Removing diesel low flow filler restrictor

[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.

[BrianJ]

I had considered the soldering iron idea, but wasn't shure if diesel fuel could ignite.
Excellent work, could you show another image of the inside of the hole now its done?

Brian

[IN2VWS]

Not pretty......but it works.

[BrianJ]

Very good, so it looks like you didn't cut right through it with the iron, you used the heat to melt it back into a bigger diameter. I think I will tackle that on mine.

Is this correct?

Brian

[IN2VWS]

yes....no cutting at all. I just used heat to melt the excess lip from the 9 o'clock to the 2 o'clock position.
As mentioned earlier, I am not sure what the earlier filler necks look like. but on my MY11 van it looks like this.
When you get out to your van, open the flap and put your finger in the hole, and make tiny little circles until you feel the sweet spot. Might as well call it a G spot, as some people might think it does not exist.

[rob64981]

I like this thread and it will make filling up easier.

Love the drawing IN2VWS...!!!

My Multi is from 2006 and has the same filler neck,

So it looks like all TDIs had the same restrictive filler hole.

Rob