78 VW Rabbit Diesel 1.5 Fuel Injector Timing Question

I recently replaced the cylinder head, head gasket, timing belt,
injector heat shields, timing belt, and tensioner on my 78 VW Rabbit
Diesel. The car will start and idle, but has no torque, and lots of
blue smoke, and dies when I pull the injector advance knob. I
concluded that now that a new timing belt and tensioner has been
installed, the injector timing is off.

I followed the steps in the Bentley manual to measure the injector
timing. Using the dial, I have found that the injection timing is set
to 1.32mm (Spec is .83mm).

I can't figure out how to adjust the injector timing....I have loosened
the three allen head bolts on the injector pump plate per the manual.
I can not remove the bolt w/ the yellow paint w/ the standard type
screw head, it's stuck. I don't know how to "turn the pump". The
instructions are vague in both the Bentley and Haynes manuals.

Do I need to loosen the screw with the yellow paint in addition to the
three allen head bolts? Have I loosened the correct screws? Now, how
do I adjust the pump down to .83mm?

Thank you!

Jeff

I don't know what bolts you removed . You loosen the mounting bolts that
hold the whole pump to the engine bracket. I think two are accessed from
the engine side, the other is from the belt side. You rotate the whole pump
side to side. loosen the fuel lines when you turn the pump and retighten
them when your done. or the lines will crack from stress. One way advances
,The other retards. Don't turn the bolt with the paint on it. Its set with
the pump on a test stand.
"JH" > wrote in message
ups.com...
>I recently replaced the cylinder head, head gasket, timing belt,
> injector heat shields, timing belt, and tensioner on my 78 VW Rabbit
> Diesel. The car will start and idle, but has no torque, and lots of
> blue smoke, and dies when I pull the injector advance knob. I
> concluded that now that a new timing belt and tensioner has been
> installed, the injector timing is off.
>
> I followed the steps in the Bentley manual to measure the injector
> timing. Using the dial, I have found that the injection timing is set
> to 1.32mm (Spec is .83mm).
>
> I can't figure out how to adjust the injector timing....I have loosened
> the three allen head bolts on the injector pump plate per the manual.
> I can not remove the bolt w/ the yellow paint w/ the standard type
> screw head, it's stuck. I don't know how to "turn the pump". The
> instructions are vague in both the Bentley and Haynes manuals.
>
> Do I need to loosen the screw with the yellow paint in addition to the
> three allen head bolts? Have I loosened the correct screws? Now, how
> do I adjust the pump down to .83mm?
>
> Thank you!
>
> Jeff
>

I want to be clear. The bolts you loosen, are the ones you would remove if
you wished to remove the pump from the engine. Mounting bolts. Just loosen
them enough to rotate the pump. .132 is so far out it isn't funny. you're
lucky it started.
"none2u" > wrote in message
et...
>I don't know what bolts you removed . You loosen the mounting bolts that
>hold the whole pump to the engine bracket. I think two are accessed from
>the engine side, the other is from the belt side. You rotate the whole pump
>side to side. loosen the fuel lines when you turn the pump and retighten
>them when your done. or the lines will crack from stress. One way advances
>,The other retards. Don't turn the bolt with the paint on it. Its set with
>the pump on a test stand.
> "JH" > wrote in message
> ups.com...
>>I recently replaced the cylinder head, head gasket, timing belt,
>> injector heat shields, timing belt, and tensioner on my 78 VW Rabbit
>> Diesel. The car will start and idle, but has no torque, and lots of
>> blue smoke, and dies when I pull the injector advance knob. I
>> concluded that now that a new timing belt and tensioner has been
>> installed, the injector timing is off.
>>
>> I followed the steps in the Bentley manual to measure the injector
>> timing. Using the dial, I have found that the injection timing is set
>> to 1.32mm (Spec is .83mm).
>>
>> I can't figure out how to adjust the injector timing....I have loosened
>> the three allen head bolts on the injector pump plate per the manual.
>> I can not remove the bolt w/ the yellow paint w/ the standard type
>> screw head, it's stuck. I don't know how to "turn the pump". The
>> instructions are vague in both the Bentley and Haynes manuals.
>>
>> Do I need to loosen the screw with the yellow paint in addition to the
>> three allen head bolts? Have I loosened the correct screws? Now, how
>> do I adjust the pump down to .83mm?
>>
>> Thank you!
>>
>> Jeff
>>
>
>

