The Ford Cortina MK1
DATA BOOK
Last Revised:- 03 July, 2006 11:03
Compiled by
©Tommy Sandham
The MK1 Ford Cortina DATA BOOK © Tommy Sandham 2005
All rights reserved.
All additions/corrections/enquiries must be addressed to the publisher.
Disclaimer:
While extreme care was taken to ensure that the information contained in this DATA BOOK is accurate, the Author, Tommy Sandham, cannot accept any liability for loss, damage or injury caused by errors in, or omissions from, the information given.
Page last updated:- 03 July, 2006 11:03
Table of Contents (Click on Hyperlink to go to the required Bookmark, use the "Return to Top" buttons to come back to this point, or just browse !)
Data and Cross Reference Information
End of month codes and Production numbers.
Where does your car come from?
MK 1 Cortina Owners Club Panels
Wheels, Hubs, Drums, Front Wheel Disc
Spare Wheel Carrier, Estate Car
Steering and Track Controls (Steering Linkage)
Engine Rear Support Crossmember
Exhaust Pipes and Silencer (Muffler)
Front Spring and Upper mounting
Pistons, Pins, Rings and Connecting Rods
Camshaft, Crankshaft and Liners
Oil Pump and Oil Pressure Relief Valve
Sump, Splash Shield, Oil Filter and oil level indicator
Gearbox (transmission) and gear change
Clutch Housing and release mechanism
Converter and Converter housing (Automatic Transmission)
Radiator, Thermostat, Hoses and Clamps
Standard Solex Carburettor Settings
G.T. Weber 28/36 Carburettor Settings
Accelerator, Choke and Throttle Controls
Instrument Panel and Starter Switch
Roof, Windscreen Opening Panel and Rear Package Tray
MK1 Cortina Owners Club Regalia and Accessories
Transmission Torque Wrench Settings
Automatic Transmission Torque Wrench Settings
MK 1Cortina alternator conversion (I've moved it.)
Smiths Tachometer Diagram (I've moved it)
MK 4 Escort Distributor Conversion
This DATA BOOK contains information relevant to the British Ford Cortina MK1 (1962 to 1966) and covers all models including the Lotus version.
Notes in bold italics are based on the experience of the Author, Tommy Sandham, MK1 Cortina Owners club members, or other interested parties.
Notes are included for guidance only.
Anglia (997cc engine) 105E - Introduced September 1959
Anglia Super (1200cc engine) 123E - Introduced October 1962
Anglia Van (997cc engine) 307E - Introduced June 1961
Anglia Van (1200cc engine) 309E - Introduced June 1961
Prefect (997cc engine) 107E - Introduced October 1959
Consul Classic (1340cc engine) 109E - Introduced May 1961
Consul Classic (1500cc engine) 116E - Introduced August 1962
Consul Capri (1340cc engine) 109E - Introduced January 1962
Consul Capri (1500cc engine) 116E - Introduced August 1962
Consul Capri G.T. (1500cc engine) 116E - Introduced February 1963
Consul Corsair (1500cc engine) 120E - Introduced October 1963
Consul Cortina (1200cc engine) 113E - Introduced September 1962
Consul Cortina Super (1500cc engine) 118E - Introduced January 1963
Consul Cortina Lotus (1558cc engine) 125E - Introduced January 1963
Consul Cortina G.T. (1500cc engine) 118E - Introduced April 1963
Note: For left-hand drive vehicles add "1" to the model number, for example 116E becomes 117E etc.
For Reference: 3014E 1300 DeLuxe MK2, 3016E 1500 MK2, 3018E 1600 MK2, 3020E - MK2 Cortina Lotus
Australia had their own model numbers, given here. In addition a GT500 was produced in small numbers (90-120 cars).
Ford identification plates, or chassis plates are found on the inner wing, near the battery tray and usually held on by two or four pop rivets. The information they contain describes the main specification of the car. Beware of buying a car where this plate is missing. Find out why the plate is missing. It could be a reason like the top of the inner wing was plated and the chassis plate was thrown away with the old rusty wing. It could also be a more sinister reason -- the car may be stolen.
Chassis plate information is very complex, the format having changed at least three times. The following information is offered as a guide. For detailed information refer to the relevant Parts Book.
Pre-1965 Plates
Early identification plates showed the model number, for example 100E or 107E, then the engine number prefixed either 100E or 105E for the 107E.
In 1962 a new system of ten digit numbering was introduced. The first digits showed the assembly plant, (A = Dagenham, B = Halewood, C = Langley, D = Southampton, N = Amsterdam, E = Cork, GA = Cologne, GB = Genk, GC = Saarlouis, WP = Valencia) the next two the body type, the next letter was the year (A = 1961, B = 1962 etc.). This was followed by the actual vehicle number.
From 1965
A new style of plate was introduced in January 1965 as follows:
DRIVE: 1 Means the car is right hand drive. (2 means left hand drive).
ENG: 1 is 1198cc (High Compression), 2 is 1198cc (Low Compression), 3 is 1498cc (High Compression), 4 is 1498cc (Low Compression), 5 is 1498cc G.T.
TRANS: Gives details of the gearbox, where: 1 is floor change, 2 is steering column change, 3 is automatic gearbox, 4 is remote control floor change (as on G.T.)
AXLE: Provides details of rear axle ratios (Otherwise known as "the final drive ratio"), where: S is standard ratio of 4.125 to 1 for 1198cc Saloons, 3.9 to 1 for 1498cc Saloons and Estate cars, and 4.44 to 1 for 1198cc Estate cars.
1 = 4.44 to 1,
2 = 4.125 to 1.
TRIM: This provides the colour and or combination of colours used on seats and carpets. See paint and trim, here.
VEHICLE NUMBER:
FIRST LETTER: B = Assembled in Britain.
SECOND LETTER A = Dagenham, B = Halewood, C = Langley, D = Southampton. (Overseas , CN = Amsterdam, CE = Cork, GA = Cologne, GB = Genk, GC = Saalouis, WP = Valencia).
NEXT TWO NUMBERS: Body and gearchange type, as listed below:
71 = Cortina, 2-door standard, floor change,
72 = Cortina, 4-door standard, floor change,
73 = Cortina, 2-door DeLuxe, column change,
74 = Cortina, 2-door DeLuxe, floor change (also for LOTUS CORTINA)
75 = Cortina, 4-door DeLuxe, column change,
76 = Cortina, 4-door DeLuxe floor change,
77 = Cortina, 2-door G.T.,
78 = Cortina, 4-door G.T.,
81 = Cortina, 2-door Super, column change,
82 = Cortina, 2-door Super, floor change,
83 = Cortina, 4-door Super, column change,
84 = Cortina, 4-door Super, floor change,
86 = Cortina Estate, DeLuxe, column change,
87 = Cortina Estate, DeLuxe, floor change,
88 = Cortina Estate, Super, column change,
89 = Cortina Estate, Super, floor change.
NEXT LETTER = Year of manufacture, where:
C = 1963, D = 1964, E = 1965, F= 1966, etc.
NEXT LETTER = Month of manufacture.
| Month | 1963 (C) | 1964 (D) | 1965 (E) | 1966 (F) |
| January | C | B | J | L |
| February | K | R | U | Y |
| March | D | A | M | S |
| April | E | G | P | T |
| May | L | C | B | J |
| June | Y | K | R | U |
| July | S | D | A | M |
| August | T | E | G | P |
| September | J | L | C | B |
| October | U | Y | K | R |
| November | M | S | D | A |
| December | P | T | E | G |
PAINT CODE. This describes the colour of the paint on the bodyshell.
| PAINT CODE | COLOUR |
| A | Savoy Black |
| M | Ambassador Blue |
| AH | Sunburst Yellow |
| AN | Monza Red |
| AP | Cirrus White |
| AQ | Morocco Beige |
| AR | Pompadour Blue |
| AS | Lichen Green |
| AU | Smoke Grey |
| AV | Shark Blue |
| AX | Vulcan Grey |
| AZ | Imperial Maroon |
| BA | Ermine White |
| BC | Lime Green |
| BH | Caribbean Turquoise |
| BJ | Anchor Blue |
| BL | Ascot Grey |
| BM | Windsor Grey |
| BN | Ford Red |
| BP | Panama Yellow |
| BR | Goodwood Green |
| BS | Monaco Red |
| BT | Aqua Blue |
| BU | Platinum Grey |
| BY | Glacier Blue |
| BZ | Spruce Green |
| CA | Sable |
| CB | Midnight Blue |
| CD | Lombard Grey |
| CF | Alcuda Blue |
| CG | Malibu Gold |
| CH | Purbeck Grey |
| CJ | Lagoon Blue |
| CL | Black Cherry |
| CM | Alpine Green |
| CN | Velvet Blue |
| CP | Seafoam |
| CR | Light Green |
| CU | Dragoon Red |
NOTE: Always cross-reference paint codes with the paint supplier. You should always try to "match" the paint wherever possible. See paint and trim, here.
NEXT FIVE NUMBERS. This is the actual number of the vehicle.
If you have an SVC number, it denotes a year of manufacture where a vehicle has been shipped abroad un-assembled and put together in another country.
NOTE: For full paint codes and trim codes, the best reference source is either the Ford Parts book, or the paint and trim page, here.
Introduced in September 1962 in three main bearing, 1200cc form and known as the 113E. In January 1963 the Super version, 118E, with 1500cc (five main bearing) motor was introduced. Also in January 1963 the Cortina-Lotus 125E was announced. Later, in April 1963 the G.T. Cortina 118E was launched.
Estate cars were introduced in March 1963 in 1200cc and 1500cc options.
In December 1963 an automatic transmission option (Borg Warner 35 type) was offered on all 1500cc models (except the G.T.).
The MK1 Cortina saloon was phased out in September 1965 and the other models were replaced by the MK2 Cortina in October 1966.
Several "face-lifts" were implemented, including a new dashboard layout with Aeroflow ventilation system for 1965 models.
Some 1,010,090 MK1 Cortinas were built between 1962 and September 1966, -- source Jonathan Wood "MK1 Cortina".
Other sources quote 1,013,391 MK1 Cortinas were built.
Car announced in May 1962. Pre-production l/h/d 2-door 1200 and 2-door prototype G.T. at Montlhery in June 1962 for corporate launch. Also 4-door version and estate.
First production car down assembly line at Dagenham June 4th 1962.
Car announced to the public in September 21st 1962 in standard and DeLuxe 113E form, 2 and 4-door 1200cc versions only. Eight inch drum brakes all round. "Consul" on bonnet, opening front quarter lights on all models. Opening rear quarter lights on 2-door DeLuxe models only. With floor or column gear change to 2-door standard was priced at £636, the 4-door DeLuxe at £687.
October 17th on display at London Motor Show.
November 1962 under bonnet throttle linkage changed to interior of car.
January 18th 1963, 1500cc Super 113E announced in 2 and 4-door versions. Nine inch front drums, chrome strips, wheel trims, quarter light frames plus two-tone paint at £689 for the 2-door version. 1500cc engine now optional on standard and DeLuxe versions.
January 21st 1963 Lotus Cortina announced as 125E. Price £1,100. Production did not start until after February 1963.
March 1963. Estate cars announced and shown to the public.
Note: This information is based on figures provided by the MK1 Cortina Owners Club in 1994.
| Total Cortinas Known to Club = 1626 | ||
| 1962 Cortinas | 35 | 2% |
| 1963 Cortinas | 217 | 13% |
| 1964 Cortinas | 266 | 16% |
| 1965 Cortinas | 436 | 26% |
| 1966 Cortinas | 619 | 38% |
| 1967 Cortinas | 53 | 3% |
Note: I suspect this is only a fraction of the total number of cars which really exist. Many thousands more, world-wide, are probably not members of the MK1 Cortina Owners Club. -- Tommy.
Rust may be found almost anywhere, but specifically:
Front of front wings round the headlight area, rear of front wings either at the top where the wing runs to a point, or at the bottom of the wing where it joins the inner wing. Rust can also creep either up or down the rear edge of the front wings.
The outer part of the inner wing, just in front of the front outrigger, is a major rust area. This probably starts on the inside and works out. Similarly, the outer part of the inner wing where the front bumper mountings locate is also a certainty for rust.
On the front valance, check both sides where the valance meets the wing. Also in the middle of the front valance rust can form in the box section.
