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Alright, I got it working last night. As mentioned somewhere, I replaced the new upper manifold gaskets with the old ones I took out. The truck was hard reset and then I also reset the adaptation values.
Important note on the upper gaskets - they are VIN specific in that there is a cutoff as DakotaTraveler noted.
So I went for a nice drive this morning and it ran great. As I was joking with my wife last night, I told her the engine light would come back... and it did after an ignition cycle. So the light and same lean codes are back and I get to order the right gaskets and do this a 3rd time. I''ll do another smoke test and see what I see although that should be after all the new gaskets are in.
Here's a PDF log from this morning's drive. Where the levels top out in the 20's for long and short term it's when I was stopped at a light, or in park idling and watching.
This is very interesting and has motivated me further to track this down.
The farthest I got with new fuel injector O-rings/seals was 75+ miles before the codes popped back. Usually after turning it off (to get gas etc). I am going to try the Evap tube trick. We shall see. I appreciate all the comments/suggestions here. I feel like Ahab chasing the elusive white whale!
I left it hanging but stuck a backwards vacuum cap in it to keep it clean.
It’s been this way now for 7 days and 271 miles of daily driving, mostly short 10-20 mile drives and several highway drives 80+ miles per hour 20-30 miles or so.
No lean codes. I still only have the P0441 evap code.
The only caution I might have from doing what I’m doing is there may be a risk of saturating the charcoal canister. I believe the purge system is responsible for keeping the charcoal clean.
I still don’t know why this seems to be keeping the lean codes away, but it is.
Another thread I dont want to read over again, plus so many people adding their issues. But.... gas cap anyone? The fuel filler cap has a critical roll in the evap system and can indeed fail causing a vacuum leak. I *think* the LR3 is suppose to be smart enough to infer a gas cap issue and throw a code for it, but I am not certain. Editing to add: I think evap only runs a purge cycle on startup and that it is generally closed. But if stuck open - gas cap failure can cause lean.
As for running with evaporation system disconnected, I really do not see any issue in doing so. Evap really is just to prevent evaporated gas from escaping into the atmosphere, purely a non-engine related emissions thing. And the charcoal is just a filter in that system. But I will advise that you should do something with the line heading back to it. While there is not a ton of vacuum, there is indeed some as the fuel tank empties. So right now you have a port open to moist air, water (rain), etc... And as for that aforementioned charcoal canister? Meh... it can probably get soaked and not cause any issue really. Just a tased evaporations system at worst. But I dont see any other damages like something to the engine itself.
But to circle back, if you had an evaporations code before and you had lean issue, sounds like you had an evaporations system leak and that is something to maybe look into anyway if not the fuel cap. Because if you go through deep water with the rig, you may have an entry point for it right into the fuel tank.
