[Vwdiesel] rabbit smoke revisited

[LBaird119 at aol.com]

> The shop has re-timed the rabbit, everything is set correctly.  The thing
>  still smokes like there is no tomorrow.  Tech says it is dumping too
>  much fuel in and it could be a bad injection pump since I put in rebuilt
>  injectors.

  I'm sure we asked this but I sure don't remember.  What color is the smoke?
White, gray or black?  White is unburned fuel.  Timing, massive overfueling,
poor compression, burning antifreeze.  Gray smoke, excessive:  burning oil,
bluish gray, poor compression, generally poor engine condition or fine
condition under full throttle.  Of course then it's not really excessive.
Black
smoke:  Partially burned excess fuel.  Poor compression, possibly timing,
bad but not hideous injector, pump volume delivery set too high, dirty air
filter, possibly even dirty fuel filter (pump pressures out of whack).  Black
smoke nearly always happens under load or near full throttle.  Otherwise
the engine will achieve a higher rpm to equalize.
>
>  After hearing off this list that a lot of rebuilt injectors can still go
>  bad, I asked him to pull and test the injectors.  The pump was working
>  fine before I tore the engine apart, but I didn't muck with the pump
>  except the rear screw for dial indicator and the idle screw.

  So why should the pump be bad then?  I set mine wrong the first time
I set it on the 5000TD.  Things were really off and bad.  I thought I'd
messed up the pump.  It turned out it was 180 off.  I called Seattle
Injector and he strongly reassured me there was NOTHING I could
have done to the pump!  He said to think of these pumps like you
would a hammer.  It's REALLY tough to damage it!  Things can
happen but the pump is not the most likely thing to fail.  It's the
least likely.
>
>  So.. if the pump did decide to just go bad the month it was sitting
>  idle, what are my options for a new pump?  vwdieselparts.com is asking
>  $400 for a rebuilt. :(

  Options are rebuild yours, exchange yours for a rebuild, put on a used
one or dare I say, find the real problem?  ;-)  Can we tell where I am on
this?  ;-D
>
>  I found a used one on ebay (currently $20).  Works but has a small leak
>  at the pulley end.  Easy to fix?
>
  The leaks on that end are from a dried out seal and generally a worn input
shaft bushing.  It will wobble when wiggled toward/away from the belt
tensioner.  If it's worn then it's a complete rebuild.  If it's not then just
the seal CAN be replaced.  Often a new seal will take care of it even
when the bushing is worn.  Beware since a worn bushing can make the
timing belt walk off.
     Loren