Thank you to all who responded. My 78 Rabbit Diesel now runs after
replacing the cylinder head, head gasket, timing belt, tensioner, and
injector heat shields. I adjusted the injector timing to .83mm
(Bentley manual spec). The car runs, but it doesn't have as much power
as it did prior to the rebuild.

Is .83mm the proper spec (in your experience) for the injector pump
timing? I have seen other posts where they suggest 1.05mm for the same
car???

If this isn't the problem, I'm thinking the injectors maybe dirty. Do
you recommend replacing the injectors w/ rebuilt injectors, cleaning,
or just replace the nozzle? I have seen nozzles advertised that have a
larger diameter. What is recommended?

Thanks in advance!

Jeff


none2u wrote:
> I want to be clear. The bolts you loosen, are the ones you would remove if
> you wished to remove the pump from the engine. Mounting bolts. Just loosen
> them enough to rotate the pump. .132 is so far out it isn't funny. you're
> lucky it started.
> "none2u" > wrote in message
> et...
> >I don't know what bolts you removed . You loosen the mounting bolts that
> >hold the whole pump to the engine bracket. I think two are accessed from
> >the engine side, the other is from the belt side. You rotate the whole pump
> >side to side. loosen the fuel lines when you turn the pump and retighten
> >them when your done. or the lines will crack from stress. One way advances
> >,The other retards. Don't turn the bolt with the paint on it. Its set with
> >the pump on a test stand.
> > "JH" > wrote in message
> > ups.com...
> >>I recently replaced the cylinder head, head gasket, timing belt,
> >> injector heat shields, timing belt, and tensioner on my 78 VW Rabbit
> >> Diesel. The car will start and idle, but has no torque, and lots of
> >> blue smoke, and dies when I pull the injector advance knob. I
> >> concluded that now that a new timing belt and tensioner has been
> >> installed, the injector timing is off.
> >>
> >> I followed the steps in the Bentley manual to measure the injector
> >> timing. Using the dial, I have found that the injection timing is set
> >> to 1.32mm (Spec is .83mm).
> >>
> >> I can't figure out how to adjust the injector timing....I have loosened
> >> the three allen head bolts on the injector pump plate per the manual.
> >> I can not remove the bolt w/ the yellow paint w/ the standard type
> >> screw head, it's stuck. I don't know how to "turn the pump". The
> >> instructions are vague in both the Bentley and Haynes manuals.
> >>
> >> Do I need to loosen the screw with the yellow paint in addition to the
> >> three allen head bolts? Have I loosened the correct screws? Now, how
> >> do I adjust the pump down to .83mm?
> >>
> >> Thank you!
> >>
> >> Jeff
> >>
> >
> >

See if the timing number is on the under hood sticker , it will have a
optimal and a range. I will find my rabbit manual tomorrow.
"JH" > wrote in message
oups.com...
> Thank you to all who responded. My 78 Rabbit Diesel now runs after
> replacing the cylinder head, head gasket, timing belt, tensioner, and
> injector heat shields. I adjusted the injector timing to .83mm
> (Bentley manual spec). The car runs, but it doesn't have as much power
> as it did prior to the rebuild.
>
> Is .83mm the proper spec (in your experience) for the injector pump
> timing? I have seen other posts where they suggest 1.05mm for the same
> car???
>
> If this isn't the problem, I'm thinking the injectors maybe dirty. Do
> you recommend replacing the injectors w/ rebuilt injectors, cleaning,
> or just replace the nozzle? I have seen nozzles advertised that have a
> larger diameter. What is recommended?
>
> Thanks in advance!
>
> Jeff
>
>
> none2u wrote:
>> I want to be clear. The bolts you loosen, are the ones you would remove
>> if
>> you wished to remove the pump from the engine. Mounting bolts. Just
>> loosen
>> them enough to rotate the pump. .132 is so far out it isn't funny. you're
>> lucky it started.
>> "none2u" > wrote in message
>> et...
>> >I don't know what bolts you removed . You loosen the mounting bolts that
>> >hold the whole pump to the engine bracket. I think two are accessed
>> >from
>> >the engine side, the other is from the belt side. You rotate the whole
>> >pump
>> >side to side. loosen the fuel lines when you turn the pump and retighten
>> >them when your done. or the lines will crack from stress. One way
>> >advances
>> >,The other retards. Don't turn the bolt with the paint on it. Its set
>> >with
>> >the pump on a test stand.
>> > "JH" > wrote in message
>> > ups.com...
>> >>I recently replaced the cylinder head, head gasket, timing belt,
>> >> injector heat shields, timing belt, and tensioner on my 78 VW Rabbit
>> >> Diesel. The car will start and idle, but has no torque, and lots of
>> >> blue smoke, and dies when I pull the injector advance knob. I
>> >> concluded that now that a new timing belt and tensioner has been
>> >> installed, the injector timing is off.
>> >>
>> >> I followed the steps in the Bentley manual to measure the injector
>> >> timing. Using the dial, I have found that the injection timing is set
>> >> to 1.32mm (Spec is .83mm).
>> >>
>> >> I can't figure out how to adjust the injector timing....I have
>> >> loosened
>> >> the three allen head bolts on the injector pump plate per the manual.
>> >> I can not remove the bolt w/ the yellow paint w/ the standard type
>> >> screw head, it's stuck. I don't know how to "turn the pump". The
>> >> instructions are vague in both the Bentley and Haynes manuals.
>> >>
>> >> Do I need to loosen the screw with the yellow paint in addition to the
>> >> three allen head bolts? Have I loosened the correct screws? Now, how
>> >> do I adjust the pump down to .83mm?
>> >>
>> >> Thank you!
>> >>
>> >> Jeff
>> >>
>> >
>> >
>

Hello Jeff,

IIRC there is a standard spec from .75 to .90 and an advanced spec of
..90 to 1.05
if you need more power (and smoke & less fuel milage). The advanced
spec is
for "worn" engines that have lost power over the years.

My best compromise has been .90 on my '81 Rabbit. (The in between
setting)

