Filler Neck.

kd4yor

Veteran Member
Joined
Mar 13, 2004
Location
Gwinnett, GA
TDI
J5
I just had a look at my wifes 06. There is a large vent at the top. Guarded by three ribs and at the bottom there are two small vents at 5 and 7 o'clock. Now reach a finger in the center hole. Feel that edge in there? the reducer is just a molded funnel. You should be able to cut it out. I'll try in a few weeks and report back.

Pat
 

Mach1

Vendor , w/Business number
Joined
Sep 27, 2005
Location
Spicewood, Tx.
TDI
05.5 Jetta 5 spd, 06 Jetta DE DSG, 04 F250 6L, 2000 F250 7.3L
I was looking at that and was concerned that the shavings would be hard to catch. The filler neck seems to be glued to the tank, a cut and splice could be made. I believe even if we modded the filler neck/opening, there is still the p-trap later down towards the tank that is going to interfere/impede with the flow to the tank. There will still be reduced flow. Its like you would have to redesign the entire fuel tank/filler neck combo. I could not even see where you could make a cut, because of the shape of the filler neck ISN'T round and is inconsistant in size and shape..

This is a tough one..Maybe a vent hose from the main tank to the filler neck at the top. But you still have to pull the tank, drill and tap/glue..There is no room to work inbetween the rear fender and the inside of the fender well..
 

StElmo

Veteran Member
Joined
Oct 15, 2004
Location
Northern Virginia
TDI
'08 Ram 2500 6.7; '15 Golf SportWagen
This is a tough one..Maybe a vent hose from the main tank to the filler neck at the top. But you still have to pull the tank, drill and tap/glue..There is no room to work inbetween the rear fender and the inside of the fender well..
The vent system already exists minus the valve present in the A4. The valve is in the fuel tank cap. Running an additional line would just increase the number of tank vents already present.
 

turnkey

Active member
Joined
Jul 16, 2005
Location
CT
TDI
jetta,2005.5, graphite blue pkg 2
Re: Filler Neck...DYI filler

I made a funnel to accomodate the larger fuel nozzel used at truck stops after finding myself low on fuel one time with no other option but to use the pump available. This one doesnt work with the largest nozzel (the one with the rim) but its a help.

I made it from 3/4 inch copper pipe and soldered copper [larger pipe]adapters to it. The copper is easy to work with, thin walled so it doesnt constrict much, and conducts static electricity (to ground out the filler system and prevent static build up)
http://pics.tdiclub.com/data/500/39378maine0060.jpg
I made the end just long enough so it could be kept in the filler compartment if used and had fuel on it:
http://pics.tdiclub.com/data/500/39378maine0059.jpg
 

CAATS_Man

Veteran Member
Joined
Jun 21, 2003
Location
South Delta, BC
TDI
2006 Jetta, Pkg2, ESP, DSG, & 8 airbags
Re: Filler Neck...DYI filler

So Turnkey, how did your mod turn out in practice? My TDI delivery date is still nine days away and I could make one to help pass the time. You know - like an expectant father.

CB
 

StElmo

Veteran Member
Joined
Oct 15, 2004
Location
Northern Virginia
TDI
'08 Ram 2500 6.7; '15 Golf SportWagen
Re: Filler Neck...DYI filler

I made a funnel to accomodate the larger fuel nozzel used at truck stops after finding myself low on fuel one time with no other option but to use the pump available. This one doesnt work with the largest nozzel (the one with the rim) but its a help.

I made it from 3/4 inch copper pipe and soldered copper [larger pipe]adapters to it. The copper is easy to work with, thin walled so it doesnt constrict much, and conducts static electricity (to ground out the filler system and prevent static build up)

I made the end just long enough so it could be kept in the filler compartment if used and had fuel on it:
Better get a patent on this like schnell! Looks good. What was the cost to make? How much would you charge? I think this is a good tool to carry around in our A5 VWs (I expect the Golf to have the same problem.)
 

turnkey

Active member
Joined
Jul 16, 2005
Location
CT
TDI
jetta,2005.5, graphite blue pkg 2
Re: Filler Neck...DYI filler

A little more detail:

These are standard plumbing parts from home depot or other hardware stores. The 3/4 pipe is about 2.5 inches long.. it needs to get beyond those metal "fingers" in the filler neck. I used two couplers/adapters (eg the middle one is 3/4x1) to increase the opening at one end to recieve the nozzel. Rather than worry about what fits what to make this, I suggest just trial fitting the peices at the store. Some brands of copper fittings are better (differently shaped,longer necked) for making this. The only thing I tried to do was make it short enough to fit the filler door area for storage, but long enough to get into the filler neck. Use standard water plumbing solder and sweat the joints normally. You might also take some foam tape and make a cradle in filler neck door area so there is no rattling around if you store the funnel in the space under the door. I generally have been keeping the part in the trunk in a zip lock, as its not needed much.

