Stainless steel manifold Zetec E

Here's a "How-to" mount the Focus Stainless steel exhaust manifold on the mondeo Mk1 2.0 Zetec E engine

1. Remove the cat. 2 nuts rear and 2 in front. [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/IMG_1898.jpg[/IMG] 2. Remove the old cast iron manifold (11 nuts). [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/IMG_1900.jpg[/IMG] 3. Clean the head with sandpaper around the Exhaust ports. [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/IMG_1905.jpg[/IMG] 4. Test mount the manifold and realize it don't fit the silvertop. 5. Cut the pipes right before the bend. 6. turn the bend towards syl. 1 and weld them together, you'll need to figure out how on your own, as you see I cut parts of 2 pipes and welded the remaining then I cut new parts to fit in the other two and welded them in place [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/IMG_1909.jpg[/IMG] 7. Cut of the pipe after the bend and weld on the supplyed pipe with a bend as seen here so that the bend goes around the corner of the oil sump like the original pipe [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/pipe.jpg[/IMG] 8. Fit the rest of the pipes to your own likeing and weld it up good. [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/IMG_1920-1.jpg[/IMG] 9. You will need to either re-route the water pipe that runs over the original manifold, will update when done, for now i just spaced it with some copper tubes and a old hose. [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/IMG_1912.jpg[/IMG] [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/IMG_1918.jpg[/IMG] 10. Weld a bolt into the little pipe going from syl. 2 to EGR... [IMG]http://i678.photobucket.com/albums/vv142/Morbidos/IMG_1906.jpg[/IMG]

Tip: water test the welds by filling the parts with water.