HappyAndy wrote:
Hopefully mad_machine will be along soon to talk his disco engine swap adventure. Even doing it the best possible way was a big PITA, and it took a while to get his fully back up to road worthiness.
it did. Cost me about 12 grand too when all was said and done. Sadly, I had an indy shop that supposedly specialized in saabs, Volvos, Rovers, and other oddball cars do it because I wanted a quick turn around.
Several months later, I got my disco back. I had a brand new 4.6 longblock put in from Rover's North. The engine itself is good, but some things Rover's North did and then what the mechanic did really screwed me.
Frist from Rovers North. they never tanked the block. I had issues from day one with overheating until I finally backflushed the cooling system using a sumppump and a 5 gallon bucket. What came out of that block looked like black sludge. It cost Rovers North a brand new radiator as it was also clogged with the gunk.
The mechanic was sloppy and I am still finding little half assed things. The oilpan almost fell off due to them not tightening it down, I needed to tighten some of the sparkplugs, and recently found that one of the manifolds has a broken stud where it meets the exhaust system. I also have a stain on the hood that I cannot get out. I will not get into how he practically destroyed the radiator mounts.
He also really bent me over for money. Rover shows that an R&R of the engine is 15 hours (I saw the book) to make it as easy as possible, I also supplied all new hoses, belts, and the radiator. I thought this would allow him to simply rip everything out and not care about the accessories. Grand total in time to R&R the engine: 40 hours billed.
He also "lost" a grand I paid as a payment.
He was not just some random mechanic, he came to me very highly recommended by a family friend. He has kept her Volvo running for years. Now I know why it always runs so terrible
As for the engine, the biggest issue with the 4.0 and 4.6 is the liners. They are simply machined into place. One overheat can drop a liner into the block causing an unrepairable head gasket problem, The Rovers North engine has "tophatted" liners that cannot sink. I think if you can get your hands on some of those, it would be worth rebuilding.