Outer sills can rust anywhere, as can rear wheel arches. If the rust is bad on the outer sill suspect rust damage to the inner sill. Similarly if the outer wheel arch is rusty, the inner wheel arch will be worse! Where the rear wheel arch meets the floor pan can also rust.
Doors seem to rust first at front or rear corners, then spreads along the bottom of the door. Front outrigger/jacking points rust first, followed by centre outrigger at the point it meets the inner sill. Rear chassis legs rust from the rear bumper mounting flange forwards.
MacPherson strut towers rust near the top, but generally this occurs long after the top of the inner wings is showing signs of damage. Most cars available now have had the tops of the inner wing plated. This may need to be cut away and replaced again.
Where floor panels rust it is generally caused by a chassis member rusting first, unless carpets are wet in which rusts starts in the car and works outwards.
Occasionally windscreen pillar rusts near its junction with the "A" post. This can be expensive to pay for and time consuming for the restorer.
Spare wheel wells rust as a matter of course, unless water drainage is properly attended to. Lower rear corners gradually rust away but can be replaced. Lower rear valance tends to go at the right hand side first, and can also rust round the bumper mountings.
Petrol tanks top forms the boot floor, so beware wet carpets on top of the tank. This can cause leaking tanks when they are well filled.
Boot floors can rust depending on the carpets fitted and the rubber seal round the boot lid. The floor extension and support panel also rust.
Over the rear axle is a reinforcing section and this must have been designed to trap water! This can be repaired but can appear daunting to a newcomer to chassis welding!
Bonnet will rust at the leading edge first, given away by pin holes of rust appearing.
Announced in January 1963 the Cortina developed by Lotus (also known as the Type 28 Lotus) or Ford 125E was fitted with the 1558cc engine. This consisted of the 1500cc Ford engine and the specially developed Lotus twin overhead cam cylinder head.
Production figures indicate that 2,894 Lotus Cortinas MK1 were built between 1963 and 1966.
The Lotus Cortina Register estimate that some 600 genuine cars are known to the club. Some 50 or 100 cars are in California alone, and not members of the Register. Many cars have been scrapped, either as a result of accident damage, rally or race damage or just plain worn out. However there appears to a large number of these cars not accounted for and hence possible restoration projects -- if they can be located! But beware, there could be at least 100 non-genuine cars around. Be sure before you buy.
For complete information about the Lotus Twin Cam, refer to Miles Wilkins, "Lotus Twin Cam Engine."
See MK1 Cortina above, plus: Battery was housed in the boot. Beware corrosion from spilt acid.
Beware competition wear and tear or outright damage. Beware replicas which are not genuine cars.
Data and Cross Reference Information
The information contained in the following pages is listed in the order it appears in the Ford PARTS LIST. Refer to the PARTS LIST for illustrations of parts and Part Numbers.
Part numbers stated in this DATA BOOK may be in two different formats.
Ford Cortinas originally used part numbers which had the following format, for example, 109E 4248, which was the oil seal for the rear axle. Similarly the differential housing gasket was 105E 4035.
In 1971 Ford introduced a new part numbering system known as Finis Codes. "FINIS" stands for Ford International Numerical System and applies to all Ford parts world-wide.
So the same oil seal is now listed as 1709525, and the gasket 1709393.
Ford parts departments should have a conversion book which cross-references the old part number with the new code.
Some 1960s parts used in the Cortina were later used on Escorts etc, so may still be available with a Finis Code.
| 1962 | 67,050 units, |
| 1963 | 264,332 |
| 1964 | 221,678 |
| 1965 | 263,353 |
| 1966 | 193,677 |
Total: 1,010,090 Cortinas.
End of month codes and Production numbers.
The following list is of the last Cortina to be built for the given month. This will help to identify your car.
June 1962, 125440 (Export 501592)
July 1962 149984 (Export 503251)
August 1962 165992 (Export 50836 )
September 1962 179749 (Export 509716)
October 1962 200991 (Export 513091)
November 1962 228454 (Export 516253)
December 1962 233089 (Export 521991)
January 1963 CC, 029070 (Export 511243)
February 1963 CK, 045267 (Export 518956)
March 1963 CD, 071380 (Export 528964)
April 1963 CE, 100200 (Export 534566)
May 1963 CL, 127418 (Export 541809)
June 1963 CY, 155888 (Export 547420)
July 1963 -- CS, ??? What happened in July 1963 ??
August 1963 CT, 252532 (Export 743864)
September 1963 CJ, 263479 (Export 750510)
October 1963 CU, 298167 (Export 758089)
November 1963 CM, ??
December 1963 CP, ??
January 1964 DB, ??
February 1964 DR, ??
March 1964 DA, ??
April 1964 DG, ??
May 1964 DC, ??
June 1964 DK, ??
July 1964 DD, ??
August 1964 DE, ??
September 1964 DL, ??
October 1964 DY, ??
November 1964 DS, ??
December 1964 DT, ??
January 1965, EJ
February 1965, EU,
March 1965, EM,
April 1965, EP,
May 1965, EB,
June 1965, ER,
July 1965, EA,
August 1965, EG,
September 1965, EC,
October 1965, EK,
November 1965, ED,
December 1965, EE,
January 1966, FL,
February 1966, FY,
March 1966, FS,
April 1966, FT,
May 1966, FJ,
June 1966, FU,
July 1966, FM,
August 1966 , FP,
September 1966 FB,
October 1966 FR,
November 1966 FA,
December 1966 FG.
I need the missing data, please!
Where does your car come from?
Registration letters indicate the area where the car was first registered and its year of registration.
Click here for a file giving UK Registration number and place of origin information.
Click here for file giving UK Registration dates and letters information.
Remember you have to consider inlet and exhaust manifolds, exhaust systems, accelerator cables/rods, starter motors, and to a lesser extent electrical connections.
Note: The following engines will either fit, or can be made to fit (realistically!) into the MK1 bodyshell:
* The 997cc (but why bother?) 1200cc, 1340cc, 1500cc, 1558cc Lotus and 1650 (over bored 1500cc).
* The MK2, 1300 and 1600 units can be adapted to fit. Changes may involve altering the sump. Rack and pinion steering cars have the deep part of the sump at the rear, MK1 Cortinas have the deep part at the front.
* The "Pinto" 1600cc and 2000cc overhead cam units as fitted to MK3, MK4 and the fictitious MK5 Cortina up until 1980 will all fit. See comments above re sumps. Latest Info: This is not easy. Awaiting further info 22/01/2001
* The V4 will fit (it was a production version of the Corsair until 1970 ish ).
* The V6 can be made to fit. Consult fellow club-members to avoid grief!
It is believed that the Volvo 1800cc and 2000cc B18 and B20 engines will fit without too much hassle. If you have further information about a Volvo conversion, please contact me. But don't ask me questions, as all I know is already here!!
Note: Use the MK1 Cortina engine mountings on whatever Ford engine block you fit. Special competition mountings used to be available.
| 1200cc | 1500cc | 1500 G.T. | 1558 Lotus | GT 500 | |
| Weight | 1775 lbs | 1863 lbs | 1960 lbs | 1820 lbs | 1803 lbs *Note |
| Top Speed | 76- 78 mph | 85 mph | 94-95 mph | 107 mph | 101 mph |
| Fuel M.P.G. | 30-35 mpg | 30-35 mpg | 26-30 mpg | 20-25 mpg | 23.5 mpg |
| 0 - 60mph | 22 - 25 secs | 21 secs | 13.5 secs | 8 - 9 secs | 10 secs |
Note: GT500s had very little paint, and 100lbs of sound deadening material removed!
Note: The following list gives reference and manufacturer's part numbers for replacement body panels. Many of these are no longer being manufactured, but the references may be useful when you find a panel at an autojumble.
LMC Panels of Quartermaster Road, West Wilts Trading Estate, Westbury, Wiltshire, BA13 4JT. Phone number: 01373 865088.
30 31 004 (Right Hand Side) or 30 31 005 (Left Hand Side) SILL,
30 31 282 (R/H) or 30 31 283 (L/H) Top Suspension Plate
30 31 284 (R/H) or 30 31 285 (L/H) Under Wing Kit (Pan and verticals)
30 31 352 (R/H) or 30 31 353 (L/H) Front Chassis extension
30 31 354 (R/H) or 30 31 355 (L/H) Main Chassis Repair plate
30 31 360 Centre Chassis Outrigger
30 31 366 Rear Spring Hanger (Saloon)
30 31 368 Rear Spring Hanger (Estate)
30 31 506 (R/H) or 30 31 507 (L/H) Rear Wheel Arch
30 31 514 (R/H) or 30 31 515 (L/H) Lower Rear Corner.
99 01 003 Plastic headlamp bowl, 7 inches.
Note: LMC use 30 30 to identify Corsair panels, 30 31 for MK1 Cortina, 30 32 for Cortina MK2, and 30 25 for Escort MK1 panels.
Note: You may be able to adapt 30 25 300 (R/H) or 30 25 301 (L/H) Front floor pan (foot wells) or 30 25 302 (R/H) or 30 25 303 (L/H) Rear Floor pan (foot well) for the MK1. The author has successfully adapted the front floor pan. See "Panel Craft" by Tommy Sandham for illustrated guide to MK1 Cortina bodywork.
Note: Many of the MK2 Cortina chassis panels will fit, such as the front chassis extension, main chassis repair plate, centre chassis outrigger, and rear spring hanger, saloon.
Note: Only the verticals of MK2 Cortina under wing kit (pan and verticals) can be adapted for use on the MK1. The hole for the MK2 suspension mounting is much larger in diameter on the MK2.
Pop On
FS6 L & R Complete Sill
FS6/1 L & R Sill less tread plate
FP2 Rear Chassis Leg
FP4 Estate Rear Chassis leg
FP5 L & R Contoured Top Suspension Panel
FP25 L & R Under Wing Kit (3 parts)
Veng (A Danish Company)
25 55 00 Outer Sill with door step (4-door)
25 55 12 Door Skin (2-door)
25 55 31 Front Wing
25 55 01 Outer Sill
25 55 42 Suspension plate
25 55 45 Strut retainer under front wing
25 55 59 Rear wheel arch
25 55 60 Rear lower corner, saloon
25 55 79 Front Chassis Member
25 56 80-0 Rear chassis leg with bush, saloon (these appear to be part numbers for the MK2 -- "56" is Mk2, "55" is MK1
25 56 81-0 Rear chassis leg with bush, estate (these appear to be part numbers for the MK2 -- "56" is Mk2, "55" is MK1
40 10 25-3 Headlamp bowl, metal
40 10 25-4 Headlamp bowl complete with insert, plastic
A.P.D. Body Panels (Birmingham)
36SK MK1 Sill - less step
36 MK1 Sill with step
36E Inner Sill
19 MK1 Top Suspension Plate
8A Rear Spring Hanger with bush
8E Estate Rear Spring Hanger with bush
FG35 NK1 Front Wing (Fibreglass)
MK 1 Cortina Owners Club Panels
C1 Front Wing (L/H)
C2 Front Wing (R/H)
C3 Front Valence (lower)
C4 Side light repair panel (L/H)
C5 Side light repair panel (R/H)
C6 Headlamp ring
C7 Front of front wing repair panel ((L/H)
C8 Front of front wing repair panel (R/H)
C9 Suspension Top Plate (L/H)
C10 Suspension Top Plate (R/H)
C11 Under wing repair kit (L/H)
C12 Under wing repair kit (R/H)
C13 Steering box repair plate
C14 Idler arm repair plate
C15 Front Jacking point (L/H)
C16 Front Jacking point (R/H)
C17 Outrigger (L/H)
C18 Outrigger (R/H)
C19 Rear of front wing repair (L/H)
C20 Rear of front wing repair (R/H)
C21 Sill (L/H)
C22 Sill (R/H)
C23 Rear wheel arch (L/H)
C24 Rear wheel arch (R/H)
C25 Lower rear corner (L/H)
C26 Lower rear corner (R/H)
C27 Lower rear valance
C28 Rear chassis leg (saloon)
C29 Rear chassis leg (Estate)
C30 Spare wheel well
Note: The MK1 Cortina Owners Club have considerable quantities of mechanical spares available. Only the panels have been listed here. Join the club to enjoy the benefits.
Click on the above picture to see most of the club panels and how they fit into the car!
The above panels are often available to Club members. Some may be out of stock from time to time.
Wheels, Hubs, Drums, Front Wheel Disc
Note: Many types of different wheels can be fitted. From 4-1/2J as fitted to the G.T. to 5-1/2J on the Lotus, there are many other wheels available. Rostyles, as fitted to the 1600E MK2 Cortina will fit, as will "pepperpots" from later Capri and the humble Post Office Ford van.
As a guide, you should be able to get the thickness of your thumb between the tyre and the MacPherson strut. Any less is risking tyre problems -- which is dangerous! Spacers can be fitted but these increase wear on the wheel bearings. If spacers must be fitted, it is better to fit longer, one piece studs.
Note: Hub caps are supposed to be the same as on the Ford Transit.
Note: From October 1964 on the MK1, until September 1967 on the MK2, the same 9.5 inch front discs were used. Maximum run-out (distortion) on a disc is 0.004 thou.
Note: The big nut 374502-ES (hub to spindle) is used on the MK5 Cortina.
Wheel bearings 1200, (front disc 11/64 - 1966) wheel bearing kit QWB 114C (Quinton Hazell)
Wheel bearings (GT and Lotus) (front disc 11/64 - 1966) QWB 114C (Quinton Hazell)
Spare Wheel Carrier, Estate Car
No information available.
Note: Brake pipe kits in non corrosive copper are available from Automec. See Addresses. They also sell silicone brake fluid.
Note: The anti-squeal shims for the G.T. front disk brakes (E71 FA 7) are in very short supply. Either keep your old ones and straighten them as necessary, or try to find new ones -- they were fitted as standard on the 1962-1964 Classic and Capri.
Note: On G.T. cars until August 1965 the Girling caliper was at the rear of the MacPherson strut, from August 1965 onwards the Girling caliper was at the front of the strut.
Note: Brake pistons for the type P16 caliper are getting scarce. However there seem to be plenty of pistons for the standard calipers around.
Note: Brake servo from BMC 1800, plus ????
Note: You can fit later P16 calipers (for example from a MK5 Cortina) but you need special bolts to fit a metric hole in the caliper but match a non-metric thread in the strut.
Note: The rear brake shoes fitted to the G.T. are the same as those fitted to the 1962-1964 Classic and Capri. Part number 109E 2220 and 109E 2221.
Note: The grommets (front brake pipe to sidemember) Ford part E279 FF 2 can be replaced with Jaguar XJ6 (XJ40) parts, number C17432.
Note: The Lotus Cortina used Girling P14 calipers until 1965. In June of that year they switched to P16s.
Note: The rear brake assembly from the 2 litre OHC Capri can be adapted to fit the standard MK1 Cortina rear axle. The backplates bolt on directly. Modify the handbrake activating rod by twisting it through 90 degrees. Lastly, convert the ends of the brake pipes to metric.
Note: Several sizes of brake and clutch master cylinder were used. Make sure you have the correct on for your vehicle or a recognised replacement.
Original brake master cylinder was 0.625 inches (1.59 cm)
Original clutch master cylinder bore was 0.625 inches (1.59 cm)
Slave cylinder bore was 0.75 inches (1.9 cm)
Note: To fit a floor-mounted handbrake on the G.T. you will need a standard handbrake lever and either modify the existing G.T. cable (shorten it) or modify the fittings on the transverse rod. It is probably easier to have the G.T. cable shortened but be careful not to use too much heat when attaching the end. The cable may go brittle and snap under relatively minor pressure.
Steering and Track Controls (Steering Linkage)
Note: Two types of track control arm have been used, known as the "welded" or the "cast". The welded can actually rust away, so if possible fit cast if replacing these items. See track control arms, here.
Note: Do not over-tighten the nuts on the steering idler arm. This could lead to stiff steering.
Note: Many idler arms available now are stiff or seized up altogether. Check before you fit to the car!
Track rod ends, part number from Quinton Hazell is QR 1019
Bottom ball joints, Quinton Hazell part number QDJ 216,
Bottom Ball Joint Repair Kits, Quinton Hazell part number QSJ 216 RK for non-Lotus, and QDJ 200 RK for the Lotus.
Drag Link Bushes (Ford part number E117-LB-1), Quinton Hazell part number QRS 1023. Note; The Owner's Club can now offer improved replacement bushes!!
Click here for an article on how to fit the club's poly bushes.
Note: You can improve the handling of the standard car by fitting a second anti-roll (stabiliser bar) underneath the first one. Kits used to be available from accessory shops. You can use a second , standard bar, with the ends cut off. You then need to make up four fixing brackets to join the bars together.
Note: An identical anti-roll bar (stabiliser bar) rubber mounting is available for the Lotus Cortina from Ford, Finis Code 6028783. Original part number 74EB 5854 CA.
There is a separate page on this now, click here
Note: Standard steering boxes used 15:1 ratio.
Note: The "early" and "late" steering columns are different in length. The early is longer.
G.T. steering boxes used 13.4 : 1 ratio. This gives 4.2 turns lock to lock.
Lotus: ratio ??? 3 turns lock to lock
Note: the emblem (plastic bit in the centre of the steering wheel) 113E 3A515B used until October 1964 are in very short supply! Later ones were available in 4 different colours and are more widely available.
Note: There is a felt bush at the top of the steering column. This can dry out and shrink making the steering column feel "loose." Carefully remove the bush, soak it in melted grease, let it cool, and then re-fit. This can be an M.O.T. fail item! UPDATE:- for a picture, see here
Note: High security lock sets used to be available.
Note: All Cortinas from 1962 until the last MK2 in 1970 used a rear axle which has a cast iron nose held to the main axle casing by 8 bolts. This means that final drives can be quickly and easily altered. See table for available rear axle ratios.
Click here to see RPM and MPH relationships for various final drive ratios.
Ford differential units are available in the following ratios.
| Ratio | Count
the teeth
pinion/crownwheel |
Comments |
| 4.7: 1 | ???? | Used on old 107E. ?? Getting scarce. |
| 4.444: 1 | 9/40 | Getting scarce. Used on Anglia vans and 1200 Cortina Estate. Good choice for rally Cortina! |
| 4.125 | 8/33 | Used as standard on MK1 1200 Cortina, and MK2 1300 Cortina. |
| 3.9: 1 | 10/39 | Standard on MK1, 1500 including estate, G.T. and Lotus. |
| 3.777 : 1 | 9/34 | Used on MK2 Lotus Cortina. |
| 3.889 : 1 | 9/35 | Used on MK2 Escorts |
| 3.545 : 1 | 11/39 | Used on MK2 Escorts |
Note: Competition ratios of 5.14 and 5.57 were available from Ford. These may be found in competition cars or dealers of Ford rally spares.
Note: If in doubt, count the teeth!
Note: The differential front oil seal is NA 583.
Note: The Lotus Cortina split prop bearing is the same as the rear wheel bearing-half shaft bearing. Part number 105E 1225A or Finis Code 1708405
Note: The halfshafts on G.T. and standard cars are slightly different in length. It is almost impossible to tell them apart. I measured them from the end of the splines to the outer edge of the flange. The G.T. is 25-5/8 inches, the standard halfshaft is 25-5/16. I don't know any other source of this information! Take a tape measure with you if shopping for halfshafts!!
Note: MK1 Cortina G.T. cars used a larger flange on the differential. This larger flange (Ford number 118E 4851 B) was used on all MK2s. When changing this flange be very careful about over-tightening as you might crush a spacer tube and damage the differential assembly. If you do over-tighten you will certainly need a new spacer tube 105E 4662 B. Refer to the Workshop Manual!
Note: The half shaft on a Lotus is machined smooth rather than left rough as on standard half shafts. The oil seal is the same as used on an Allegro.
Note: A heavy duty crossmember was available, Part Number 118E 5019B. This can be identified easily as it extends further towards the front suspension unit, that is, it projects beyond the inner chassis rails.
Note: The bolts holding the track control arm to the crossmember should be fitted so that the nut is at the rear of the crossmember!
Engine Rear Support Crossmember
It is believed that the MK1 Escort gearbox mount can be used on the MK1.
Battery Clamp
No info available
Exhaust Pipes and Silencer (Muffler)
Note: Mild steel exhaust systems are still available. See MK1 Cortina Owners Club.
Note: Stainless steel exhaust systems are also available. See Addresses.
Note: There should be an insert (spacer) between the end of the G.T. exhaust manifold and the front silencer box. This is NOT illustrated in the Ford Parts List, but is listed as EOTA 5258. If you do not fit this, all the mounting points on the exhaust system will not match up! This is the same as the later Escort spacer.
Note: MacPherson struts can be overhauled by several organisations. Ask first at your local motor factors. ALWAYS replace or repair suspension units as a pair!
Front Spring and Upper mounting
Note: The upper suspension seat (the bit that goes on top of the coil spring) comes in two different styles. Part Number 113E 5A306 was used on everything except G.T.s, while E51 DA 1 was fitted to G.T. cars.
You MUST ensure that suspension units are the same on both sides, otherwise serious handling problems could occur.
Note: The spring length on the 1200cc Saloon is approximately 12.25 inches,
The spring length on the G.T. is 10 inches,
The spring length on the LOTUS is 11.75 inches ???
These lengths are the free (not compressed) length.
Note: Stiffness in the steering could be caused by lack of lubrication in the bearings at the top of the MacPherson strut. Refer to the Workshop Manual.
Note: 1200cc cars have 4 leaves in the rear springs, 1500 and G.T. cars have 5 leaves. Estate cars have 6 leaves.
The following table shows the relationship between the springs and the leaves contained in each spring.
|
Rear Spring leaf no. |
113E-5560-C Except Heavy Duty or GT |
113E-5560-D Estate Car (except heavy duty) |
113E-5560-E Heavy duty (except Estate Car) |
113E-5560-F Estate Car Heavy duty |
118E-5560-B G.T. from 3/63 - 6/63 (replaces 118E-5560-A) * |
118E-5560-C G.T. from 6/63 |
|
Leaf 1 |
113E-5564-C |
113E-5564-D |
113E-5564-E |
113E-5564-F |
118E-5564-B |
118E-5564-C |
|
Leaf 2 |
113E-5565-C |
113E-5565-D |
113E-5565-E |
113E-5565-F |
118E-5565 |
118E-5565-B |
|
Leaf 3 |
113E-5566-C |
113E-5566-D |
113E-5566-E |
113E-5566-F |
118E-5566 |
118E-5566-B |
|
Leaf 4 |
113E-5567-C |
113E-5567-D |
113E-5567-E |
113E-5567-F |
118E-5567 |
118E-5567-B |
|
Leaf 5 |
113E-5568-A |
113E-5568-B |
113E-5568-C |
118E-5568 |
118E-5568 |
|
|
Leaf 6 |
113E-5569-A |
113E-5569-B |
||||
|
Leaf 7 |
113E-5570 |
*
No data currently available on spring 118E-5560-A. No further reference in Parts Book.Note: I don't know if part numbers are engraved on spring leaves. I've never seen a brand new spring!
| Parameter | 1200cc | 1340cc | 1500cc | 1558cc Lotus |
| Bore | 80.97mm | 80.97 | 80.97mm | 82.6mm |
| Stroke | 58.17mm | 65.08 | 72.74mm | 72.74mm |
| Max Power | 48.5 bhp | 54 bhp | 59.5 bhp (G.T. 78 bhp) |
105 bhp (115bhp) |
| Combustion chamber volume | 39 cc | 41 cc | 41.12/42.12cc
high comp. 52.25/53.25cc low comp. 36.65/37.65cc for G.T. |
|
| Compression Ratio | 8.7 : 1 | 8.5 | 9:1 high
compression, 8.3 : 1 low compression, 9 : 1 G.T. |
9.5 : 1 |
Note: The MK2 pre-crossflow motors use the same bore size, but different strokes:
1300: 62.99 mm
1500: 72.82 mm
Crankshafts have 6 flywheel bolts while the MK1 has 4 bolts. A different (better) oil seal is fitted to the rear of the MK2 pre-crossflow cranks.
| Valve Sizes | Inlet head diameter * | Exhaust head diameter |
| Valve Size 997, 1200cc & 1340cc | 1.262 - 1.272 inch | 1.183 - 1.193 inch |
| 1500cc | 1.432 - 1.442 inch | 1.183 - 1.193 inch |
| 1500cc G.T. | 1.405 - 1.415 inch | 1.24 - 1.25 inch |
| 1558cc Lotus. | 1.526 - 1.530
inch Big Inlet valve models had 1.560 - 1.566 inch inlet valves. |
1.321 - 1.325 inch |
* Note: WARNING: Do NOT grind in the INLET valves. They have a protective coating. Use a dummy valve for lapping in! Refer to the Workshop Manual.
