Replacing KV6 Thermostat - (Keyhole Method)

[SD1too]

Originally Posted by Mgaz

Cheers! Makes sense.

Thanks Gareth!

PM sent.

Simon

[Mgaz]

Okay.. so I've been unsuccessful in fitting the thermostat with the keyhole method and I've ended up trying to remove the inlet manifold.

The thing I'm stuck on now is trying to disconnect the fuel rail from the metal pipe on the left hand side.

Though I might have enough room leavering up the inlet to get In there now?

[kaiser]

The fuel line is held in place and sealed by a small O-ring, sitting on the end of the metal pipe. The metal pipe is pressed against the O-ring while a metal holder is pressed over the pipe, locking it in place against a plastic stop.
The loosen the rail, you gently press the ss pipe against the O-ring and pull/lift the metal "fork" out. Don't loose the holder or the O-ring.
You might have to do this both ends of the ss pipe. Be careful all plastic parts are brittle, and there can be residual pressure in the fuel line.

[vitesse]

Done a few KV6 thermostats now and learnt a few lessons. I no longer even attempt at disconnecting the fuel rail between the inlet manifolds, just lift out the two sections carefully with the fuel rail attached having previously disconnected the long fuel pipe at the clip union behind the battery.

Regards

[Mgaz]

Originally Posted by vitesse

Done a few KV6 thermostats now and learnt a few lessons. I no longer even attempt at disconnecting the fuel rail between the inlet manifolds, just lift out the two sections carefully with the fuel rail attached having previously disconnected the long fuel pipe at the clip union behind the battery.

Regards

So you're saying remove both inlet manifolds?

Quick question :

What torque wrench setting should be used to tighten the manifolds back up?

Or doesn't it matter too much?

[vitesse]

Yes, remove both, replace both paper gaskets and try to make them waterproof, I use a smear of hylomar, Kaiser uses paint. The gaskets are cheap, and having to replace them at a later date due to leaks is not much fun.

Haven’t used a torque wrench but tried to achieve an even tightening sequence by diagonally tightening and final tightening using fingertip pressure.

Regards

[SD1too]

Originally Posted by Mgaz

The thing I'm stuck on now is trying to disconnect the fuel rail from the metal pipe on the left hand side.

As Vitesse says, you only have to disconnect the fuel supply hose connector from the fuel pipe at the back of the engine bay above the plastic manifold chamber. Leave the connection above the LH bank alone.

Originally Posted by Mgaz

So you're saying remove both inlet manifolds?

You only need to remove the LH bank manifold for good access to the plastic components.

Originally Posted by Mgaz

What torque wrench setting should be used to tighten the manifolds back up?

25 Nm, working progressively from the centre outwards.

Simon

[Mgaz]

Cheers for all the advice so far

I'm currently looking for inlet manifold gaskets and I see there are two different types on offer.

A black one like the ones sold by DMGRS or a green type like I have on the car already.

Also noticed a different shape black one on ebay. *

So other than the difference in shape/size and colour, are there any other reasons for the differences?

DMGRS black:


EBAY black with a different shape.


EBAY GREEN: (Like I have on my car)

[SD1too]

Review post no. 69 Gareth:

Originally Posted by SD1too

I've never had any problem with the inlet manifold gaskets on my engine .... I always renew them using a genuine MGR part ...

Don't take risks with this part, particularly with those of unknown origin via e-bay.

Genuine inlet manifold gaskets available from Rimmer Bros. here.
Type LKJ100992 into Google and you'll find alternative suppliers. I can recommend E Car Parts Ltd in Sandy, Bedfordshire.

Don't forget to treat yourself to a torque wrench so that the gasket can seal the joint as designed.

Simon

[Mgaz]

Originally Posted by SD1too

Review post no. 69 Gareth:

Don't take risks with this part, particularly with those of unknown origin via e-bay.

Genuine inlet manifold gaskets available from Rimmer Bros. here.
Type LKJ100992 into Google and you'll find alternative suppliers. I can recommend E Car Parts Ltd in Sandy, Bedfordshire.

Don't forget to treat yourself to a torque wrench so that the gasket can seal the joint as designed.

Simon

Cheers! Though DMGRS website states theirs are genuine MGR part too.

And I could combine postage on a few other bits I need?