Since the issue is cited as the HPFP overheating, I suspect the ambient temperature you drive in has a lot to do with it. U.S. desert southwest, be careful. Canadian winter, not so much.lol i dont subscribe to the mass paranoia...ive filled tdi for 15 years below the fuel light almost every tank, never had a single issue with the 5 or 6 ive owned...fuel quality is far more of a factor by far
The engineers who designed the engine put the fuel return line in there for a reason. They knew the engine cooling requirements, so I will indulge them and be sure to feed cool fuel into their cooling system. I usually fill between 1/8 and 1/4 tank. Very rarely below 1/8, partly for this reason, partly because the low fuel warning hides some of the info being displayed (like odometer, which I kinda need to track my miles driven for tax purposes).