Replacing 4.0 with 4.6 - Defender Source
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  #1  
Old December 11th, 2004, 09:48 PM
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Replacing 4.0 with 4.6

The block on my '97 D-90's 4.0 needs replacing (overheating damage). Seems like the perfect opportunity to upgrade to a 4.6. Question: do I do just the short block, or the whole farm (long block)? What would be the advantages of swapping out everything that's included in the long block but not the short block?
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  #2  
Old December 11th, 2004, 10:32 PM
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Maybe check on the RPI website, I know they have a LOT of info about engine swapping.... if you can find it. What a mess that website is.

-Hans
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  #3  
Old December 12th, 2004, 05:27 PM
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The only different parts are the 4.6 short block and a 4.6 cam. Everything else is the same between the two.

Ron

PS I have an almost new 4.6 cam.
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  #4  
Old December 13th, 2004, 06:34 PM
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What would happen using a 4.0 camshaft with a 4.6 short block....?
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  #5  
Old December 13th, 2004, 08:49 PM
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Humm,

Probably just have power like a 4.0

I know putting a 4.6 cam in a 4.0 is BAD (as in it makes it blow up, or so I am told I never tried it) but the other way around . . . why?

I won't charge you $500 Like the dealer

Ron
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  #6  
Old December 14th, 2004, 12:51 AM
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I checked with my mechanic, who says the 4.6 and 4.0 cams are the same?
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  #7  
Old December 14th, 2004, 01:43 AM
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The 4.6 short block makes the compression chamber bigger, so the pistons will suck more air and fuel into the chamber regardless of any change in the size of the valve port opening (controlled by the cam). Thus more power. Crane makes several cams that will do well with the 4.6 short block, but then you'll want to change lifters and rockers too. Or just stick with the cam you have or get a factory replacement if its been over 70K miles or so....

My 2 cents. Good luck -- you'll really enjoy the power.

Doug W.
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  #8  
Old December 14th, 2004, 11:12 AM
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Thanks, Doug, Ron, and Hans, for your suggestions! I think for now I'll stick with just the displacement upgrade, and leave well enough alone.
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  #9  
Old December 14th, 2004, 01:34 PM
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if one wanted to purchase the TDI, where can that be done for a DIYer?
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  #10  
Old December 14th, 2004, 01:40 PM
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  #11  
Old December 14th, 2004, 01:41 PM
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One has several options. Roversdownsouth will procure you a 300tdi or td5.

or Britrest.com will gladly sell you a 2.8 IH.

Google it - many more places.

EwS
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  #12  
Old December 14th, 2004, 01:44 PM
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thanks fellas, once again you have really helped
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  #13  
Old December 14th, 2004, 07:19 PM
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The 4.0 and the 4.6 block are the same... The rods and pistons are all that is different.. Well at least as near as I can tell by checking the cam on the lathe with an indicator... To get 4.6 performance out of the 4.6 you would need to have the fuel map changed in the ECU with a Rovacom... Both maps are in there... Additional performance upgrades would be a nice low end cam, these GEMS cams are expensive most everywhere... We plan to offer, on an exchange basis, a Gems cam that will offer better low end performance with a slight loss in power above 5000 RPM..
We will be testing our first grind early next year or when I bend a pushrod...

I may have a complete 300TDI available if the current bidder doesn't get to me with confirmation soon... Motor, tranny and proper t case (and everything else)

Later
Keith
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  #14  
Old December 14th, 2004, 08:44 PM
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Regarding the fuel map, I'm currently running the PowerChip designed for the D-90 4.0. http://www.powerchipgroup.com/ I haven't checked with them yet as to how their ECU will adapt to larger displacement. May need to have them do some reprogramming....
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  #15  
Old December 14th, 2004, 10:07 PM
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Well I am not sure who your mechanic is, but they have different part numbers. I also do not have the book infront of me but the overhaul manual lists specs which would tell you for sure.

IIRC 4.2 cams have the same lift as 3.9s but less duration (please do not quote me this is from memory) which if it carries over to 4.0 and 4.6 might explain why they appear to be the same from a simple mic.

4.6 cam stock seemed decent in a range rover I am sure it will pull like a bear in a light D90

Ron
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  #16  
Old December 14th, 2004, 10:58 PM
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what happens when you put a 4.6 cam in a 3.9?
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  #17  
Old December 15th, 2004, 07:18 PM
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"what happens when you put a 4.6 cam in a 3.9?"

Can't 4.6 cam does not have the drive gear for the dizzy. This is why people who swap 4.6s into 3.9 vehicles use 4.2 cams
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  #18  
Old December 15th, 2004, 10:21 PM
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Keith Kreutzer
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You can also use a cam by Crane or Crower made for the 215 Buick.. You either use a Cam button to control end play in the came or machine the cam to use the stock rover cam retainer plate..
Still to the 2 milder Hydraulic cams or you will have lifter problems.
Couple these with a 4.2 Chip for you ECU and you have well performing engine!!

Keith
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