4.0 engine in an 03 disco
Camel Trophy
Joined: Nov 2012
Posts: 3,717
Likes: 248
From: Longview, Texas
When I swapped from a 4.0 to a 4.6 the latter had SAI and the former did not. There were plugs in the heads of the 4.0 that I removed and placed in the same spot on the 4.6 after removing the SAI.
In other words, both sets of heads had the same holes for interchangeable SAI or plugs.
Actually, there was a step in the middle where I used the old threaded ends from the SAI tubes and filled them with welding material, but then I noticed the plugs on some spare heads. Either work. My truck is non SAI.
Deputy is right. I forgot! There is a slightly different setup on the back end of the crank that made the flywheel and flex plate different and not interchangeable between the 4.0 and the 4.6, including a spacer or larger end on the end of the crank of some sort. I'd forgotten that (and I don't fully remember it now, clearly!). But they booth bolted right up to my transmission and torque converter. If the OPs new engine comes with a flywheel and flex plate installed, he will be good to go.
I did not have an issue with plugs or holes for the sensors, with the sole exception of the oil sensor; one front cover had a different sized hole, and one oil sensor had a single blade, but the other had double blades (there is an AB video on what to do if you have the wrong harness plug for the oil sensor... video about replacing front cover). Also, one crank sensor was spaced out from the flywheel, and the other flush. I can't remember which was which but it was obvious when installing the wrong one if it touched they flywheel; maybe not so obvious the other way around, but the end of their sensor floats close to the flywheel. I recall the sensors being identical but the spacers or bolts being different, in order to correctly position the crank sensor.
In other words, both sets of heads had the same holes for interchangeable SAI or plugs.
Actually, there was a step in the middle where I used the old threaded ends from the SAI tubes and filled them with welding material, but then I noticed the plugs on some spare heads. Either work. My truck is non SAI.
Deputy is right. I forgot! There is a slightly different setup on the back end of the crank that made the flywheel and flex plate different and not interchangeable between the 4.0 and the 4.6, including a spacer or larger end on the end of the crank of some sort. I'd forgotten that (and I don't fully remember it now, clearly!). But they booth bolted right up to my transmission and torque converter. If the OPs new engine comes with a flywheel and flex plate installed, he will be good to go.
I did not have an issue with plugs or holes for the sensors, with the sole exception of the oil sensor; one front cover had a different sized hole, and one oil sensor had a single blade, but the other had double blades (there is an AB video on what to do if you have the wrong harness plug for the oil sensor... video about replacing front cover). Also, one crank sensor was spaced out from the flywheel, and the other flush. I can't remember which was which but it was obvious when installing the wrong one if it touched they flywheel; maybe not so obvious the other way around, but the end of their sensor floats close to the flywheel. I recall the sensors being identical but the spacers or bolts being different, in order to correctly position the crank sensor.
Last edited by Charlie_V; Sep 21, 2018 at 07:06 PM.
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Three Wheeling
Joined: Mar 2018
Posts: 53
Likes: 1
Wow you guys are awesome, i couldn't imagine figuring this all out without the forum. At least i know its going to work, ill deal with the check eng light after.
Yea my engine is complete right now so i think ill be set but 2Guiness might still need some help
Yea my engine is complete right now so i think ill be set but 2Guiness might still need some help
Baja
Joined: Aug 2013
Posts: 6,891
Likes: 787
From: Huntington Beach CA
They are not a direct swap, crank sensors are different, mounting area for crank senors are different and plug for crank sensors are different. Flywheels have to be used with corresponding parts, 4.6 flywheel with 4.6 sensor, etc. Folks have modified the mounting area of the 4.0 block, (search for threads/topics), by removing the mounting area from the 4.6 block and aluminum weld it in place on the 4.0. Then it uses the existing harness and sensor...and 4.6 flywheel.
Thought l read somewhere, where they changed the wiring harness for the crank sensor, to accommodate the 4.0's sensor...but, the search function is not working for me...since they changed the forum software here. So, i'm not a hundred percent sure of this option.
Brian.
Thought l read somewhere, where they changed the wiring harness for the crank sensor, to accommodate the 4.0's sensor...but, the search function is not working for me...since they changed the forum software here. So, i'm not a hundred percent sure of this option.
Brian.
4.0 Bosch and 4.6 Bosch sensors are the same as well as mounting
edit: according to Charlie and deputy I am wrong.
ive got a 4.0 in my 04’ and don’t remember any sensor issue/swap
Last edited by abran; Sep 21, 2018 at 10:15 PM.
Camel Trophy
Joined: Oct 2016
Posts: 4,860
Likes: 1,401
From: Michigan
^^^Now, l'm not sure^^^
Maybe l am thinking Gem and Bosch differences? To many years wrenching, to many different engines, so few brain cells anymore...leads to much confusion...lol.
Brian.
Maybe l am thinking Gem and Bosch differences? To many years wrenching, to many different engines, so few brain cells anymore...leads to much confusion...lol.
Brian.
Camel Trophy
Joined: Oct 2016
Posts: 4,860
Likes: 1,401
From: Michigan
Okay, after a bit of research...it looks like l was thinking about Gem/Bosch swap...so...disregard my post.
According to PTSchram (land rover guru)...over on the LROnly.com...the engine is a direct swap. He says the ECU doesn't even need to be reconfigured, and will run fine with 4.6 fuel programing.
I'm going to edit/delete my earlier post, so folks in the future (searching for info) won't get messed up by my mistake.
Brian.
According to PTSchram (land rover guru)...over on the LROnly.com...the engine is a direct swap. He says the ECU doesn't even need to be reconfigured, and will run fine with 4.6 fuel programing.
I'm going to edit/delete my earlier post, so folks in the future (searching for info) won't get messed up by my mistake.
Brian.
