Instruction Sheet No.A2054-477

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Part Number 57-0156
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INSTALLATION INSTRUCTIONS

Parts list:

1 x Air Filter. 1 x Flexi Cold Air Hose. 1 x Rubber Intake Hose. 1 x Literature Pack. 1 x Fixing Kit :1 x Studded Rubber Mount. 2 x M6 Hex Nut. 2 x 6mm Spring Washer. 2 x M5 Nylock Nut. 2 x M5 button Head Bolt. 2 x 5mm Spring Washer. 2 x Long Plastic Tie. 1 x Short Plastic Tie. 1 x #40 Hose Clamp. 1 x #44 Hose Clamp. 1 x Short Angled Bracket. 1 x Long Bracket. 1 x Plastic Breather Tube. 1 x #8 Hose Clamp. 1 x #60 Hose Clamp.
Ford Escort 1.6L & 1.8L 16v Zetec 1992-96 Ford Fiesta 1.6L & 1.8L 16v Zetec 1992-95
Unclip & remove the breather hose from the air box base. (Fig. 1) Unclip & remove the intake hose from the MAS. (Fig. 2&3) Remove the two nuts securing the plastic intake pipe to the engine & remove the securing clamp. (Fig. 4) Pull the plastic intake pipe from the throttle housing & carefully remove the intake pipe / hose assembly from the vehicle. (Fig. 5) Bend the intake pipe securing stud / bracket down using a pair of pliers. (Fig. 6) Unbolt & remove the engine lift bracket. Unclip & remove the electrical harness connector from the MAS (Mass Air Sensor). (Fig. 7) Unbolt & remove the air box assembly from the vehicle. (Fig. 8&9) Carefully unscrew / unclip the MAS from the air box lid. (Fig.10) Secure the short angled bracket to the thermostat housing using the original bolt. (Fig.11) Attach the studded rubber bobbin to the angled bracket using a spring washer & nut supplied. Secure the long bracket (single hole end) to the rubber bobbin using a spring washer & nut supplied. (Fig.12) Secure the slotted hole on the MAS to the two holes on the mounting bracket using the dome head bolts, spring washers & nylock nuts supplied. (Fig.13) Secure the large end of the new rubber intake hose to the throttle using the #44 hose clip supplied. (Fig.14) Secure the small end of the intake hose to MAS using the #40 hose clip supplied (Ensure sufficient clearance between the intake hose & cam cover). (Fig.15) Fit the new air filter onto the MAS & firmly tighten the clip supplied (Ensure that the K&N logo on the lid is straight). (Fig.16) Reconnect the electrical harness plug to the MAS. (Fig.17) Insert half of the plastic adaptor into the end of the breather hose & secure using the #8 hose clip. Insert the other half of the adaptor into the small hole in the base of the air filter. (Fig.18) Carefully lengthen the flexi cold air hose, feed the hose down to the lower grille & secure using the plastic ties supplied. (Fig.19) Secure the top of the hose to finish approx 10cm / 4 from the air filter using a plastic tie supplied. (Secure the hose away from the gear selector / clutch lever). (Fig.20) Carry out a final check of the height / alignment of the K&N induction system before starting the engine. Installation is now complete.
WARNING: Before starting the engine carry out a final fitment check of the K&N performance kit. It will be necessary for all intake systems to be checked periodically for realignment, clearance and tightening of all connections. Failure to follow the above instructions or proper maintenance may void the warranty.

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