Ooops just immobilised my D3

[MikkiJayne]

Yeah a dremel is the best tool for this. I had a few like this on my D2. Cut the heads off the nuts to remove the tank, and then cut the nutserts off the body from underneath. I've got plenty of spares plus an improvised tool to set them so PM me if you need a few, or cable tie it for now and swing by next time you're passing

Alternatively you could also melt through the plastic with a soldering iron, if you don't want to put a saw near the bottom one. Or heat up an old kitchen knife with a blowtorch and melt it with that.

[47p2]

You have access to the bolts from under the wheel arches, have you tried putting the mole grips underneath and holding the captive nut? If that doesn't work then as said a Dremel or some careful drilling them out and just put a normal nut & bolt in to hold the new expansion bottle in place

[mannyo]

Thing is that I only have basic tools at home plus the car is parked on gravel with no hardstanding available to jack up and remove the wheel. but I can get a soldering iron from work to see if I can melt the plastic.

If I can get the pipes back on, and as long as not too much coolant flows through the crack I wonder if MikkyJayne can get the car up on the lift again although I am busy for the next few weekends.

Either way the D3 maybe off the road now for a few weeks, but I still have the Volvo as a working car (albeit that has its own issues).

[47p2]

Shouldn't need to remove the wheel for access, I've just had a look at mine and can easily access the underneath where the bolts come through

[mannyo]

Good point, could try lift mode.

[mannyo]

Had another look this evening,

Yes you can get to the bottom of the nuts, the bad news is that no matter how hard I grip them they just keep spinning.

I've now put the hoses back on, only problem is that all the wiggling to get the return pipe off must have enlarged the crack as all it now leaks more than before and not much I can do to reduce the flow as the split is right up as far as you can push the pipe.

I've worked out that if I tie wrap the pipe one of the brake pipes I can reduce the size of the gap thats now formed and reduce the flow. Hopefully enough that I can drive to a local german car specialist and let them finish the job. Not sure I would trust driving it further.

I might have a go at the soldering iron, but then I've still got to the the nuts out later.

[47p2]

As a temporary measure can you not insert a smaller diameter piece of tubing into the expansion bottle and exit tube and use epoxy glue to hold it in place?