"cut and splice the return line."
I think this may be the way to go. However, I have never run across a line
like this. Question is... is there metal in this line and is the rubber just a sheath? If so then instead of just cutting it with good snips I would use a hacksaw blade? Snips would deform the line if it is metal.. I would think.
If you have done this, any insight would be great! The fewer new bits an pieces and parts I have to buy the better!
I did get it out to the point where I could see in the tank and it appears to be very clean.. no sludge or crud.. so that is a good thing.
If the pump appears to be good I will still replace any lines in the tank and also the supply line between the tank outlet and the external pump.
I also am going to put a new coil in as it is listed as one of five factors for the air bypass valve (ECU input for engine speed) I checked the resistnce across the terminals an it didnt match what the manual specs it to be. But I am using a Chilton at the moment. Haynes is on my list ;-)
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vw bus site - http://www.geocities.com/vw_bus_74/index.html