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Discussion Starter #1 (Edited)
Hi. A good friend of mine had a 1988 Rascal that he loved until it was stolen by joyriders (I kid you not!). To replace it we found a 1995 Suzuki Carry with just 60,000 mls on the clock that had been left standing for around 3 yrs. He's not the most mechanical minded and I've done a lot of work on it for him. However it continues to fail its MOT test on high emissions of hydrocarbon, the co's are fine. It is as though it is running rich and there seems to be no mixture adjustment as there was on his old non-cat Rascal.

It's had a new cat, air filter, distributor cap, rotor arm, ht leads, Bosch Super 4 plugs, lambda sensors working as they should. All rubber pipes have been checked for splits, electrical sensors connected. Is there something I've missed? It runs 'lumpy' at tickover when cold but smoother when warmed up. 1 & 2 cylinder plugs look fine, 3 & 4 look a bit sooty so that's where the fault could be, but surely the carb feeds all 4 pots evenly, why 2 cylinders running rich?

My friend suggested maybe head gasket symptoms but being a Rover V8 man myself I am very familiar with head gasket problems!! It doesnt seem to overheat, lose coolant, pressurise the system or anything like. We haven't done a compression test yet but I'm (reasonably) confident that all is ok mechanically in the engine. We've scoured the Haynes comic, sorry workshop manual but they only cover up to 94 and gives very little info on the cat models.

What should the ignition timing be set at for cat models, the Haynes quote 8 degrees BTDC for the non cat, is it the same for cat models?

Any advice greatly appreciated, this has been driving us nuts for days and my friend is sick of walking to work!
 

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Hello mate 8 degrees BTDC is right for cat models. Sounds like you have covered everything.The chokes not sticking at all is it? they have the stupid cold start system on them seen problems with them before. You could try it with out the airfilter to try lean it out a bit might scrape through the test.
 

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Discussion Starter #3
You've got a supercharged Supercarry!!? I'm impressed, wait till I tell the owner of this one. :)

The choke knob pulls out and holds then releases when it gets warm and the mechanism on the carb seems to be doing as it should smooth enough. We will probably be stripping the carb tomorrow looking for blocked jets or dirt, it had been stood some time, apparently after the exhaust fell to bits.

Out of curiosity what is the function of the relay thing with two pipes connected, it's forward of the charcoal canister. We can feel it 'ticking' sometimes but not others.

It's just occured to me, I did a hot to cold water test on the two coolant sensors using an ohmeter. The forward one in the 1 & 2 cyl inlet manifold was closed when hot and open when cold (or was it the other way around). The rear one in the 3 & 4 cyl inlet (sooty plug cylinders) remained closed as in always in the 'hot' setting. I wonder if this is not right. I'm going to swap them over first tomorrow, if it sends 1 & 2 sooty we've found the culprit. i'll let you know.
 

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If its what i think it is, its part of the cold start system.That was one of the first things that went in the bin then the carb then all the pipes a pish that went with the carb and cold start. The super charger now draws through a SU carb (nice and simple)
 

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I think we have, it was a case of checking everything but the blindingly obvious!!:rolleyes:

For some reason I thought it had hydraulic tappets. I got the rocker cover off and found normal screw & locknuts and I found there was almost no clearance on the exhaust tappets, thus when it gets hot they would leak (hence the lumpy tickover) and let out unburnt fuel.

Also there was a small M6 bolt trapped under the bottom of the inlet valve spring on number 2 cylinder. How it got there and for how long I have no idea. Some very awkward screwdriver fiddling and it was out and appears to have done no lasting damage. With tappets done and this sorted the engine now ticks over and runs very sweet.

The MOT re-test will tell us for definite, still got both rear brake pipes to replace and a front caliper to unseize but thats straight forward enough. It was covered in moss and had been standing under a tree for around 3 years and had to be rescued!

Do you know anywhere that does the pattern front wheelarch panels, a local bodyshop supplied the last lot for his old Rascal but now cant get hold of any more. They're not an mot failure but look rough and really need replacing.
 

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Discussion Starter #8
Well the carry went for it's retest, the CO's were down from 0.371% to 0.000% and hydrocarbon from 324ppm to 38ppm. It's passed!!:grin: He owes me a big big drink :beer:

Thanks for the link Monometalico, a goldmine of parts. I'm sure it'll come in useful, he loves the Rascal/Carry and hopes to keep this one for some time. He dreams of driving it to Marakesh, whether it will happen or not time will tell.
 

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What was your fuel consumption by the way?

After these checks etc, what is the mgp? I am trying to find out what a notmal mpg for a suer carry is as I think my mgp is too (low 33-35 mpg)
 
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