4.0 to 4.6 parts? - Defender Source
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  #1  
Old August 12th, 2005, 10:29 AM
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Christian Shea
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4.0 to 4.6 parts?

I have been looking for sometime for a way to rebuild my current 4.0 into a 4.6 or replace it with a 4.6 short or long block. In searching I have found it near impossible to find anyone who lists stocking 4.6 parts. From what I understand the differing parts are the crank, cam, pistons, and con rods. Also a 4.6 ecu would be necessary. I have seen a couple 4.6 long blocks on ebay from 2800-3200. RPI also has a kit that would cost somewhere around 2100 with the current exchange rates. Would an engine rebuild using the parts from RPI cost about the same (ie 1000 bucks or so)? I don't know much about what a good engine shop or rover mechanic would charge so any suggesions/info would help. I know there are multiple threads out there but nothing that seemed to totally answer the question I am looking for.
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  #2  
Old August 12th, 2005, 10:50 AM
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Robert Dassler
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If you go with a complete short block, you will need a motor from a GEMS car (P38RR up to 99). The mounting for the crank sensor and knock sensors is different than on a Bosch 4.0/4.6 block as used in D2s or 2000 & up P38RR. Or you can use your block and put in new internals...rebuild labor and machining costs should be the same. I would reuse your computer...I think it will be fine or you could probably change the chip set (it has a removable PROM chip set). You will also want to look at the nose length on the crank...if the 4.6 crank nose is longer it will stick through the crank pulley and you may need to fabricate a spacer for it.
Rob
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Old August 15th, 2005, 04:19 PM
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Christian Shea
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If I were to do this soon would any engine rebuild shop be ok or is there a good rover place in the Southeast or anywhere for that matter that could carry this out for me?
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Old September 10th, 2010, 08:10 PM
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Christian,

You will have less issues with your '97, as it has already a 4.0L.

You can keep the 4.0L ECU and have the shop remap it to a 4.6L. I've have not done mine yet. But most likely it will get done in the next couple of weeks. The truck runs fine anyway.

They will have to reuse the 4.0L fuel rail. The 4.6L fuel rail intake is feed from the back and the 4.0L is feed from the side (maybe it's the other way around...I'm getting old... lmao).

Also, you will need to reuse the front cover. I know I'm missing a couple of things... but you get the idea.

Good luck!!!
Pedro
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Old September 10th, 2010, 08:52 PM
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I believe this site can provide

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Old September 10th, 2010, 09:27 PM
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Eric Brown
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Quote:
Originally Posted by Roadsiderob View Post
Or you can use your block and put in new internals...rebuild labor and machining costs should be the same. I would reuse your computer...I think it will be fine or you could probably change the chip set (it has a removable PROM chip set).
I want to do what you stated above at some point. I was quoted $5500 to use my own block and put new internals in it at a reputable rover shop here in the OC. He said he would use my own ECU. That price is parts, labor, etc... out the door. Not sure if that is a competitive price or not.
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Old September 11th, 2010, 08:40 AM
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Daniel Chapman
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I'm in the process of doing the same thing. Sort of.

First, it does not matter weather it's a GEM's or Bosch block. The knock sensor ports are the same. The D2 uses a knock sensor that has a 90* turn in it, where as the D1 knock sensors are straight. Many folks will run D2 knock sensors in their D1/90 when using headers because of clearance issues. As for the crank sensor bracket, they're interchangeable from a GEM's to a Bosch. It's just a 1/4" tac-weld holding them in place.

On the motor I'm putting together I'm using a 4.0 block, 4.0 pistons, 4.6 crank, and 4.6 connecting rods. My cam will come from D&D Automotive. This is referred to as a stroker engine. The 4.0 pistons are a bit taller, and with the longer stroke of the 4.6 crank and rods, you're gaining more CI's. It's not as radical as using a Buick 300 crank and going for 5.0liters, but it will have a little more umph than a traditional 4.6L.

I got my 4.6 crank from Will Tillery. It's not something he has all the time, but he does get one in from time-to-time. It will need some machine shop time to get set-up correctly, but that's a good idea in any case.
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