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Project D3: my eBay 2005 HSE - repairs and upgrades
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 853

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3
Project D3: my eBay 2005 HSE - repairs and upgrades

I’ve been happily driving my Freelander 2 for five years now but have always fancied the bigger, better specced and far more capable Discovery. In particular I wanted an early high spec model, auto in dark grey with black interior. The FL2 is great as a daily driver but is falling short in a few areas, particularly on our two most recent camping trips where the lack of boot space was a real problem and the long-drive comfort was not quite as a good as it could be. It’s also a manual, which I’m not keen on.

I’ve had a ‘saved search’ on eBay for some while now for just the right D3, more out of curiosity rather than genuine intent to buy one. But when the (seemingly) perfect vehicle popped up a week ago just 10 miles from home and at the low bidding price of £3600 I though I couldn’t pass up the opportunity. With just a few hours to run on the auction I popped over to see the D3, took it for a low speed spin around the traffic and stuck a maximum bid of £4500 on the auction. A few hours later and at a pleasingly low £4000 I won the auction and picked up the car the following morning. Delighted.




2005, HSE with 134,000 miles. It hasn’t got a lot of paperwork with it other than the log book so I’m going to be safe and do all the basics on it, belts etc, just in case they’ve been missed.

Following some useful advice from many of you on the various bits I should be tackling (this feed here: https://www.disco3.co.uk/forum/just-bought...8800.html) I thought I’d set up this new feed where I can detail the overall progress of my project as it goes on over the coming months.

Having now driven the car for a week I’ve built up the below list of jobs. I’ll be updating the list as I go.

Red - outstanding items.
Green - completed (page number for ease of reference and the total cost of repair)

PRO Jobs to do

Pro Job 1: Both drive belts front and rear, and aux belt. PAGE 2 and £508.00
Pro Job 2: Fuel filter
Pro Job 3: New torque converter, gearbox flush, additive and new sump cover. PAGE 2 and £1499.00
Pro Job 4: Refurbish/powdercoat the wheels. PAGE 2 and £453.00.
Pro Job 5: Oil pump
Pro Job 6: Repair leaky steering rack
Pro Job 7: Tracking or alignment out, is pulling to the right
Pro Job 8: Air con re-gas. PAGE 2 and £75.00

My driveway DIY jobs

DIY Job 1: New headlight washer (missing) and new bonnet windscreen was her (split)
DIY Job 2: Oil service, oil filters, air filters and cabin filter
DIY Job 3: Coolant replace
DIY Job 4: Replacement speaker on the instrument cluster
DIY Job 5: Replace sidelight bulbs. PAGE 2 and £15.00
DIY Job 6: Replace rocker switches in the right of the steering wheel
DIY Job 7: New windscreen wipers. PAGE 2 and £40.00
DIY Job 8: New folding control latch to the second row seat
DIY Job 9: Sort out the dropping Bluetooth connection
DIY Job 10: Full valet inside
DIY Job 11: Add DAB somehow
DIY Job 12: New battery. PAGE 1 and £134.00.
DIY Job 13: Touch up paint to the numerous scuffs and hedge scratches
DIY Job 14: Sort faulty parking sensors
DIY Job 15: Sort rust and paint door tread panel
DIY Job 16: Re-affix loose interior panels to the boot area
DIY Job 17: Investigate excessive damp/condensation to the boot area. PAGE 1 and £0.00.
DIY Job 18: Add towbar and electrics
DIY Job 19: Rebuild EPB and repair actuator/module. PAGE 3 and £107.12.
DIY Job 20: Swap interior lights to LED (Powerfuluk)
DIY Job 21: Sort rusty rear towbar bumper and replace bolts
DIY Job 22: Add private plate to hide car age. PAGE 1 and £38.99.
DIY Job 23: Resolve serious water ingress to footwells, both sides. PAGE 1 and £15.47.
DIY Job 24: Check, then clean or replace MAP sensor
DIY Job 25: Swap brittle rubber engine bay hoses for silicone
DIY Job 26: Replace brake lines with braided hose and refurbish/paint callipers
DIY Job 27: Replace MAF as it is original
DIY Job 28: Cruise control has stopped working (since I did the battery swap)
DIY Job 29: Replace missing bung on the inside of front passenger seat
DIY Job 30: Suspension seems to rest lower on the drivers side
DIY Job 31: Add facelift D4 rear lights. PAGE 2 and £125.00.
DIY Job 32: Replace current remote key and purchase a spare
DIY Job 33: Debadge / remove faded and tarnished lettering, replace with new
DIY Job 34: Remove nasty chav-tastic Chrome mirror and handle trim. PAGE 3 and £0.00
DIY Job 35: Paint bumpers, arches and black trim with Plastidip or similar

