2002 vue 3.0 thermostat change

[dzabo]

Does anyone have the instructions (hopefully with pics) to change the t-stat. have read other threads and no one has them posted. i do not want to join a site, so don't send me to all data . com. thanks

[Matt42]

Check with the dealer. When I bought S series t-stats from them, they included a diagram in the box.

[Matt42]

I have the 2002-2003 factory technical service manual on my lap, open to pages 848-850. That covers how to get to the thermostat, and also how to change the thermostat element. I'll start by saying that it is unlikely that the dealer part will have a useful diagram in the box. The thermostat setup on the 3.0 V6 is, in my opinion, inexcusably stupid.

The procedure below is quoted verbatim from the TSM. The V6 is engine L81, and the thermostat differs from that in the L series cars.

Removal.
Step 1: Drain coolant. Refer to "Draining the Cooling System" procedure in this section.
Step 2: Lift and support intake manifold. (Refer to "Intake Manifold Lift and Support Procedure - L81" in the Induction section of this service manual.)
Step 3: Disconnect radiator hose from coolant pipe. [This looks like the upper hose near the timing belt end of the engine.]
Step 4: Remopve coolant pipe/engine lift bracket bolt.
Step 5: Rotate oil level indicator and tube away from pipe.
Step 6: Remove thermostat extension pipe.
Step 7: Remove and discard O-ring seals.
Step 8: Remove thermostat with housing:
Step 8.1: Remove bolts. [Yes, the TSM really lists these as sub-steps!]
Step 8.2: Tilt rear of the thermostat housing upward.
Step 8.3: Lift out the housing.
Step 8.4: Remove and discard O-ring seal.

Installation.
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 bolt threads.
1.4: Install the housing bolts.
Torque: Thermostat housing bolts: L81: 20 N.m (15 ft-lbs).
2. Lubricate the coolant pipe O-rings with coolant.
3. Install O-rings on coolant pipe.
IMPORTANT: The correct stack-up should be cylinder head, engine lift bracket, coolant extension housing, oil level indicator tube bracket and bolt.
4. Properly position engine lift bracket.
5. Install coolant pipe into thermostat housing.
6. Rotate oil level tube into position.
7. Install coolant pipe engine lift bracket bolt.
Torque: Coolant pipe engine lift bracket bolt - L81: 20 N.m (15 ft-lbs).
8. Connect radiator hose to coolant pipe.
9. Install intake manifold. (Refer to "Intake Manifold Lift and Support Procedure - L81" in the Induction section of this service manual.)
10. Fill the coolant system. Refer to "Coolant Replacement" procedure in this section.

We fortunately no longer have the car, but we still have the four-volume technical service manual that weighs about 20 pounds in total. The manual is in pristine condition. (I let the dealer work on the silly thing until we got fed up and sold it.) I would be willing to sell the whole TSM for $90 plus shipping. It would be difficult to scan just those pages, since they refer to other pages on removing other things necessary to get the job done. That section of the TSM is very thick, and it won't open wide enough to fit on the scanner. Perhaps a Haynes manual might have what you need for much less than $90.

[dzabo]

thanks for the assist.
i am in germany and there are no saturn dealers here. the local gm dealer doesn't speak much english and is not very helpful with saturn products. i don't want to start flyin' blind under the hood. i might be able to get some tools for help with this procedure.
how long does this process take for a shade tree mechanic. have a new born and the vue can't be down for toooooo long.

[Gerry Proctor]

It takes around five hours if you don't hit any snags, like not having the torx bit to remove the intake bolts. And this one: "Step 2: Lift and support intake manifold. (Refer to "Intake Manifold Lift and Support Procedure - L81" in the Induction section of this service manual.)" is going to be the part that takes the longest and has the most detail.

There's not much that's intuitive in the repair. Do another search on the forum. It may have been sccarman that posted the text for the intake lifting. I know I've seen it. But you really need that part of the repair spelled out. Also, strongly suggest you do get the factory service manuals (perhaps from Matt) before you dig into this. They will pay for themselves many times over.

[VTchemist]

I agree with the 5 hour estimate.

I had my 2003 V6 in the dealership for a T-stat replacement. The labor bill showed 5.0 hours.

It's a non-trivial replacement. Nothing like replacing the T-stat on a 1980's RWD GM vehicle.

Since you don't have a dealership where you are, you could take a look at the alldata web site

http://www.alldata.com/vehicle_owner/index.html

Folks have had nice things to say about them. The pics would be a great help in getting the manifold off and then navigating all the pieces to the T-stat.

Hope this helps.

