Removing Fuel Filler insert

bugnout · **Posted:** Fri Jun 16, 2006 11:46 pm

Anyone tried to remove this insert? I find it frustrating to not be able to use any diesel pump at the station. At least once I've had to head on down the road because the only pump at the station with the small size nozel was broken.

glaspak845 · **Posted:** Sat Jun 17, 2006 12:01 am

I was thinking of ordering this piece and enlarging the filler hole to accomodate the larger pumps but haven't gotten that far yet. I thought some of the CRD's had the large filler necks but who knows, all I know is that my '06 has the smaller neck and it's annoying.

0311_DoC · **Posted:** Sat Jun 17, 2006 12:45 am

I guess i got lucky, mine fits with the larger nozzles....

RFCRD · **Posted:** Sat Jun 17, 2006 7:37 am

Some of the larger nozzles will fit but they wont if they have the flared end. I'm also looking at opening up the hole slightly (won't take much) to accommodate a large nozzle. Just hasn't been a priority.

oldnavy · **Posted:** Sat Jun 17, 2006 9:15 am

There are 3 standard sizes used in US for diesel,

1.) The really big one that my wife can't even pick up, that is the high volume nozzle for OTR rigs and the tanks that farmers have in the back of the PU trucks. This one will NOT fit into a CRD, it would just barely fit if you took out the whole filler restricter insert.

2.) Standard diesel nozzle used for PU trucks & delivery vans and it may be the old leaded regular gas nozzle and this one just barely fits the hole and sometimes needs to be wiggled if you are not holding the nozzle just right. This nozzle may not be the exact old leaded gas nozzle but a newer and slightly bigger nozzle then the old leaded gas nozzle.

3.) Then there is a nozzle that I believe is the same nozzle as the unleaded gas nozzle, but may be a new size that's a little bigger then the unleaded nozzle, anyway it is most often used at the auto/PU truck pumps.

I would rather use the #3 nozzle as it is easiest to handle and does a better job of allowing to do slow fill for less foam then others.

The #1 nozzle will fill our 20 gal tank in about 10 seconds at full flow, which means you often got splash back when filling the '03 and earlier VW's that would take these nozzles. Been there, done that.

I have never done an actual search on the net but there may be other size nozzles made for the commercial filling station use but I doubt that is the case, probably just some of the old nozzles from the leaded gas days still around in warehouses or station parts shelves trhat end up being used on the diesel pumps for auto/PU trucks.

spoonplugger1 · **Posted:** Sat Jun 17, 2006 9:31 am

My '05 fits everything I've pulled up to. It luckily also seems to fill with little foam, it takes about 1 1/2 qts extra to top off from when it first shuts off.

RFCRD · **Posted:** Sat Jun 17, 2006 10:22 am

RFCRD wrote:

Some of the larger nozzles will fit but they wont if they have the flared end. I'm also looking at opening up the hole slightly (won't take much) to accommodate a large nozzle. Just hasn't been a priority.

Should also add, anyone looking to do this should take the time to remove the fuel fill assembly from the Jeep before trying to cut/grind on it. It wouldn't take but a small piece of plastic to fall into the tank and get sucked into the fuel lines to cause a big mystery problem.

oldnavy · **Posted:** Sat Jun 17, 2006 10:53 am

spoonplugger1 wrote:

My '05 fits everything I've pulled up to. It luckily also seems to fill with little foam, it takes about 1 1/2 qts extra to top off from when it first shuts off.

You just haven't been lucky enough to pull into the high volume pump for the big semi's as yet, it's about 1/2" to 5/8" to large in diameter to go through the flap hole. :wink:

Goglio704 · **Posted:** Sat Jun 17, 2006 11:13 am

The problem I've run into is that the Farmer's Co-op where I can buy B99 only dispenses #2D through the monster nozzle. As a result I can't fill with a blend there. The timing of this thread is interesting because I was thinking about opening up the filler this weekend.

Goglio704 · **Posted:** Sat Jun 17, 2006 5:33 pm

Well, I did it. I took out the three torx head screws that are exposed when you open the filler door. This allows you to move the thing around enough to loosen the hose clamp that attaches the rubber hose to the bottom of the filler neck. Unfortunately, the hose was severely stuck, and I wound up removing the hose at the tank. It came off the tank easily, but then you have to feed the hose back through the frame. Not fun, but possible. The vent line is clipped to the filler neck with a plasic clamp and there is a ground strap from the filler neck over to the body. It simply pushes over the sheet metal edge. With all this done you can work the whole assembly out the bottom. Once it was out I drilled nearly adjoining holes all the way around the edge of the restriction, cut it out, and used a small drum sander in a drill to clean it up. Washed the crud out of it and put it back in. It looks like it was built that way. You'd have to be looking for it to notice the mod.

bbo · **Joined:** Fri Sep 30, 2005 5:17 pm **Posts:** 382

I don't suppose you have a pic ? .. .have you had to fill up yet?

Goglio704 · **Posted:** Sun Jun 18, 2006 10:25 am

bbo wrote:

I don't suppose you have a pic ? .. .have you had to fill up yet?

Haven't filled yet, but here's a pic. Click for larger.

bugnout · **Posted:** Sun Jun 18, 2006 4:32 pm

Very Nice, Sounds like a couple of hours of work to get it out, modify and replace it.

Thats next weekends project!!!

vtdog · **Joined:** Fri Sep 30, 2005 11:27 am **Posts:** 640

The only time I had a problem with not finding the smaller nozzle to fit the CRD was at a truck stop where the attendant told me "we don't fill cars here-go to the car diesel pump down the street". His attitude was pretty bad, but then he's the one making minimum wage, not me.

Anyway, the fix seems like too much work for the reward. I don't think I will bother taking the fuel filler apart. I will just drive down the street.

Goglio704 · **Posted:** Sun Jun 18, 2006 8:59 pm

vtdog wrote:

The only time I had a problem with not finding the smaller nozzle to fit the CRD was at a truck stop where the attendant told me "we don't fill cars here-go to the car diesel pump down the street". His attitude was pretty bad, but then he's the one making minimum wage, not me.

Anyway, the fix seems like too much work for the reward. I don't think I will bother taking the fuel filler apart. I will just drive down the street.

That works too, but I have been places (the boonies) in the past where the only diesel pump had the large nozzle. Don't really know why DC did it the way they did unless it is simply a carryover from the gas?

P.S. It also makes it much easier to pack the tank full when you can see better.

Removing Fuel Filler insert

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