Hi, I am new to this forum, but not new to VW's or diesels. I have owned a couple 1.6TD Jetta's and many 1.9TDI Jetta's. I have been a mechanic for many years, work on all my own stuff, plus did a lot of semi-truck diesel repair, which does not necessarily help out a lot on these old 1.6TD. Anyways, I recently purchased a Suzuki Samurai with a VW 1.6TD/Acme conversion. I have been all over the rig, and it seems like everything was done right. It has been together and running for about 5K miles. The engine was completely rebuilt(I was told) and it seems to be true. No blowby, no oil usage, seems to run great, good power, only black smokes under heavy load/acceleration, will make 10PSI boost. I started looking in to it because of several things I have noticed, the major one being is that it is getting HORRIBLE fuel mileage. About 21-22MPG. I was expecting 35 MPG, and have seen reports of 40MPG with my same set up. I was told they took a complete engine out of a running car and rebuilt it, so everything should be matched together, and it seems so. By my best guess, the engine is out of about a 1986 Jetta, it has a mechanical head, 12MM head bolts, looks like the correct TD fuel pump and the correct wastegated turbo. So I started looking in to stuff, fuel pump seems set stock, has all the plugs and yellow seal marks on it. All the obvious stuff seems ok, and like I said, it has good power/runs good but it has a effective 5.25:1 rearend gear ratio, so anything would seem to have good power in a 2700 LB vehicle. My first thought was a timing belt/injection timing issue/error for a couple reasons, the obvious terrible fuel economy(I wouldn't think a good running 1.6TD would get as bad as 21MPG if you ran it wide open all the time) AND because the cold start/warm up lever has NO effect on how the engine runs(It is properly adjusted), my understanding is that lever advances the injection timing. So, I pulled the belt cover to first check that all the marks line up and I am having difficulty there, I can not find a timing mark on the cam gear anywhere, I can not use the flywheel mark to determine TDC, because it is now mated to a Suzuki transmission with a ACME flywheel. I was able to line up the injection pump mark correctly and verify that the tool locks in, the cam lobes looked like they were properly in the up position. I would think that if the cam was even one tooth off from TDC, the valves would hit, but I am not positive. It makes good boost, but you have to get it wound up to do it. It seems like the injection timing is retarded, could it be a full tooth off, or could it be retarded that bad on the plate? I know all the procedures, I just hate to tear half the motor apart for something that could be simple/nothing. Any help would be appreciated.