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I was getting into this thread and read through the bad news. It's ok. Damn. Smoke problem could be cured through removing the cat, bigger diameter exhaust, and using Biodiesel (B20). Make sure she has a good size air filter. I'd be happy with the 3300 rev limiter. Diesels are low rpm units, most the torque at the bottom end. I'd say try to keep the RPMs below 2000 at 55 mph. Short shifting ok in my book, especially for hypermiling. Not really a comparison, but my F250 diesel has 4.10 gears and I do 1750 rpm at 55 mph. I think I am running around a .70 (+/- .02) overdrive.
Edison didn't get the light bulb right on the first try. What a rush though getting that diesel Metro on the road. I woulda loved to be riding shotgun, tools in hand! Hope you get it worked out...
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