[kcfoxie]

Hi! Some things I'd suggest:

The clunk you hear is likely the wheel bearing. Get that replaced, infact, I'd go ahead and drop the $ to have the front end rebuilt. Mine made it to 230k but it was also sitting a half inch shorter due to worn out parts... at 160k if it hasn't been done it's time.

PSI plays a role but I'd worry about my suspension hardware being in good shape first before playing with the PSI, just my opinion.

CLEAN THAT INTAKE!! And DO block it off. Software can eliminate that CEL, talk to RocketChip, Unitronic, or any of the other chip vendors (TDIClub.com for reference, note they're heavily biased towards Jeff at Rocketchip).

The B20 is worth the price in regards to the reduction of sooting in the intake and the lubricity it brings back to the Ultra Low Sulphur Diesel. Your injection pump may thank you for it, but then again it may never. I'm a big supporter/believer in Bio and neither of my cars run without at least 10% in them for long periods of time if I can help it. Presently I gave 2.99 for B100 -- thats 9 cents over the D2 or B20 price. Totally worth it since it's made in state with in state crops.

70-80mph with this car will get no better than 46mpg I don't think. Slowing down to 60-65 will bring that up about 7mpg, to close to 53mpg. A software flash, and I base this off a local guy's 2000 TDI that was recently flashed, can add up to 6mpg. I say can because you shouldn't expect that. He was getting 55mpg regularly and after the flash he has had two 60mpg tanks. I don't know how slow he's driving, but I imagine it's pretty slow...

Change all your filters: fuel and air. This makes a big improvement, I actually had a clogged fuel filter so bad I was losing all power in 2nd and 3rd above 3500rpm... it would just sit there and choke and buck.... changed the filter out and now I've got 130mi and I'm not anywhere near the quarter mark on the tank yet.

VENT your tank. Remove the pass. tail light, you'll see the white plastic inside the filler neck... use a flat head to pop the tab free and remove it, press the two tabs on the sides and pull the little device you removed apart and take the spring and switch out then reinstall. This adds about 1.5 gallon capacity to your car, ALWAYS fill to the neck (JUST below that valve -- don't let fuel get into the valve or it'll fill the airsack with diesel fuel). Diesels don't need the airsack bladder but they used the same tanks gas and diesel, the change being to the filler neck. IT's perfectly OK to perm. disable this baldder as the MkV and laters don't have one *at all.*

It takes at least 3 tanks to get a real average. Make your mods and then get 3 tanks under the new belt and do an average calc in a spreadsheet. I think you'll see a big improvement.