the intercooler mounted? I've got a small one here but was just slightly too big to fit with the electric fan in place.

Did you remove the bypass thermostat thingy in the oil filter block when you blanked off the cooler?

Evening all, Just a quick post to say I'm just back from a road test in the 109 since installing my 200 tdi conversion, and wow, what a difference it makes. I know that seems a bit obvious, but it's just so much more usable in every way. I...

Bump, price drop. £70

No, fuel cut off is entirely mechanical.

The outer doesnt go in very far from the back if I remember rightly.

There are two small grub screws holding it in, one holds the sheath from the back and another holds or acts as a guide on the bit you pull.

There's no science here, just sticking two things together. Use a good bead but not enough that it enters the sump, torque the fixings up appropriately and that's it.

What have you replaced the nylon hoses with? I'd suggest replacing them with clear fuel line so you can see any air leaks/bubbles and track them.