Bosch intake on a D1

every once in a while I see reference to this usually on foreign websites, but never any pics and 14cux is almost always ditched for something else. Figure I'll give this a try since the engine seems to really only have any grunt above 2500 RPM it'll be nice to lower that powerband.

issues

1. throttle cable
2. kickdown cable
3. cruise control diaphgram
4. idle air control
5. coolant temperature sending unit (gauge)
6. coolant temperature sending unit (ecu)
7. thermostat housing
8. fuel rail
9. TPS sending unit
10. throttle body to intake manifold duct

throttle body, kickdown, and cruise control will be dealt with by making custom brackets and swapping to a cable drive cruise control like a D2. Ashcroft makes a really long ZF kickdown cable for custom swaps that I have on order. Grabbed a 200/300 TDI throttle cable that I hope is long enough, if not theres always the 98 50th edition 4.0 defender cable, but thats likely way to long.

idle air will be a custom housing where the D2 IAC went

ECU temp sensor threads in place of the Bosch sending unit. There is an untapped boss on the left side of the lower manifold that the gauge sending unit fits

Thermostat housing will take some machine work. One of the 3 bolt holes lines up, there is a casting boss for the second bolt, blind drill and tap takes care of that. The pocket for the thermostat will have to be farmed out to a shop with a mill with some Z height, I can't do that at home and don't want to mess it up.

Early range rover fuel rail looks like it fits. I'll lose the schraeder valve, but I'm sure I can work around that. Feet either need to be hacked up or removed and re-brazed in the correct location.

TPS needs an adapter, got that designed and it'll be printed out of high heat tolerant material

Throttle body to MAF duct work is going to be an ugly hack. I'll figure that out later.

The plan so far:

No. The runners dont line up, different plenum bolt pattern

ashcroft kickdown cable showed up. Looks like it will work. Going to only have throttle and kickdown on the bracket I'm making. Cruise cable bracket can bolt on top of that. Keeps things simple.

Flipped the IAC housing around so the wires point to the back. I didn't like the radius of the wire bend that it would take to have it face forward. Hope to knock it out of aluminum this weekend.

looks like the D2 heater pipe from the manifold to heater core will work. Does not look like the D1 pipe from the waterpump to heater core will work, not sure if hacking it up or making a new one is the right path yet.

IAC housing done

This one may be difficult to make, but its the ideal heater line design, factory one ghosted behind it

the oil filler is in the way of the throttle linkage, going to have to switch to D2 valve covers. The coolant line iteration 1 won't clear, going to have to route it around the filler. Found a shop that can do 2.5D bends at low volume. The biggest problem with multi bends is keeping the start and stop far enough apart for the equipment. If they cant do it it'll end up with a 4D bend and look like a bunch of hoolahoops stuck together.





AMR3606 for the throttle cable looks like a winner. Plenty of length to route it correctly

More interested in BSFC than power. This manifold should lower peak power

yes I do. How much? TBD

Sure I came up with this a few years ago. I can't find the excel sheet I used to come up with the length or what the target RPM was. was going to pair it with the plenum volume spacer that one of those UK companies make. Hood height was a limiting factor.

When I shopped it out it was stupid money to have made and beyond the extents of my machine. Since it was already a compromise between packaging and desired powerband I skipped it.



maybe I'll put it on my stockish disco, but its already a torque monster with the 4.6/4.0 piston combo and seems to shit a critical drivetrain component once a year.

3 posts down, someone who actually did this

https://www.aulro.com/afvb/technical-chatter/66141-thor-manifold.html

TPS adapter. Need to pick up a 6200 bearing. Thought the local hardware store would have it, wrong.




factory D2 throttle linkage linkage




throttle linkage spindle adapter



spindle adapter with factory cruise control linkage installed over it.




need to cut out sheetmetal next

Brackets cut out. Welding up next