I think I understand. I have done the same project just on a 560sel. I always found I was rich when I put it back. It is not the base setting it is actually the fuel air mixture setting. Steve told me to make it lean by default and he was right. When you start it the air plate actually drops lower than where it is when sitting this richens the fuel and floods the car. so adjust the fuel air mixture lean. I then had the wife start the car while I pushed on the air flow plate untill I got it where it would start correctly and adjusted the fuel air mixture accordingly from there.
m

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Martin Ingram
Colorado Springs
2005 320 CDI
2006.5 VW Jetta TDI
1991 560SEL (179000 Sold)
1972 280SEL 4.5 ('The Lead Sled' 320000 miles when sold.)
1972 220D (225000 when sold)