The oil pressure switch for the G.T. is the same as the D-series Ford lorry. Finis code 1702727
Note: Cylinder blocks may have one of several different part numbers:
All 997cc, 1200cc and 1340cc blocks were marked 109E 6015. There then followed blocks marked 116E, 120E, 2733E, 2727E and 681F -- and suffixed by 6015. Later blocks used 711E 6015 either AA or BB.
All blocks were bored to 3.1875 inches, except the Lotus which achieves its 1558cc by a bore of 3.250 inches.
Note: There is a lot of mis-information regarding the legendary "L" block. Blocks with 120E 6015 were selected for use by Lotus. When a particular block matched the required specification for concentricity and metal jacket thickness, the number 120E 6015 was ground off. Any reference to "L" is related to the casting or mould from which the block is cast. -- Courtesy MK1 Cortina Owners Club magazine. Update:- This has the best info on Ford blocks I have seen:-- http://lotus-cortina.com/library/block/blocks.htm -- Tommy.
Note: Core plugs are still available from motor factors and Halfords etc. Take an old one with you to match the size.
Note: You need four core plugs. They are all the same size and are fitted at the rear of the cylinder head (1), at the rear of the cylinder block (1 which needs the gearbox removed to get at it), and two on the right hand side of the cylinder block looking from the front of the engine.
Note: Always fit new core plugs when rebuilding an engine. It will cost only a few pounds and will save you having to remove the engine or gearbox again shortly afterwards when the old core plug leaks!
Insulators
Front Cover and Timing Chain Tensioner
Note: There are high and low compression heads for the 1200cc engine, the same for the 1500cc engine, but only one head for the G.T. engine.
Cylinder heads can be identified by a stamping on the machining pads above the ports. "L" indicates a low compression head, "H" is high compression. G.T. heads have "GT".
The G.T. head has an extra drilling above the temperature gauge drilling at the front, right hand side of the head. It also has recesses in two of the inlet ports to locate the inlet manifold.
See cylinder head identification
The correct sequence to tighten cylinder head bolts is as follows:
8 6 2 4 9
10 3 1 5 7
where "8" and "10" are at the FRONT of the engine. Torque is 65 - 70 ft/lbs.
To save you any grief, the Lotus head must be tightened in the following order:-
9 3 1 5 7
8 6 2 4 10
where "9" and "8" are at the front of the engine. Torque is 60 ft/lbs
Note: If the cylinder head is skimmed to increase the compression ratio, the rockers may go out of adjustment. You may have to fit shorter push-rods.
Note: Two lengths of cylinder head bolts have been used:
1198cc and 1500cc G.T. 3.531 inches /89.69mm
1500 3.75 inches /95.25mm
Pistons, Pins, Rings and Connecting Rods
Hepolite pistons, number 18400 will suit all blocks. Standard bore is 3.1870 inches (80.950mm)
These are available in the following oversize:
2. 5 thou oversize,
5 thou oversize,
15 thou oversize,
30 thou oversize,
40 thou oversize,
60 thou oversize (1.524mm oversize)
Camshaft, Crankshaft and Liners
Note: Main bearings are available in 2 thou, 10 thou, 20 thou, 30 thou and 40 thou oversize.
MORE INFO AND PART NUMBERS REQUIRED
Note: It is very important that the dust shield (Part number 109E 6382) is fitted between the engine and gearbox. The "trick" is to tie it to the engine block with twine! When the engine-gearbox are located then cut away the twine!
Note: Early crankshafts were hollow, while later ones were more solid. This is something to be aware of, not worried about, as all versions of the 5-bearing crankshaft are well designed for the job! If you are building a "competition" engine, select a later crankshaft.
Note: The crankshaft sprocket is different on 1500cc engines and 1200cc engines. It is narrower on the larger engine, and identified by a groove on the front boss. Part number 105E 6306C on the smaller engine and 116E 6306 on the 1500 engine.
For lots more Ford camshaft data, click here!
| Camshaft | Timing | Valve Lift |
| 109E as fitted to 997cc, 1200cc, 1340cc and non-G.T. 1500cc motors. Identified with band of white paint. | Inlet opens
17° BTDC Inlet closes 51° ABDC Exhaust opens 51° BBDC Exhaust closes 17° ATDC |
Inlet valve,
0.315 inches (8.001mm) Exhaust valve 0.319 inches (8.103mm) |
| 116E shaft fitted to 1500cc G.T. MK1, plus MK2 1300cc G.T until October 1970 and 1600cc G.T. Identified by 116E stamp on rear end of shaft. | Inlet opens
27° BTDC Inlet opens 65° ABDC Exhaust opens 65° BBDC Exhaust closes 65° ATDC |
Inlet 0.344
inches (8.727mm) Exhaust 0.335 inches (8.519 mm) |
| Camshaft LOTUS | Timing | Valve Lift |
| Lotus, until end of 1966 B-type camshaft, (105bhp motor) | Inlet opens
22° BTDC Inlet closes 62° ABDC Exhaust opens 62° BTDC Exhaust closes 22° ATDC |
0.375 inch |
| Lotus, after 1966 C-type camshaft, (115bhp motor) | Inlet opens
26° BTDC Inlet closes 66° ABDC Exhaust opens 66° BBDC Exhaust closes 26° ATDC |
0.3498 inch |
Note: Refer to "Lotus Twin-Cam Engine" by Miles Wilkins for full Lotus information. See Bibliography
For all other Cortina camshaft data, click here
Note: Three types of cam followers have been used, depending on the block. See Cylinder Blocks.
Early followers were 105E 6500. These have a thin base or foot. They can only be used with original 109E or 116E camshafts.
The later 681F type followers have thicker and larger bases, but the same size stem. These should be used with later wide-lobe cams but will run okay with narrow lobe cams.
From 1970 onwards cam followers 711N have a larger diameter stem so will only fit blocks 711E 6015 AA/BB.
Note: You must turn the engine upside down when replacing a camshaft, otherwise the cam followers may fall into the sump when the shaft is removed. Refer to the Workshop Manual.
Note: Two weights of flywheel can be used. The 105E 6398 B weights 14 lbs and can be fitted to the 1500 engines. It will improve acceleration, but make the car more unpleasant to drive. Tick-over will also need to be set higher.
Flywheel 109E 6398 B weighs 18 lbs and is the correct flywheel for the 1500 engines.
Note: Push rods on the 1200cc engine are 6.625 inches (168.3mm) long, while 1500 and G.T. push rods are 7.438 inches (188.9mm)
Gasket -- as escort ??
Oil Pump and Oil Pressure Relief Valve
Note: The original oil pump used a paper cartridge, and provided an extra half pints oil capacity. The older paper filter is also used on the Allegro.
If you use the Escort oil pump you will need a screw canister type oil filter.
Note: You must remove the old rubber sealing ring before fitting the new one when replacing the paper cartridge type oil filter. Two rubber rings will result in leaks.
Sump, Splash Shield, Oil Filter and oil level indicator
Note: Two dipsticks have been used. One is shorter than the other. ENSURE you have the correct one for your engine, otherwise serious damage could be done to your engine.
Gearbox (transmission) and gear change
Note: Parts for column gear-changes are getting hard to find!
Note: data corrected 31st January 2003 - Thanks to Tim Isles.
| Gearbox | Ratios | Fitted to: |
| 4-speed, all synchromesh | 3.543, 2.396, 1.412, 1 to 1. Reverse 3.963 to 1 | Anglia 1200cc 1962-68, Cortina 1200 1962-67, Classic 1500 1962-63, Capri 1500 and Capri G.T. 1962-64, Cortina 1500 and 1500 G.T. 1963-1967, Corsair 1500 and 1500 G.T. 1963-66, Corsair V4 1664cc, 1966-70, Cortina 1300 MK2 1967 - Cortina 1600 MK2 1968 -,, Capri 1300 and 1300 G.T. 1969- Capri 1600 1969, Cortina MK3 1300 and 1600, 1970 -- |
| 4-speed, all synchromesh | 2.50, 1.64, 1.23, 1 to 1. Reverse 2.810 | Fitted to Lotus Cortina from January 1963 to July 1964. |
| 4-speed, all synchromesh | 3.543, 2.04, 1.412, 1 to 1 | Known as
the "up-rated 2nd gear kit", fitted as standard to Lotus
Cortinas from July 1964 to October 65, and available as an option on
the 1500 GT. |
| 4-speed, all synchromesh | 2.972, 2.01, 1.397, 1 to 1. Reverse 3.342. | Known as the 2000E box. Fitted to Lotus Cortina 1966-70, Corsair 2000E, 1966-70, Escort twin cam 1968-71, RS1600 1970 on, Mexico 1970 on, Cortina 1600 G.T. 1968-70, Cortina 1600E, 1968-70, Capri 1600 G.T. 1969 - , Capri 2000 G.T 1969 --, Cortina MK3 1600 G.T. 1970 - |
Note: The gearbox fitted to the 1500 G.T. is the same as that fitted to the normal 1500. Many people think it has a "special" or different gearbox. The ratios are the same.
In October 1965 the Corsair V4 got a new set of ratios. This gearbox, now known as the 2000E box was fitted to G.T. cars from early 1967, Lotus Cortinas from the autumn of 1965. Ratios are given above.
Note: The 2000E's remote gearshift needs a hole in the floor about 6 inches back from the original. EITHER cut a new hole, OR fit the standard tailpiece from the standard box onto the 2000E box and use a remote change
| ENGINE | GEARBOX | COMMENTS |
| 997cc, 1200cc, 1340cc pre crossflow. | Use the original box or swap to 2000E box. | Don't use the original 997 gearbox as it had no synchromesh on 1st gear. This box was also fitted to Classics and Capri 1962-64. |
| 1500cc pre-crossflow | Use the original box or swap to 2000E box. | If you have installed a 1500 engine in place of a 3-bearing engine, the original exhaust front pipe will (may) be too close to the passenger floor. |
| 1500cc G.T. pre-crossflow | Use the original box or swap to 2000E box. | The original box is the same as on the 1500. Best to go for the 2000E box. |
| 1650cc (over-bored 1500) pre-crossflow | Use the original 1500 box or swap to the 2000E box. | Best to go for the 2000E box or a competition box. |
| V4 | 2000E - still the best gearbox around! | The 2000E box was fitted to the V4 as standard! |
| V6 | 2000E box | Need a lot of work on manifolds etc. |
| MK2 1300 Crossflow | Use original MK2 box or swap to 2000E box. | Use the crossflow exhaust system and throttle linkage. |
| MK2 1600 Crossflow | Use original MK2 box or swap to 2000E box. | Use the crossflow exhaust system and throttle linkage. |
| MK1 Escort 1300/1600 | ||
| MK1 Escort 1600 | ||
| OHC 1600 | ||
| OHC 2000 | ||
| Volvo 1800/ 2000 (B18 / B20) | Volvo gearbox or adapt the 2000E |
Note: A special bellhousing is available which allows you to fit 4 or 5 speed Cortina/Sierra/Capri/Rocket gearbox onto a pre-crossflow engine. It also fits MK2 Cortinas, MK1 and MK2 Lotus and MK1 Escort Mexico. See Flow Tech Racing, in Addresses.
Datsun ??? boxes
If you change the final drive ratio on your car you must change the speedometer drive gear in the gearbox.
| Speedometer Drive Gear | Number of Teeth on Driven Gear | Colour of Driven gear | Axle Ratio / Tyre size |
| 6 teeth | 22 | Natural (White) | 4.125 :1 with 5.20 x 13 tyre |
| 6 teeth | 23 | Black | 4.44:1 with 5.20 x 13 tyre |
| 6 teeth | 22 | Natural (White) | 4.125 :1 with 5.60 x 13 tyre |
| 6 teeth | 23 | Black | 4.44 :1 with 6.00 x 13 tyre |
| 7 teeth | 23 | Black | 3.9 :1 with 5.60 x 13 tyre |
| 7 teeth | 22 | Blue | 4.125 : 1 with 5.60 tyre |
| 7 teeth | 24 | Green | 3.9 :1 with 6.00 tyre |
Note: The remote gear change from the 1962-1964 Ford Capri G.T. is about 2 - 3 inches shorter than the Cortina G.T. remote gear change and will allow you to fit a floor mounted-handbrake. Alternatively, off-set the original floor-mounted handbrake to allow the remote change to be installed. The part number of the Capri item is 116E 7K006 B while the Cortina item is 118E 7K006 B.
