Max RPM on early IDI's?

[CarlosA]

So i`ve been driving another 1981 diesel I picked up on CL for a little over a year now - i've troubleshooted and fixed many issues, and like driving it. My biggest issue is pulling the long grades, it seems like the 1978 rabbit I had with a 4 speed (GC) would easily fly up the passes at 60-70 mph.

This one has a 1.6 with the FN trans

How much harder should I push it? I don`t have a tach so I did the math and it looks like i`m shifting way too early (it sounds terrible and expensive now). 45 MPH in 3rd is only 3351 RPM. This is usually where I shift to 4th. The math says I can easily stay in 3rd up to 55 (4096 rpm) or even 60 (4469).

Does this sound right? If I`m shifting too early then that likely explains the white smoke problem I have - which is just lugging it around too much.

[vanbcguy]

4400 RPM is safe but far outside of the engine's most efficient operating range. For cruising you want to be around 2200 or so.

White smoke won't be caused by your shifting. It's much more likely to be a timing related issue or a turbo on its way out.

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[ORCoaster]

The differences I see in your setup is that you switched engines and 4th gear ratios.  The older GC transmission had a .97 ratio in it and the FN moves it down to a .91.  Now they did have a GC transmission later, 1981 and on that had that same .91 fourth ratio. 

I run a FF post 7/80 version in my 1.6 NA Rabbit.  I generally don't have a problem with keeping up with traffic in fourth as I start to climb an extended grade.  There are several however where I have to drop down to third and catch the 1.29 versus the .91 ration to keep it going.  Same if I have it loaded with more than myself and a suitcase and tool box.