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PostPosted: Mon Aug 11, 2008 6:59 pm 
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Location: Norwich
Drives: 2litre Si
Fitting a Ashley Tubular manifold to 1994 Fiesta Si 2 litre Zetec.

Firstly the new Ashley manifold i brought would not fit with the longer BOSCH starter motor which is 193mm long from mounting flange face. I needed to swap to alternative shorter one on right, I think it’s a AC Delco only markings it had was made in Italy.
I have emailed Ashley direct and they do say they offer a alternative downpipe which will miss the larger starter so worth checking with them first.
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Firstly in good Haynes manual tradition disconnect the battery then undo the Lamba sensor, Remove the cross member/exhaust hanger, existing down pipe/catalytic converter and cast iron exhaust manifold, I was worried about undoing the manifold stud bolts as appeared corroded, but cleaned the threads with a wire brush and WD40 and then noticed they were bronze nuts and came undone easily.

Remove the starter motor and unplug the flywheel trigger sensor, fit the manifold from underneath it’s a tight fit but mine just went in with the manifold at an angle with the outlet over towards the alternator.
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At this stage fit new manifold gasket and just hang the new manifold on the studs before bolting up refit the starter motor (I couldn’t get it back in once the manifold is fitted) and plug back in the flywheel trigger sensor. Tighten up manifold evenly. and refit the Lambda sensor

Install the 2 into 1 collector onto the manifold down pipe being careful to support the manifold as it was a tight fit and all the pulling and pushing you are doing is levering against the manifold studs, I packed the manifold out against the front cross member with wood to temporarily brace it.

Once the manifold and collector is fitted, it would not connect up directly to the existing stainless exhaust system,
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I measured up the pipe diameters (internal on exhaust, external on manifold) and overall length required allowing extra for sleeving and ordered a purpose made flexi pipe connector from http://www.xtremestainless.co.uk/
The manifold to exhaust needs some form of flexible connection rather than a solid pipe to allow for engine movement, which was done by the spring cone connector to the standard cast manifold.
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With the exhaust all connected up, started the engine up with no blowing but lots of smoke of the paint on the manifold as it heated up.

Last job to do was refit the cross member, I had to remove the original catalytic converter hangars. And notice that the collector now sits directly on the cross member and will require a further support bracket to avoid it knocking.
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I made a basic support cradle with a 8mm stud and elongated one of the existing holes so it sat in the centre of the pipes to keep it of the cross member.
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i will add a revised photo when the manifold is re-fitted as ive just had to take it all off again to re-fit the cat for the MoT which is something to considder

just refitted the manifold and lot easier 3rd time in less than 2hours laying on the drive! Picture of exhaust manifold cradle fitted
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Hope its of help it was not a straight bolt on job, however it may have been simpler if you are fitting the complete Ashley manifold and system as im sure they would be made to fit together!!

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Last edited by will121 on Sat Jan 08, 2011 11:07 pm, edited 2 times in total.

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PostPosted: Wed Aug 13, 2008 12:25 am 
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i think you have the wrong manifold there... it looks like hte kit car one as opposed to the direct fit one :doh:

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PostPosted: Wed Aug 13, 2008 1:12 am 
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Im sure Happypaul had to weld a bit in as well! :doh:

Good guide though! :thumbsup:

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PostPosted: Fri Aug 15, 2008 10:49 pm 
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Top guy helped me loads with my manifold problems in the end used Fiesta rs turbo starter motor, Its a good inch smaller than the fiesta si one so if any one else has problems finding a starter motor the turbo one does fit an works perfect.

good guide mate cheers for all the help:thumbsup


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PostPosted: Sun Aug 17, 2008 10:18 pm 
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any fwd cvh starter will do the trick
mk4 escort, mk5 escort etc etc

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PostPosted: Sun Mar 15, 2009 10:12 pm 
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Location: newcastle upon tyne weyaii man
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How much do cvh starter moter's cost :hmm:

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PostPosted: Thu Apr 16, 2009 11:07 pm 
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Just followed this guide to fit one on mine. Didn't need to make a bracket though because for some reason the collector clears the S-brace by almost an inch. The mid-section of the exhaust is a bit low though.

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PostPosted: Sat May 02, 2009 10:04 pm 
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Tweek wrote:
Just followed this guide to fit one on mine. Didn't need to make a bracket though because for some reason the collector clears the S-brace by almost an inch. The mid-section of the exhaust is a bit low though.


:shock: you lucky bugger.. mine used to sit on the s brace.. havent bothered putting the s brace on the pickup due to it :red: :lolz:

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PostPosted: Sat May 02, 2009 10:06 pm 
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Well, I ended up having to get a bracket welded for the back of the midsection cos it was so low so that made up for it lol.

I did try the W-bracket for the s-brace but it just made it rattle :lol:

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PostPosted: Sat May 02, 2009 10:34 pm 
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Tweek wrote:
Well, I ended up having to get a bracket welded for the back of the midsection cos it was so low so that made up for it lol.

I did try the W-bracket for the s-brace but it just made it rattle :lol:


Yeah I never even bothered with it when it was on my RS

I'll rather live without the S brace than have vibrations and rattling again, I get enough of that from the rest of the exhaust as its too big of a bore :rolleyes: :lolz:

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