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replace thermostat in saturn vue v6 2003

Customer Question
is there an easier way...
is there an easier way than fooling around with the intake manifold
Submitted: 9 years ago.Category: Car
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Answered in 3 minutes by:
2/23/2008
Auto Mechanic: MikeB85, ASE Certified Technician replied 9 years ago
MikeB85
MikeB85, ASE Certified Technician
Category: Car
Satisfied Customers: 354
Experience: ASE Certified, I-Car Trained and Certified, Automotive Technology Degree
Verified

Hi there,

I just need some quick info from you.

Is this the AWD or FWD model?

Thanks.

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Customer reply replied 9 years ago
awd
Customer reply replied 9 years ago
AWD
Auto Mechanic: MikeB85, ASE Certified Technician replied 9 years ago

Here is the procedure for removing and replacing the thermostat in your vehicle. Unfortunately you have to loosen the intake manifold in order to remove and replace the thermostat.

Removal Procedure

  1. Drain the coolant.
  2. Lift and support the intake manifold. Refer to Intake Manifold Replacement .
  3. Disconnect the radiator hose from the coolant pipe.
    Object Number: 896501  Size: SH

  4. Remove the coolant pipe/engine lift bracket bolt.
  5. Rotate the oil level indicator and tube away from the pipe.
    Object Number: 894725  Size: SH

  6. Remove the thermostat extension pipe.
  7. Remove and discard the O-ring seals.
    Object Number: 896494  Size: SH

  8. Remove the thermostat with the housing.
    8.1. Remove the bolts.
    8.2. Tilt the rear of the thermostat housing upward.
    8.3. Lift out the housing.
    8.4. Remove and discard the O-ring Seal.

Installation Procedure

    Important: The SUV thermostat housing is different from L-Series.


    Object Number: 896494  Size: SH

  1. Install the thermostat with housing.
    1.1. Install a new O-ring seal.
    1.2. Position the thermostat with the housing.
    1.3. Apply thread sealant PST 565® to the bolt threads.
    1.4. Install the housing bolts.

    Tighten
    Tighten the thermostat housing bolts 20 N·m (15 lb ft).


    Object Number: 894721  Size: SH

  2. Lubricate the coolant pipe O-rings with coolant.
  3. Install the O-rings on the coolant pipe.
    Object Number: 896501  Size: SH

    Important: The correct stack up should be cylinder, head, engine lift bracket, coolant extension housing

  4. Properly position the engine lift bracket.
  5. Install the coolant pipe into the thermostat housing.
  6. Rotate the oil level tube into position.
  7. Install the coolant pipe engine lift bracket bolt.

    Tighten
    Tighten the coolant pipe engine bracket bolt to 20 N·m (15 lb ft).

  8. Connect the radiator hose to the coolant pipe.
  9. Install the intake manifold. Refer to Intake Manifold Replacement .
  10. Fill the cooling system.

Intake Manifold Replacement

Tools Required

J 37088-A Fuel Line Disconnect Set
J 44095 Fuel Pressure Adapter Fitting
SA9127E Gage Bar Set

Removal Procedure

    Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.


    Object Number: 963963  Size: SH

  1. Disconnect the negative battery cable.
  2. Loosen the clamp at the air cleaner assembly and throttle body assembly.
  3. Remove the attachment bolts from the outlet resonator/duct assembly to support bracket.
  4. Remove the outlet resonator/duct assembly.
    Object Number: 963185  Size: SH

  5. Remove the resonator outlet duct assembly bracket from the manifold.

    Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.


