Volkswagen diesels made between 1975-1995


75-95 Volkswagen Troubleshooting
Problem: Lacks power, runs rough, stalls on vegetable oil and/or diesel.
*Before attempting to troubleshoot this or any other fuel system problem, verify vegetable oil filter and diesel filter are not clogged. 
*Verify all plumbing connections are correct and match manual exactly.
*Verify wiring is correct: Use a test light to observe that both A and B valves energize when on veg, Only B valve energizes on purge and no valves energize when on diesel. Also confirm that valves are grounded securely.
You can also test operation by listening/feeling the valves, they should produce an audible click when turned ON or OFF.
 Air leaks: To find an airleak, a clear section of fuel line can be installed in various locations throughout the fuel system to determine the source of the leak. Run the engine to observe any air bubbles in the clear line. If necessary, move the section of clear line to other locations to determine the exact location of the leak. A vacuum/pressure gun (Mityvac or cylindrical type suction gun) can be handy to apply pressure or vacuum to fuel system to help find the source of an air leak.
1) Inspect injector return lines for leaks, replace as necessary. These are often in poor condition and will cause air in system when on vegetable oil due to the presence of vacuum on these lines while on veg with looped fuel system.
            2) Check all hose connections, especially hose connection at return from injection pump. The return line connection on these engines uses a smaller hose barb and an adaptor may be necessary to get a good seal. 
            3) Verify pex line in tank is submerged and is secured to bottom of tank. 
            4) Verify drain screw on filter is secure.
            5) Verify filter is tightened securely and seal is intact.
6) Verify solonoid valve stems are tight. These are the parts in the center of valve which screw into the body. If the stems requires tightening, a spanner wrench is the appropriate tool. If no spanner wrench is available, you can lock two nuts together at the top of the stem and then tighten with wrench. Do not use pliars to tighten stem as it is easily dented and will cause valve to jam.
Restrictions/excessive vacuum: To check for restriction, use a vacuum gauge to monitor vacuum while engine is running, preferably under load. Install the vacuum gauge at the inlet of lift pump, if vacuum exceeds 14”, a high vacuum condition exists and can cause poor performance, cavitation, air leaks and decreased filter life. A vacuum gun (mityvac) or suction gun can be used to apply vacuum or pressure to help diagnose restrictions and to clear any obstructions.
1) Clogged filter, change filter and inspect contents. Poor filter life can usually be attributed to inadequete filtration, poor oil quality or the presence of algea contamination in fuel system.
2) Tank not venting, verify vent in fuel cap is not plugged. To test for this leave cap loose or remove a screw from hatch plate. If ever there is a vacuum in the tank after driving on vegetable oil, the vent is probably plugged. Also verify diesel cap is venting, the diesel cap must vent well since when purging, the volume of fuel displaced from tank is increased due to return fuel being sent to veg loop. This can cause increased vacuum in diesel tank at shutdown and may cause fuel to be drawn back to tank (loss of prime).
            3) Debris in tank obstructing pex line or covering inlet of pex line, inspect tank and pex line for debris.
            4) Kinked fuel hose or pex line, excessively long lengths of fuel hose or pex line.
            5) Obstruction in valve, verify that valve flows freely and seals in both positions.
Problem: Vegetable oil tank filling with diesel:
            1) Left on purge cycle
            2) B (return valve) stuck in ON position when on diesel, sending returned diesel to veg tank
            3) A (supply valve) not energizing when switched to veg or has poor ground, causing diesel to    return to veg tank
Problem: Diesel tank filling with vegetable oil
            1) Not purging long enough or frequently switching between fuels.
            2) B (return) valve not energizing or has poor ground, stuck in N.O. Position
            3) A (supply) valve stuck in ON position
Problem: Filter and tank not getting warm, coolant not flowing.
            1) Coolant hoses air locked, try filling hoses with coolant and then driving vehicle for      approximately 20 minutes. Monitor coolant level and add as necessary, as air is displaced, coolant level will drop.
            2) Coolant hoses kinked or routed excessively high.
3) Coolant hoses not plumbed correctly. Supply coolant must be plumbed into heater supply hose from Cyl head, return coolant hose must return to water pump.
            4) Coolant level low, not refilled after installation.
Problem: Low vegetable oil temps.
            1) Verify meter is accurate, double check with thermometer or another meter. Verify that meter is wired correctly and is grounded well.
            2) Incorrect vegetable oil filter installed and does not fit in coil securely, causing poor heat transfer. If a crossover filter is used, use a strip of aluminum flashing or foil tape around the filter so that it fits in the coil securely.
            3) Low coolant temps. Verify coolant is approximately 190F, if running to cool, replace thermostat.
4) Filter or hoses exposed to direct wind, insulate as necessary and avoid excessive hose length.