XM doesn't want to live

[XMBloke]

Wasn't sure where to post this as had several problems such as transmission, exhaust, engine, bodywork, trim, electrical, brakes etc.
In 27 years of working on cars of all makes, I've never experienced a car that just gives the impression it wants to die.
First off the transmission failed with a loud bang and then headgasket started to show signs of imminent failure with a constant stream of bubbles in the coolant tank when engine was running. So took it off the road before any major damage done and started to strip the front end off ready to pull the engine and box.
First of, the ABS pump pipework refused to budge. It's taken a week of soaking in plusgas and heating with boiling water until today the unions finally released - except one which had to be cut off at the pipe. Judging by the rounded unions, I think someone else has had a go and had to stop.
Then on getting ready to disconnect the exhaust pipe found two rounded off and rusty exhaust downpipe flange bolts. Managed to release the 'easy one' but the awkward one right by the 90 degree bend from the turbo/exhaust manifold refuses to budge. Even tried special worn bolt-head & nut removal tool but even that wouldn't grip. May have to cut the exhaust aft of the subframe just to get the damn engine out. Having seen prices of exhausts for XM's assuming suppliers can get them, I'm rapidly losing my patience with the car. I don't mind fixing cars but I loathe having to constantly chase repairs around it like some 'automotive Fourth Bridge'.
So now got to find or make new steel ABS pipe.
Replace transmission
Replace headgasket
Replace or weld cut exhaust.
Fix sunroof.
So time to dull my resentment of the car with copious amounts of beer and then hope I feel better in the morning.

[citroenxm]

Unless you cant make your own... I might be able to find a pipe for you if you KNOW which one it is...

As for exhaust bolts, I find a small Dremmiel with circular grinding disc Perfect for cutting through the nuts on the bolt ends...

Sorry your getting bad times with the car!

[Vieil Homme]

Some of the great native American indian chiefs walked out in the desert against the sunset...............

[captainhaddock]

give it a few good kicks, have a couple of beers and give it a few more kicks.

After you've calmed down, give it another go and you'll be happier when you've overcome those few problems, you will be amazed how fast you will forget (we all hope!:) )


ps I don't understand how you can use boiling water to undo a stubborn bolt. There are spraycans who freeze bolts but I've never had to much success with them.

[XMBloke]

Thanks everyone - need some morale boosting.
Regarding the ABS pipe unions - The boiling water seems to heat and expand the metal sufficiently to break the corrosion and general grot between the union outlet and pipe. The threads were all good except the one that had to be cut - which was the pipe that loops from the ABS block to the pressure switch that's bolted to the ABS bracket. I've marked it in red.
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[Dieselman]

Don't panic. Just work through the strip and rebuild steadily.

If the exhaust won't come apart, undo the manifold nuts and let it slide off the studs.

[citroenxm]

Don't panic. Just work through the strip and rebuild steadily.

If the exhaust won't come apart, undo the manifold nuts and let it slide off the studs.

Far easier said then done on an egr car.. you should know that will..

[XMBloke]

Morning all, think I'm going to have to Dremmel the exhaust bolt heads as just can't get the Dremmel up past the various pipes, brackets, exhaust, height corrector etc to cut the 10mm exhaust bolt nuts. Strange how one bolt can be ok and another look like it was dug up by 'Time Team' even though it's on the same component. I'll be using maritime grade bolts come reassembly time.

[XMBloke]

For those who are thinking about working on their 2.1 TD exhaust, here's what it looks like from underneath.
The left hand bolt is virtually hidden away under the exhaust casting. Just hope yours hasn't been rounded off by some Fast Fit gorilla with a big wrench.
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Here's the offending bolt. Going to have to cut it off as heat, WD40, Plusgas and loads of swearing haven't shifted it.
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Maybe able to get a small Dremmel type drill and cutting disc up there to cut the flange nuts but it's like carrying out key-hole surgery by feel.
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[southerner]

I am breaking up a 1.6 Turbo diesel estate (L reg) for parts, if any thing that will fit yours lets us know.