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I am not familiar with all you done to your engine but did you replace the plunger at all, maybe by mistake put it down on the table an picked up a different one or if you swapped pumps and it came with the plunger, did you compare them to be sure they are the correct ones? The only other thing would be as you did check the Dizzy is turning with the engine to ensure the cam. So if all the above are correct I can only suggest that the lobe where the plunger rides has excessive wear, highly unlikely but possible. David 67 Baltic Blue Fastback ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org