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Old 16-07-2010, 21:13   #1
davidjames84
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Default repairing inlet manifold kv6

hi guys
i remeber seeing a thread about reparring or even removing the butterflies in the inlet manifold on the kv6 as my zs 180 needs a new one and was thinking of trying to repair it.
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Old 16-07-2010, 22:00   #2
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Default Re: repairing inlet manifold kv6

Can't recall anyone repairing an inlet manifold.
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Old 16-07-2010, 22:04   #3
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Default Re: repairing inlet manifold kv6

Don't do anything too drastic. Replacement power valve operating arms will soon be available.
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Old 16-07-2010, 22:25   #4
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Default Re: repairing inlet manifold kv6

Quote:
Originally Posted by sheddist View Post
Don't do anything too drastic. Replacement power valve operating arms will soon be available.
I remember you saying you were close to producing a replacement but couldn't find your post.lol
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Old 17-07-2010, 01:03   #5
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Default Re: repairing inlet manifold kv6

Quote:
Originally Posted by sheddist View Post
Don't do anything too drastic. Replacement power valve operating arms will soon be available.

I currently have a rattling plenum in a cupboard awaiting the release of this
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Old 17-07-2010, 11:30   #6
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Default Re: repairing inlet manifold kv6

shredist how long do you think this will be untill its ready? i have a leaking thermostat and i have to take the inlet manifold off to do it so i thought id do it in one lot.
also do you think there would be a big power increase?
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Old 18-07-2010, 21:40   #7
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Default Re: repairing inlet manifold kv6

First one is ready



The arm is plated steel with modified spherical ball joints. A plastic part connects the arm to the motor.

Each spherical joint has some adjustment in the arm and is secured with a nut clamping the arm between washers.



The whole assembly is designed not to fall apart. steel locknuts are used and split pins stop the nuts coming off the end of studs and to lock studs into the spherical coupling.
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Old 18-07-2010, 21:50   #8
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Default Re: repairing inlet manifold kv6

Great stuff, Looks much more substantial! If only as much effort had gone into developing the plenum in the first place!!

Any idea when they will be available?
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Old 18-07-2010, 21:51   #9
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Default Re: repairing inlet manifold kv6

oh brilliant
looks much much better than the standard one!
when would i be able to get my hands on one and have you a rough price for them yet?
is it a exhance basis?
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Old 18-07-2010, 22:02   #10
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Default Re: repairing inlet manifold kv6

You sir are a legend.

Have you had it running yet?
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Old 18-07-2010, 22:04   #11
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Default Re: repairing inlet manifold kv6

i want one now / with reconditioned vis motors then i know ill have 100% issue free zs
plus if this is any where near as good as his clutch mod then its a must buy even if your inlet works fine
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Old 18-07-2010, 22:21   #12
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Default Re: repairing inlet manifold kv6

All very well, but how are you going to seal the plenum, since this is the real issue other than the butterfly mechanism?
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Old 18-07-2010, 22:49   #13
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Default Re: repairing inlet manifold kv6

prob something like tiger seal cant be that 5h1t
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Old 18-07-2010, 23:00   #14
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Default Re: repairing inlet manifold kv6

Quote:
Originally Posted by roverdave View Post
prob something like tiger seal cant be that 5h1t
Tigerseal or sikaflex wont work!
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Old 18-07-2010, 23:10   #15
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Default Re: repairing inlet manifold kv6

Looks like what my Z needs, how do I get my hands on one?
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Old 19-07-2010, 00:57   #16
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Default Re: repairing inlet manifold kv6

Quote:
Originally Posted by KevG View Post
Tigerseal or sikaflex wont work!
plastic weld would
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Old 19-07-2010, 12:31   #17
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Default Re: repairing inlet manifold kv6

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Originally Posted by dave mgt View Post
plastic weld would
Ultrasonic plastic welding would too.
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Old 19-07-2010, 12:47   #18
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Default Re: repairing inlet manifold kv6

Sheddist...

How much and when can I get them? I assume if your building them you require the old units in exchange?

Either way I need two! I have one 180 that the mani has completely gone in and other on its way out!
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Old 19-07-2010, 13:11   #19
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Default Re: repairing inlet manifold kv6

a major issue is opening the manifold in the first place!!

Wouldn't that be too heavy for the vis? the original arm weights nothing at all, and with no support on the far end from the vis I'd have thought you would start to get issues?
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Old 25-07-2010, 21:42   #20
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Default Re: repairing inlet manifold kv6

Quote:
Originally Posted by sheddist View Post
Don't do anything too drastic. Replacement power valve operating arms will soon be available.
Thats great news Sheddist,could we have a price and availability when your ready to start supplying, as i think many of us need this fantastic upgrade ! well done keep up the good work. PS i also need a clutch kit as well..
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Old 25-07-2010, 22:50   #21
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Default Re: repairing inlet manifold kv6

Thanks for the interest in this.
At the moment, replacement arms are on offer at £67. I know this is not "cheap", but a lot of work goes into each one and the parts are not cheap. But it is around 10% of the price of a new plenum.

With respect to exchange plenums. This is something I do not have the time for, also this carries some risk as what if on splitting, the cover moulding is broken or it will not seal etc. If I cannot fix it or there is a delay, then you car cannot be driven. Not a responsibility I am prepared to take. Perhaps someone on here has the inclination and time to take this on.

