Replacing the housing assembly, but the 2003 AJ34 has T-27 Torx rather than the 5/16-8mm fasteners. The 5/16 hex head would be easier since the "bent wrench " would loosen & tighten. The T-27 will not allow a bend. There is a metal plate on the plastic intake secured by (4) 5/16 head bolts that should allow some additional room for the socket and extension. Is this a simple remove the plate for access and replace it when job is complete? Perhaps I should secure some S.S. hex head bolts to replace these (2) fasteners. Any other suggestion welcomed.

 

I pulled that plate off on my 03 when I replaced my stuff as you are doing. Nothing much to the plate, remove the bolts, leave the green gasket in the intake housing or put it back in if it stays stuck to the back of the metal plate. Taking that off allows you to reach the back left bolt on the t-stat housing. For me I could not get that one off with the plate one. Make sure you torque things back down properly so ya don't crack anything.

 

I replaced the entire coolant outlet duct assembly (including the thermostat) on my wife's 2006 XK8 in late November. Her Torx bolts were T-30, not T-27. I could not get my 1/4-inch socket drive on those two rear bolts until I removed the manifold front plate (it was held on by four 8mm hex bolts). Once I removed that plate (and its old gasket), I was just barely able to get my 1/4-inch socket drive and 6-inch extension with my T-30 bit on the two rear bolts and get them out. Put a rag under that area when you're pulling those bolts so it will catch them in case you fumble them.

That manifold front plate gasket will be pretty cooked, so work it out carefully with needle-nose pliers and your fingertips. By being careful and taking my time I was able to get it out all in one piece. Be sure to get a new one before you start the job. The Jaguar part number is AJ87991. It is green in color. List price at my local dealership was about $9.00. I asked for a deal as I always do and they sold it to me for $4.50.

Good luck and let us know how it goes....

 

I used angled crows foot type of small ratchet wrench to get to mine. Off in no time.