Gas to diesel swap, Fuel Filler Fix

[2mAn]

yanked the 16v out and installed a diesel. i know i have to mod the filler neck so it works with the diesel fuel fillers. i cant find the thread on how to do it and the only one that came up on my search had broken links on the pictures and it was already modified anyways so no help there.

ive heard the hammer and chisel method is the best way, but i recall seeing something that was easier.

school me 

[81 vw pu]

What I did on my 81 caddy was take the filler neck out, then I heated the very top connection to melt the soldier and pull apart. then heat the part inside and pulled it out the bottom. then resoldier the neck back together and install.

[GEE-BEE]

Dont forget to replace the 8 inch section of hose, 42 mm I.D.

Fuel tank hose ( rubber )  tank to inlet pipe...

I paid 15.00 for a clean one ( pipe )

GB

[lovinthedeez]

good luck simon.  getter done

[2mAn]

Dont forget to replace the 8 inch section of hose, 42 mm I.D.

I paid 15.00 for a clean one ( pipe )

GB

what 8" section?  not sure what you are talking about

im wondering if there is another way that doesnt require welding because i dont have a welder

[81 vw pu]

You don't need a welder, just a small propane torch and a small roll of soldier. You could also clamp it it a vise and drill it a couple of sizes larger than the diesel pump nozzle Which ever way you do it be sure to blow it off with compressed air to remove any chips or debris, and don't attempt to do it while its still on the car. 1 spark  is all it takes to get yourself an ER visit.

[overdrivegear]

What I did on my 81 caddy was take the filler neck out, then I heated the very top connection to melt the soldier and pull apart. then heat the part inside and pulled it out the bottom. then resoldier the neck back together and install.

Did you do this with the tank out of the car? I need to do this to my Cabriolet. Any one have pics? I haven't even figured out how the filler neck comes off while still in the car.

[81 vw pu]

No, I did not remove the fuel tank on my 81 caddy to remove the filler neck. There are 3 screws/bolts around the fuel cap that hold the top of the filler neck to the body, then follow the metal filler neck down to where it connects to the rubber hose and loosen the clamp and remove. It has to come out from under the fenderwell. I also had a vent tube I had to remove also. I see your working on a cabriolet so the metal pipe should be longer than my caddy. I  Have a 81 rabbit and the filler neck is alot longer than my caddy. it drops down behind the tire before it meets the rubber hose right beside the spare tire well.
This is my 81 rabbit, remove these 3 screws.

View from under back of car. loosen hose clamp and remove here.