Mike L


JH wrote:
> Thank you to all who responded. My 78 Rabbit Diesel now runs after
> replacing the cylinder head, head gasket, timing belt, tensioner, and
> injector heat shields. I adjusted the injector timing to .83mm
> (Bentley manual spec). The car runs, but it doesn't have as much power
> as it did prior to the rebuild.
>
> Is .83mm the proper spec (in your experience) for the injector pump
> timing? I have seen other posts where they suggest 1.05mm for the same
> car???
>
> If this isn't the problem, I'm thinking the injectors maybe dirty. Do
> you recommend replacing the injectors w/ rebuilt injectors, cleaning,
> or just replace the nozzle? I have seen nozzles advertised that have a
> larger diameter. What is recommended?
>
> Thanks in advance!
>
> Jeff
>
>
> none2u wrote:
> > I want to be clear. The bolts you loosen, are the ones you would remove if
> > you wished to remove the pump from the engine. Mounting bolts. Just loosen
> > them enough to rotate the pump. .132 is so far out it isn't funny. you're
> > lucky it started.
> > "none2u" > wrote in message
> > et...
> > >I don't know what bolts you removed . You loosen the mounting bolts that
> > >hold the whole pump to the engine bracket. I think two are accessed from
> > >the engine side, the other is from the belt side. You rotate the whole pump
> > >side to side. loosen the fuel lines when you turn the pump and retighten
> > >them when your done. or the lines will crack from stress. One way advances
> > >,The other retards. Don't turn the bolt with the paint on it. Its set with
> > >the pump on a test stand.
> > > "JH" > wrote in message
> > > ups.com...
> > >>I recently replaced the cylinder head, head gasket, timing belt,
> > >> injector heat shields, timing belt, and tensioner on my 78 VW Rabbit
> > >> Diesel. The car will start and idle, but has no torque, and lots of
> > >> blue smoke, and dies when I pull the injector advance knob. I
> > >> concluded that now that a new timing belt and tensioner has been
> > >> installed, the injector timing is off.
> > >>
> > >> I followed the steps in the Bentley manual to measure the injector
> > >> timing. Using the dial, I have found that the injection timing is set
> > >> to 1.32mm (Spec is .83mm).
> > >>
> > >> I can't figure out how to adjust the injector timing....I have loosened
> > >> the three allen head bolts on the injector pump plate per the manual.
> > >> I can not remove the bolt w/ the yellow paint w/ the standard type
> > >> screw head, it's stuck. I don't know how to "turn the pump". The
> > >> instructions are vague in both the Bentley and Haynes manuals.
> > >>
> > >> Do I need to loosen the screw with the yellow paint in addition to the
> > >> three allen head bolts? Have I loosened the correct screws? Now, how
> > >> do I adjust the pump down to .83mm?
> > >>
> > >> Thank you!
> > >>
> > >> Jeff
> > >>
> > >
> > >

JH wrote:


>
> If this isn't the problem, I'm thinking the injectors maybe dirty. Do
> you recommend replacing the injectors w/ rebuilt injectors, cleaning,
> or just replace the nozzle? I have seen nozzles advertised that have a
> larger diameter. What is recommended?
>

As I recall, the manual recommends replacing the injectors
every 50,000 miles.

I think I put 80,000 miles on my injectors (don't have a clue
how many miles they already had on them), before I replaced
them. The new injectors definitely made a difference.

--
Paul Stevens

JH wrote:
> Thank you to all who responded. My 78 Rabbit Diesel now runs after
> replacing the cylinder head, head gasket, timing belt, tensioner, and
> injector heat shields. I adjusted the injector timing to .83mm
> (Bentley manual spec). The car runs, but it doesn't have as much power
> as it did prior to the rebuild.
>
> Is .83mm the proper spec (in your experience) for the injector pump
> timing? I have seen other posts where they suggest 1.05mm for the same
> car???
>
> If this isn't the problem, I'm thinking the injectors maybe dirty. Do
> you recommend replacing the injectors w/ rebuilt injectors, cleaning,
> or just replace the nozzle? I have seen nozzles advertised that have a
> larger diameter. What is recommended?
>
> Thanks in advance!
>

Did you check the valve clearance, after the head was
reinstalled?


--
Paul Stevens

I had mine on .90mm too. i tried the worn specs once and it wouldnt start in
winter. .83mm wouldnt cut it in my book.
"Paul Stevens" > wrote in message
...
> JH wrote:
>> Thank you to all who responded. My 78 Rabbit Diesel now runs after
>> replacing the cylinder head, head gasket, timing belt, tensioner, and
>> injector heat shields. I adjusted the injector timing to .83mm
>> (Bentley manual spec). The car runs, but it doesn't have as much power
>> as it did prior to the rebuild.
>>
>> Is .83mm the proper spec (in your experience) for the injector pump
>> timing? I have seen other posts where they suggest 1.05mm for the same
>> car???
>>
>> If this isn't the problem, I'm thinking the injectors maybe dirty. Do
>> you recommend replacing the injectors w/ rebuilt injectors, cleaning,
>> or just replace the nozzle? I have seen nozzles advertised that have a
>> larger diameter. What is recommended?
>>
>> Thanks in advance!
>>
>
> Did you check the valve clearance, after the head was
> reinstalled?
>
>
> --
> Paul Stevens
>