Check the wear in the gear-change mechanism linkages, (plastic bushes) but also check that the "ball and socket" is not scored or damaged. This will result in rough gear-changing. The Owners Club can supply new "balls" but it is pointless fitting a new ball to a scored or damaged socket! Update!!:- You get an AMAZING improvement in gear-changing if you replace worn 070-7K022 Gear Change Lever Bush on your remote gearchange. While you have it dismantled, also fit a new 070-7A138 Seat, gear change lever spring (Lotus/GT). Available from the Club for a total of £3.!!! Click here to see how.
You will also need a 116E 7200, which is the draught-proof seal between the gear change housing and the floor.
Note: The clutch slave cylinder can be repaired with kit SP 20198.
Note: Repair kits are available for master cylinders. Ensure you have the correct master cylinder fitted, or a recognised replacement.
Clutch Housing and release mechanism
Note: The clutch slave cylinder is often hard to remove due to corrosion between the alloy of the cylinder and the cast iron bell housing. Allow lots of time and patience to removing this part otherwise it will break or become damaged beyond repair.
Note: When removing the clutch slave cylinder take care not to damage the alloy cylinder. If the large circlip (EOA 7059) breaks, a suitable replacement circlip can be bought from a motor factors or a company selling seals etc. Take the old bits to match a new one.
Note: When changing (swapping) gearboxes, make sure you have the bellhousing you need for the swap. Standard Cortina MK1 bellhousings 113E 7500 have mountings for hydraulic clutch operation, while on other, later models, cables were used.
Note: The clutch cover assembly (pressure plate) is 7-3/8 inches in diameter.
The clutch driven plate is 7.25 inches in diameter. The spline is 20 X 7/8 inch.
Quinton Hazell reference numbers are given first, followed by the Ford part number. Then a list of other vehicles which use the same clutch components is given. Finally, other manufacturer's reference numbers are given, where known.
Borg and Beck 50803
Cortina 1200 Cover Assembly Q 30001 (Ford 105E 7563D) Also used on Ford Anglia 105E, Anglia 123E, Ford Prefect 107E, Ford 5/7 cwt Thames Van and Anglia Van. REPCO R638CA, ITO AUTO CCA-106,
Cortina 1500 Cover Assembly, Q 30016 (Ford 109E 7563B). Also used on Ford Capri and Classic, Ford Corsair (not-V4). REPCO R706CA,
Cortina G.T. Cover Assembly, Q 30019 (Ford 116E 7563B). Also used on Corsair G.T. (not V4). REPCO R793CA,
Cortina 1200 Driven Plate C 359 S (Ford 105E 7550E, C). Also used on Datsun 311, 312 and WP12 (1962-1968), Datsun 410 and 411 Bluebird (1964-1968), Anglia 105E, Prefect 107E, Cortina MK1 1200, 1500 and G.T. Capri and Classic, Corsair G.T. (not V4) and Ford 5/7 cwt Thames and Anglia Vans. REPCO R7262W, Datsun reference 30100-04403, and 30100-09403, and 30100-14801, RAYBESTOS 804/MR,
Thrust Bearing for 1200, 1500 and 1500 G.T. CCT24 (Ford 105E 7580B). Also used on Anglia 105E, Prefect 107E, Capri and Classic, Corsair G.T. (not V4) and Ford 5/7 cwt Thames and Anglia vans. SKF 408504,
Pilot Bearing number is CCT 37
Note: Three different pilot bearings have been used. The first was a bronze bush with a large hole in the centre. This will mate with any of the standard gearboxes. Later bushes had a much smaller hole to match the small "nose" of later gearboxes (for example the 2000E box). Still later a needle roller bearing was used (Escort gearboxes).
I have decided to add this MK2 data, due to popular engine swaps etc.
Note: The cover assembly is 7-1/2 inches in diameter.
Borg and Beck assembly on a Lotus Cortina 1966 Mark 2. Part
numbers are:-
NCA 98330 for the cover assembly, and BCS for the disk (driven
plate).
| Clutch Cover Assembly | 7-1/2 inch Q76139/22 1966-1970 MK2 1300,1500 and 1600.
Also MK2 GT 1966-1967. (Ford 2730E-7563C)
MK2 GT and 1600E 1967-1970 Q76139/21 (Ford 2730E-7563B, D |
| Clutch Driven Plate | C752S (Ford 2735E-7550C) All MK2s |
| Thrust Bearing | CCT79/CCT95 (Ford 3014E-7580C / 3014E-7548C |
Converter and Converter housing (Automatic Transmission)
Note: A Borg-Warner type 35 automatic transmission system is used.
Pumps, Gears and Clutch (Automatic Transmission)
Servo Units (Automatic Transmission)
Main Control and Tubes (Automatic Transmission)
Exterior and Manual Control (Automatic Transmission)
Radiator, Thermostat, Hoses and Clamps
Note: Earlier radiators had a plastic drain tap at the bottom. Later radiators don't have this drain.
Note: The 1200cc radiator and 1500cc radiator provided a water capacity of 9 pints (without heater) and 10.5 pints with heater.
For information, the 1340cc Classic/Capri had a capacity of 10.75 pints without heater and 11.75 pints with a heater.
Note: Make sure you fit the correct low pressure radiator cap. The correct rating is 7 psi for the 1200cc engine, and 10 psi for the 1500cc and G.T. If you fit a modern high pressure cap you could damage radiator, heater and core plugs.
Note: The 1200cc thermostat begins to open at 82-88°C (180-190°F) and is fully open at 101°C (214°F).
The 1500 and G.T. thermostat begins to open at 85-89°C (185-192°F) and is fully open at 99-102°C (210-215°F).
Note: Later, Escort radiators will fit. The only problem is that later radiators did not have a drain plug on the bottom.
| Volume of anti-freeze % | Protection | Anti-freeze without heater | Water without heater | Anti-freeze with heater | Water with heater |
| 10% | - 8° C (17° F) | 1 pint (0.58 litres) | 8 pints (4.52 litres) |
1-1/4
pints (0.72 litres) |
9-1/4
pints (5.08 litres) |
| 15% | - 13° C (7° F) | 1-1/2
pints (0.93 litres) |
7-1/2
pints (4.17 litres) |
1-3/4 pints (1 litre) | 8-3/4
pints (4.8 litres) |
| 20% | - 19°
C (- 3° F) |
2 pints (1.1 litres) | 7 pints (4.1 litres) |
2-1/4
pints (1.3 litres) |
8-1/4
pints (4.68 litres) |
| 25% | - 29°
C (- 20° F) |
2-1/4
pints (1.3 litres) |
6-3/4
pints (3.8 litres) |
2-3/4
pints (1.6 litres) |
7-3/4
pints (4.4 litres) |
Note: The water pump from the MK2 Escort will fit.
Note: Radiator top hose the back one for a Lotus can be replaced with a MK3 Transit radiator hose Finis Code 1510935. The front hose is the same as a Commer van ???
The bottom hose for the Lotus can be replaced with a Chrysler Alpine hose, part number D 017795800. This will need 1" cut off the top.
Note: The 1200cc thermostat begins to open at 82-88°C (180-190°F) and is fully open at 101°C (214°F).
The 1500 and G.T. thermostat begins to open at 85-89°C (185-192°F) and is fully open at 99-102°C (210-215°F).
Note: Most Cortina MK1s will run well, in NORMAL use, without the fan blades. They are slightly quieter, and warm up quicker. Take them off and try it!
If you have overheating problems, (there is probably something wrong!) try fitting the multi-blade plastic fan from the MK2 Cortina, MK1 Escort or MK1 Capri. Check also that you have the correct 1500 radiator in your 1500, and not a 1200 radiator which is smaller.
Note: Lotus fan belt number is SPZ 750 from a belt stockist.
Note: The fuel tank capacity of the standard MK1 tank is 8 gallons (36 litres).
Note: The MK2 fuel tank can be fitted to the MK1. This tank is deeper and will increase your tank capacity to 10 gallons. You will have to "bodge" the inlet filler pipe. Well, not bodge, see the answer, here!
Note: The Lucas petrol tank sender unit (Ford number 211E 9A307) is the same as that fitted to the Austin Allegro.
Note: The petrol tank sender sealing ring (Ford number 211E 9276) is identical to that used on Austin Allegro.
Works rally MK1s used modified MK1 estate fuel tanks mounted on a bracket bolted between the inner wheel arches. The problem is the filler neck. Unless very carefully positioned, it will foul the boot lid's leading edge. See photos here.
MK1 and MK2 Escort tanks will fit as rally tanks. Also Austin A60 tanks if you can find one!
Fuel pump repair kits for the standard glass-bowl pump are still available -- part number ????. Also a more modern pump is available -- part number --- which does not have the glass fuel bowl. These cannot be overhauled.
I have been told that there is a G.T. - specification fuel pump. I can, however, find no record of this anywhere ! ??
Note: If acquiring a 1500 engine (that is non-G.T.) from a Classic or Capri, note that the exhaust manifold is different (shorter) on the Classic and Capri engine.
For all my notes on G.T. manifolds, click here
Note: On the standard 1500cc car the carburettors are usually all right until they wear out mechanically. However, there is an economy diaphragm which leaks and causes loss of power, see below. This leak may be accompanied by a whistling noise. It costs only a few pounds to replace this diaphragm. Refer to the Workshop Manual.
Standard Solex carburettor settings
| Jet etc | Size |
| Main jet | 105 |
| Main jet correction | 200 |
| Accelerator pump jet | 35 |
| Idling jet | 50 |
| Auxiliary air bleed | 60 |
| Choke tube diameter | 23 mm |
| Progression | 2 x 80 drilled in ?? |
| Needle valve | 1.6 mm |
G.T. Weber carburettor Settings
Note: The following table gives basic settings for the Weber 28/36.
For data on the 40 DCOE Webers as used on the Lotus, click here.
Note: Most parts books show an exploded diagram of the Weber. They almost always show the diagram with Starter plunger parts missing. The "correct" diagram appears below and on page 127 of "Restoring Small Fords."
| Primary | Secondary | |
| Venturi Diameter | 26 | 27 |
| Auxiliary Venturi diameter | 4.5 | 4.5 |
| Main Jet | 140 | 155 |
| Air Correction Jet | 230 | 180 |
| Emulsion Tube Jet | F 30 | F 30 |
| Slow running petrol jet | 50 | 70 |
| Slow running air jet | 200 | 70 |
| Progression holes | 2 x 120 | 1 x 120 |
| Slow running volume control port | 1.5 mm | -- |
| Air bleed in throttle plate | -- | 1 mm |
| Needle valve | 1.75 mm |
|
| Float Travel | 8.5mm |
|
| Starter petrol jet | 100 |
|
| Starter air passage | 6 mm diameter |
Note: The Lotus Cortina air filter element EFA11 is similar to the Fiesta, Finis Code 1438016.
Note: There should be a support E55 CK 7 between the inlet manifold on a G.T. car and the engine mounting. If this is missing the inlet manifold may crack under its own weight. Further note, my manifold DID fracture with a bracket fitted, at the bracket support!!!
Note: Loss of power and stalling instead of ticking over are symptoms of an air leak between the inlet manifold and head, which could be caused by a blown gasket or the manifold stubs working loose.
Note: Weber 28/36 carburettors can be overhauled. See Addresses.
Accelerator, Choke and Throttle Controls
Note: Several variations on the accelerator linkages have been used. Ensure you have the correct parts for your bodyshell. Refer to the Parts List.
Note: The choke cable from a MK5 Cortina estate can be used on a 1500 G.T. It needs about 4 inches cut off the end, and a slight enlargement of the hole in the dashboard.
