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 4.6 Bosch into 4.0 gems truck

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KingKong8247
ABS Modulator Fondler
KingKong8247


Posts : 197
Join date : 2011-03-27
Age : 39

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PostSubject: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeFri Oct 03, 2014 1:03 pm

So I came across a great deal on a 2002 4.6 with 56k miles out of a range rover. I am pretty sure it is a bosch engine but will check it out this weekend.

Anybody on here swap a bosch engine into a gems truck? Any tips?

I found this site but thats all the info I came across so far
http://bahnstorm.com/rover/engine.htm

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KingKong8247
ABS Modulator Fondler
KingKong8247


Posts : 197
Join date : 2011-03-27
Age : 39

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeSun Oct 19, 2014 11:34 am

So I pulled the engine out of this yesterday:

4.6 Bosch into 4.0 gems truck IMG_20141018_175016_648_zps3w7rj85o

About 53k miles. Going to slowly put it into my truck in the coming weeks.

From my research this is what needs to be done:
-Swap intake manifolds
-Grind off the crank position sensor bracket and weld the 4.0 CPS on there
-Swap the cam shaft position sensor and gear
-Use 4.6 ecu but the 4.0 one will work too

I figure I'll post my progress in this thread
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devildog01
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devildog01


Posts : 617
Join date : 2010-11-29
Location : Your moms bed

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeSun Oct 19, 2014 4:39 pm

Hate to say it Billy but as long as you've got the engine out you should probably do the head gaskets.
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Hilltoppersx
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Hilltoppersx


Posts : 3183
Join date : 2010-09-28
Location : Westchester, NY

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeSun Oct 19, 2014 6:22 pm

agreed. might as well rebuild it now.
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KingKong8247
ABS Modulator Fondler
KingKong8247


Posts : 197
Join date : 2011-03-27
Age : 39

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeMon Oct 20, 2014 7:02 pm

devildog01 wrote:
Hate to say it Billy but as long as you've got the engine out you should probably do the head gaskets.

Good call. Definitely easier to do it now while it's out.
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devildog01
Industrial Strength Dickhead
devildog01


Posts : 617
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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeTue Oct 21, 2014 9:55 pm

On a lighter note that thing should run like a raped ape with a 4.6 in it.
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KingKong8247
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KingKong8247


Posts : 197
Join date : 2011-03-27
Age : 39

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeThu Apr 23, 2015 3:51 pm

Alright so I spent all of last weekend doing this swap. Took Thursday and Friday off thinking that I could then spend the weekend buttoning up the swap or doing other stuff. Started Thursday morning around 10ish and didn't finish until Sunday evening.

Here she is ready to get her heart ripped out
4.6 Bosch into 4.0 gems truck 20150410_180649_zpsakrhotyv
Getting there
4.6 Bosch into 4.0 gems truck 20150411_144244_zps7lefqaaa
At first I was not going to remove the wiring harness but then thought it might be easier while the engine was out of the truck to get to some of the plugs under and around the sides. Unplugged everything up top and then realized it would be a huge pain to unplug everything from the transmission. That is when I changed my mind again and decided to just leave the harness in the truck.
Ready to be pulled:
4.6 Bosch into 4.0 gems truck 20150411_163421_zpsei2ninbb
I spent the most time trying to get the upper bolts out that hold the transmission to the block. Using long extensions and only having myself, there was a lot of climbing on top of the truck, lining up the sockets, going back under only to have the sockets come off the bolt head. There has gotta be a better way but eventually they all came off.

Got the oily beast out:
4.6 Bosch into 4.0 gems truck 20150416_163751_zpsgdvegqih
4.6 Bosch into 4.0 gems truck 20150416_163759_zpsqddhv872
You can kind of see the oil on the old engine in the last pic but the head gaskets were leaking like crazy at the back of the heads. Oil everywhere! The coolant I drained also had signs of oil contamination. So this swap was just in time.

