Syncro filler neck unleaded restrictor removal Hans Solved

[MarkWard]

Hello, I did use the search, but may not have composed my search string well enough. I want to remove the unleaded fuel restrictor before I reinstall the syncro filler neck assembly. It is my intention to run the WBX engine for a while longer while I sort the driveline conversion out. I intend to convert to diesel power at a later date. I'd like to take the filler assembly apart only once.

Has any member dissected one of these syncro filler necks? I can see two spot welds that seem to secure the restrictor, but the fit is too good for me to believe all I need to do is to drill out the two spot welds and collapse the restrictor. Seems like a hole saw if I can secure the neck while I drill out the restrictor might be a better solution.

While I was searching, I did find a post that someone cautioned that you could not fill the tank with unleaded once the restrictor was removed. Something about the unleaded pump not being happy. Anything to that? Thank you.
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[hans j]

That is the only thing holding it in. I used an air hammer with chisel to get mine out. I might have photos in my gallery of it?
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1986 Canadian Syncro Westy TDI - 1989 Syncro Single Cab - 2001 Audi S4 - 1981 VW Caddy ABA - 1980 VW Caddy EV - 1973 VW T-181

[MarkWard]

Found it Hans.

That helps. Still wondering about not being able to fill it with unleaded for the time being. I have filled numerous jugs for my generator during hurricane season and not had a problem dispensing fuel into them.

Thanks for the info. Mark

Edit: Removed. I used a grinding burr on the inside of the restrictor to thin the metal around the two factory spot welds. With a combination of two air hammer bits I have for removing exhaust pipes, I was carefully able to remove the insert without damage to the outer piece. Thank you Hans. A picture is worth a thousand words.
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[AndyBees]

Mark, it has been 8 years ago, but based on the comments I made in my TDI Club gallery, I used a Dremel to enlarge the filler neck opening. It has worked just fine using Auto Pump Diesel dispensing nozzles. I've never tried that big nozzles at the Truck Stops.

Here are a couple of pics (before and after)

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'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003.