Thread: 2011 D4 'Gearbox Fault' warning

Cheers.

I was very relieved when it cranked over. Engine shook like an amusement park ride till - I’m guessing - all cylinders had fuel. Then it smoothed out. Even with the scene from Giant happening under the bonnet the car was running well.

I did reuse the fuel lines and had no leaks. I’ll take that as a win. And now I have to reuse the line for cylinder 6 a 2nd time.

I bought a seat cutter set and reamed each seat and cleaned the wells to a mirror surface as part of the job. But that rear passenger side one was difficult to access. I may not have done a great job.

I pulled the injector yesterday and find it to be quite loose.

I hope I found the culprit. Looks like I may have knocked something onto the seat when installing the injector. Check out the dents in the washer. I’m guessing whatever caused the dents eroded away leaving the injector loose. I recut the seat and cleaned the well and surround. It sparkles. I’ll need to borrow a washer from an old injector. I’ll re anneal it and lap it smooth first. Hopefully that will work.

I also bought an $8 endoscope from AliExpress which has been useful. Not a terribly good focal length but super helpful and the next best thing to an eye on the end of your finger for those spots where a mirror on a stick can’t help.

Mmm. That that didn’t work. Guess I’m in the market for a new washer (and a bunch of spares).

It’s encouraging however that the car runs well.

So, turns out I'm chasing the wrong issue. Injector seems to be sealing fine and probably did the first time around.

Good thing, I get to go to bed knowing the issue. Bad thing....I must have punched a hole in the inlet manifold when wrestling with the stuck injector. Seems I turned it too far. I think the bracket was the culprit. Oh dear.

Learning curve is a vertical line at the moment.

A good degrease and JB Weld till I can get a new inlet manifold?

You could try, but those manifolds are notoriously difficult to get stuff to stick to on a reliable basis.

Thorough degrease around the area then sand where you want the stuff to stick with 60 Grit paper leaving no shine. This will give this type of repair the best chance of success.

DL

And use JB Weld it is very good

Thanks guys.

I ended up doing a Pebble Beach Concours level degrease, applied a plastic primer and made a neat little beer can patch backed with Sikaflex 227.

I’ll order a new cover and psych up to it. Seems to be a classic Landrover game of remove-just-about-everything-to-get-at-the-bolts.

What a silly mistake.

I have little doubt that mine is not the first Landrover to have been fixed using a beer can.

Originally Posted by Bananas

Thanks guys.

I ended up doing a Pebble Beach Concours level degrease, applied a plastic primer and made a neat little beer can patch backed with Sikaflex 227.

I’ll order a new cover and psych up to it. Seems to be a classic Landrover game of remove-just-about-everything-to-get-at-the-bolts.

What a silly mistake.

I have little doubt that mine is not the first Landrover to have been fixed using a beer can.

May as well fit the new alloy ones if yours is a 3L.