Rust stains on block around thermostat housing?

Yep, this is a gasket or the cross over from the thermostat housing. The intake will need to be loosened and propped up slightly.

Here is a video to show you what you need to do:

https://youtu.be/N3Iqjo2jhdc?si=lBFLaJ3nWnlmYXMl

Please let us know what happens.

Hi Ken,
What do you mean that the intake needs to be propped up slightly?
Do I use gasket maker or buy one?
I will see if I can fix it myself, should be fun.
Thanks,
Charlie

It appears that the crossover is part of the intake on my Town Car.
Do I just replace the new intake or can this one be fixed?

I would get a new intake, I would check amazon, here is one for $125.00:

https://amzn.to/3Rib3oe

Let me know how it goes.

I will order it .
Can you provide me replacement instructions?
Thank you Ken

Sure here is how to change out the intake manifold and the torque specs and sequence as well. Check out the images (below). Let us know if you need anything else.

Hello Ken,

I removed the thermostat housing and there was "no thermostat or O-ring" installed.
Surprise.
I will install new ones with a little gasket maker and see if that works B4 replacing the intake manifold.
I will let you know if it is fixed.

Thanks for the advice,
Charlie

Yep, they kind of need the thermostat and gasket, let me know how it goes, have a good weekend.

Hi Ken,

I now have a DTC code P0205 Cylinder 5 injector malfunction.
Maybe caused by the leak?
Any advice?

Thanks, and have a good weekend yourself,
Charlie

Sorry, we only handle one problem per thread, please post your new question here, you must be logged in.

https://www.2carpros.com/questions/new

Did you get the coolant leak fixed?

thank you

Hi Ken,
I am ready to install the new intake.
Do I need to reuse the foam cover on the bottom?
It is kind of falling apart.

Can you upload an image so I can see what you are talking about?

I guess this is called a heat barrier and noise suppressor.
I taped it up so I will use it.
I guess the part is discontinued.
Also, image of part that failed (plastic channel broke off) and leaked.

Yep, that is a heat soak barrier, it should be good the way you repaired it. Also, thanks for uploading the coolant leak problem, once you get the engine back together the problem should be fixed. Let us know if you need anything else, we are here to help.

I am going to finish up putting parts back in today,
Hopefully it will start up and run well again.
Thank you Ken

I have confidence you can complete the job and get back on the road! Let me know how it goes and have a good weekend!

Got the job completed yesterday and it runs much better without any leaks.
Check engine soon amber light is on.
I will try to see what it is for.
Thanks for your help Ken
have a good weekend yourself,
Charlie

Nice work :) please start a new thread if you have other problems, we are happy to help.

Thank you Ken for all the help,
Charlie