Note: The following table shows the relationship between dynamo, regulator and battery.
| Dynamo | Regulator | Battery |
| Lucas C 40 (22 amps) Maximum output 240 watts) Ford Part 105E 10001 B See LUCAS Information. | Lucas 37344 (Ford Part 622E 10505 A) | 38 amp hour (standard) battery |
| C 40 L (25 amps) Maximum output 300 watts) Ford Part 109E 10001 See LUCAS Information. | Lucas 37342 (Ford Part 622E 10505 B) | 51 amp hour heavy duty battery |
Note: The regulator number is supposed to be stamped underneath the base of the regulator. Having inspected dozens of regulators -- it isn't always visible!
An alternator can be fitted to the MK1 Cortina. Lucas 15 ACR (LRA 102 104) provides 28 amps, 16 ACR (LRA 100 101) 34 amps, 17 ACR (LRA 106) 36 amps, 18 ACR (LRA 103 147 226) 43 amps, 22 ACR (LRA 469 358 279 157) 55 amps, 25 ACR (LRA 127 406 177 189) 65 amps, and LRA 384 giving 75 amps. No regulator is needed with an alternator.
NOTE: You must convert to negative earth for an alternator. There will be no problems with electrical equipment EXCEPT tachometers must be specially converted to negative earth, and ammeters may cause problems. Refer to an auto electrician, or if you know what you're doing, see here!
The dynamo (generator) is the same as the early Mini.
Note: A high output dynamo (25 amps rather that the standard 22 is available under Lucas number C40 L. This is about 1/4 inch longer than the standard C40.
Note: The C40L was fitted as standard to the 1962-1964 Classic and Capri. It was also fitted to the early (not-V4) Corsair.
The high output dynamo bracket 109E 10151 is different to the standard bracket. It may be hard to find, so use the standard bracket with a nut as a spacer.
Note: I believe a steel dynamo pulley was also available ??
Regulator and Cut Out
Batteries still available from motor factors. Specify either standard 38 amp hour, or heavy duty 51 amp hour (at 20 hour rate) See LUCAS Information.
The starter motor is the same as the early Mini ... ??
Starter Drive
9 or 10 tooth ???
Instrument Panel and Starter Switch
Note: The following table outlines various changes to fuel and temperature gauges and senders.
| Item | October
'64 Onwards
5 volts |
Before
October '64
10 volts |
| Fuel Gauge Sender | C5BH 9275C
(Saloon) C5BH 9275D (Estate) Appear white. |
113E 9275C
(Saloon) 113E 9275D (Estate) Appear yellowish. |
| Temperature Gauge Sender | C5EH 1088B Round Terminal |
C4AH 10884
(now changed to Finis 1784077),
spade terminal |
| Voltage
Stabiliser
See NOTE !!! |
C5BH 10804, rectangular with 1 male and 1 female terminal, screwed to rear of speedometer. | 113E 10804,
has 4 male terminals fixed to facia behind/under dash. |
| Fuel Gauge (not G.T.) | C5BH 9305A, two round push-on terminals. | 113E 9280B, two spade terminals. |
| Temperature Gauge (not G.T.) | C5BH 10970B, two round push-on terminals. | 113E 10883B, two spade terminals. |
Note: Up to October 1964 the Voltage Stabiliser voltage was 10 Volts. After October 1964 the voltage was changed to 5 Volts. It is important that you do not mix up voltage stabilisers otherwise damage could occur.
Lighting, Direction Indication and Horn Switch
Coil is 12 volt, oil filled. At 20° C (68° F) the primary resistance should be between 4 and 4.4 ohms.
The secondary resistance should be 7,000 to 8,000 ohms.
If you suspect a faulty coil, check the resistance of
primary and secondary windings. Do this when the coil is hot, and again when
cold. Also measure from the outer case to each connector on the coil.
Note: Distributors are Lucas type 25 D.
These were also used on the Mini and 1300 range of cars. You need to remove the drive and fit a Ford distributor drive gear, Ford number 105E 12390. Be VERY CAREFUL, as this gear is supplied with no hole and must be drilled. I once broke an entire engine and I blame this on the hole not being drilled correctly. It must be done in a "proper" drilling machine.
Note: The above gear is NOT the same as the one on the oil pump, Ford number 105E 6551, which is listed under "Valve mechanism and covers" in my Parts List. I believe it should be listed under Oil Pump and Oil Pressure Relief Valve.
Distributors have the following numbers stamped on the outside:
Standard: (LOW Compression) 40856. Colour code Yellow, Vacuum unit: 5 - 16 - 12 (previously wrong - corrected 3/6/2006 - Ref Chris Seymour)
Standard: (HIGH Compression) 40857. Colour code Brown, Vacuum unit: 5 - 17 - 10 (previously wrong - corrected 3/6/2006 - Ref Chris Seymour)
G.T. : 40927. Colour code Blue. Vacuum unit 6 - 17 -7
Automatic advance retard springs for Low compression distributor are E 427 Z 1. The Vacuum unit is
Automatic advance retard springs for the G.T. are 116E 12322. Vacuum advance is 6-17-7, part number 116E 12370. The cam assembly is 109E 12179A.
Note: Distributor 40847 F, vacuum unit 5 - 17 - 10 also fitted to 1500cc engines. (Source January 1989 Cortina club magazine. Not supported by Lucas catalogue. Further information required.)
Note: Distributor Motorcraft part number 12100 C6 AH A-99C, fitted to Cortina MK2 will also work in the MK1. (Source January 1989 Cortina club magazine).
Note: Distributor Lucas 41737 A, vacuum 5 - 14 - 7 is recommended as a suitable alternative by Lucas. (Source January 1989 Cortina club magazine. Not supported by Lucas catalogue. Further information required.)
Note: Lotus engines used three different distributors at various times. These were: 40930, 40953, and 41189A. For full information about distributors and the Lotus engine, refer to "The Lotus Twin Cam Engine" by Miles Wilkins. See Bibliography.
Note: The wire between the ignition coil and the distributor can have a high resistance due to its size (electrical specification). This could make starting difficult. Remove the wire and measure the resistance with a multi-meter. Replace the wire with a thicker (that is, lower resistance wire. Measure the resistance. It should be lower than the first wire). Consult an auto electrician if in doubt.
The condenser is rated at 0.18 to 0.22 micro
farads. Check for faulty condensers with the Ohms
function of a multi-meter. You should see the
resistance rise from 0 to infinity as the condenser charges up. Make sure you
test both ways. Make sure you test both hot and cold. Any other reading
indicates you must replace the condenser. If the condenser is still on the car,
make sure the points are open when you test.
When you decide to fit electronic ignition, click here!
The rotor arm, contact breaker, distributor cap are the same as the early Mini.
Note: Use the Mini Cooper points which were rated at a higher spring pressure, which will reduce points bounce on a hard-driven engine.
Firing order
Note: The firing order is: 1 - 2 - 4 - 3., where number 1 is the cylinder nearest the radiator!
Note: The firing order for LOTUS ENGINES ONLY is: 1 - 3 - 4 - 2.
Note: The initial ignition timings are:
| Engine Size | Initial (Static) Timing |
| 1200cc | 6° Before Top Dead Centre |
| 1340cc | 6° Before Top Dead Centre |
| 1500cc not-G.T. | 8° Before Top Dead Centre |
| 1500cc G.T. | 10° Before Top Dead Centre |
| 1558cc Lotus | 14° Before Top Dead Centre. Approximate figure only as the Lotus requires accurate setting. |
Click button to read about timing with a Strobe Timing-Light.
| Engine | Plug | Plug Gap |
| 1200, 1340, 1498 (Not G.T.) | Champion
N5 Autolite AG 32 or AGR 32 |
23 - 28 thou ** |
| 1500 G.T. | Champion N4 or Autolite AG 22 | 23 - 28 thou ** |
| Lotus 1963 - 1964 | Lodge 2 HLN | 23 - 28 thou ** |
| Lotus 65 - 66 | Champion N3 or Autolite AG 22 | 23 - 28 thou ** |
** Note: A Ford Service Bulletin recommends setting the spark plug gaps to 23 thou to improve starting.
| Points --- CS1 or CS5 | Lotus used
54413568 CS1 same as Mini, Mini Cooper, etc. |
Gap 14-16 thou (All models)
Normal 7 inch sealed beam is rated at 60w, 70 watt are available, as are 100w (may not be legal !).
Wing Lamp (Parking Lamp) and front flasher
Miscellaneous
Note: Not many people know that the direction flasher unit is FUSED. It is the only fuse fitted as standard on the MK1. It is a 5 Amp glass line fuse, physically located about 2-3 inches from the flasher unit.
No info ...
Stop Light Switch and Dimmer Switch
Note: Part number 113E 13543 is the same as the Ford Escort MK1, Finis code 1467382.
Interior Lamp
Horn
Note: G.T. wiring looms are getting scarce. Be prepared to repair your existing loom! Update! New wiring looms for all Cortina models, available here, for about £155 (Sterling) Tell them you got the information here!!
Note: Wiring loom clips, 113899-ES, are no longer available in Grey. Use the Escort ones which are black, and use Humbrol model paint if authenticity is required. You need eight per car!
Revised June 1999 -- NOW AVAILABLE FROM MK1 OWNERS CLUB
Cigar Lighter
Long Range and Pass Lamp
Reversing Lamp
Tools
Speedometer
See SPEEDOMETER DRIVE GEARS
Tachometer -- G.T.
Windscreen Wiper
Windscreen Washer
Rear View Mirror
Use the Morris Minor mirror, available from the Morris Minor Spares Centre. See Addresses.
Note: Chrome bumper bar bolts and nuts are available from Ford, Finis Code 6001103 for the bolt, and 1436267 for the nut.
Note: Anglia van rear 1/4 bumpers can be used. They are virtually the same as MK1 Escort 1/4 bumpers but the bolt holes are in different positions.
Note: Many different makes and models of rear shock absorbers were available. Ensure you have a pair -- that is both the same -- installed, for safety's sake!
Note: Mysterious water leaks and engine overheating, could be caused by a leaking heater radiator core. Check for wet carpets or other signs of leaks inside the car. The heater radiator core can be repaired just like any other radiator.
Radio (Domestic Only)
Miscellaneous Kits -- Too many to list. Refer to Ford Cortina Parts Book
Accessories -- Refer to Ford Cortina Parts Book
See also "Re-Manufactured Parts"
Note: The G.T. quarter panel badges E585 AM -1 are getting scarce. Buy the best second-hand set you can find.
Back and Tailgate
Note: The bonnet badge on pre said CONSUL. This was changed in October 1964 to CORTINA.
Note: There are two types of grilles. The "early" cars (until October 1964) had a grille which did not extend round the sidelamps, while on the "late" cars the grille wrapped round the sidelights.
Note: Grilles are attached with pop rivets. To allow easy access behind the grille replace the pop rivets with small nuts and bolts.
Note: New front grilles are becoming hard to find. It will be almost impossible to make new ones, so find the best second-hand ones available while you can!
Note: Door are complicated! They take up a very large section in the Parts List.
All doors are "different." For example the 4-door saloon doors do not fit estates. All estate door glass is different to saloons. All 2-door glass is different to 4-door glass, including quarter lights.
Note: Door/window weather strip is available from several sources. Refer to Addresses.
Note: Corsair inner wings can be made to fit MK1 Cortinas. A modification is required which means cutting some metal off the top of the inner wing.
Note: The bonnet stay used on the Lotus Cortina is similar to those used on B.M.C. cars such as the 1100. Also used on the 105E and 123E Anglia ??
Note: Lotus Cortinas have the battery in the boot. The battery tray (bolted to the boot floor at the driver's side) is the same as the one at the front of standard cars, but with the mounting/support brackets removed.
Note: Rear screen from the Corsair will fit the Cortina MK1. Ford number 113E 7042006.
See also Four into Two won't go!
Seats
Side
Note: Front screen from a Corsair will fit the MK1 Cortina. Ford number 113E 7003100 A (Right Hand Drive, zone toughened, or 113E 7003100 B Laminated.
Engine Compartment
Floor, Back Panels and Members
Roof, Windscreen Opening Panel and Rear Package Tray
Note: Headlinings. Two types = Lodestar and Confetti.
The 4-door headlining will NOT fit a 2-door.!
Roof panels are different, so you CANNOT convert a four door car to a two door car by changing the rear quarter panels. Ref: Tommy Sandham. See Four into Two won't go!
