TE cortina with au I6

[PhantomXR8]

Originally Posted by corty80

The 4.0litre into a cortina is definatly doable, but pre AU would be the way to go mainly due to the issue with the sump. Not to say you couldnt find a solution to the sump issue, it just would be very expensive. Now Iam in the process of doing this conversion using an EL 4.0litre into a TE cortina. Now the issues I have faced atm are :-

Sump - the 4.0litre block is slightly wider than a xflow so you will need to use a 4.0litre and xflow sump. What I did was use the top half of a 4.0litre sump and the bottom of the xflow and weld them together.

Engine mounts - use the xflow ones and just modified them slightly.

Gearbox mounts - xmember - used and modified the xflow ones.

Gearbox - used a t5 so had to cut the floor due to it sitting further back. It just clears the handbrake also.

Starter motor - this is on the passengers side on the 4.0 instead of the drivers side on the xflow, so firewall needs to be massaged for clearance. In a way its a blessing as less heat will mean less chance of frying the starter, and you can run a bigger exhaust.

Tailshaft - Just use a cortina one fits fine aslong as you use the stock cortina diff.

Engine - the intake manifold will fowl the heater box, so that will need to be removed or modified. I ended up using an aftermarket heater unit.

Wiring - because Iam going to be running lpg only this should be easier than if I was the run petrol as I dont have to worry about the smartlock etc. Also because I have gone to all this trouble I have decided to use a new wiring loom.

Cooling - this is going to be a little more difficult problem to solve. Due to the lack of space the thermo fans that are normally used will not fit in the standard position. This I still need to look into.

I went this way with a ED 6 and T5, got the Cortina radiator inlet & outlets swapped around, bingo! Thermo fan sat at back of radiator close to water pump pulley but no issues. Car idled for an hour, no heating issues, all good!!!!!