OK I just need to address a few issues that were pre-existing when I bought my Disco and am looking at repair options.

1) Slight bottom-end knock exists which has not changed in the last 3,000 miles but is quite noticeable under load.
2) Loses coolant, I have always suspected head gasket, mechanic recently confirmed the head gasket is on it's way out.

So do any of you have suggestions about which approach will be most cost effective & time effective, assuming I plan to keep the Rover for at least the next 5 years? I'm also concerned about getting any possible performance gains if I'm putting this much money into it. I'm kind of over-committed in terms of time due to my college coursework, and I have money in the bank, so assume all work will be done by a competent professional other than myself.

A) Keep existing 4.0L V8, repair only.
B) Keep existing 4.0L V8, have rebuilt locally.
C) Install a used replacement 4.0L V8.
D) Install a rebuilt 4.0L V8 crate engine (can get one for $3600 I believe).
E) Swap in a 4.6L V8, used or rebuilt.

I'd kind of like to explore option E if it's at all feasible because perhaps it will have enough torque to compensate for my 32" tires without re-gearing and therefore save me money in the long run. I'm also wondering if I were to have the 4.0 rebuilt locally, are there any straightforward & inexpensive performance modifications I could specify to achieve the same end (less sluggish overall, lol). I really am open to anything I'm just trying to make an informed decision.

And yes, as of tonight the Rover will be parked until I can take it to the shop. In the meantime, I'll have fun driving my 2WD Ford Ranger in the snow!

 

I like option E the best also. It's completely do-able, almost direct bolt-in if you get a P38 Range Rover 4.6.

Check these people out, they've done it before:East Coast Rover Co.

They specialize in Defenders now, but not long ago worked on disco's and rr's also.
Call or e-mail them, they'll let you know what's involved with a 4.6 swap(I believe just a new chip in the ecu is all it takes), and the parts necessary for it.

 

Thanks for the heads-up, I will contact them before moving ahead.

 

I like option D myself if you plan on keeping it long term, that would be like new wouldn't it?

If you build it up much, you still got the same spider gear so you may want to beef up driveline as well for max benefit if you do go bigger HP or whatever.

There are a few sites on the web that offer high end replacement motors.

 

Or if you get a solid used one and have it gone thru completely.

 

Danny Lee, what would constitute going through it completely? I would assume new head gasket and all external oil seals/gaskets, anything else that needs special attention? Anything remanufactured will be stretching the budget a bit, looking at $3600 for a 4.0 and $4100 for a 4.6, plus labor. I really do want to keep the Rover for at least 5-10 years, but my primary concern is to do something that will get me through the next 2 years while I finish school. Then when I can work full-time perhaps I'll be able to afford a better swap. I'm looking into the requirements for a 4.6 swap, but if I stay 4.0 are there other cams or cranks that won't confuse the ECU? Not looking for huge horsepower but anything over stock would be nice. Not worried about spider gears yet, they'll give me an excuse to install lockers some day... LOL.

 

It looks like I can get a used 4.0 or 4.6 for about $1300 plus freight.

 

Sent the following email to ECR:

Holly, or whom it may concern,

I was referred to you by someone who told me you used to do engine swaps on Discoveries and Range Rovers. I understand your focus is now Defenders, but I'm curious to know what is required for a 4.0 to 4.6 swap. I have a 4.0L 1996 Disco with engine troubles and am considering swapping in a 4.6L P38 Range Rover engine. What is needed in terms of computer/electrical changes, relocation of components or accessories, exhaust and coolant rerouting, or other adaptations to allow the swap? I am under the impression that the two engines share essentially the same block. Any direction would be appreciated as you are a specialist in the field of Land Rover repairs and I am not.

Thanks in advance...

I've also scheduled a shop appointment on Thursday, I'm asking my mechanic's advice on whether my existing 4.0 is worth using for anything. Besides a boat anchor, that is... If I can get everything done for under $3k I'll be happy, less is better. Over $3k and I may be looking for a different Disco.

 

Since it is a good topic and could impact several of us one day, I did some research to see what options are out there, not an endorsement of anyone.

1. Land Rover Remanufactured Engines

2. Land Rover Remanufactured Engines

3. Land Rover Discovery Engines, Motors, Blocks, Cylinder Heads (Remanufactured, Rebuilt, New, Crate, Used, Salvage)

4. Used Engines for Sale, Ultra Low Engine Prices

5. Remanufactured Land Rover Engines by ASU >> All Land Rover Models Available >> Used Land Rover Engines


Also most of our usual part specialist sell motors as well.

 

Thank you, Danny Lee, excellent reference there. I received the following response back from East Coast Rovers:

The 4.6 is a bolt in. No modifications, no special anything required.
Just swap the long block from the RR into your Disco and use all the Disco parts on it.
No mods required. you'll need to make sure the block you are going to use has the same mount for the crank sensor. If it doesn't you can change these, but it requires tig welding, so it is best to get the block you need.
If you want the most performance from the engine you will need to get a chip set from Tornado System in the UK, but it will run on the stock 4.0 tune if you like.

Any ideas of how I can confirm the type of crank sensor bung or mount if I'm buying an engine and having it shipped to me?

EDIT: I just fielded the same question to ECR and will post the response here.