4.6 conversion experiences - Defender Source
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  #1  
Old November 10th, 2008, 08:37 AM
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John
D90 SW -- 2.8PS
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4.6 conversion experiences

Does anyone have any experience when making the 4.6 conversion in the D90?

Specifically to later upgrading the heads, valves, rockers, etc to performance versions??

Is this a straight "bolt on" without the need for much adjustments? I know it's not literally a bolt on as the gaskets, etc need to be changed and the bolts replaced, etc.
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  #2  
Old November 10th, 2008, 12:23 PM
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Johnathan Tisdale
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Check with Eric at Pikes Peak Rovers, I bought his XRRA comp car that has a massaged 4.6 in it; although not a D90 it is...was a rover to start with. It definately isn't your average rover motor!

www.pikespeakrovers.com
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  #3  
Old November 10th, 2008, 12:27 PM
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Thanks Jonathan......I will.
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  #4  
Old November 10th, 2008, 02:16 PM
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Bryan Tate
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I just did mine and a buddies (with help) and have "recipe" rough draft here it is:
Converting a ’94 d90 to a 4.6, serpentine belts and Automatic transmission

Engine Swap
I got a used Gems 4.6 block had the machine shop re-ring the pistons, crower cam, (don’t forget Pushrods, Lifters, Cam and Timing chain, keyways, Bearings Cam/rocker/main Gaskets)
timing cover from a 95 disco (has the hole for distributor and the crank driven oil pump is in the cover, so go ahead and get a oil pump rebuild kit for a ’95 discovery)
New Water pump for 95 disco and a belt
I put a 180’ thermostat- CTH60208 from Carquest

From serpentine driven truck (95RRC or disco 1’s):
Alternator
Metal shim/lift bracket that acts as a spacer behind p/s pump
Compressor and bracket
Idler pulley
Power steering pump and pulley
Fan from D1 (counter rotating),ended up using flexfan due to heat issues
Crank pulley and bolt
Water pump pulley
Lower radiator hose for 97 defender
Coolant reservoir for 97 defender or take yours and have a fitting welded in for the hose return (the 97 hose has an additional branch off the lower hose that goes to the reservoir)

Fan Shroud from a 97 defender (upper and lower)-critical for cooling
This one was tricky- separate the two metal coolant pipes. Re-use the inner one, it should bolt to the air intake bolts. Then order the longer inner metal pipe that bends down and goes in front of the heads. It will also bolt onto the air intake. You will need the heater pipe hose that goes from the new metal pipe to the heater box.
Engine mounts for 94 defender (not 4.6’s)
I got another used oil Pan and pick up tube, to leave my old engine sealed up
*you will need to remove index pin from the back of crank, I used locking pliers and pulled it out

Reuse: air intake/plenum/upper radiator hose/valve covers (I went to the newer black ones and rigged the PCV lines) metal motor mounts off the block
and 4.6 chip
....may have left something out as I didn't proof too much before I posted
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  #5  
Old November 10th, 2008, 02:25 PM
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Holy Hell Bryan......that was great. I wish I had gone that route. I like the idea of the "hybrid" engine with serpentine front, ie Disco Hybrid timing cover. I am assuming you are still running hotwire with 14CUX ECU and not GEMS even though block is GEMS, correct?

I just had 4.6 short block change keeping the heads and front from the 3.5.

What I was wondering about was anyone who has had any "performance" upgrades on the heads, ie stage 2 or 3 and/or the intake manifold and/or plenum?? Was wondering how easy it is to do that......does it need a lot of adjustments of the rocker arms with shims, etc???

Thanks Bryan for the post.
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  #6  
Old November 10th, 2008, 03:03 PM
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Why do people want a serp motor?

Other than changing the water pump, there is little advantage to it.
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  #7  
Old November 10th, 2008, 03:24 PM
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Bryan Tate
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My mechanic who is alot more experienced than I am said it is a better system....
Don't see to many new v-belts at the dealers.......figured newer may actually be better?


I looked into the mods, port matching etc....the advice I received that there is a point of diminishing returns.

