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If it only runs on the choke, it's running lean isn't it? Either your mixtures out on the carb or as you say, you've got a leak on the inlet side of things which is letting air in and leaning the mixture out.

Bang some core plugs/freeze plugs into the coolant holes when you do the intake manifold. I think i used 20mm plugs

Sorted out the inlet manifold today, thinking that it was one of the only things left that could be causing a vacuum leak. Well... it needed doing. The bolts holding it on were loose and the gasket and O rings were an absolute mess:



We got everything cleaned up, flushed out the manifold (the cooling system will get a proper flush once it's running) and fitted a new gasket and O rings. I would've put core plugs in but I wasn't sure where to get them on a Sunday and I already had the O rings. After that we tried to start it but it's still not happy, I need to put the carb back to its' base settings and look at the timing still - thanks for your instructions Tool.

Yeah that has seen better days. Nice to rule that out now as a possible problem.

Hi

How did your inlet clean up, and how do the engine coolant passages look on the outside wjen you stripped it all down, looking similar to mine apart from the corrosion on mine

Still bet it feels great to know everything is getting fixed and is running as should be

Rich

To be honest the manifold didn't clean up particularly well, but this is no show car! There was a bit of corrosion, we cleaned it up as best we could. Importantly the mating faces were sound enough, they just had to have all the old gasket scraped off. It's not leaking any coolant so far as I can see and I don't see why it would be causing a vacuum leak but because the car still isn't running properly it's hard to tell. Recently the weather's been putting me off going up to the garage, that and I'm putting in plenty of overtime at work to try to cover the costs of my new toy, a BMW 740i...

So not much has happened with this recently, I've had my hands full but as the weather's getting better I should really pull my finger out with the poor old thing! I'm going to go have a play with it this weekend, but I've just had a thought - on my engine block, the ports that I have match up with this manifold (just a picture off google to illustrate my point), i.e. there's a rectangular port underneath the two centre ports:



The manifold/gasket that I have for the car does not have this rectangular port (see picture a few posts above). What's the deal?

Also, if there's anyone that would fancy coming up for a day (maybe with some known good spares) to see if we can get it going, I'd be happy to provide beer/lunch and cover your time/travel. I think I need the motivation of having it running to get me to crack on with the rest of the car, if you can help it'd be great to hear from you

That's the EGR port. You'll need the right gasket.

I think I've got a spare, plus the 2 water o rings for the housings.

Where do you live?

Thanks for that Tool, I'm in Reading, just updated my profile. Not a million miles away from you! So the EGR port on the centre iron leads into the intake of the engine? That figures, it has never been blanked off at all - the manifold I have for it which came with the car doesn't cover it, which would explain why I'm still getting symptoms of a massive vacuum leak. I guess I'd just need to make up a blanking plate then?

EGR = Exhaust Gas Recirculation

It'll sound like a tractor if not sealed up properly.

You can see it here: http://ausrotary.com/viewtopic.php?f=4& ... it=egr+12a

IDA manifolds block this off so I don't run one. It feeds back into the intake, or vents to atmosphere if blocked and you use the wrong gasket.

You're just up the road, bro. Bring over what you've got and we can sort it out.