I am well into the teardown to replace the housing, but the last corner bolt on the lower housing fitting is captivated by the intake manifold. I don't want to pull off the intake manifold, so I am inclined to leave it. In my case it was the upper housing that was leaking anyway. Has anyone heard of this lower fitting giving any problems ie. cracking in the future?
Thanks,
John

 

When I did mine I was able to get the housing off without touching the manifold. I shortened bolts for the rear positions and made it easy to re-install the housing.

 

I used this guide when I did mine. I can't remember what I did for that back bolt though.

jaghelp.com: How to change the thermostat housing on your Jaguar XJ

 

Thanks for the help.

To finish this thread off, I went out and picked up a hand file (I am not at my main shop) and filed the bottom of the intake manifold just above the bolt. I took just a 1/16 inch or a little more, and then the bolt could squeeze out.

As suggested I filed the bolt down a bit to make the reinstall easier. All back together now and no more leaks.