[tjr002]

Originally Posted by dzabo

Does anyone have the instructions (hopefully with pics) to change the t-stat. have read other threads and no one has them posted. i do not want to join a site, so don't send me to all data . com. thanks

I have an 03. I did mine last weekend and took photos. Took every bit of 5 hrs. Seems like everyone wants to know what they are getting themselves into first. I'll post them tonight.

[BobbyP]

Originally Posted by VTchemist

I agree with the 5 hour estimate.

I had my 2003 V6 in the dealership for a T-stat replacement. The labor bill showed 5.0 hours.

It's a non-trivial replacement. Nothing like replacing the T-stat on a 1980's RWD GM vehicle.

Since you don't have a dealership where you are, you could take a look at the alldata web site

http://www.alldata.com/vehicle_owner/index.html

Folks have had nice things to say about them. The pics would be a great help in getting the manifold off and then navigating all the pieces to the T-stat.

Hope this helps.

IMO 5 hours to replace a thermostat is not acceptable. Many thanks to the people out there willing to help share the information on how to do the job.

On my 1985 Olds Calais Tech-4 2.5L the thermostat was under the radiator cap in a seperate housing. It took all of 5 seconds to replace or remove it. It did fail once, I overheated within a few miles. I was able to pull it out and get back on the road quickly.

There's really no excuse for the engineers and stylist to make replaceable items like thermostats and headlights hard to replace. Making their vehicles difficult to service will just push the owners to replace them with more user friendly vehicles. They have nothing to gain from building a car that is difficult to maintain. The owner benefits even if he doesn't do the work themselves by having a lower price repair bill when they pay someone else to work on their car. The argument that most owners don't work on their cars doesn't have any merit.

[shofast]

Does anyone know if a new dealer thermostat comes with all the needed orings?

[Chazberry]

Originally Posted by shofast

Does anyone know if a new dealer thermostat comes with all the needed orings?

Fwiw - Rockauto lists the T'stat and gasket separately. They also list a redesigned Housing.

[Chazberry]

Originally Posted by BobbyP

On my 1985 Olds Calais Tech-4 2.5L the thermostat was under the radiator cap in a seperate housing. It took all of 5 seconds to replace or remove it.

My '83 Olds Firenza had the same arrangement. Those kind of good designs are few and far between nowadays!

[/QUOTE]There's really no excuse for the engineers and stylist to make replaceable items like thermostats and headlights hard to replace. Making their vehicles difficult to service will just push the owners to replace them with more user friendly vehicles. They have nothing to gain from building a car that is difficult to maintain.[/QUOTE]

Doncha think it's done intentially to discourage the shade tree mechanic, so as to bring the service dept more biz? Is there really such a thing as a 'user-friendly' vehicle today?

[VueGuy168]

oem comes w o-rings took me 2 hours by saving time using a block of wood to move the intake manifold out of the way.

02 saturn vue v6 awd 120k
01 sc2 129k

[tjr002]

Originally Posted by tjr002

I have an 03. I did mine last weekend and took photos. Took every bit of 5 hrs. Seems like everyone wants to know what they are getting themselves into first. I'll post them tonight.

Here they are. Hope they help.
Drain radiator.
Remove 5 intake bolts on upper intake. These are under the black plastic cover on the upper intake. You will need a 6" long T35 torx bit.
Remove the 6th intake bolt. This is located just under the throttle body.
Pull out the red clip on the wiring harness on the driver side in the intake and disconnect harness.
I took a few short cuts. I did not disconnect the fuel line or remove the throttle body.
Once the 6 intake bolts are out and a few brackets and hoses are removed from the intake, lift up the intake and support it. I used my trusty Craftsman screwdriver.
Remove the lower intake bolts. This requires an E12 female torx socket. Be careful and take your time removing these bolts. They are held in with threadlock and you can strip the heads easily.
Remove the lower intake to reveal the thermostat housing.
Before removing the housing, remove the thermostat tube first. To do this you will need to remove the bolt that attaches the thermostat tube to the engine. It is just behind the dipstick tube. Once this bolt is out you will have to rotate the thermostat tube counter clockwise. You will not be able to pull the tube straight out because these is a long ear on the tube that goes behind the dipstick tube. Once the ear is at the 12 o'clock position you will be ale to remove it.
Now remove the thermostat housing bolts and the thermostat housing.
Replace thermostat and reassemble.
Good luck.

[coolgreany]

dzabo,

Where in Germany are you? I have an 02 Vue with the same problem (2nd time T-stat has crapped out) except mine is in Florida - I'm military stationed in Stuttgart and can try to hel you if you DIY.

My sister brought our Vue in for oil change and they said "rear oil seal" (don't know if it is a serious leak or not) was leaking in addition to thermostat.