Engine swap parts list
#31
07-12-2017, 07:22 PM
I have read that legally they had to provide replacement blocks until 2014, as auto manufacturers are supposed to supply parts for 10 years after production dates.
#32
07-12-2017, 07:31 PM
The blocks used for replacement were Coscast blocks. A company that was hired to fix their block issues for the warranty replacements.
When you think about it, during their casting process they ended up with 3 grades of blocks. Red, Yellow, and Blue. Red was for 4.6 motors that went into RR. Blue for 4.0 and yellow was used for either when the prescribed one was not available.
Keep in mind, the grading was based on the random output of the casting process, they could not necessarily control the process, it gave them what they got.
In 2002 14,095 D2s with 4.0 motors came into the US. Same year 3,927 Range Rover P38s were imported. Some SE and Some HSE, but I do not have the breakdown. For arguments sake, lets say all were HSE, hence all were 4.6.
We can then make the deduction that 78% of the blocks used were Lower quality. Granted, I'm taking some liberties with my theory and numbers.
Do you think once 03/04 production came when they no longer were putting these motors in Range rovers, meaning they were only making 4.6 motors not 4.0(which was the lesser of the production numbers) that they discarded 78% of the blocks and only used the red ones for the full production numbers?
To me it makes perfect sense. Also, I have bought and sold many Discos and can say hands down that I have seen more failed 03/04 disco motors than anything else. Thats why it is advised to buy a P38 4.6 for rebuild.
But hey, I am just a monkey with a wrench...
When you think about it, during their casting process they ended up with 3 grades of blocks. Red, Yellow, and Blue. Red was for 4.6 motors that went into RR. Blue for 4.0 and yellow was used for either when the prescribed one was not available.
Keep in mind, the grading was based on the random output of the casting process, they could not necessarily control the process, it gave them what they got.
In 2002 14,095 D2s with 4.0 motors came into the US. Same year 3,927 Range Rover P38s were imported. Some SE and Some HSE, but I do not have the breakdown. For arguments sake, lets say all were HSE, hence all were 4.6.
We can then make the deduction that 78% of the blocks used were Lower quality. Granted, I'm taking some liberties with my theory and numbers.
Do you think once 03/04 production came when they no longer were putting these motors in Range rovers, meaning they were only making 4.6 motors not 4.0(which was the lesser of the production numbers) that they discarded 78% of the blocks and only used the red ones for the full production numbers?
To me it makes perfect sense. Also, I have bought and sold many Discos and can say hands down that I have seen more failed 03/04 disco motors than anything else. Thats why it is advised to buy a P38 4.6 for rebuild.
But hey, I am just a monkey with a wrench...
One comment. Since flanged liners are pretty much the standard in rebuilds now, it really shouldn't matter which block you choose as long as it's a cross bolt and not damaged in some fassion other than the Crack in the cylinder. Discrepancies in the wall thickness no longer matter with the new sleeves.
#33
07-12-2017, 07:47 PM
#34
07-12-2017, 08:09 PM
That's fair. I'm trying to approach it from a do-it-yourself yourself standpoint, in which case the budget would me minimalist. I.e. prob not a budget for another block. Just order some liners from turner or the like, have a shop install and bore them, do the rest of the measuring and assembly yourself.
#36
07-13-2017, 01:15 AM
#37
07-13-2017, 10:24 AM
Or a P38 4.6 from a 98 - 02...
From the reading I've done the only time flanged liners fail is when they are improperly installed. I believe it was that Robinson site that described the meticulous process of heating the block and cooling the liners.
Which begs the question, if they can't heat aluminum blocks to pressure test them at
operating temps at most machine shops, how do they heat them to install flanged liners?
Sounds like very few people do the flanged liner job correctly.
From the reading I've done the only time flanged liners fail is when they are improperly installed. I believe it was that Robinson site that described the meticulous process of heating the block and cooling the liners.
Which begs the question, if they can't heat aluminum blocks to pressure test them at
operating temps at most machine shops, how do they heat them to install flanged liners?
Sounds like very few people do the flanged liner job correctly.
#39
07-13-2017, 10:47 AM
Has anyone seen a low mileage, perfect Disco or Range that deserves a new OEM Rover engine?
#40
07-13-2017, 10:52 AM
Agree.... IF they are installed correctly. The Darton O-ring liners should not be heated, but carefully installed using a coating of silicone grease so the O-rings make it to the bottom of the bores in tact and undamaged. Critical, since the cylinder boring process removes material which makes coolant jacket leaks even more likely if not inevitable.