Note: The pop rivets used to hold the chrome trim strips on the 1500 Super should now be available from the Club. The rivets are NOT used on some Triumph cars as earlier thought. When fitting new pop rivets put a dab of bitumastic on the rivet head, chrome and the hole in the bodyshell to prevent further corrosion. See Rivets, here.
Note: Headlining. Available from Aldridge Trim. See addresses.
Note: Weather strip available from several sources. See Addresses.
Note: Front windscreen chrome trim MUST be fitted AFTER the rubber and glass is installed.
Note: Screen rubbers available from several sources. See Addresses.
Note: Contact the MK1 Cortina Owners Club as they keep a stock of panels.
Front wings
Headlamp rings
Outriggers (front)
Outriggers (centre)
Lower rear corner repair panels
Sills
Rear valance
Front Valance
Late-type front sidelamp bracket
Inner wing repair panels
front of wing repair panels
lower front of wing repair panels
front chassis crossmember closing panel
Inner sills ???
MacPherson strut towers (cup and legs)
Floor panels (escort ?? LMC ??
Boot floor panels / boot floor extension panel
Spare wheel well
door skins
door skin repair panels
Automec Equipment and Parts Limited, Arden House, West Street, Leighton Buzzard, Bedfordshire. Telephone 01525 375775. (Silicone Brake Fluid, brake pipe kits etc)
Aldridge Trimming, St Mark's Road, Chapel Ash, Wolverhampton, WV3 0QH. Phone 01902 710805/ 710408
Burton Performance Centre Ltd, 631 Eastern Avenue, Ilford, Essex, IG2 6PN. Phone 0208 554 2281
T & J Enterprises, PO Box 1963, Hall Green, Birmingham, B28 9LP, Telephone 0121 777 3386. (Obsolete Lucas specialists)
Vehicle Wiring Products, 9 Buxton Court, Manners Industrial. Estate, Ilkeston, Derbyshire, DE7 8EF. Telephone 0115 9305454
Cortina Spares Unlimited, (Dale Stevenson ) Phone 01509 264550 between 4.30 pm to 8.30 pm. Answering machine at other times.
Classic Components, 01535 635829 (Obsolete Ford parts for 1950s, 60s 70s and 80s)
Earlwood Motor Products, Beaufort Road, Birkenhead, Merseyside, L41 1HE. Phone 0151 652 1572.
Flow Tech Racing Ltd. Phone 01424 772202. Gearbox bell-housings etc..
Ken Tingey, Ford 50 Spares, Phone 01202 679258
London Stainless Steel Exhaust Centre, 251 Queenstown Road, Battersea, London, SW8 3NP, Telephone 0207 622 2120.
Newford Parts Centre, Abbey Mill, Abbey Village, nr Chorley, Lancs, PR6 8DN. Phone 01254 830343.
Weber Concessionaires Ltd, Dolphin Road, Sunbury, Middlesex, TW16 7HE, Phone 01932 788805
Willow Publishing (Magor), Barecroft Common, Magor, Newport, Gwent, NP26 3EB. Telephone 01633 880524
If any-one knows of any other (reliable) source of spares or parts contact me.
Tow bars are available from C.P. WITTER. Part number F24P. (Witter Towbars, Cheshire, 01244 341166
Note: Ford rally Cortinas were initially white. Later they were red, and the official identification of this paint is Ford Venetian Red Number 1. The "number 1" refers to a variant of the red. You must specify the full description when ordering paint.
Note: Oil seals are described with three measurements. These are shaft diameter, outside diameter of the seal, and width of the seal. Look closely at a seal and you should find those numbers. A new seal can be specified from a seal supplier.
When using a compression tester to diagnose engine problems, the following readings should be achieved (at sea level):
| Engine | Compression Reading @ RPM |
| 1200cc | 175 psi @ 400 RPM |
| 1500cc Low Compression | 144 psi @ 450 RPM |
| 1500cc High Compression | 173 psi @ 400 RPM |
| 1500cc G.T. | 179 psi @ 400 RPM |
| 1558cc Lotus (HOT !) | With CR of
9.5 160 psi With CR of 10.3 170 psi (All must be within 20 psi) |
To see how to carry out a compression test, click here
Use the "rule of 9" - take 1 away from 9 and adjust valve 8 as below:
Number 1 fully open -- adjust 8 (exhaust)
Number 2 fully open -- adjust 7 (inlet)
Number 3 fully open -- adjust 6 (inlet)
Number 4 fully open -- adjust 5 (exhaust)
Number 5 fully open -- adjust 4 (exhaust)
Number 6 fully open -- adjust 3 (inlet)
Number 7 fully open -- adjust 2 (inlet)
Number 8 fully open -- adjust 1 (exhaust)
ALL ENGINES
| Rocker gap 1200cc | |
| Rocker gap 1500cc - Not G.T. | Inlet
(cold) 8 thou ( Exhaust (cold) 18 thou ( |
| Rocker Gap G.T. | Inlet
(cold) 12 thou Exhaust (cold) 22 thou |
| Spark Plug gap | 23 thou (see Ford Service supplement) |
| Idling
Speed: G.T. idling speed |
600 rpm 700 rpm. |
| Fan belt tension | 1/2 inch at middle of longest run. |
Valve Clearances: Inlet 10 thou hot, Exhaust 17 thou hot.
Where no setting is given for a particular nut or bolt the following table may provide the answer.
| Nut or bolt size | Torque Wrench setting Lbs feet | Torque wrench setting Kg meter |
| 1/4 inch -20 UNC | 5 - 7 | 0.69 - 0.97 |
| 5/16 inch - 18 UNF | 12 - 15 | 1.66 - 2.07 |
| 5/16 inch - 24 UNF | 12 - 15 | 1.66 - 2.07 |
| 3/8 inch - 16 UNC | 17 - 22 | 2.35 - 3.04 |
| 3/8 inch - 24 UNF | 22 - 27 | 3.04 - 3.73 |
| 7/16 inch - 14 UNC | 30 - 35 | 4.15 - 4.84 |
| 7/16 inch - 20 UNF | 40 - 50 | 5.53 - 6.22 |
| 1/2 inch - 13 UNC | 45 - 50 | 6.22 - 6.91 |
| 1/2 inch - 20 UNF | 50 - 60 | 6.91 - 8.29 |
| 9/16 inch - 12 UNC | 60 - 70 | 8.29 - 10.37 |
| 9/16 inch - 18 UNF | 65 - 75 | 8.98 - 10.37 |
| 5/8 inch - 11 UNC | 75 - 85 | 10.37 - 11.75 |
| 5/8 inch - 18 UNF | 100 - 110 | 13.82 - 15.20 |
MK1 Cortina Owners Club Regalia and Accessories
Key Fobs, Grille Badges, Cloth Badges, Windscreen Stickers, Tax Disc Holders, Sun Strips, T-Shirts, Sweatshirts, Enamel Badges, Books, Mugs, Tin Badges, Jumpers.
Much of the literature relating to small Fords is freely available on the second-hand market. Try second-hand bookshops, autojumbles, www.ebay.co.uk or the owners club magazine. See Bibliography
OILS
| Oil Type/ Specification | Capacity | |
| Engine | SAE 20W/50 or 20W/40 | 1200cc -
4.5 pints including filter 1500cc - 6.5 pints including filter |
| Gearbox | SAE 80 EP Hypoid | 1.75 pints |
| Rear Axle | SAE 90 EP Hypoid | 2 pints |
| Steering Box | SAE 90 EP Hypoid | 0.75 pints |
| Description | Value |
| Castor: | 1° 12' - 2° 42' |
| Camber: | 0° 40' - 2° 10' |
| King pin inclination | 4° 26' - 5° 56' |
| Toe-in | 1/8 inch to 1/16 inch. (1.6mm - 3.2mm) |
| Tow out | on turns (20 degrees at outer wheel) 1° 08' - 2° 38' |
| Model | Front Pressure | Rear Pressure |
| Saloon (Radials) | 24 psi | 28 psi |
| G.T. (Radials) above 80 mph | 26 psi | 30 psi |
| Estate (Radials) | 24 psi | 30 psi |
Main Bearing Caps 55 - 60 lb ft / 7.60 - 8.29 kg m
Big End Bearing Caps 20 - 25 lb ft / 2.76 - 3.46 kg m
Flywheel bolts 45 - 50 lb ft / 6.22 - 6.91 kg m
Crankshaft Pulley 24 - 28 lb ft / 3.32 - 3.87 kg m
Cylinder head bolts 65 - 70 lb ft / 8.98 - 9.67 kg m
Manifold nuts 12 - 15 lb ft / 1.66 - 2.07 kg m
Manifold nuts G.T. 15 - 18 lb ft / 2.07 - 2.49 kg m
Crankshaft rear oil seal carrier 12 - 15 lb ft / 1.66 - 2.07 kg m
Oil pump 12 - 15 lb ft / 1.66 - 2.07 kg m
Oil pump to filter bolt 12 - 15 lb ft / 1.66 - 2.07 kg m
Rocker shaft/Cylinder head 17 - 22 lb ft / 2.35 - 3.04 kg m
Rocker adjustment bolt 10 - 14 lb ft / 1.38 - 1.93 kg m
Sump bolts 7 - 8 lb ft / 0.97 - 1.11 kg m
Sump drain plug 20 - 25 lb ft /2.76 - 3.46 kg m
Camshaft sprocket 12 - 15 lb ft / 1.66 - 2.07 kg m
Camshaft Thrust Plate 2.5 - 3.5 lb ft / 0.35 - 0.45 kg m
Timing Cover bolts 5 -7 lb ft / 0.69 - 0.97 kg m
Spark Plugs 24 - 28 lb ft / 3.32 - 3.87 kg m
Exhaust manifold to downpipe 7 - 10 lb ft /0.97 - 1.38 kg m
Rocker cover set screws 2.5 - 3.5 lb ft / 0.35 - 0.48 kg m
Generator bracket to block 20 - 25 lb ft / 2.76 - 3.46 kg m
Transmission Torque Wrench Settings
Flywheel to crankshaft bolts 45 - 50 lb ft / 6.22 - 6.91 kg m
Clutch to flywheel 12 - 15 lb ft / 1.66 - 2.07 kg m
Clutch bellhousing to gearbox 40 - 45 lb ft / 5.53 - 6.22 kg m
Gearbox drain & filler plugs 25 - 30 lb ft / 3.46 - 4.15 kg m
Gearbox extension to gearbox 20 - 25 lb ft / 2.76 - 3.46 kg m
Gear lever housing 15 - 18 lb ft / 2.07 - 2.49 kg m
Gearbox top cover 15 - 18 lb ft / 2.07 - 2.49 kg m
Mainshaft retaining nut 20 - 25 lb ft / 2.76 - 3.46 kg m
Clutch slave cylinder bleed nipple 5 - 7 lb ft / 0.7 - 1.0 kg m
Prop shaft flange to diff pinion flange 15 - 18 lb ft / 2.07 - 2.49 kg m
Diff carrier to axle housing 15 - 18 lb ft / 2.07 - 2.49 kg m
Rear axle filler plug 25 - 30 lb ft,
Universal joint to rear axle drive pinion 15 - 18 lb ft,
Differential housing to rear axle 15 - 18 lb ft,
Crown wheel to diff case bolts 30 - 35 lb ft ????