I went with the low end cam, upgraded the injectors and the chip only. I am happy with it.
The above mechanic has worked on one of the 5.2 Pursuits, the compression is so high the guy has to run airplane fuel to keep it running smooth.
Just my $.02
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  #8  
Old November 10th, 2008, 04:46 PM
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John
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Quote:
Originally Posted by evilfij
Why do people want a serp motor?

Other than changing the water pump, there is little advantage to it.
I think the belt itself is supposed to be more reliable but as long as you carry spares and know how to change them I see your point.

Follow-up Post:

Quote:
Originally Posted by btate
I went with the low end cam, upgraded the injectors and the chip only.
Are they just new injectors or are they different in some way?
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  #9  
Old November 10th, 2008, 04:57 PM
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"I think the belt itself is supposed to be more reliable but as long as you carry spares and know how to change them I see your point."

Not true, if one bearing seizes (and breaks the belt), you lose everything, including the water pump (which you need to run). On a v-belt truck, if something goes, you lose it but not the whole system.

Yes, I admit, it is hard to set tension and getting some parts on and off is harder (water pump mainly), but why switch around what you have for no good reason?

Ron
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  #10  
Old November 10th, 2008, 05:05 PM
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agreed......no argument from me......it just seemed when people were doing the conversion they seemed to favor or tried going with hybrid timing cover.....just ASSuMEd it was better. glad to hear v-belt system may be better or the same.
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  #11  
Old November 10th, 2008, 07:59 PM
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Bryan Tate
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the yellow bosch injectors, saw them on ECR and ordered from http://www.fiveomotorsport.com/

clain to have a better atomization of fuel (least that's what I recall)
This advice is worth far less than you are paying for it.....
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  #12  
Old November 10th, 2008, 08:37 PM
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Ford yellows work good, but make sure you don't get the DENSO made ones (all Five-o is selling right now).
The older version of the Ford pink tops are the best for a mild 4.6, best pattern, best rate.
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  #13  
Old November 10th, 2008, 10:10 PM
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Fidel.....are these the one's you are referring to.....
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  #14  
Old November 10th, 2008, 10:47 PM
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With regard to the heads. I'll be pulling my 4.6 to make way for a diesel and had a set of 4.6 heads- with the 28mm combustion chamber for higher compression, with over sized valves and some performance porting for sale soon. I put in a hot cam and free flowing exhaust and it ran great. Also ran a tvr ecu- which ran rich at lower rpms and scream up top
brian bertolini
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  #15  
Old December 6th, 2016, 08:20 PM
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Joe Sheehan
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I'm new so I'll start by apologizing if this has already been asked. I'm converting my 1995 D90 3.9 v8 to a 4.6 drop in from British Atlantic USA. What transmission, work case etc works best with this engine?
Thanks Joe
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  #16  
Old December 7th, 2016, 12:37 AM
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  #17  
Old December 7th, 2016, 07:34 AM
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What kind of warranty do they have on their blocks. They've unfortunately had a number fail. To a point now that an indie shop owner I know well can't trust the workmanship any longer. For years he exclusively used AB but after several failures in a row he feels he can't afford to risk another customer's inconvenience.
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  #18  
Old December 7th, 2016, 08:11 AM
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Bill Adams
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For what should be only a few grand more, you can have an LS motor. Go read the thread, it'll get you all excited.
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  #19  
Old December 7th, 2016, 09:09 AM
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Question

Quote:
Originally Posted by 1of40 View Post
What kind of warranty do they have on their blocks. They've unfortunately had a number fail. To a point now that an indie shop owner I know well can't trust the workmanship any longer. For years he exclusively used AB but after several failures in a row he feels he can't afford to risk another customer's inconvenience.
Why are they failing?
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  #20  
Old December 7th, 2016, 09:47 AM
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Quote:
Originally Posted by Grover View Post
Why are they failing?
Why? I'm assuming improper liner machining. The failures are at the liner, similar to the OE blocks.

What I know is AB has been replacing blocks that fail but all the other work involved is on your dime.
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