81 rabbit diesel 5spd

[phantom59]

Well I have now gone through my first tank of fuel in the new car and I am not impressed It only got 35 mpg and has very low power. It has been a while since I owned a Rabbit so I couldn't remember about the power but I do remember 43 MPG. It was a 79 diesel 5spd.
So where do I start? 

[rabbitman]

Check for fuel leaks and see if there's air in the fuel line, helps if the line is clear . Also check the timing.

[theman53]

Run it and change oil/filters/fuel and see. Usually when I get one that is "new" they have been sitting and take a little to get going. I would almost bet the injector return lines are leaking if it sat for a bit .

[Vincent Waldon]

"Low power" is a clue that something is amiss as opposed to just not optimal.

Bigger things you can check:

- nozzles... get 'em poptested or just replace 'em if you think they have more than 100K on 'em
- timing... should be in the 0.9mm - 1.00mm range for an NA
- compression test... how does it start when cold?
- fuel system:  change filter, check carefully for leaks

In addition... some more subtle things:

- check/replace air filter
- synthetic oil change
- dragging brakes?
- old tires?
- tires properly inflated?
- heavy right foot?

[phantom59]

Thanks
I allready changed both filters (it has an aftermarket prefilter) and got a bunck of black junk out of the canister.
I don't believe I have any fuel or air leaks. all the lines are in good shape. Had a bit of a problem getting the drain on the prefilter to seat but no bubbles now.
Not sure how to check the timing or the nozzles. I have the Bentley Manual so I will have to read up.
Will replace the air filter hadn't done that yet
Oil is clean. Previous owner changed it don't think it is synthetic.
Brakes ok
Tires new and properly inflated
As I said before this car was on blocks from 1987 to 2007 when it was purchased and a local mechanic suposedly went through everything  and made it road ready. He said there was an oil leak on the front of the engine and the timing belt was replaced then but I wonder if he timed it right?
The previous owner has put about 3,000 miles on the car since 2007.

[theman53]

I would say the black gunk is bad in the fuel, keep changing filters there. Also if the guy did the timing belt and isn't a member here I would bet it isn't correct. The first one I did and I had a manual I did incorrectly. I would pull the covers off and check to see if it is spot on and then time the pump.

[phantom59]

The guy that did the work is a professional mech. but I don't know how much he knows about VW diesels.
I guess I am going to have to buy the timing tools and learn how to do it myself. What is the best thing to clean the tank and fuel system out with? With the black slime in the filter the tank has to have some in there.
What do you think about DieselVW.com? They have the timing tools at what looks like a good price.

[theman53]

Yeah the first time I timed the 1.6L I had a ford certified diesel tech helping me. It ran afterwards, but we didn't use a single timing tool or take the sprocket off the cam  . The next time with my same friend we did the same thing...bent every vavle in the head. Then I came this forum learned and talked to him about it. He had never heard of such an issue. He said it must be an interference fit...YUP. At the very least the pump could be too retarded or too advanced and causing some power/milage issues.

On the supplier mentioned, sometimes you get what you pay for. Timing tools I wouldn't worry, nor on the body peices, but I would steer clear of the engine components. That is just my opinion, add a dollar to that and you might be able to buy a coffee somewhere.

[Baron VonZeppelin]

On the timing tools, you'll get 10 times better quality for about the same cost, by using the German guy on eBay.
$80-85 including shipping from Germany.
Takes about a week after paying to get the kit at your doorstep.

The dieselvw.com/Prothe kit is cheap stuff and comes with a Harbor Freight dial indicator. And it will be standard measure - not metric. Can be dealt with by using conversion tables - but i'll stress again - the difference in quality is tenfold. Plus its Metric measure/German quality. Not China/Taiwan.

All of my data on things like that are trapped on a recently crashed desktop - but i can get you the seller name on eBay if you want it - from "My eBay" archive.

You could also look into the new timing gauge product that member Libbybapa is offering. Then you could just buy the cam and pump locks to go with it. For about $50 total .

You shouldn't need to use more than half the throttle pedal to be a general member of traffic flow - coming off a dead start. MPG should be in lower 40's minimum. Well tuned with mostly highway driving should be closer to 50 range. If you're driving economically minded and under 65. Over 60'ish i start dropping almost 1 mpg per every mph.

9 out of 10 professional mechanics have never touched a VW Diesel timing operation (correctly). And thats probably conservative. If he isn't a real Diesel biased tech - its probably off - in regards to Inj timing specs.

I would start running a product like Power Service Diesel Kleen/Fuel Lubricant, or Stanadyne, in every tankful. And Shell/Rotella synthetic oil.

The tank probably should be inspected through the access cover with a strong flashlight. Under back seat or in cargo area (forget which on rabbit). May need to come out of car and be cleaned to whatever degree you feel is necessary after a visual.

[phantom59]

Thanks
Who is the German guy on Ebay? I see El Paso Tool has a kit listed but that's it.
As for the mechnic the one I normaly use is good with diesels. He replaced the pump on my Jetta and it runs great.

[Baron VonZeppelin]

He used to start them at $60 plus shipping.

Been 65 for a while now.

Every so often he will still start one at 60.

The dial gauge comes in a padded case.

http://cgi.ebay.com/ebaymotors/VW-Audi-Jetta-Diesel-Injection-timing-Set-New_W0QQitemZ140355005991QQcmdZViewItemQQptZMotors_Automotive_Tools?hash=item20adcf6e27