So, what is proposed is this:
Order an arm. This will be assembled and a shipping date given - Car is OK to drive with a rattly plenum.

As with clutch kits, you will be notified when an arm is available and payment will be requested. Not before.

Hopefully you will be able to split the plenum, replace the arm and seal it up again- Perhaps plenum splitting and resealing techniques will form a good thread on here.

If you are unsuccessful in splitting and resealing your plenum then you can return the arm for a £47 refund.
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Old 26-07-2010, 12:39   #22
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Default Re: repairing inlet manifold kv6

I am defiantly interested. Do you have a recommended method of spitting the cover moulding? Thanks.
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Old 01-08-2010, 18:23   #23
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Default Re: repairing inlet manifold kv6

Any update on the avalibility of these sheddist?
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Old 02-08-2010, 12:05   #24
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Default Re: repairing inlet manifold kv6

So could this fix the noisy rattling my car has lol (visís are ok)
The only problem is I donít have the mechanical experience to split fix and seal it back up sheddist is this something you could do as I would probably try re seal it with some good old spit lol. or could you sell a manifold with this mod already done?
I desperately need this rattling fixing I am being called the local yella tractor at the moment I am loosing my street cred every gear change lol
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Old 11-08-2010, 22:43   #25
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Default Re: repairing inlet manifold kv6

will definately be wanting one of these when available...any updates??
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Old 12-08-2010, 07:14   #26
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Default Re: repairing inlet manifold kv6

WE ARE NOT WORTHY ! A GENIUS ! Bandit123 Mr Sheddist has answered all of your questions in his last post.
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Old 12-08-2010, 18:33   #27
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MG Re: repairing inlet manifold kv6

Ditto

I have Sheddist's clutch kit - 3 years + now and not a single issue. I too would like this mod and I think £67 is very reasonable for the clear effort that has gone in + we should all support this type of effort anyway - its in every KV6 owners interest. Grand work Nigel.

Count me in please - it would just be real nice if we could organise a garage/mechanic willing to do the fit. Many of us (me included) do not have the time and/or skill to complete this so we need the fitting option as well to really make this mod run. Also a good cross sell for the fitter would be a VIS check and repair at the same time. Seems logical to me and everyone will need it at some stage.

If something gets organised please give me a PM - cash waiting.

Paul
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Old 13-08-2010, 08:12   #28
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Default Re: repairing inlet manifold kv6

The holes evident in the casing. Tell me, are these where the two halves are screwed together or is it not so simple as that?
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Old 27-09-2010, 16:17   #29
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Default Re: repairing inlet manifold kv6

Read this with great interest as my manifold is now rattling and cant afford a replacement and dont mind getting my hands dirty so would be interested when they are ready well done
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Old 01-10-2010, 16:36   #30
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Default Re: repairing inlet manifold kv6

Has anyone done this replacement yet? looking into this as i for sure will have one in the near future.
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Old 13-10-2010, 14:47   #31
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Default Re: repairing inlet manifold kv6

Quote:
Originally Posted by nath86 View Post
Has anyone done this replacement yet? looking into this as i for sure will have one in the near future.
Not as far as im aware, I have a spare plenum awaiting release of parts!! Least then if I screw it up for any reason the car is still mobile, as mine is rattling
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Old 13-10-2010, 15:38   #32
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Default Re: repairing inlet manifold kv6

Its a pity that you technical guys havn't come up with a way to split and glue the plenum yet.
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Old 13-10-2010, 16:41   #33
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Default Re: repairing inlet manifold kv6

What's the issue with splitting the plenum? Is it just to ensure that you don't break either part?
As for resealing, what type of plastic is it?
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Old 13-10-2010, 19:24   #34
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Default Re: repairing inlet manifold kv6

From what i have read its like splitting a atom lol and if you break the cover your rooted. As for the plastic cant help there
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Old 16-10-2010, 08:49   #35
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Default Re: repairing inlet manifold kv6

I suspect that the plastic is ABS so should work with plastic weld or similar.

I'm very interested in one of these kits. I took the plunge and bought a new manifold (£440) in mid 2009 (build date 2008) and had it fitted along with replacing the leaking thermostat and a new water pump just over a year ago. Fitted a set of VIS indicators and an oil catch tank and was happy with the result.

I will pull the old manifold apart as soon as I get a chance and see what the damage is. It had done about 45000 miles. If I get it apart successfully I'll be on the waiting list for a new actuator kit.

I did get the old balance VIS motor apart and fixed a burnt out PCB track and secured the microswitches (use nylon screws/nuts to avoid any shorting problems), but haven't yet got the butterfly VIS motor apart (contacts well and truly stuck to the casing). At least I have one spare if I need it.

Unfortunately since then the manifold has started to rattle, and lately the VIS indicators have been giving very strange indications. Both LEDs are green at start-up, but after giving it a bit of welly both change to red as expected but on lifting off the balance valve remains on red and green lights up as well (how is that possible?) and the butterfly valve green LED flicks on then off again. On steady driving after that I have balance valve red and green and butterfly valve nothing at all. It may revert to a different pattern if I give it welly and lift off again, but generally it's as described.

Weird, and expensively annoying.
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