Hello -


I was driving the other day and my CEL came on and my temperature gauge bottomed out. I checked the code and it came back as P0116.


I have replaced the temperature sensor.


I was thinking about replacing the thermostat as well, however, it seems like a much bigger job than I anticipated. The thermostat is located under the intake manifold assembly on the engine block between the heads.


I have not had any luck finding clear DIY instructions on how to do this. It appears that the intake manifold (top, middle and bottom) all need to be removed, but I haven't seen instructions on how to do this efficiently.


I also assume I will need to purchase a new intake manifold gasket kit once I do this.


Has anyone performed this task by themselves? Is it work the time/energy or should I just schedule an appointment with the mechanic?


The www is very lacking in this department as I have tried multiple sites to no avail.


Thanks in advance for your help!

 

It's not that bad of a job. Make sure you have a shop vac ready to catch any crap that might fall down into the ports. I filled each port with a rag each time I removed a manifold. Yes, you have to remove the upper, middle, and lower manifolds and you should replace them. The hardest part is cleaning the mating surface on the block. I had a tough time separating the upper radiator tube from the old thermostat. I broke the tab on the upper radiator tube and had to remove the turbo charge pipe to replace it. I used the one from autozone that is for a catera v6 3L and longer bolts. It's alot cheaper. If you have the entire day, you might want to replace the oil cooler with one for a catera v6 3L. If you don't, you will have to remove the manifolds all over some day when the aluminum oil cooler fails and spits oil in your coolant (and all the fun of overheating and flushing).

thermostat opening on front of the block, oil cooler opening just behind it.