4.6 Rebuild has started - Any Secrets not in the manual?

bendts

Well-known member
Jan 27, 2015
277
18
Farmland
I see a lot of folks rebuilding these motors but isn't one of the weakest points the cylinder liners. Why not just top hat the block while you are "in there" or did I miss that somewhere and that is just standard practice?

Was going to do it but at $4700 +/- i had second thoughts.
 

rovercanus

Well-known member
Apr 24, 2004
9,643
244
Just picked up some parts from my machinist. Left the oil pan, pick up tube and front cover to have cleaned. The oil pump was in three pieces. I'll be pulling the dowels on the block when I get it back.
He did a great job pinning the sleeves.
Crank measured good and it's been polished. Just waiting for him to hone the cylinders and switch the 4.0 pistons to the 4.6 rods and the block will be set.
 

jymmiejamz

Well-known member
Dec 5, 2004
6,008
361
35
Los Angeles, Ca
I see a lot of folks rebuilding these motors but isn't one of the weakest points the cylinder liners. Why not just top hat the block while you are "in there" or did I miss that somewhere and that is just standard practice?

No, the block cracking behind the cylinder liner is the weakest point. It doesn't matter if the cylinder liner moves, it won't cause the vehicle to overheat.
 

bendts

Well-known member
Jan 27, 2015
277
18
Farmland
IT"S IN! - Holy fuck what a puzzle. Yeah its my first rover engine pull and replacement.

Lucky i had a couple of extra hands to help push twist and push.

Got the motor in, and proceeded to snug up the bolts to the bell housing. Got them torqued and then went to install the oil pan - Oh shit the front cross-member is in the way, and in attempting to get that off 2 of the bolts on the passenger side are "welded" in with rust or whatever - so that got cut off with a sawsall so it can be welded back together later.

Ok back to the oil pan - shit - now the bolt wont line up with the threads on the block - and as i have just put on the sealant, i now have to rush to UN-Torqe the engine to bell housing bolts - shake the motor a bit and it finally fit right.

Re-torqued the engine bolts to bell housing, got the motor mounts installed (though they need replacement near future), ran the wires to the injectors etc., then installed the combo-clusterfuck of the coil pack and plenum.

Tomorrow is the exhaust after i drill out the busted bolts and replace those, new cooling sys hoses, add some oil and coolant - then start her up.

The figure out how to remove the remaining part of the front crossmember so i can get it welded and re-attached.
 

ubuntu

Well-known member
Apr 16, 2014
225
1
Mosquito Alley
You should have put the oil pan on the engine before installing the engine. It's like removing your pants before taking a dump.
Things are a bit easier if you drop in the coil pack and upper intake manifold before you put in the engine mounts. You're lucky you don't have SAI as well...
Drill out the cross member bolts, then drill and tap for larger bolts.
 

bendts

Well-known member
Jan 27, 2015
277
18
Farmland
You should have put the oil pan on the engine before installing the engine. It's like removing your pants before taking a dump.
Things are a bit easier if you drop in the coil pack and upper intake manifold before you put in the engine mounts. You're lucky you don't have SAI as well...
Drill out the cross member bolts, then drill and tap for larger bolts.

I used to have SAI.
 

rovercanus

Well-known member
Apr 24, 2004
9,643
244
Walter,what was the cost to pin the sleeves? I am surprised that is not done by more people, but never heard a cost figure.

I'll let you know when I get the bill.
He quoted me $275 for all the work but I don't know if he had that factored in.
 

ukoffroad

Well-known member
Jan 13, 2010
2,125
168
Lynchburg, Va
Seems like a pinned sleeve would be as useful as a top hat but for WAY less money. What would the advantage be to a top hat? I have a spare engine in this parts truck and I am mulling this whole process over.
 

jymmiejamz

Well-known member
Dec 5, 2004
6,008
361
35
Los Angeles, Ca
Seems like a pinned sleeve would be as useful as a top hat but for WAY less money. What would the advantage be to a top hat? I have a spare engine in this parts truck and I am mulling this whole process over.

People often confuse cracked blocks and slipped liners. If a liner 'slips' it just moves, which causes no harm to the engine as far as I know from experience. A crack in the block behind the cylinder liner will allow combustion gases between the liner and block making their way into the cooling system. With a top hat liner, there will likely be no symptoms if the block cracks behind the liner. I've had multiple machine shops tell me that I could install top hat liners in a cracked block and that would fix the overheating due to combustion gases in the cooling system.
 

bendts

Well-known member
Jan 27, 2015
277
18
Farmland
Please let us know how much more power the new cam and displacement feels like. Thanks

Got it running today and it runs great. After about 1/2 hour at 1800-2000 rpm I took it for a short rolling hills drive -About 50 miles. Runs much smoother than i remember, has much better acceleration getting up to highway speed.

have a little bit of exhaust work to do but all is good sofar.