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Old 12-20-2002, 15:12   #1 (permalink)
rastan
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carby help needed

-- short version--

Does anyone know where I could get any information-help-tips on cleaning out a carby ? specifically one from an XF falcon ? Is it hard-easy etc... ?

-- long version --

We needed to replace the welsh plugs in my mates XF falcon (non EFI), and got every bolt off the exhaust manifold, except for one that connected a metal pipe from the manifold to a round, UFO shaped thing that bolted in just under the carby (im guessing the cat).

Well we couldnt get it off the manifold so we tried to unbolt the pipe from the cat and pull it off that way. Unsuccessful, the pipe just would go thru its mangked path (I dont know why they made that pipe travel the path it does).

Anyways to get the threaded pipe into the cat, it was easier to unbolt the cat. When It was off the engine I noticed that it holes were blocked with crap, so i gave them a poke with a screwy and a coathanger to clear it. I did this to the cat, and the hole under the carby where it connected.

MISTAKE No 1 - it wasnt broke, I shouldnt have touched it!

When we bolted it all back together, the car ran for a minute, then conked out, and wouldnt start again, seemingly starved for fuel. Im guess that the crap I unblocked went into the carb and blocked it. If so how should I go about unblocking it and-or testing my theory (i.e. should I just pour petrol into the top of the carb when we are trying to start it ?).

The only thing which seems strange is that the cat seemed to bolt in under the carby, but I havent had a 2nd look and I dont know a great deal about theses things.

The car was running fine before we started this, and by the way we never got that pipe off and only replaced the 3 welsh plugs we could get to.

Any help or infos much appreciated.
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Old 12-20-2002, 23:00   #2 (permalink)
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Sounds like you are talking about the Exhaust Gas Return unit. Pipe goes from exhaust manifold to unit below carb. It bleeds exhaust gas intake the intake to help? emissions. I'd open it up again and clean it properly. Doesn't matter if the unit doesn't function, but you have risked dropping carbon bits down the intake which could be chunky enough to hold open a valve. Beyond that, check the usuals.
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Old 12-20-2002, 23:38   #3 (permalink)
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As WBT56 says it is the EGR valve, When you were "poking" about with the screwy and coathanger are you sure you didn't damage the diaghragm inside. if that is damaged it can upset the Air/Petrol ratio and stall the engine. Or another one, when you put it back together did it have a gasket on it - same results.

I used the XF manifold on my XD 250 and I cleaned everything up when I installed it. It is possible to remove the EGR by making up a blanking plate to bolt over the holes but don't forget to blank off the Exhaust Manifold end as well.

Cheers

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Old 12-21-2002, 23:55   #4 (permalink)
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Yeah mate just block it off. Make a plate out of any sort of metal and drill holes the same as where the egr bolts onto the intake manifold. Then bolt it all back on with the plate sandwiched between the egr and the intake so that no exhaust gas is actually going in. But leave the pipe and everyhitng attached so if you get checked by cops they cant tell that it isnt functional.
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