Blows Huge Clouds of White Smoke

Vwfixer1234

New member
Joined
Jul 1, 2025
Location
Natoma Kansas
TDI
1.6 Turbo Diesel Jetta
So we bought a brand new injection pump for my 1991 1.6L Turbo Diesel and I have had a struggle timing it. I retarded it a tooth and it would barely run. Then I put it back to the original tooth and then in blows huge clouds of white smoke. Anyone have any suggestions on where I should go next?
 

d24tdi

Veteran Member
Joined
Jan 6, 2019
Location
MT
TDI
BHW x3, BEW x2, ALH x2, AHU, 1Z, AFB, AKN, AKE, BCZ, BDH
What homework have you done on the process for setting injection pump and camshaft timing on this engine? Do you have any service materials?

Are you aware that the timing is adjusted in increments much finer than a full belt tooth, using a dial test indicator?

The process is easy and the special tools are widely available and very cheap, but if you try to cut corners and do it with paint marks, you will get defeated. Even more so than an electronically managed TDI, the old mechanical engines are totally intolerant of "workaround" attempts. You would think they would be simpler, and they are, but that actually makes them more demanding since they have no way to compensate for any fudge work. The timing has to be set correctly, to the right spec, using the right process and right tools. That's the ONLY way. If it's not, it'll run like dog crap.

Check out @Vince Waldon 's great website for lots of info on the old IDI era engines. Ask him questions if something doesn't make sense.


Why was the injection pump replaced to begin with? Was the timing belt changed as well? If not, do you know how old the belt is?
 
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