Removing diesel low flow filler restrictor

[BrianJ]

I am tired of going to a garage to fill up and find they have only one low flow diesel outlet surrounded by petrol bowsers that are all in use. I have no idea why VW put this restrictor in the inlet but its a real pain.

I have looked at it from the filler hole and it looks like it is just a plastic device locked into a metal filler pipe, that should be easy to remove if the filler pipe was taken out of the van.

Has anyone done this? It looks like if the tank cover is removed from under the van then the filler pipe could be disconnected and the restrictor pushed out with a rod from the filler side.

Rant;
Why do most garages have one low flow diesel pump and more than ten petrol when most people own a diesel car these days?

I rang VW but they didn't even know this was a big problem!!!

Brian

[The_Hawk]

Why do most garages have one low flow diesel pump and more than ten petrol when most people own a diesel car these days?

I think it's as simple as history. Unless lots of people complain it's not a problem worth spending money on fixing and I assume that adding new pipe work and/or storage tanks isn't cheap.

Newer or newly renovated servo's tend to have a few diesel pumps, but then there are still places like Gundagai (I think it was there anyway) who have ONE low flow in amongst 4+ high flow diesel pumps off to the side. When I was there last with the Van it was clogged up with diesel cars/van/utes rather than trucks all waiting for the one pump.

I remember reading about an adaptor:

http://www.vwwatercooled.org.au/forums/f136/high-flow-filler-neck-55379.html

but have never seen one in person. I'd imagine you would have to be a little careful so you don't wear the fuel, would also be a little concerned with the stench of the adaptor in the vehicle afterwards. I'm thinking sealable plastic box + gloves, hell maybe even that in another larger box.

[top_oz_bloke]

Interesting to see where this thread goes as I didn't realise the high flow fillers wouldn't fit until I went to use one the other day when the one diesel pump was out of order.

[BrianJ]

What I need to know from anyone who has removed the tank from a transporter is how do I remove the upper part of the filler pipe. It looks like the tank guard needs to be removed and probably then remove a flexible sleeve. Is this correct, and if I disconnect the sleeve, do I need an empty fuel tank or is the tank inlet pipe opening above the fuel level?

Anyone know anything on this.

P.S. I have followed up on adapters mentioned in the old thread, but everyone I rang knew nothing about such a device.

Thanks
Brian

[Sunny43.5]

I think you will find the reason for the hole size is not so much about flow but more to prevent accidental filling with petrol at the bowser . That is why its made that way .

[mikinoz]

Possibly relevant

Grease Works shop notes: '99 Eurovan TDI conversion & manual trans conversion: day 7

[BrianJ]

But the unleaded petrol small nozzle will fit in, so although that may be the answer in Europe, it is no use in Australia.

VW should have modified this for Australia, but unfortunately we are too small a market.

Brian

[mikinoz]

I'm more referring to it as a removal method. How you modify it is up to you.

[BrianJ]

Thanks, I missed your link, I am checking it out now, but it looks like a different model to my 2006 2.5TDI, and the reducer looks different also. In the later tank inlet the reducer is a plastic thing trapped just inside the filler opening.

Brian

[T5 Double off road]

Yes it can be done - Sorry for not seeing this along while ago, this was one of the first mods I did 6 years ago on T5 94kw tdi dual cab, if V W have not changed anything on later models they all might have the same filler ( TDI ). All I used was a sharp strong pointed knife (fishing type) and narrow-nosed pliers with a helper holding powerful torch so you can see what you are doing in a black hole ! Hold the restrict-or part firmly with the pliers (you my have to make a small opening at the side of the main filling hole so you can poke one half of the pliers though it so you can get a good grip of it - then carefully cut it out twisting the blade as you go round in a circle, DON'T push the blade in to deep or side ways or may puncture the filler pipe itself BE WARNED because its all moulded to the fuel tank ! I was careful and had no problems, I can fill up with the truck high-flow at full rate - magic. If any of you member's wish to re-post this info on an up to date site - please do-so as I can do more with engineering than with computers, sorry. DC off-road.

[IN2VWS]

Removing the flap/cover does nothing other than to confirm it is all one piece.
It appears that you only have to cut away the top lip of the current hole.

[BrianJ]

If I understand this correctly, it looks like the restrictor is actually a thinner waist of plastic and you are saying that you used a sharp knife blade to cut the top part of the waist all the way around. Here is a couple more questions: I assume the part closest to the external opening stayed there, but the lower plastic was parted from the upper, what happened to it, did it slide down the pipe? or did you rip it up out of the opening with the pliers?

Thanks for this info
Brian

[IN2VWS]

Does anyone know the diameter of the high flow nozzles?

[BrianJ]

Does anyone know the diameter of the high flow nozzles?

I measured them once and the low flow is 25mm and the high is 30mm as I recall.

Brian

[IN2VWS]

Thanks. If it is 30mm (which I will find out next time I fuel up), then my filler hole is now large enough.

Caveat: - Don't try this at home kids.......I take no responsibility if you stuff your filler neck, but it has worked for me.

When looking at the filler hole, from the 9 o'clock to the 1 o'clock position, there is a lip that needs to be removed in order for the high flow nozzle to fit in. (This is on a MY11 van, not sure if earlier vans are the same)

I have a big mofo soldering iron which I used to melt the plastic lip out of the way. see pic:

I melted a little bit at a time, until the hole was large enough.