Some of my vacuum hoses are missing, cut or swinging in the breeze. I have the manual with the schematic but I am not sure what some of the arts are or where they are located.
1. The schematic shows a tube from the secondary diaphragm of the carby to the Thermal Valve. Is the thermal valve what is on the underside of the inlet manifold on the right hand side?
2. Where is the EGR valve located?
3. IS the purge valve located down near the charcoal canister?
4. Where is the vacuum outlet located?
There are two vacuum switches on the fire wall. One is for the economy lamp but what is the other one?

Tools

http://www.aussiemagna.com/forums/showthread.php?t=40090&page=3 post 23 thanks magna buff

Thank you

Tools

http://www.aussiemagna.com/forums/showthread.php?t=40090&page=3
i had a look at this yesterday. its a carby with loww km

Hi ya tools,
I assume its a carby magna.
There are two units on the bulkhead. One has two hoses and is the 'idle up' switch to activate the vacuum motor on the carby.
The other is the 'idle cut-off switch'. This has only one hose connected. This switch is normally closed and will open circuit when a vacuum level of around 40kPa or higher is applied. The vacuum hose for this is connected to the 4 way vacuum connector/distributer which applies vacuum from UNDER the throttle.

Tools,
the secondary diaphragm is connected through a 'tee' to the carby port just below and next to where the diaphragm is located. The through connection from the 'tee' goes to the Thermal Valve. This valve has 3 ports. All ports are open to atmosphere when cold (below 20degree C). Above 20, one port closes and Vacuum can be developed in this vacuum line. The other two ports are open when the water temp is below 50 deg C, but must close when the water temp rises above 55 to 60 deg C. The secondary diaphragm is one of these. Have a look at 'carby parts questions' by Coldamus in this forum. It is important that the diaphragm in the secondary does NOT LEAK. To testy this a vacuum gauge is needed. Alternatively, if you suck on a tube connected to the secondary diaphragm and then stick your tongue over the tube end, you will feel suction on your tongue; this suction should be maintained for at least 10 seconds.

Tools,
The purge valve is located on the cannister. Have a look at my post on how to rejuvenate this unit. (will post it soon)
This cannister MUST NOT leak carbon granules.
Go through Coldamus postings on the 'carby Parts questions'
rumpfy.

The EGR valve is located down below the carby and sits on a plate which holds the VRV

Wow Rumpfy, thanks for going to so much effort! I have tried to follow the manual in the past with not a lot of luck as it seems that my car is somehow a little bit different. I will print your posts out and have them with me when I look at the hoses. I have been following the posts from Coldamus but will go back and refresh. Thanks again.

Tools

No worries tools,
I been through hell and back with my TP. Its not wotrth spending money on it so I do a bit of reverse engineering. havent got much else to do although she who should be obeyed disagrees.
just follow my posts here and use Coldys post on carby parts. I have a vacuum/pressure gauge which I got at a flea market; goes from 70 kPa pressure to 70 kPa vacuum. VERY VERY useful.
Just going to describe the cannister repairs now. see post.

Rumply, looks like you are talking about the unleaded model and mine is the leaded which is slightly different. I think I have sorted most of it out except for a couple of things.
1. Is the secondary diaphragm on the top at the back left hand corner of the carby?
2. On thE fire wall of I have the economy lamp switch and something else on the left that I can't identify. It has a hose coming out of the bottom with a tee on the end and a hose coming out of the top, as well as a couple of wires. I cant see any other vacant spots that these hoses could go to. I have photos but don't know how to post them. Any ideas what this valve might be?

Looking further in to it it looks like what I thought is the secondary diaphragm is called the dashpot. That doesnt appear in the schematic for the vacuum hoses! On the front left of the carby is what I originally thought was the secondary diaphragm but there is nowhere to connect any hoses to it.
Tools

If you have airconditioning there is an idle up one for that as well so idle is not too slow when you switch the aircon on !! Vee

This is a vacuum diagram for leaded models:
http://users.tpg.com.au/acheson1/images/vacdiag.jpg

Note that it can be misleading as it is a theoretical diagram. It does not show the precise physical routing of the hoses. You'll see what I mean in a moment.

