When S3 fuel tanks go bad...

[Sparky]

Did tanks for Colin @Choppa last week down at his lovely place in Dorset.  Stayed over and we had a drink or six, smashing.  This job was notable as it was the first time I've had to butcher a tank insitu to get it out.  No way was that LH tank moving with the engine in place.  Forunately I had my Milwaukee reciprocating saw handy.  It was messy.

[Bibs]

Tank tape, job done! No?

[Sparky]

Just needed a couple more inches.  A constant niggle.

[Choppa]

1 hour ago, Sparky said:

Just needed a couple more inches.  A constant niggle.

That's what my wife says 

[peteyg]

Is that what E10 does...?

[Sparky]

To be fair, he did get the lump hammer work for free.

[DrieStone]

On 10/03/2022 at 15:25, Sparky said:

Did tanks for Colin @Choppa last week down at his lovely place in Dorset.  Stayed over and we had a drink or six, smashing.  This job was notable as it was the first time I've had to butcher a tank insitu to get it out.  No way was that LH tank moving with the engine in place.  Forunately I had my Milwaukee reciprocating saw handy.  It was messy.

Interesting, I just pulled both tanks with the engine in place. Had to remove seatbelts and the mounts for the struts for the hatch, but got them both out and refurbed and back into the car. It's certainly a tight fit that took some wiggling. The right side is the worst for sure.

I wonder if there are some differences between Domestic and Federal (US) cars that mean that it's possible on US cars but not UK cars?

[Sparky]

S3 N/A tanks are an entirely different shape, as is the surrounding area.  I'll pull Turbo tanks out all day with no major issues!

[Choppa]

1 hour ago, DrieStone said:

 The right side is the worst for sure.
 

That photo is actually the LH tank on my S3, the one that doesn't have the fuel sender. Sparky was able to pop the RH one out without a problem, with all the trunking and air boxes out of the way it took maybe 15 minutes, plus a few expletives.

Mine is a 85/6 car and I've since noticed that the earlier S3 cars have a different shelf arrangement over the tanks which may mean that the tanks on both sides come out without an issue.

[DrieStone]

1 hour ago, Sparky said:

S3 N/A tanks are an entirely different shape, as is the surrounding area.  I'll pull Turbo tanks out all day with no major issues!

I guess I'm happy I have a turbo then! Good to know!

[GreenGoddess]

Interesting. I'm fairly sure the tanks on my 84 Turbo need replacing. Is it a job a mere mortal can do? Obviously I won't be removing the engine as that is way beyond my capability.

And if you had to cut one of the tanks to remove it then how did you get the new tank installed?

[Gis]

Can be done without engine out. The new tanks are usually a bit smaller so install is easy

[Sparky]

@GreenGoddess yours is a Turbo, so nowhere near the hassle.  However, the LH tank may not clear the engine easily.