I tried other things too... a disposable water bottle with the neck sanded down and bottom cut off, tapered funnel etc. But all restricted more, or weren't long enough.

This thing works but is no substitute for VOA making a bigger filler neck. You can control the flow somewhat from the large fuel nozzels when filling, but you will get spitting back if your not careful. But its alot better with this then my first experiance was filling up at a truck stop that only had the big nozzels. It doesnt come up as a problem often around here... many stations carry both pump nozzel sizes.

[As an aside, I saw a new tdi owner last month at the station, highly embarrassed, trying to fill up for the first time using one of the large nozzels, and with fuel all over the ground. I pointed out another pump that had the correct nozzel... he didnt realize there were different sizes.]
Cost was around 5.00.
 

jimlockey

Veteran Member
Joined
Jan 17, 2003
Location
Mesquite, Texas
TDI
14 TDI Jetta & 09 TDI Sportwagen
If diesel was toxic there would be a bunch of people dying because most of us that use diesel get diesel on our hands often.

At most truck stops, on the truck side, the pump closest to the building has a small nozzle.

Also at most truck stops they use a high speep pump and we can't vent without get diesel all over the place. Even on the car side some of the diesel pumps are hucked up to the high speed pump.

I've been driving diesels for twelve years and there is a lot more diesel pumps for us to choose from.
 

nmea2020

Veteran Member
Joined
Oct 1, 2005
Location
N.W. Florida
TDI
2010 Jetta DSG Silver 2006 JETTA DSG
Thanks for the bump

StElmo said:
James You Da Man
Thanks for the BUMP. You really are a nice guy underneath it all. Somebody has to be the "Search Saint"(sounds better than "search ****")
I'm glad you have a good sense of humor... Saintly attribute

Seriously though, Thanks for sharing those under carriage shots…nice camera work.

I will get to work making one of these copper adapters just in case.
Man this will be almost as much fun as putting anti siphon in my paintball Co2 tanks. We have a trip to Mi coming up soon so thanks to you I should be well prepared.
 

redbarchetta

Veteran Member
Joined
Sep 18, 2005
Location
North Texas
TDI
06 Jetta TDI, pkg 1, 5 speed
rez311 said:
If you guys think this is bad, the superduty trucks have this standard too.

My 2001 F350 powerstroke diesel can't even take the big nozzle. Yes. 35 gallons of SLOW pumping diesel. Now that is stupid engineering. I had to fill up with a big nozzle once. It sucked.

Here is my theory. Big rigs fill up at the big rig section. Superduty and passenger diesel vehicles fill up in the commuter car section.

It might have something to do with slowing truckers down. Not that it would be a problem, but just a though.
The Dodges don't have this problem. I can fill up at the big rig pumps.
 

TDKozan

Active member
Joined
Apr 4, 2005
Location
Northern Colorado
TDI
'06 Jetta, Reflex Silver
Thanks for the idea turnkey!

If you use a 1.5" -> 1" adaptor for the first stage, it fits the rimmed nozzles around here. I've added one minor modification to make mine less prone to spraying: A homemade "O" ring inside the first stage gives a decent seal. Since I couldn't find anything the right size in a couple hours of poking around town, I ended up taking five inches of 1/4" x 7/64" fuel line and used a screw with the head cut off to pin the ends. It's still a pain to use but it eliminates the spraying back.

TK
 

kstef

Veteran Member
Joined
Aug 8, 2005
Location
Sweet Valley, Pa
TDI
Jetta 2005.5 Black
TDKozan, Can you post a pic of yours fuel nozzle adapter?
Thanks
Keith
TDKozan said:
Thanks for the idea turnkey!

If you use a 1.5" -> 1" adaptor for the first stage, it fits the rimmed nozzles around here. I've added one minor modification to make mine less prone to spraying: A homemade "O" ring inside the first stage gives a decent seal. Since I couldn't find anything the right size in a couple hours of poking around town, I ended up taking five inches of 1/4" x 7/64" fuel line and used a screw with the head cut off to pin the ends. It's still a pain to use but it eliminates the spraying back.

TK
 

TDKozan

Active member
Joined
Apr 4, 2005
Location
Northern Colorado
TDI
'06 Jetta, Reflex Silver
Hi, Keith. The Mk. 1 is pretty much a dead-ringer for turnkey's, pictured above. If it helps, here is some detail on the pieces-parts'n'bits:




From left to right, the copper parts are 3" of 3/4" Cu tubing, a 1" -> 3/4" adaptor, and a 1 1/2" -> 1" adaptor. The o-ring material is 1/4" x 7/64" fuel line and a stainless steel screw, just large enough for the threads to bite inside the tubing.



Detail of the assembled o-ring. Cut fuel line to 4.9", and cut the head off the screw with whatever implement of destruction you prefer. You may have to trim the line a bit but it should fit snugly inside the 1 1/2" adaptor.

