Hello all,
What I hope to learn is the differences between the Bosch 4.0 / 4.6 motors for an up coming project. I'm looking at a 2003 D2 with a bad motor, don't know if it has dropped liners or head gasket issues yet, still waiting to meet up with the seller. Currently I have a 99 D2 Bosch 4.0 with modified heads (roller rockers) and possibly 4.6 crank / cam according to previous owner (not the individual who did the work). Since my 99 D2 is suffering from some rust issues, I'm thinking about using it as a parts vehicle for the yet to be purchased 03 D2. Are the engine blocks the same, just the crank / cam different between the 4.0 / 4.6? I'm thinking about using my 4.0 and confirming if the crank / cam are from a 4.6. Not so sure about keeping the roller rocker heads, the baffles were removed under the valve covers for clearance. The PCV valve has been disconnected from the intake manifold because of high oil consumption because of missing baffles. Most likely I'll use standard heads. Also, I have a 96 D1 w/factory 5 spd. Vehicle is rough shape, so the big plan is to move the R380 transmission into the new D2 during the motor swap.
I appreciate anyone's comments.
Karl

 

There are no difference between the two other than the rotating assembly (crank, rods, and pistons). There were, however, two variations; SAI equipped and non-SAI equipped. You would likely want to retain whichever is stock to your truck, or replace the ECU, Instrument Cluster, and BCU with the one from the other truck.

As for swapping the transmission, that is a MUCH more involved job than just swapping the mechanical pieces. There are numerous electrical issues to overcome that I highly suggest you research in depth before beginning. You would not be the first to abandon the project and sell your half completed project if you go in unprepared.

 

The crank sensors are different. Needs to be address, lots of topics already about the needed changes.

Brian.

 

Thank you for the comments. I have studied the thread regarding a R380 transplant into a D2 https://landroverforums.com/forum/di...al-swap-79203/
Major wrenching on a project isn't a problem, I have the shop, tools and motivation. I'll assume the 03 D2 will have secondary air, my current 99 D2 which will be the donor does not. So if all this comes together I'll use the 4.0 block and swap the internals from the 4.6.
I found the thread from the original owner who modified the 4.0 in my 99, these are the mods he listed.
LA Sleeves installed (Top Hatted)
Pistons measured and fitted to bore
New rings
New Rod and Main bearings
New Buick style oil through lifters
New Harland Sharp 1.6 ratio Roller Rocker Arms
Custom mount plate for above rocker arms, with correct geometry
Competition Cams 8.025 oil through lightweight pushrods
4.6 Land Rover camshaft
Inspection of cam bearings and mild buff (OK)
Cloyes timing chain and new gears
Inspection of oil pump clearance and gears. (OK)
Mild porting on exhaust manifolds and heads
Cylinder heads inspected and valves given a 3 angle machining
1 used injector replaced on fuel rail
Inline thermostat mod with a 180 degree thermostat

This truck now has 70k miles since this rebuild, so if this block is used I'll have it freshened up.

This all started when I was able to pick up a 96 D1 5 spd, this one is running / driving but in rough condition. Picked it up for $500 + $175 transport. I had initially planned to find a D1 donor and rebuild the 5 spd into a nice vehicle. Finding a reasonable (less than $1000) D1 with all the needed major parts has been tough. There are plenty of nice D2s in the area for under $1500. Since I already have an ARB winch bumper and roof rack for a D2, this is leaning me in the direction of doing the D2 5 spd project.
I'm waiting to here back from Tornado Systems on the cost of a re-programed ECU for the D2 w/5spd.
Thanks again, Karl