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Old 10th May 2019, 15:32   #81
ricebridge
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AFAIK, the DMGRS is original. I just ordered a couple and they were the green ones alright.

On a side note, originals may not always be the best choice. Elsewhere on the forum, the original gaskets have been slammed for being of poor quality and quite frankly I believe that when examining them closely. I chose to add a thin layer of aluminium paste before fitting them (not copper paste as that will interfere with the aluminium parts) and hopefully that'l make them last longer.
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Old 13th May 2019, 18:15   #82
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There are a few green marks on the mating serface's of the head and manifold.

Tried some spirt, but won't all come off.

Should I use a blade from a Stanley knife?

Or maybe a razor?
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Old 13th May 2019, 18:43   #83
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Scraper or Stanley Knife will do fine. Maybe use the the blade only.
You are likely to cut yourself with a a razor blade
How did the gaskets look??
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Old 11th June 2019, 02:39   #84
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I am at the reassembly stage of a T-stat replacement on my new-to-me ZT190.
Having had a manifold gasket fail on my KV6 Freelander sending a jet of coolant across the vee I decided to replace the gaskets. I can vouch that the green gaskets with the silicone tracks are the factory gaskets.
I reached the stage where it's time to re-install the plenum and also discovered a mystery plug. This must be the same one as described before. I have wasted an hour trying to find where it goes and am relieved to find out it may be for non-existent traction control.

Kaiser, can you verify that this plug is the same as my mystery plug please? Mine has a very nice right angle boot stamped with BMW molded onto a cable.
I will post a pic here when my photo hosting site is back up.

I do have to say the later type intake manifolds (for engines with 6 pencil coils) are much easier to re and re. They lack the cast in webs that make it more difficult to get a straight shot at the bottom manifold mounting bolts.
Has anyone converted to the later coil system?
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Old 11th June 2019, 05:47   #85
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Quote:
Originally Posted by Rich in Vancouver View Post
I am at the reassembly stage of a T-stat replacement on my new-to-me ZT190.
Having had a manifold gasket fail on my KV6 Freelander sending a jet of coolant across the vee I decided to replace the gaskets. I can vouch that the green gaskets with the silicone tracks are the factory gaskets.
I reached the stage where it's time to re-install the plenum and also discovered a mystery plug. This must be the same one as described before. I have wasted an hour trying to find where it goes and am relieved to find out it may be for non-existent traction control.

Kaiser, can you verify that this plug is the same as my mystery plug please? Mine has a very nice right angle boot stamped with BMW molded onto a cable.
I will post a pic here when my photo hosting site is back up.

I do have to say the later type intake manifolds (for engines with 6 pencil coils) are much easier to re and re. They lack the cast in webs that make it more difficult to get a straight shot at the bottom manifold mounting bolts.
Has anyone converted to the later coil system?
I cannot verify anything, because I cannot remember how it looks, and it is years since I was there! But I might well have written about it sometimes and I certainly remember there was a spare plug, somewhere near the ABS module/battery area. I think this plug is there at all times, and if you have no TC, it just lies there with no purpose.
So if you have no TC, expect at least one spare plug!
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Old 11th June 2019, 12:10   #86
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Thanks, thats reassuring. The plug certainly looks like it is part of a system. The photo hosting site I use is back up so I will add the pic to this post.
I will finish assembly and see if it starts and runs.
Fingers firmly crossed!

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Old 11th June 2019, 12:24   #87
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Why don't you post a pic of the engine. I am having a look at the one inlet manifold, and it does not look like what I remember, if I am right. (Unless that is a rubber pipe in front and not a shadow?.)
Is that the new? pencil coil unit you were mentioning.?
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Old 11th June 2019, 12:55   #88
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Quote:
Originally Posted by Rich in Vancouver View Post
The plug certainly looks like it is part of a system.
I've got one of those Rich. According to RAVE it's the connector for the secondary TP (Throttle Position) sensor which I believe is used for traction control.

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Old 12th June 2019, 03:07   #89
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Thanks everyone! The plug was redundant and now the car is back together and running well with no leaks. I am happy now!
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Last edited by Rich in Vancouver; 12th June 2019 at 03:12..
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Old 31st October 2021, 10:02   #90
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Just thought I'd add my experience (as a debutant) of the keyhole method.
First of all, thanks to Canonite and others for all the useful info on this subject.


Had a bit of bother removing the filter box but by levering against the battery box, it came out ok.
Next snag was removing the battery box. The rear two torx screws came out ok but the front two were stuck. My torx bits are part of a 1/4" drive socket set and I could feel the extension bar twisting. Luckily, I had a 1/4" to 3/8" adapter and removed them with the 3/8" wrench.
Throttle body removed ok but then I had to nip out and buy a pair of snipe nosed locking pliers to release the hose clips.
https://www.toolstation.com/irwin-vi...-pliers/p51419
Now, hats off to others who have been able to get their hands in there with a wrench to undo the mounting bolt but no way I could do it. Maybe you have to remove the engine lifting bracket ?
Anyway, using the 1/4" socket set with extensions and universal joint, I was able to reach the bolt through a gap in the manifolds.


In the picture below you will see the 1/4" drive taped together with masking tape to stop it falling apart in use.Other items include a miniature inspection light to see what you're doing and various bits of bent wire to help guiding the socket onto the bolt. The magnetic retrieval tool and/or grabber came in useful when inevitably you drop something into the "V" .
The curved tube came ok as did the main thermostat body and greasing the seals on the new item with Vaseline, ensured a(relatively) easy installation.
Later, I cut the old unit open and dropped the element into a pan of boiling water and sure enough, it didn't move.
For me, this was a very tricky job but got there in the end
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