The parts pictured above are available from Home Depot, with the exception of the fuel line and screw I got from Ace Hardware. Total cost is ca. $8.50 US.

Assembly is trivial: Sand and clean the inside and outside of all the slip fittings, flux, assemble with the 1 1/2" fitting held in a vise, pointing up, heat with a torch, and solder.

I also made a Mk. 2 using a 1 1/2" -> 3/4" adaptor I found at Big R. That cut a couple of bucks off the price and a minute or so off the assembly time. I don't have it around to give you a picture of since it became a Christmas present for a hunting buddy who also drives a TDI but, it's pretty much what you'd expect.

Clear as mud?

TK
 
Last edited:

StElmo

Veteran Member
Joined
Oct 15, 2004
Location
Northern Virginia
TDI
'08 Ram 2500 6.7; '15 Golf SportWagen
More like murky pond water, translucent, not transparent, which means there is substance to your post and it allows us to see the light! I might try making your Mark II adapter. Thanks for the how to post.
 

Chico

Well-known member
Joined
Sep 7, 2005
Location
Pittsburgh, PA
TDI
Jetta 1998 white
With the temperatures in single digits, and the car pumps frozen the truck nozzels were the only option. Then it took 20 minuites to get 5 gallons of fuel. There need to be an addapter, my hands took over half an hour to thaw out.

My thoughts are to get an addapter that screws on like the cap then widens out to compensate for the vent and the fill. Anyone else got ideas?
 

TDKozan

Active member
Joined
Apr 4, 2005
Location
Northern Colorado
TDI
'06 Jetta, Reflex Silver
If you've got a lathe, drill press, and a block of of the right plastic, you could turn out something like you're describing. Better yet, a CAD whiz with the all the relevant measurements and a CNC mill could bang one out of plastic fairly easily too.

Problem is that either solution needs a hobbyist doing it for the love of a challenge or a specialized shop cranking them out at low volume for painful amounts of money.

The solution you seem to be looking for would be for a manufacturer to set up an injection-molding operation to crank them out and sell them for $12.95 US. (Well, if VOA were to fix the problem. . . Nah, never happen; and we'd all still be stuck.) The difficulty with convincing a specialty manufacturer is that they'd need to sell a stack of these gizmos to recoup the cost of the design, molding, production run, marketing, &c, &c. Unless there's a guaranteed market for someone to sell a few thousand of these puppies, it'll never happen.

My answer was to take turnkey's idea and tweak it a bit. I'm not a nuclear scientist but it's the best solution I can come up with. It takes about the same time using the Cu adaptor on a high-flow pump as it does to fill up with a regular nozzle except you have to stand there and hold it the entire time.

Assuming you're not inclined to throw one together for yourself, a friend with the right skills would probably kick one out for the price of the parts and a few bottles of his (her?) favorite adult beverage. A plumber could probably do it for you for less than $25 too.

Unless you know a speciality shop, I'm afraid that's the limit of your options.

TK
 

adeep42

Member
Joined
Dec 6, 2008
Location
Fort Lee, NJ
TDI
'09 Jetta TDI 6 Speed, Black with Tan Interior, Sunroof and 17" wheels
Any more recent updates on this issue. I recently bought an '09 Jetta TDI 6 speed And ran into this problem on my second refueling.
 

lars12

Member
Joined
Apr 29, 2005
Location
Western Colorado
TDI
Jetta,2009
Simple solution. Get a 3/4 to 1 inch copper fitting. Put a 3 inch copper nipple on the on the 3/4 end. The 3/4 end fits nicely in the filler and the fuel nozzle fits nicely into the other end. Just take it easy on the trigger. Put it in the trunk and use it when you need to use the truck pumps.
 

jimlockey

Veteran Member
Joined
Jan 17, 2003
Location
Mesquite, Texas
TDI
14 TDI Jetta & 09 TDI Sportwagen
The biggest problem might just be the high speed pumps. Some of the pumps have so much pressure I don't begin to top it off.
 

BrentRN

Veteran Member
Joined
Mar 17, 2006
Location
New London, PA USA
TDI
Used to have many. Now a Golf TSI.
So are these adapted kits working well? Do they handle the high pressure nozzles? Looks like a good thing.
I consider the adapter for emergencies only. In some rural stations I have encountered only the large nozzle. You have to have a gentle touch on the pump handle to avoid splashing. I would recommend having one.
 

JSWTDI09

Top Post Dawg
Joined
Jan 31, 2009
Location
Las Vegas, Nevada
TDI
2009 JSW TDI (gone but not forgotten)
So are these adapted kits working well? Do they handle the high pressure nozzles? Looks like a good thing.

They are not perfect, but in an emergency, they are great. I keep one in my car all the time, but I have not yet had to use it.

They have two issues:
1) You must pump slowly, they cannot handle the full flow rate of the large truck nozzles.
2) The auto-shutoff will not work. You need to be careful or you will get diesel fuel all over the ground and yourself.

Have Fun!

Don
 
Top