Diesel Filler Tube Mod for A/C P/S

[?Waldo?]

Anyone fitting a Mk3 TDI engine with A/C has probably noticed that the filler tube interferes with the compressor. I recently modified a stock filler tube (still available new) in order to tweak the angles a bit and alleviate the interference.

This mod was done on a van that is using the later mounting bars so the engine is more rearward than the '82 bars.

This is where the stock filler tube was sourced:

https://www.vw-t3-bus-shop.de/en/oil-fill-tube-syncro-t3-2wd-and-td-correspond-to-068115304b

I purchased a 1' section of 1-1/4 OD x 1.124 ID steel tube from Speedy Metals.

I made the appropriate cuts and welded a section of the steel tube over the filler tube at the appropriate angle/location.

It fits very nicely around the A/C compressor, power steering pump and right side carrier bar. At its tightest points i can still fit my finger between the tube and its nearest neighbors. Access from the license plate door is excellent.

Someone could probably do it without the sleeve of steel tubing and just cutting and butt welding the tube but I figure it was worth the $ to make it easy on myself.

When welding I wrapped a wet towel around the metal tube where it enters the plastic extension to prevent it from getting too hot.

[ALIKA T3]

This is great Andy!

I have the same set up ass you but on Syncro, that seems rather easy to do, and I have the filler tube already
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[Gnarlodious]

Thanks, I need to do that before my engine gets old and starts using oil. Did you imply that the tube is long enough to cut and reassemble or did you add that sleeve as an extension? I have one of those but to hold it in place it doesn’t fit. Is that because my AAZ wasn’t made for the Vanagon, but the tube is for a JX with P/S pump?
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Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[ALIKA T3]

[?Waldo?]

Thanks Alika, I imagine the mod would be similar on a syncro but with the engine lower relative to the license plate door you might have to tweak the angle a little differently.

Gnarlie, there are several different version of diesel filler tubes. That tube was a later design than the stock '83 tube and will accommodate engines with or without power steering. If you do not have A/C, then the filler tube should fit on an AAZ without modification. If you do have A/C, then the tube interferes with the compressor. The sleeve is not needed for additional length but rather to change the angles slightly. I actually shortened the tube a bit.

Here's a pic side by side with an unmodified tube of the same design.

[Team WorldTour]

I'm SO glad I paid the $$ for the aluminum straight tube! I have an AAZ, and of all the problems I have/ had, this is not one of them!
I hope these work for you.
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[Paulbeard]

[?Waldo?]

[Paulbeard]

[Gnarlodious]

I have AAZ with the (larger) Jetta power steering pump and have not found a tube that fits. If anyone has any suggestions...
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Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[?Waldo?]

The stock unmodified tube that I have linked above fits fine around the stock Mk3 Jetta AAZ power steering pump. The interference is with the A/C compressor. If you do not have A/C then the stock unmodified filler tube I have linked above should fit fine. If you doubt that, then I can remove the compressor and bolt it up and take a picture tomorrow. If there is further question about it, then post a couple pics of your engine and accessories so I can see what the issue is.

[Paulbeard]

I have an A/C compressor I don't use so if it came down to it, I could take off the belt. I'll know more when it all arrives and I can check fitment. If there are measurements I can provide, I can do that.
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Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs

[?Waldo?]

[Gnarlodious]

This is the tube I bought thinking it would fit:

Probably not what you want to see but a bottom shot of my engine, its pretty tight in there:

I figured to make it bolt on I would need to remove the muffler and carrier bar and possibly the reservoir. I thought I should be ready to reposition my muffler. What’s your opinion and thanks for the advice Andrew. This has been on my to-do list for a year.
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Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[?Waldo?]

It's a bit hard to tell from the pic but you probably don't need to remove anything other than the plate that is currently blocking the hole in the pan (and the oil first, of course). If you look at the initial pics I posted you can get a good idea of the routing of the tube but from what I can see it looks like the muffler is well below where the tube goes.

[Paulbeard]

These pictures (in all manner of orientation) are from my ABA with P/S and A/C. I think the compressor is far enough to the drivers side (behind the overflow tank) to be a non-issue.

The tube and associated parts are ordered so I guess I'll find out soon enough if this will work.
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Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs

[?Waldo?]

My concern on your setup would be interference with the alternator. It appears to be a custom bracket so I'm unsure. Please report back when you know.

[Paulbeard]

[?Waldo?]

[Gnarlodious]