This list will no doubt grow over time, but that’s plenty to be getting on with. I’ll be keeping the FL2 running too just in case these jobs take time and keep it off the road. I need the car for work so that’ll be a necessity. When the Disco is complete I’ll be flogging the the FL2.

Onwards...!
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 


Last edited by DIY Ace on 10th Oct 2021 7:03 pm. Edited 22 times in total 
Post #202894816th Feb 2019 6:30 am
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 853

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Courtesy of the ever brilliantly helpful Ray at Citroemech in Wokingham, I got the Disco up on the ramp yesterday afternoon.

First proper inspection underneath the car since collecting it, I am delighted that there are no obvious issues. No leaks from the engine, diffs, transfer box nor gearbox etc. Suspension all reasonably tight (but may upgrade to Polybush at some point).

It raised a couple of issues that are now added to the list above. Steering rack leaking and the weird scraping noise to the NSR hub.










 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #202894916th Feb 2019 6:40 am
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 853

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

DIY Job 12: New Battery

Met with a slow glow plug warmup and HDC fault on the info display, I’ve changed the battery last night.

Pleased I did as the old one is underpowered and of a cheap brand that I’ve never heard of. New Yuasa battery from Halfords at £134.00 has cured the HDC message. Great. BUT it has weirdly meant that radio and Sat Nav screen have gone blank. No power at all. This might be cured by a hard reset which I’ll try later today.

Out with the old and in with the new...


Click image to enlarge
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #202895116th Feb 2019 6:49 am
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ClassikFan
 


Member Since: 02 Nov 2016
Location: Surrey
Posts: 1025

United Kingdom 2008 Discovery 4 3.0 SDV6 HSE Auto Loire BlueDiscovery 4

Others might be along to give more info later but from what I've read poly bushes aren't the way to go on a D3.
 Just 'cause you got the power... that don't mean you got the right.
 
 
Post #202931717th Feb 2019 9:29 am
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timmyt79
 


Member Since: 18 Oct 2016
Location: Pemrokeshire
Posts: 585

Wales 2005 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

+1 DON'T be fooled into poly bushing! I recently have against all advice on here.. I thought I knew better and listened to the blurb from a reputable polybush supplier... Wish I hadn't.... I now feel EVERY bump and road line 😢🙈
So Needless to say I now have the expense and time of dropping the front wishbones back off... Replacing and then getting alignment done again!! 🙈
Be warned..
  
Post #202931917th Feb 2019 9:37 am
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DiscoJeffster
 


Member Since: 27 Feb 2016
Location: Perth
Posts: 204

Australia 2010 Discovery 4 3.0 TDV6 HSE Auto Nara BronzeDiscovery 4

Advanced factors can supply updated arms without using polybushes. They use a solid rubber bushing instead of a hydro bush. As mentioned, avoid their poly option. It’ll turn your discovery into a Nissan Patrol.
  
Post #202932217th Feb 2019 10:02 am
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kajtzu
 


Member Since: 10 Aug 2017
Location: Helsinki
Posts: 6538

Finland 2005 Discovery 3 4.4 V8 HSE Auto Cairns BlueDiscovery 3

The solid bush is a Meyle one I think? Would be good to hear people’s experiences after 1-2 years of use.
  