Below is a photo I took of my carby just before I took it off to replace the inlet manifold. Mine is a TP and therefore an unleaded model but the leaded carby layout is not much different.

http://users.tpg.com.au/acheson1/images/carb1.jpg

The view is into the engine bay from the drivers side with the firewall to the left and engine to the right. The secondary diaphragm is the brass canister near bottom right, just below the throttle cable support bracket. (the throttle cable has already been removed and some hoses have already been disconnected.) The other brass canister on the left is the dashpot you were referring to.

The thing to note is that the vacuum diagram shows the hose from the secondary diaphragm going directly to the top port of the thermal valve. In fact it does nothing of the sort. It goes to a short pipe on the side of the carby almost directly below the canister itself. If you look carefully at the picture, you can just see the hose curling back on itself and attaching to a pipe indicated by the red arrow. There's only one pipe there of an appropriate size so you can't miss it. There's a larger pipe near it which that big disconnected hose on the right goes to.

The actual hose to the top port of the thermal valve comes from the opposite side of the carby. On mine, it goes from a brass thingy screwed into the side of the carby that has four vacuum outlet pipes on it. In the diagram, it only has 3 pipes and is shown detached from the carby body and labelled as "vacuum outlet". I don't think it matters which of those pipes but, as rumpfy mentioned, on unleaded models the hose doesn't go directly but via a tee connector to another hose that goes to one of the other devices serviced by the same port of the thermal valve. I'm not sure that applies on leaded models. If I were you, I would route the hoses exactly as shown in the theoretical diagram and then close off any left over vacuum outlets or inlets (such as the one below the secondary diaphragm canister) with small pieces of vacuum hose plugged with screws.

G'day coldamus,
That is the schematic that I have been following from the manual but as you say it isn't all that accurate. My secondary diaphragm is connected with the short hose as you describe already. I wonder if the factory manual gives any better information than the one that I have or is it just the same thing? I reckon I pretty much have things piped up like the schematic but still have additional hoses and ports that I dont know what to do with. I looked through the whole manual yesterday to see if they are part of another system but I couldn't find them anywhere. Having put back on everything that I could work out yesterday the car certainly seems to idle a lot better. I took it for a drive yesterday foe the first time since doing the head gasket and it seemed to run ok, except that it started spurting oil from the breather holes on the underside of the fuel pump. It was ok when I removed it so not sure why it has crapped now. So it is really down to just sorting out these vacuum hoses now. Does anyone know if the factory manual is more detailed than the generic manuals?
Tools

I have a factory service manual for the TP series but it doesn't cover leaded versions because that only applied to the TM. My first Magna was a TM (unleaded) but I only have a Gregorys manual for that. The factory manual is more detailed, particularly in relation to the auto and manual transmissions, efi diagnosis and other stuff but there's not a lot more info regarding the carby. That might be different for the TM because they were all carby.

Just noticed someone has a TM factory service manual on ebay right now for $14 plus $11.50 postage. That's a bargain, so I suggest you grab it. They usually go for about $65. It is eBay item number 200726268541. Just do a search there using that number.

Coldamus, yes I had seen that on ebay and thought it was cheap. I have the gregorys manual but it is pretty crap really. There probably won't be much competition for the manual as TMs are getting fewer and fewer on the road.

Tools

Well I bought the TM factory manual for $14 and it was finally delivered on Friday. The Gregory's manual that I have had for years is crap in comparison and the factory manual has so much more detailed information. It will certainly help me with getting the vac lines correct so I can proceed and tune things up properly.

Tools

Tools,
looks like you've got some heavy reading to do!
The others have covered things well. When I first started on my TP, the biggest problem was to find all of the bits and relate them to the manual. This is important to get right so your head dont spin when you read the text.
By way of explanation, the 'Thermal Valve' responds to the temperature of the cooling water and its ports are open to atmosphere when the water is below a certain temperature. When the ports are open to atmosphere, there are no vacuum signals developed. When the ports close, then vacuum from the carby ports is allowed to rise and operate the relevant functions.
If I am correct, your magna does NOT have the 'Air Injection Valve' and the associated air injection pipe. This stuff is part of the catalytic converter which is not used with leaded petrol. It does have EGR I think and this is not active until the water temp is above 55 deg C. In fact I think both ports on your thermal valve open at the same temperature. Dont quote me on this. The secondary diaphragm operates the carby second stage throttle and is locked out of operation until the water gets to 55 deg C.