30G Ipod Video, exchange for defect, now new problem

I had a 30G video Ipod, audio jack was defective, apple store gave me a new one. Problem is, the new ipod will only download itunes playlists (752 songs/audio books) but will not download the library, 1152 total songs. Ipod 800 # was not helpful after downloading any updates and wiping out ipod to factory settings.
I am about to toss this thing in the trash!!! How do I get the songs from the itunes library onto the ipod? They are NOT purchased but burned, and I got them on the old 30G. I am using windows XP, fujitsu N series new lifebook.
30G video ipod   Windows XP  

Have you checked the iPod options in iTunes to make sure it is set to sync all songs and not just playlists? When the iPod is connected CTRL-click on the iPod icon, and select "Options". Make sure the sync settings are as you want them.

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