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.
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.
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,
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
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.
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.
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.
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
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!!
