I have both a 100bhp tdi and a 130 tdi, the 100 returns 50mpg at best and the 130 has averaged 60mpg over the last 2600 miles.
I am in the process of discovering the reason for the 20% better frugality of the 130.
I have fitted a new thermostat (now opens at 89.1 as opposed to 78.6) and a new coolant temp sensor, no change in mpg.
I swapped the manifold airflow sensors, no change.
I fitted a new manifold pressure sensor (they are incompatible as the 130 is an 05 and the 100 is an 02 car) no result, well the mpg did not go up but the car went into limp mode at 3000rpm, I refitted the old one and no problems (except the mpg discrepancy). I have sent a message to Ebay seller su_nioj informing him that his product is either the wrong part (VW part number had been removed!) or it is a faulty part he sent me.
I have checked the brakes for dragging, no problems.
Anyone have suggestions as how to trouble shoot this problem?