My 2004 land rover discovery needs a new engine due to a gouge in the block and head. I am trying to find some on ebay that I can have shipped. Is it ok if I get an engine without secondary air injection? The current one has secondary air. It is possible to retrofit the new engine with secondary air using the parts, or are the heads different. I live in an area in California that only requires emissions testing when buying/selling a car. What other places can I get an engine? Are there other engine models that fit?

 

Heads need to be swapped for SAI.

 

1. Direct swap in with no mods: 2000-2004 4.6 with SAI heads (D2 or P38)
2. Direct swap in with no mods but need to change ECU/BCU/Instrument cluster with the engine for it to start: 1998-2002 4.0 Thor engine with SAI (D2 or P38)
3. Direct swap but need to swap ECU or reflash so SAI codes are no thrown : 1997-2004 Thor V8 (D2 or P38)

 

Extinct, I’m confident you know what you’re talking about here, but I have a couple questions, please.

• First, I understand that a 4.0 SAI engine is different from a 4.6, but what about the displacement would result in the OP’s truck not starting with a 4.0 SAI?
• Next, are there providers out there who can flash an ECM from SAI to non-SAI? Who are they?

My questions are academic for me; my ’99 is happily non-SAI. Thanks.

 

Just take whatever engine you get and put in your existing heads. Done. If you buy a used engine it’s very wise to just do a head gasket anyway while it’s out of the vehicle. At this time put in your existing heads if they are good

 

The OP wrote surfaces of both the block and head were gouged, so reusing the heads is a problem.

That said, I recall reading posts describing new metal being welded into mating surfaces of damaged blocks and/or heads and then milled flat. That may be an opportunity here, depending on resources available to the OP.

 

1. Poor choice of words on my part. You need the BCU to go with the ECU for it to start. You only need the 4.0 ECU so that it has the correct fueling for the smaller engine.

2. Yes, if a shop has the original Rover test book or the model that came after that. (I don't remember what it was called) they can Flash a different ECU over your existing one. Some years back I had a non-sai truck and a spare Sai ECU and I had them flash it with a non-sai program

 

1. Got it. Correct fueling from the ECM for a 4.0 makes sense. The BCU is derivative of that.
2. I'd expect a shop with an original Testbook is scarce as hens' teeth these days. Probably "easier" to replace the ECM, BCU & cluster.

 

I know Eurover in Greenville SC had one a few years back, they did mine. I hope the ones that had one kept it, it has a lot of functionality the new systems do not.

 

Is the Thor V8 4.6L? If I don't reflash the ECU, will it drive fine with the SAI codes?


Here are some images of the block and head. Not sure if the metal welding and smoothing will work.