Diff bearing locking plate bolts 12 - 15 lb ft / 1.66 kg m - 2.07 kg m
Bearing cap bolts 45 - 50 lb ft / 6.22 kg m - 6.91 kg m
Axle shaft bearing retaining nuts 15 - 18 lb ft / 2.07 kg m - 2.49 kg m
Automatic Transmission Torque Wrench Settings
Drive plate to crankshaft 45 lb ft / 6.2 kg m
Filler tube connector adapter to case 25 lb ft / 3.46 kg m
Filler tube to connector sleeve nut 18 lb ft / 2.49 kg m
Oil pan drain plug 12 lb ft / 1.6 kg m
Pressure take-off point plug 5 lb ft / 0.6 kg m
Starter inhibitor switch locknut 5 lb ft / 0.6 kg m
Support crossmember to transmission casing 12 lb ft / 1.6 kg m
Torque converter to drive plate 40 lb ft / 5.5 kg m
Transmission casing to converter housing 9 lb ft / 1.2 kg m
| Gasket | Payen Reference Number | Comments / Used on other vehicles etc. |
| Cylinder Head | AH 760 | Standard head gasket for 998, 1340 and 1500 pre-crossflow engines. |
| Cylinder Head | AH 270 | For engines with oversize bores up to 87mm. Not included in sets. |
| Head Set | CH 760 | Includes valve stem seals. |
| Conversion Set | EH 760x | Includes oil seals. |
| Manifold | JA 432 | |
| Rocker Cover | JM 364 | |
| Sump | HC 068 | |
| Valve Stem Seals | KH 252 | Set of 8 |
| Water Pump | KA 114 | |
| Timing Cover | JR 265 | |
| Crankshaft Front Oil Seal | NA 576 | |
| Crankshaft Rear Oil Seal | ||
| Front Hub Oil Seal | NA 580 | |
| Rear Hub Oil Seal | NA 470 | |
| Transmission, Manual Front Oil Seal | NA 171 | |
| Transmission, Manual Rear Oil Seal | NA 167 | |
| Transmission, Auto Front Oil Seal | ||
| Transmission, Auto Rear Oil Seal | ||
| Pinion Oil Seal | NA 583 |
| Location/ Description | SKF Bearing Reference | Comments / Ford Part Number |
| Front hubs, inner cone | K 07100SA FX (2 required) | 105E 1201 A |
| Front hubs, inner cup | K 07210X FX (2 required) | 105E 1202 A |
| Front hubs, outer cone | K 03062/4 FX (2 required) | 105E 1216 A |
| Front hubs, outer cup | K 03162/4 FX (2 required) | 105E 1217 A |
| Steering gear | 5/16TH Steel Balls (13 required) | 353081 - S |
| Steering Shaft | 7/32nd Steel Balls (24 required) | 353083 - S |
| Generator, drive end | 6202 FX (1 required) | YE 10094 |
| Water pump spindle | 408949 FX (1 required) | 105E 8530 |
| Clutch withdrawal | 408504 FX (1 required) | 105E 7580 B |
| Constant mesh pinion | 408341 FX (1 required) | 105E 7025 A |
| Mainshaft, front | 3/16TH X 0.527 inch rollers (13 required) | EOA - 7118 |
| Mainshaft, rear | 6305 FX (1 required) | 113E 7065 |
| Layshaft, front and rear | 404553 1/8TH X 3/4 inch needle rollers (40 required) | EOA - 7121 |
| Bevel pinion, cone | K M88043/11 FX (2 required) | 105E 4621 A |
| Bevel pinion, cup | K M88011/15 FX (2 required) | 105E 4616 A |
| Differential, cone | K LM485499X/22 FX (2 required) | 105E 4221 A |
| Differential, cup | K LM48510/22 FX (2 required) | 105E 4222 A |
| Rear Hubs | 407327 FX (2 required) | 105E 1225A |
| Part / Description | Lucas Reference | Notes / Comments |
| Distributor | 40857
40856
40927
???
40953 |
Anglia,
Cortina 1962-1966 (High Compression). Cortina, Classic, Capri, Corsair 1061 - 1966 (Low Compression) Cortina, Capri & Corsair G.T. 1963-1966. Cortina Lotus. Classic, Capri, Corsair (High Compression) 1962-1965 fitted to later cars. (Also fitted to later 5/7cwt vans) |
| Condensor | C1 | C2 used on later Anglia so may be okay. |
| Contact Set | CS1 or CS5 | Lotus used
54413568 CS1 same as Mini, Mini Cooper, etc. |
| Cover Distributor Cap | DC1, DC4 or DC5 | Variously specified at different times ?? |
| Rotor Arm | RA1 (Some Anglias RA2) | Lotus use 54412165 |
| Ignition Coil | CL1 | Some Anglias CL2 |
| Starter Motor | 25083 | |
| Starter Motor Brush Set | BS1 | |
| Starter Pinion and Sleeve | 54252212 | |
| Starter Main Spring | 250404 | |
| Dynamo | 22700 or 22716 | 22716 believed to be High output dynamo (25 amp) used on Capri etc.. |
| Dynamo Brush Set | BS3 | |
| Dynamo Brush Spring Set | 227542 | |
| Control Box | 37542 | 37477 used with High Output dynamo |
| Wiper Motor | not Lucas | |
| Horns | 54068094
High Note, 54068095 Low Note |
Lucas replacements for originals. |
| Flasher Units | FL 51 | |
| Headlamps | 58811 | |
| Headlamp (Sealed Beam ?) | 54521872 | |
| Adaptor or Bulb Holder | 553738 | |
| Plate (??) | 54521913 | |
| Sidelamps | Not Lucas | |
| Flasher Lamps | Not Lucas | |
| Rear Lamps | Not Lucas | |
| Ignition Switch | 34680 34680 |
1962 -1964 1965 - 1966 |
| Starter Solenoid | 76485 or 76495 | Round ? or square ? |
| Stop Lamp (??) | 34542 | Same as Anglia, Classic, Capri, MK2 Cortina |
| Heater | Not Lucas | |
| Dipper | 35980 | Is this
the "late" indicator stalk ?? Not Lucas on 1962-1964 cars. |
| Direction Indicator | 35980 | Is this
the "late" indicator stalk ?? Not Lucas on 1962 - 1964 cars. |
| Bulbs | 643 989 380 382 |
12v, 2.2
watts, single contact, MCC cap, Coil filament (use on
instrument panels) 12v, 6 watts, single contact, MCC cap, Coil filament (used for number plate lamps) 12v, 21/6 watts, Double contact, SBC offset pin cap, Transverse filament (used for stop/tail light, or flasher /sidelight) 12v, 21 watts, single contact, SCC cap, Transverse filament, (used for sidelights)?? |
| Wiper Arms | WA 9 | 1962-1965 all models (Same as Classic, Capri, Corsair, 1969 1100s, Maxis, Morris 1800 etc. |
| Wiper Blades | WB 7 54701324 |
1965 - 1966 Cortina G.T. |
| Fog and Spot Lamps Brackets | 23 FB 38 FB |
(Above
bumper) Ordering number 54052464 (Below bumper) Ordering number 60084009 "D" |
| Batteries | 3AB9-8-85 or AB11/13-8-85 | Same as Classic, Capri, Cortina, Corsair and Anglia. |
| Air Filters | Crossland 806 ?? | |
| Oil Filters | Crossland paper 505 | Same as Anglia, Prefect, Classic, Capri, in-line Corsair, Ford Commercial 5/7cwt |
| Thermostats | LT1 Normal
type LT2 Heater type |
LT1 same as Mini, etc |
| Radiator Filler Caps | LC 18 (Lucas Number) | RC 18 AC Number |
| Spark Plugs (all cars except Escort Twin Cam and Lotus Cortina 1960-1969 | N9Y | From Lucas catalogue. See SPARK PLUGS |
| Spark Plugs Escort Twin Cam and Lotus Cortina 1962- 1969 | N6Y | From Lucas catalogue. See SPARK PLUGS |
| Fan Belts | LV 939
(Lucas / Ferodo Number) also listed as V 939 ** V 4999 V 4920 |
Anglia,
Prefect, Capri, Classic, Corsair (not V4), Cortina
(including Lotus) and Escort (not Twin Cam) RAYBESTOS
Number R 308, MINTEX number WFT 292 1965 -1966 Cortina with Lucas Alternator 1965 -1966 Cortina G.T. with Lucas Alternator |
V 939 specification is 13/32nd top width, inside circumference 27-3/8th inches, outside circumference 29-17/32nd inches, thickness 11/32nd inches, angle number 40.
Note: I have a large file of Lucas cross-reference data between old and new part numbers. It is too large to include on the web-site, so please ask if you need help.
Click here to see all the alternator conversion data. I've moved it to its own file!
Reprinted from the Cortina Owners Club Magazine, - July 1999 with kind permission from Mike Jordan.
Distributor
The parts required are very popular with people so be prepared to search.
Here goes with the ingredients and the method;-
Ingredients
1. Distributor off a late MK2 Fiesta or MK4 Escort. It must be the O.H.V. version and will have a flat box approximately 2" x 3" stuck on the side of it with a three-spade socket.
2. This socket should have a plug attached to it with three wires (red, green and black), you need this with about 6" of wire.
3. Coil off the same car. It is an electric coil and differs from what you have on the MK1.
4. Both LT wires off the coil as they will be round terminals that you push on, again get about 6".
5. Cap and rotor arm if you are lucky and any plug leads.
6. Clamp off the bottom of the distributor.
NOTE: The distributor is in exactly the same position as on our cars and is held using a 10mm bolt. Do not damage the box on the side of it, that is instead of the dreaded points and is crucial.
Method
1. Car on level ground, all electrics off and handbrake on, gears in neutral.
2. Disconnect the battery (earth first), and remove it from the car.
3. Remove distributor having set it to fire on number 1 cylinder etc. as per manual.
4. Disconnect and remove the coil from under the battery shelf.
5. Bolt on the electronic coil noting the + and - terminals on it.
6. Fasten the distributor as per the old unit.
7. Disconnect the dynamo leads and pull out of harms way.
8. Now plug in the plug on the side of the distributor and prepare to concentrate.
9. Wiring up;-
- Green plug goes to - ve on the coil.
- Red plug goes to earth. Fasten in with coil retaining bolt.
- Black lead goes to the white loom lead and then to the +ve on the coil. That means joining the white loom lead to the +ve lead from the coil and the black lead from the plug.
10. Connect the HT leads as per normal.
11. Now reconnect the battery earth. THIS MUST BE THE NEGATIVE TERMINAL AS THIS IS HOW YOU WILL HAVE TO RUN NOW SO IF YOU HAVE A RADIO SORRY IT WILL HAVE TO COME OUT OR BE CONVERTED.
12. Next connect up 2 feet of ordinary cable to the +ve terminal and carefully stoke the other end on the small terminal of the dynamo a couple of times. This converts the dynamo to run on -ve earth, you will see a small blue spark.
13. Remove the wire from the +ve terminal.
14. Reconnect the dynamo.
15. Double-check all that I have said.
16. Connect the +ve terminal on the battery and fire it up.
17. Adjust the timing as per normal dependant on model.
NOTE. Some plugs on these distributors use different coloured wiring, seek advice as I cannot help with the wiring up. Please read through this so you fully understand what's involved and it has to be negative earth.
The Club is endeavouring to supply new standard units so the choice is yours. This is a cheap way of overcoming a problem that will only get worse with time.
FOOTNOTE: Mike advises that the spark plug gap may need more frequent adjustment; probably because of the much improved spark ! Tick-over is also noticeably better.
Click here for up-to-date information on the conversion, plus wiring diagrams!Click here for Timing with a Strobe-Light text
Information supplied by Graham Chapman QLD Australia
| Part | Australian ACL Part Number | Comments/ Notes |
| Piston Rings | C1540 or PS1540 | |
| Piston Assembly | RY 2197 | |
| Piston Kit | 4 KRY 2197 | |
| Valve Guides | IN & EXH VG 554 | |
| Con-Rod Bearing set | 4 B 1043 4 - 2785 CP |
|
| Main Bearing set | SM 2152 4249 M |
|
| VRS Gasket Set | CH 760 | |
| Conversion Gasket Set | EQ 920 | |
| Oil Pan Gasket | HC 251 | |
| Rocker Cover Gasket | JM 364 | |
| Thrust Washer Set | 1 T 2152 2786 BF |
Note: no info about sizes ?? |
| Cam Bearing Set | 3 C 330 1459 M |
|
| Small End Bearing | RB 902 | |
| Valve Stem Seals | HR 257 | |
| Manifold Gasket | Standard
JA 408 GT JA 432 |
|
| Bearing Seal Set | HN 015 | |
| Timing Cover | HG 015 | Is this the bearing ?? |
| Pistons | AE parts 18400 or 18400 VI Federal Mogul 12365 PR | |
| Piston Rings | AE Parts R
16106 Federal Mogul R 16106 |
|
| Pin Bushes | 4-2784 Y | |
| Inlet Valve | Standard S
1746 GT S 1746 |
?? |
| Exhaust Valve | Standard K
1681 GT K 1763 |
|
| Timing Chain | 38 R 46 | |
| Timing Chain Tensioner | TT 1088 | |
| Head Gasket | Standard
Ch 760 GT CH 761 |
Click here to return to the Welcome Page