2003 Saturn L300 Thermostat

You dont need a special tool to release the intake boot clamps all you need is a small pockect screwdriver you insert it into the gap of the opening where the clamp locks over itself then move the screwdriver up. The clamps pops open I have done it a ton of time while resealing the leaking oil cooler plates and thermostats. To close the clamp I use the small channel lock end cutters they work great. You do need a gm fuel release too to remove the fuel lines and reverse torx sockets and torx sockets to remove the bolts. You also need to be careful when remove thermostat extension tube from the thermostat housing that you dont break its retaining tab. You do have to remove the upper and lower intake plentuims and intake spacer plate.

I think for the average do it yourselfer it will be challenging. You can reuse all the seals except if you only replace the thermostat and not the whole housing I would replace that seal. Another thing you have to watch out for is tearing the intake boots.

Untill you pop the thermostat tube out of the housing the housing wont come out. Leave the housing bolted down then remove the bolt by the dipstick tube that goes into the tab holding the tube in place. Then try pulling and rocking twisting the tube out of the housing. If that doesnt work then you will need to pry gently on the retaining tab close to where it connects to the tube. You have to be really careful that tab is pretty easy to break. Also that housing is a tight fit you have rotate it and pull it out. Also I hope you got two new orings for the end of that thermostat tube?

If you break the tab you will have to replace tube that tab is the only thing that holds that tube from coming out of the housing. You just have to work that tab loose from its place another thing that really helps you probably didnt notice is there is a 10mm nut over in that area. Remove the nut and pull that tab off the stud the nut screws on. There probably lies your problem I bet you never removed that nut. As far as that hose clamp the best way to get that clamp off is with a pair of remote cable operated hose clamp pliers which you probably have never see before. The best place to get those orings would probably be a caddy dealer. Since they use the same motor in there catera. The other gm dealers would probably be puzzled if you asked for those orings. Let me know what happens and what ever you do dont break that tab.

I said a 10mm nut not bolt remove it its to the right if the bolts you took out then grab the hose and pull the tab off of the stud the nut goes on. That should give you the room you need. If it was a saturn dealer at one time or its a saturn specialist then they should have them or the caddy dealer. Take that nut off like I said it really helps. Let me know what you find.

Further over to the right there is a 10mm nut that holds the power steering hose in place by a tab.I remove the nut and slide the tab off the stud. Then pull the hose down and that gives me enough room to pull the tube out of the housing. Thats how I do it.

You dont have to pull the tube all the way out to replace the orings you just use a small 90 degree pick to remove the orings.I would replace the orings because if they leak do you want to do this job all over?Also I always spray a little silicone spray in the opening of the housing so the tube slides right in. Glad you found the nut I was taking about that makes it possible to pull the tube out far enough to remove the housing.

Your welcome iam always here to help as far as the better mileage from the plugs I think thats wishfull thinking lol. So you had a code P0128 thats why you changed the thermostat?

No thats right the saturn vues had the same problem they used the same engines in the 2002 and the 2003 but the vues had a different intake so changing the thermostat was a lot easier.