TE cortina with au I6

[111alex]

im wanting to fit an AU I6 into a TE cortina, currently has a 4.1ltr, will the sump of the 4.1 fit onto the AU block?

[P100 Ute]

alex.
the AU sump bolts to the bottom of the crank to give support.. and also it is a cast sump.. not a tin sump.

unless your gonna get a cast sump made to suit (expensive)

EA --> EL motors fit because the sump is Tin and can be modified to suit the car.
and the AU head can bolt up (except the VCT heads which cant)

but theyre still is the other problems related in a 4.0L swap. wiring up the ecu, engine mounts, fitting the motor.. but if your gonna do the swap.. then you'll be able to overcome these as theyre is a few people who have done this now.

try this link for some pix and info from an older thread on the swap.

http://www.fordforums.com.au/showthread.php?t=100520

[drracing108]

speaking on behalf of alex, would it be better to rebuild the 4.1 and use some sort of aftermarket injection?? also what sort of gearbox would be best to use??

[drracing108]

anyone???

[P100 Ute]

yeh u can build a 4.1L with injection..

if your gonna go manual.. use a T5 out of a E series falcon and use the XF T5 bellhousing to bolt it up to your motor.

and u just need to cut 100mm out of your tunnel as the shifter sits 100mm back from standard.

[drracing108]

cheers, what parts would you recommend to rebuild it with?? any proven set ups??

[DRIFT_TE]

A supra box sits 6cm back from the original shifter hole, and can be hidden under a gear boot, and no mods are dont to the underside. but finding a bellhousing is an issue.

Id also suggest rebuilding the crossflow with an EF Crank, and aftermarket injection. probably end up costing a little less than the 4.0lt conversion and less of a hassle.

[fmc351]

Theres a website of one guys TC Cortina with a full on 4.0 or 3.9 with a large turbo setup. Ill see if I can find it.

Cortina wiring isnt complicated so using an EA - EL loom with a few bits of Cortina loom shouldnt be overly complicated. Aftermarket electronic speedo if you cant run the cable speedo, even an aftermarket ECU.

Depends how much he wants to spend but it could be worth it depending on his desires, its his money. If he wants to do it cheap then the 4.1 is easier, if he doenst care and wants what he wants, then anything is worth it.

He'll need a diff too and Id highly recommend brake upgrades.

[BigCav]

there is a guy on ebay who sells modified sumps to suit the au motor into xf's so dunno if thats the same mod needed or not.

thouoght about running it on straight gas? should be easier

[drracing108]

he doesnt want to spend alot on the engine, just wants reliability and a bit extra performance, brakes and suspension will be happening as its going to be 50% tarmac rally set up

[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.

[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!!!!!