The only problems in almost 5 years and a little over 20000 miles of
ownership other than wear and tear replacements have been with the cooling
system. It’s had:
Header Tank (cracked and leaking onto the manifold)
Hose from Header Tank to Thermostat Housing (split)
Water Pump (worn impeller)
Thermostat Housing (branch to header tank hose cracked and leaking
coolant onto serpentine belt)
I decided to use an aftermarket aluminium Thermostat Housing rather than
another plastic OEM assembly from Jaguar. It came complete with Housing,
Housing Cap, Thermostat Cover and the 3 rubber seals. I’d fitted a new
Thermostat last year when I changed the Water Pump so re-used this.
It looked a simple job:
drain the coolant
disconnect the top and bottom radiator hoses
disconnect two bypass hoses
disconnect two wiring harness connectors clipped to the side of the
Housing
undo four M6 x 25mm bolts holding the Housing to the block
I was at item (5) after 30 minutes and then the problems started. The rear
Housing bolt are clearly visible from above but I couldn’t get to them with
a 1/4 inch drive socket on a universal or a flexi. A ring spanner fitted but
the Housing prevents it being turned. In the end I had to bend (sacrifice)
the end of an open ended spanner by 45 degrees and use a screwdriver through
the other end to turn it, undoing the bolts a quarter turn at a time
Anyone changed a Thermostat Housing? If so, what did you use on the rear
bolts? There has to be an easier way.
Graham Gardner
2001 XK8 Coupe
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In reply to a message from Graham Gardner sent Mon 27 Jun 2011:
This is a widely discussed and (cussed) issue on these engines.
After making a few special tools (bending up some 8 mm wrenches) I
finally bit the bullet and loosened up the intake manifold. I
didn’t completely remove it, just backed off some of its bolts so
that I could raise up the front and inch or two. Then I was able
to get at it with a universal socket extension.
I did not replace the manifold gasket and, after tightening and
retorquing the bolts, did not detect any vacuum leaks. Don’t
recall the torque spec.
Others have reported a similar experience with no resultant problems–
Glen - 69 E-type OTS, 2000 XK8, 59 MGA
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In reply to a message from Glen Jarboe sent Mon 27 Jun 2011:
Since you are replacing the old housing it is a lot easier
to break apart the plastic with a pair of pliers allowing
access to the rear bolts. I ground down a 1/4’’ socket until
it fit, as above, some bent a wrench but a crows foot wrench
is the correct tool to use. If you will Dremel a
screwdriver slot into the bolt head it makes it a lot easier
to run down. Others have replaced the 8mm bolts with Allen
socket head bolts.–
Tom Porter
Ellijay, United States
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Thanks to TC, Glen and Tom for the various options and confirming this is
known to be an awkward job.
Graham Gardner
2001 XK8 Coupe
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In reply to a message from Graham Gardner sent Thu 30 Jun 2011:
I know I’m late to the party, but Tom’s right. I broke up my
plastic one with pliers being careful not to get any pieces in the
engine. On seemed easier than off with a bent wrench (hopefully the
O rings do their job w/o alot of torque on those back bolts). My Al
replacement was a good fit, although the casting seemed a little
rough. Some have had problems with the threads on top and mine were
a little funky, but they’ve held okay so far.
Mike–
The original message included these comments:
Thanks to TC, Glen and Tom for the various options and confirming this is
known to be an awkward job.
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In reply to a message from Mike P sent Wed, 6 Jul 2011:
I didn’t mention the quality issue with the aftermarket aluminium housing in
my original post thinking I’d just been unlucky. The first one I received
was a very rough casting and the threads on top would only screw on by one
and a half turns. Sent it back and it was replaced with a super smooth cast
of similar quality and finish to the original E-Type cam covers. Threads on
top as easy as a bottle of 25 year old Single Malt
Graham Gardner
2001 XK8 Coupe
The original message included these comments:
My Al replacement was a good fit, although the casting seemed a little
rough.
Some have had problems with the threads on top and mine were a little
funky, but they’ve held okay so far
Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !Date: Wed, 6 Jul 2011 18:51:28 -0700
From: “Mike P” mike66@cox.net
Subject: Re: [xk8] Replacing the Thermostat Housing - am I missing a trick?
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