Here is the 4.6 ready to get stripped. I have a ton of extras from this engine if anyone needs anything. Ignore the garage btw.
4.6 Bosch into 4.0 gems truck 20150411_163400_zpsw8uvssc6
Stripped and ready to be put back together
4.6 Bosch into 4.0 gems truck 20150417_125027_zps6nqhdmyb
So everything swapped over pretty easily. You need to use the front cover, camshaft sprocket, intake manifold, flywheel, oil pan, and crank sensor.
Here you can see the front cover bolted on with the intake manifold.
4.6 Bosch into 4.0 gems truck 20150417_180532_zps2nqhi5ch
So at this point, I think it was Friday evening, I was pretty tired from pulling the engine and swapping parts from each one. I try and bolt on the oil pan but it appeared to be hitting the oil pickup tube and was about an inch from bolting on. The 4.6 has the oil pickup tube coming from the front cover while the 4.0 has it bolted to the middle of the block. So not knowing what the hell I was missing I started calling people. Tried Lucky8, Brett and Jarek.  Thanks guys for taking the time helping me out. Brett suggested just cutting an inch or so off the pickup tube and welding it back together. I ran this by Jarek and he explained how the oil pickup is based off of suction so rather then weld it he suggested flaring one end and brazing it like a plumbing fixture. I figured great idea but will have to wait til tomorrow. I bolted a few more things onto the 4.6 from the 4.0 and called it a night.

The next morning I went back outside and reevaluated how I would do this oil pickup modification. This is when I noticed this dumb ass stud sticking out of the bottom of the block. The 4.6 pickup tube bolts to the stud for support since it runs to the front of the engine. A quick snip with the cutoff wheel fixed this problem and the oil pan bolted right up nice and easy.
4.6 Bosch into 4.0 gems truck 20150418_115828_zpsheqxmyv6
4.6 Bosch into 4.0 gems truck 20150418_115833_zps5qx9lpzj
Glad that was done and moved on.

Another thing on the 4.6 block is the secondary air injection system. There are tubes that run out of the block on both sides above the exhaust manifolds that need to be closed since the 4.0 does not have this system. A bolt and some jb weld fixes that problem real quick.

So now I have everything bolted up and ready to go back in:
4.6 Bosch into 4.0 gems truck 20150418_124649_zpsrziutxbx

4.6 Bosch into 4.0 gems truck 20150418_143229_zpsey6mtpou
Back in:
4.6 Bosch into 4.0 gems truck 20150418_145833_zpssaiah6cw
Damn bumper is too big
4.6 Bosch into 4.0 gems truck 20150418_145839_zpsst9xu39k
Due to the bumper I couldnt reach the tranny
4.6 Bosch into 4.0 gems truck 20150418_145849_zps99kk49cw
A lot of shouldering the chain and slowly moving it around, the new engine goes in.
4.6 Bosch into 4.0 gems truck 20150419_172634_zpsw4ueclbp
Of course I only had 2 things left. Put the coolant overflow tank back in then bolt up the intake. The crappy old plastic tank decides to break where the lower hose bolts up. Very frustrating after 4 days of working to hear this beast run. Ordered a new one which arrived yesterday. Filled her up with coolant and she started right up.

Drove around for about 20 minutes or so. No codes so far and everything seems to be running smoothly. Not crazy fast but sure is quicker than the 4.0.

It is going to be nice not having oil leak everywhere I go, for now. Can't wait to hit the trails again.
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Hilltoppersx
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Hilltoppersx


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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeThu Apr 23, 2015 4:24 pm

legendary work good friend. that good ole truck deserved all the loving you gave it. she has really been a winner for you. always got you home even after beating the piss out of it. thanks for the write-up.
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KingKong8247
ABS Modulator Fondler
KingKong8247


Posts : 197
Join date : 2011-03-27
Age : 39

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeFri Apr 24, 2015 10:43 am

Thanks Ed. She has definitely been a fun truck and now hopefully Ill get a lot more years of wheeling with the new engine.
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Thebloody323
NELRC Original Gangsta
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Location : Ewing, NJ

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeWed Apr 29, 2015 11:32 am

How is the old girl running? You scaring the shit out of little ricers and their civics?
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KingKong8247
ABS Modulator Fondler
KingKong8247


Posts : 197
Join date : 2011-03-27
Age : 39

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeWed Apr 29, 2015 7:43 pm

Runs really well! Only have a code for the evap canister but it may be because of the vacuum hose. Going to look into that. Plus the radiator is cracked. Expansion tank cracked so why not the radiator too. So I am going to get a new one and do a transmission service so she'll be top shelf for sure.
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my92tealcp
Mud Tire Addict
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Join date : 2012-12-06
Location : Exton Pa

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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitimeSat Oct 24, 2015 12:57 pm

what are you doing with the Range?
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PostSubject: Re: 4.6 Bosch into 4.0 gems truck   4.6 Bosch into 4.0 gems truck I_icon_minitime

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