I got the low coolant light and found that coolant was leaking onto the water pump pulley and crank damper. It was coming from the thermostat housing above. I ordered a new housing which was unusually low priced at $58. It comes with the thermostat which appears to be specific to this housing as it is built into the housing cover. The thermostat alone is obviously not replaceable without the housing cover it is in.

The procedure I used was as follows:
1. Remove engine cover
2. Disconect MAF and remove air intake tube.
3. Drain coolant, remove plastic crankcase vent fittings by pressing the sides together at
the bottom, remove vacuum signal tube, disconnect 2 throttle body wiring plugs.
4. Remove coolant pipes to EGR, Throttle Body and thermostat housing.
5. Unbolt EGR pipe from underneath, disconnect EGR wiring harness, leaving the EGR valve
on the throttle body housing, save the metal gasket. I did not remove the EGR from the
housing because the mount was very corroded and I was afraid the bolts might wring
off.
6. Unbolt Throttle Body housing from front of intake manifold, 4 bolts. No need to
separate the throttle body valve from the housing. Take care not to damage the large
green O-ring type gasket in the intake manifold.
7. Once the Throttle body housing is loose, disconnect the small coolant pipe underneath it
and place it out of the way.
8. Unbolt the old thermostat housing and discard it.
9. Clean off all the sealing surfaces and be sure they have no rough spots or contamination
on them.
10. Install the new thermostat housing, bolting up all 8 various flange bolts. I just gave
them a fair torque for reinforced plastic to get them about where they were when I
removed them. I used a 1/4" ratchet in the palm of my hand to keep torque low.
11. Reconnect the small coolant hose under the throttle body,
position the unit in place to be sure everything is clear of the mounting points and
rebolt the throttle body housing to the intake manifold.
12. Slide the metal EGR gasket in position and reinstall the 2 bolts to the EGR pipe.
13. Reconnect all the wiring connectors and coolant pipes to the EGR and Throttle body.
14. Reinstall the intake air pipe and reconnect the MAF.
15. Remove the small plastic screw on top of the coolant tank and refill the coolant until
coolant comes out the hole without bubbles in it. Adjust coolant level in the tank and
start the engine without the cap on. Wait until the engine is up to operating temp and
install the cap and let it cool. Check for leaks.
16. Drive the car about 15 miles and let it cool again, then check the coolant level and
check for leaks..

 

Where did you find a complete Thermostat Housing for $58?

 

Coventry West, my go-to parts guys.

 

I also should mention that the new housing comes with a new coolant sensor as well, an unusual deal for OEM Jag parts. This part is an aftermarket part but is made by the OEM supplier. When I got it, it was identical to the original in every way.

 

Thanks 'oldmots'. Looks like a good source for parts.

 

Great Post!


We generally keep these in stock also, OEM and completely as original. JF member price $49.04.

www.sngbarratt.com/ProductDetails.aspx?id=08cefbf1-968a-4dac-ad61-c2bf21d6f9c2