2003 Saturn L300 Thermostat

Tiny
KALE171
  • 2003 SATURN L300

Engine Cooling problem
2003 Saturn L300 6 cyl Front Wheel Drive Automatic 101565 miles

I need to figure out how to remove a thermostat on 2003 saturn l300 3.0 V6. I know it is at least a four hour job. Im just not sure what all it takes to do it

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Wednesday, February 17th, 2010 AT 6:36 PM

32 Replies

Tiny
BASSTECH
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It requires removing the upper intake manifold for starters, and to do that you'll need a special tool to release the clamps going to the manifold. Then you have to remove the lower manifold and fuel injector rail. If you need more info I can help you out, but it is a bit entailed.

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Thursday, February 18th, 2010 AT 5:19 PM
Tiny
JIMLEVAN
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Is it necessary to remove the injectors and lower manifold? Or can it be done just by removing upper manifold? I have a manuel that says the latter yet the pic they provide shows everything removed.

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Tuesday, November 29th, 2011 AT 1:38 AM
Tiny
SATURNTECH9
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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.

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Tuesday, November 29th, 2011 AT 7:18 AM
Tiny
JIMLEVAN
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Is it just me or is that a whole lot of work just for a simple thermostat? Do I need to replace all gaskets/seals/o-rings while doing this?

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Wednesday, November 30th, 2011 AT 4:01 AM
Tiny
SATURNTECH9
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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.

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Wednesday, November 30th, 2011 AT 7:03 AM
Tiny
JIMLEVAN
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I have removed the plenum, the fuel rail/lower intake, the spacer and now I find that the thermostat housing cannot be removed. It won't fit. I cannot remove the extension tube due to the dip stick tube is in the way. Any suggestions?

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Sunday, December 4th, 2011 AT 3:39 AM
Tiny
SATURNTECH9
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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?

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Sunday, December 4th, 2011 AT 4:46 AM
Tiny
JIMLEVAN
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I have done all that. The tab for the tube is behind the dipstick tube and I cannot remove the hose from the end of the tube because some ******* who built this engine has the hose clamp tabs behind the the timing belt housing. Where would I get those extension tube o-rings? What happens if the tab is broken on the extension tube?

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Sunday, December 4th, 2011 AT 2:43 PM
Tiny
JIMLEVAN
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Saturntech9, I just want to say thank you as well. My problems are not doing the work itself. My problems are the what if I break this or that. You have been a big help.

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Sunday, December 4th, 2011 AT 2:47 PM
Tiny
SATURNTECH9
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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.

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Sunday, December 4th, 2011 AT 3:17 PM
Tiny
JIMLEVAN
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There were two bolts one for the tube and one for the dipstick tube, I have removed both of those which was a pain because the power steering line ran right in front of both of them. Are those orings a special or could I just take them in and match them up? And I would love to meet the engineer who designed this engine just to kick him in the schins repeatedly while shaking his hand so he couldn't get away. So a caddy dealer huh? A certified saturn repair dealer wouldn't have those?

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Sunday, December 4th, 2011 AT 4:14 PM
Tiny
SATURNTECH9
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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.

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Sunday, December 4th, 2011 AT 4:22 PM
Tiny
JIMLEVAN
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Ok. There is no nut. There were only two bolts one to hold the dipstick tube and the other to hold the extension tube. The tab is free and can move freely however the dipstick tube is in the way and keeping me from pulling extension tube out. Any suggestions?

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Monday, December 5th, 2011 AT 4:35 AM
Tiny
SATURNTECH9
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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.

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Monday, December 5th, 2011 AT 4:42 AM
Tiny
JIMLEVAN
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Holy sh--! I thought that line was welded on. Now, how important is replacing those o rings? They look good to me and i'm not so sure I can pull the entire tube out.

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Monday, December 5th, 2011 AT 5:26 AM
Tiny
SATURNTECH9
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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.

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Monday, December 5th, 2011 AT 5:51 AM
Tiny
JIMLEVAN
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Ok. Mission accomplished. Don't see any visable leaks. There is some smoke from what I am guessing is just residual coolant left from opening up the system. Will know in a few days for sure. Have taken on a test drive around the block. Let sit and idle to temp still no warning lights or obvious problems. Thanks again for all the help. I should mention that I have 2 left over torx bolts. Not sure where they go. I double checked everything. I also changed the spark plugs I had bosch platinum +2 and now I have bosch platinum +4. Will that help with better performance and mpg and what not or am I just dreaming?

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Monday, December 5th, 2011 AT 10:54 PM
Tiny
SATURNTECH9
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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?

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Monday, December 5th, 2011 AT 11:00 PM
Tiny
JIMLEVAN
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Yes I had a code that said the coolant temp did not match the regulated thermastat temp. Yes p0128. Is that not the right fix?

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Monday, December 5th, 2011 AT 11:06 PM
Tiny
SATURNTECH9
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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.

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Monday, December 5th, 2011 AT 11:15 PM

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