Timing?

[rabbitman]

Maybe an italian tune up would be the fix .

Blue smoke usually indicates burning oil while white smoke is unburnt fuel.

The fact that it runs with the cold start pulled but not with it pushed in tells me that the timing is definitely retarded since pulling it out advances it.

What year is this? If it's got the high idle that will help it run better too along with the advance you get from pulling the cold start out.

If it were me I'd advance it until it runs good/no smoke (except black ) and call it good, provided it wasn't clattering too awful much.

[8v-of-fury]

it would smoke before at startup with your 0.80-0.83mm setting of the timing, then go away once warmed up..

now after the mod it smokes constant blueish-white.. and will sputter and die once the cold start is pushed in... whoa this is a weird one. maybe you knocked a piece of something in and one of the nozzles is clogged??? Farfetched... but you never know? I have no idea.

[rabbitman]

Try advancing it until it runs right and then check the timing, if it shows 1.20mm or something really high then you'll know something's up with the internals.

Could the little shim between the cam plate and plunger have gotten left out ? If that's missing I believe it would change the injection curve (injection would start/stop at a different point on the cam plate) so then the dial indicator wouldn't mean anything anymore.

[ffgb]

Before I resealed the pump, the smoking would stop when the motor was warmed up.  After the reseal, I checked the timing, it was at .80-.83mm.  I tried starting the motor with those settings, but had to leave the cold start valve out just to keep it at a somewhat idle.  Then I advanced the timing to .98mm, it starts but still smokes, same problem, cold start in, stalls/stumbles.  I know I didn't leave any parts out of the IP, I made sure that everything was put back in the same order.  I don't think I could advance it anymore, the motor claps pretty loud now with the hood open.  I closed the hood, sat in the car with it idling, and it was a lot louder than normal.
My car is a 1984 rabbit N/A.

[8v-of-fury]

try starting it up and leaving the cold start lever out just the tiniest bit.. So that it will only be fast idling and not advancing timing.

maybe.. the idle stop screw is set too low?

[Rabbit on Roids]

i think you arent checking your timing right or something. those are classic symptoms of grossly retarded timing. (wont start/idle without cold start lever pulled, and bluish white smoke)

but it also could be that your injectors are soo crappy and worn that they cant function properly.

[ffgb]

I had my injectors pop tested at a diesel shop and all 4 where bad.  They popped around 100 bar, and all were dribbling fuel, essentially they wouldn't hold that much pressure.  So I put in some Bosch remanufactured units, now everything is back to normal!

[Rabbit on Roids]

good to hear.