Thread: One problem after another

Well,

My inlet manifold on the drivers side finally let go 227000ks. Ordered parts, used this to do a part list, thanks everyone. Didn't change injector pipes, don't see the point.

Ordered both manifolds, manifold refit kit (injector seal kit, EGR pipe gasket) EGR pipe clamps (don't need them), coolant junction (mine was original) and LCA rear bushes (because it's a D4 and it eats them for lunch). Ordered from LR direct as I often do. Expected here by Friday afternoon for me to start the job. They got here the Monday before the Friday. Winning!

Started Thursday night. Just about got the manifold off but the stud that holds the engine cover on broke and I couldn't make noise.

Friday after work. Off and on with that manifold injectors back in started on passenger (lhs) manifold.

Saturday Mrs at work I had kids (4 and 5) got a bit done, not alot

Sunday finished the job around midday, went to start car without assistance. Long crank no start. Mrs came home and cranked so I could bleed. Instant start. Running. 1 min. Then dead. Didn't worry, suspected air. Attempted re start. Needed bleed again. Got out of shed for a wash.....

Lucky to get back in shed. Hooked up gap. Fuel rail pressure fault. Wiggled wires. Pressure came and went. Zipetied in position were they were working....
DCDC converter performance fault.
Turbocharger position sensor fault.
Fuel rail pressure sensor fault
Let the games begin.

Changed the plug and repaired wiring on rail pressure sensor. Came good. Only
DCDC converter performance error &
Turbocharger position sensor error left.

Anyway after allot of diagnostic testing. Called Cambo at old Jaguar because when he sorted my cd player I quickly worked out he's a guru. We ran through some ideas. In the end it looked like a engine ECU. Both of us agreed it was unlikely but there was nothing left. I was lucky he was available and I asked him to come up to Newcastle to help me out. I rang all 4x4 who had a ECU in stock and picked it up. Cambo has the gear to make the replacement ECU work in my car. I doubt gap can do that. But I didn't look.

Cambo came up. Checked my work and lucky for me the reflash worked and my ECU came back to life and the unit I got from all 4x4 stayed on the passenger seat. I returned it the next morning. His service was awesome as the car was stuck in the shed and the only other option was a tow to get it somewhere.

Then the fuel rail sensor fault came back. This time high input error. Original fault was low error. This time when I tested the sender it was at 4.8v so I ordered a new sensor. Replaced it and all is good.

You can replace a fuel rail sensor on a D4 without a complete rail. The cheapest way is LR genuine at $230 part number LR020693, it's off a RRS V8 but the Bosch number is the same.

The plug for the sensor is hard to come by. The easiest way is to buy the wrong plug from cool drive or AFI Australia and use a razor blade to cut the locating teeth off on the side opposite the clip.

Anyway without Cambo it would still be in the shed. He's allot smarter then just radio upgrades and more reasonable priced then a flat bed. He's also got Apple car play working with them. Which wasn't a big deal to me until the Kia Rio I hired to replace the disco had it. Now it seems I'll be driving to his house to have that fitted.

There was no reason for any of these faults. Just a typical case of bad luck.

I will add. Those worried about EGR can have that fixed with Cameron also. But, at my mileage the manifolds were still very clean. We are obviously not suffering the same as the Jap diesels in this regard.

Cheers

Originally Posted by DiscoJeffster

Wow. My manifold came off and on. I was surprised but I didn’t even need to bleed anything. Seems you had a run of bad luck!

Yeah was likely a long crank due to the rail pressure sensor which was dead. The harness has a tight bend the plug and was hard to get off, I had conceded that was just heavy handed of me when moving harness around to get manifolds off.
I left the cam belt covers in place too. The actual job went really fast. I was in no hurry. Which is why I think I got the electrical errors. All jobs must come with a degree of difficulty. And that's what happened. It made it difficult.
I was actually so relaxed when trying to start it. That I just decided it was air and waited for her to come home.
It actually made me like it more not less which was weird.