Post #202932317th Feb 2019 10:03 am
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 853

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Cheers for the feedback. I might give those poly bushes a second thought then...!
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #202949417th Feb 2019 8:06 pm
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Erea
 


Member Since: 19 Mar 2012
Location: Munster
Posts: 1509

Ireland 2006 Discovery 3 TDV6 Commercial Manual Zambezi SilverDiscovery 3

ClassikFan wrote:
Others might be along to give more info later but from what I've read poly bushes aren't the way to go on a D3.

+1
If you have 17” wheels then they are great for stiffening things up a bit. But mine had poly bushes and then I swapped from 17”to 19” wheels and I could feel every bump and pothole, it’s being gradually changed away from poly and it’s so much smoother now. My Indy said he only uses poly with 17” wheels
  
Post #202950517th Feb 2019 8:22 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 853

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

DIY Job 23: Water ingress to footwells

I finished the dreaded job of replacing the sunroof drain tube ends/valves today. I changed the valve ends two weeks ago and left the car on the drive. We’ve had some pretty terrible rain and I am pleased that there is no more water getting in. The carpets are still damp but they are certainly drying out albeit slowly.

Today’s job was putting the CJB back in, which was fun. I took the advice of another forum post and attached a ziptie to the ends of the levers on the rear. Made the job a million times easier. Helped also by my tiny office hands.

Took about an hour to refit the various interior trims too, car fired up nicely and all electrics seem good so I’m pleased with the result.

The only cost was one new tube and valve and three jubilee clips.
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #203898321st Mar 2019 8:10 pm
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ibruceuk
 


Member Since: 20 Mar 2018
Location: Lancashire
Posts: 105

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

RichardMaby wrote:
DIY Job 12: New Battery
cheap brand that I’ve never heard of.


Numax are good value but are a pretty good battery make actually very well regarded in the marine field...
  
Post #203904721st Mar 2019 10:36 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 853

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Ah I stand corrected! Good to know for future reference. The Numax I took out was underpowered for the car though so I’m pleased I changed it anyway. New one has been performing well since I changed it so fingers crossed it remains good - no more HDC messages etc

R.
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #203907522nd Mar 2019 3:21 am
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CY
 


Member Since: 16 Aug 2005
Location: Warwickshire
Posts: 4502

Scotland 2008 Discovery 3 TDV6 HSE Auto Tangiers OrangeDiscovery 3

Richard,

Love these kind of threads - looking forward to following the progress on your D3!

I had the blank sat nav screen issue after changing my battery too, it's also happened immediately after I've had to disconnect the battery to work on the car. Always comes back with a hard reset or sometimes even sorts itself out after a couple of restarts, think it's just a tantrum after losing power!

Cheers,
Chris
 2007 Porsche Boxster (987) 2.7
2008 Discovery 3 TDV6 HSE G4 Challenge (1 of 68)
2023 Defender 90 D250 X-Dynamic HSE 
 
Post #203909022nd Mar 2019 7:29 am
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 853

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

DIY Job 22: Add private plate to hide car age

Pleased with the service from A1ShowPlates. £38.99 for front and back plates with a black surround and a Disco3.co.uk web link at the bottom. That included a fixing kit and delivery too.

The old ones were original from 15 years ago (still had the main dealer details on them) and were so brittle that they snapped apart when removing. Using thin wire to ‘cheese wire’ the sticky pads behind them worked a treat. Then used GT85 (a WD40 competitor) to clean the area and then a body shop panel wipe to clean off the residue oils. New ultra-sticky foam pads keep the new plate in place.

Before:



After:



Nice plug for the best car forum!

 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #203961923rd Mar 2019 4:59 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 853

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

DIY Job 17: Excessive damp/condensation to the boot.

I traced the huge levels of condensation in the boot side pockets (where the jack etc is stored) to the water ingress through the perished sunroof drain tubes. Looking at the route of the water it was flowing down the inside of the sills and pooling into a large puddle. I’ve used a brilliant flexible 10mm-tubed hand siphon to extract the water and fixed the sunroof tubes (see DIY Job 23). The condensation is clearing up nicely and I’m confident will stop entirely when the carpets eventually dry out completely.
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #203962323rd Mar 2019 5:14 pm
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