I finally gave up on my '83 and simply adjusted my expectations. It meant to go full out on acceleration so that it wouldn't flare.

For a month or two I built an insert piece that leaked some air but not all of it. I thought I had a brilliant solution, but that ended up not resolving my problem as well as I'd hoped.

Its unfortunate that the first shift is so hard without vac, otherwise you could simply disable it like I ended up doing.

I'm assuming that you've read the 'Steve Brotherton' article (5 pages....the guy is the ultimate guru). If not, search under "flaring" (diesel don) and it has a link there.

Don

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DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed