Major trouble

[travisdj]

The water trap (you are calling it the expansion tank??) is often a source of an air leak into the fuel system. The cheap plastic construction breaks down in cracks so that the fuel is getting air as the pump attempts to draw from the the fuel tank beyond.  Bypass it with some neoprene hose, hose barbs and clamps. You will probably find that this is your problem zone. Besides, with the generally good quality of fuel here as well as the throw away fuel filter under the hood, you probably don't need the separator anyway.

Ok, I'm sorry for the using the wrong terminology. I appreciate the help. I will replace the lines today and see how it goes. That should take care of it. The fuel would make it to the water trap but would not make it past it. I guess there is something wrong with the trap. I really do appreciate everyone's help. I am trying to learn everything I can about both of my diesels and you guys are a great help.

[burn_your_money]

This is probably what's wrong with your water strainer

http://vwdiesel.net/phpBB/viewtopic.php?t=7353

Don't worry about all that crap in the picture, your other filter will get it

Just by-pass it, only mk2 diesels have it, VW dropped it in 1993

[madmedix]

And be really careful with the anti-drainback valve. Fragile and about the price of 3 2-4's.

Andy

[travisdj]

Well got the fuel flowin and the motor runnin, but the pump is leaking like crazy. Pulled the pump and waiting for my buddy to help me reseal it. The main shaft seal won't come off and one of the head bolts stripped right out. Once I get the pump taken care of I'll be in business.

[travisdj]

Got it running and it is running pretty darn good if I say so myself. I drove it on a 310 mile trip and got roughly 43 mpg while doing 65 to 70. I am going to do 55 on my trip home and see how well it does. I appreciate everyone's help. You guys rock.

[rabbitman]

Hey, what was your mpg when you go 55?

[travisdj]

Hey, what was your mpg when you go 55?

My rough estimate is 48-50mpg. Now all I need to do is lube the throttle cable and have the exhaust fixed.

[rabbitman]

wow, thats better than I can get