    Object Number: 952269  Size: SH

  6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  7. Disconnect SA9127E , or equivalent and J 44095 , or equivalent, after the pressure has been relieved.
  8. Disconnect the fuel transfer line at the quick connect from the fuel line using J 37088-A , or equivalent blue tool.
    Object Number: 959866  Size: SH

  9. Disconnect the electrical harness attachment from the manifold and position harness away from the manifold.
    Object Number: 963217  Size: SH

  10. Disconnect the attachment of the purge solenoid and line from the rear of manifold.
  11. Disconnect the brake booster line from the intake manifold.
  12. Disconnect the fuel injector and intake manifold control solenoid connectors.
    Object Number: 959298  Size: SH

  13. Remove the PCV fresh air hose at throttle body.
  14. Remove the throttle body bolts from the throttle body.
  15. Remove the throttle body cooling hose bracket bolts.
  16. With the coolant lines connected to throttle body, lay the throttle body assembly over the mast cylinder.
    Object Number: 959544  Size: SH

    Important: To remove the 5 upper manifold bolts, use a 1/4 inch drive T-30 TORX and long 1/4 inch drive extension.

  17. Remove the upper manifold to spacer plate bolts.
    Object Number: 952138  Size: SH

  18. Remove the lower intake manifold bolt near the throttle body.
  19. Remove the intake manifold assembly.
    Object Number: 946642  Size: SH

  20. Remove the lower intake manifold spacer plate bolts.
    Object Number: 951932  Size: SH

  21. Remove the intake spacer plate.
  22. Seals are re-usable if not damaged. If O-ring seals re being replaced, remove seals from both sides.
    Object Number: 963025  Size: SH

  23. The intake spacer plate has O-ring seals on both sides.
  24. Clean the spacer plate bolt holes and bolts. Remove all thread locked material.

Installation Procedure


    Object Number: 951932  Size: SH

  1. Transfer all components to the new intake manifold.
  2. Install new O-rings to spacer assembly, if necessary.
    Object Number: 946642  Size: SH

  3. Install the intake manifold spacer plate.

    Important: Do not over torque the intake manifold spacer plate bolts.

  4. Install the 12 intake manifold saver plate bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

    Tighten
    Tighten the bolts to 16 N·m (11 lb ft).


    Object Number: 959544  Size: SH

    Important: Do not over torque the intake manifold bolts.

  5. Install the intake manifold assembly into position.
  6. Install the 5 intake manifold bolts.

    Tighten
    Tighten the bolts to 7.5 N·m (66 lb in).


    Object Number: 945757  Size: SH

  7. Install the throttle body gasket.
  8. Install the throttle body assembly bolts.

    Tighten
    Tighten the throttle body-to-intake manifold bolts to 7.5 N·m (66 lb in).

  9. Connect the PCV fresh air hose at the throttle body.
  10. Install the outlet resonator duct assembly bracket to the manifold and tighten nuts.

    Tighten
    Tighten the outlet resonator duct nuts to 5 N·m (44 lb in).


    Object Number: 963217  Size: SH

  11. Connect the intake manifold control solenoid and injector harnesses.
  12. Connect the electrical harness to the intake bracket near the intake manifold runner control solenoid.
  13. Connect the brake vacuum hose to manifold.

    Important: An audible click noise can be heard when the fuel line is installed. Slightly pull rearward on line to assure the connection is fully seated.

  14. Connect the fuel line to the fuel transfer line.
  15. Connect the purge solenoid and line to intake manifold.
    Object Number: 959866  Size: SH

  16. Attach the electrical harness to rear of manifold.
    Object Number: 963185  Size: SH

  17. Install the outlet resonator duct assembly into position and tighten clamp at the throttle body assembly.
  18. Position the outlet resonator duct assembly to support bracket and install bolts.

    Tighten
    Tighten the outlet resonator duct-to-bracket nuts to 10 N·m (89 lb in).

  19. Tighten the clamp at the air cleaner assembly.
  20. Connect the negative battery cable.
MikeB85
MikeB85, ASE Certified Technician
Category: Car
Satisfied Customers: 354
Experience: ASE Certified, I-Car Trained and Certified, Automotive Technology Degree
Verified
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Auto Mechanic: MikeB85, ASE Certified Technician replied 9 years ago
The reason they have you loosening the intake is because there may not be enough room to remove the thermostat. You can try doing it without loosening the intake but I am afraid you will find that you will have to do the steps in the procedure above.
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MikeB85, ASE Certified Technician
Category: Car
Satisfied Customers: 354
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