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[Bionic]

Ok, I have thoroughly cleaned out the breather system as per the guides and made certain that all of the pipes are not kinked or twisted iny way and are fully clean inside. I cleaned the metal breather box on the side of the engine (X25XE) as best  could as per the guide.
There is still a smell coming from the engine that smells like burnt carbon as though the breather system was blocked. Just as it was before I had cleaned it out and it was ok for a few days after which the smell returned inside the car. It is there even if using the re-circulation system. No, there are no oil leaks dropping onto manifolds etc and there are no water leaks either. I know the smell of both of them all too well! There is very little mayo in the oil filler neck either and the coolant water is clean and bubble free. The thermostat is a new one and is working properly.
I have bought another plastic breather box that is now totally clean internally and all holes are clear, a low air pressure passes through them all without obstruction. This will be fitted after I have re-done it all again.
Question is; How, if it is possible, can the metal engine breather box be removed and stripped to ensure that it is iteself unblocked and free to work? I have ligically already used a small drill bit to clean out the small hole and a large one to gently twist into the large one to gradually remove the carbon build up. It was done very slowly and steadily, with a little grease applied to act as an adhesive so very little, if any, was pushed down into the box.
Can't go on stinking like this so my final solution would be a complete engine change. It is not as though it is poorly serviced or cheap oils and filters used. I do it myself so I know that it was done correctly every year without fail.
Come on guys, stretch your brains cos mine are about to snap....................

[TheBoy]

is the vent to carbon canister attached properly? From memory, think it goes off to OSF wing?

[Andy H]

The breather box is attached to the top of the block by 4no 6mm bolts. 2 are relatively easy to get to (with the plenum off). The other 2 are hidden by the exhaust manifold heat shield).

I fitted a new breather box to mine when I had the engine out so I haven't actually had to get to the two bolts under the heat shield.

IIRC the breather box cost about £40 new and I decided it was easier to buy a new one rather than clean out the hardened crud.

[Bionic]

Thanx.
Hm.. Carbon Canister? What is its purpose?Something else to go seek find?
At least the day is a bit warmer and the sun is out!

Breather box removal? I think I will try to blow some air through it and see if it comes freely from the Oil filler neck. If it does I suppose that will prove the metal box is clear enough.

[Andy H]

The petrol tank breathes through the carbon canister. I think it is in the drivers side wheel arch (hidden up above the wheel arch liner).

The pipe from it should connect to a solenoid valve attached to the back of the engine. This solenoid valve connects to the smallest spigot on the back of the plenum with a small rubber pipe.

When the ECU decides that it is time to suck the fuel fumes out of the carbon cannister it open the solenoid valve. If the pipe from the carbon cannister to the solonoid valve were unattached I suppose you would smell petrol vapour but I can't see how you would smell burnt carbon :-/.

[Andy H]

Is it possible that you have fixed everything but old oil is still being burnt off?

[Bionic]

No, there has never been a smell of petrol at all, Just a burnt carbon smell.
Right bleedin carry on - spent till 3:30 stripping it down to eradicate by inspection, testing and re-assembly everything I could think would cause the stink. I have made certain that the engine breather system is fully clear from start to finish. I have blown through every pipe and gallery and they are all free and clear, all without any restrictions at all. Then I took it further and took off the plenum and inlet manifolds. I saw nothing but a small damp patch on the lower seam of the left cam cover. 'K' sez I to myself; lets do the t@@t and get it out of the way. Fortunately I had a set of VX seals so knew they would fit as they should, but gave them a dose of Blue Hylomar to be certain. I know I can trust that stuff! Job went well and found nothing of any real concern. Made certain that the joints were oil tight and secure so that was that. After putting it all back together and re- antifreezing it I gave it some welly down the old ring road of Leicester. If no-one knows about it it is not really a ring road but a Leicester City Council joke! Like everything else they do in fact! We even have a grinning monkey as the mascot - oops - sorry, that is the council leader and chief plunderer!
The test run went ok and there are no leaks, the heaters are fine and the stink has quite possibly gone too.
Time will tell I suppose but I dare say it will do a Swartzenegger on me. If it does I will have to pick my nose cos my brains are all out of ideas!