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Thermostat & coolant temp sensor replacement
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Posted by jeff in MD (more from jeff in MD) on Fri, 23 Feb 2007 10:49:31 Share Post by Email
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Here's a nice Saabnet success story for you. I think ;)

Last week my wife reported a CEL in our '03 Aero. It's got about 67.5k on it. I noted the symptoms (temp guage wasn't going as high as it should, frequently dropping to the bottom) and checked the code, P0116.

Came and researched here, concluded that replacing the thermostat and/or temp sensor were the likely culprits. Ordered the parts from eEuroparts on Tuesday night - they arrive Thursday afternoon, and that was with the free shipping.

Did the work this morning. Replacing both parts took me 3 hours. That includes a trip to Advance Auto Parts halfway through to buy a 19mm combo wrench and a 19mm deep socket. Those were necessary for removing and installing the temperature sensor.

I've never done this job before on this car or any other. My observations:

Never knew a coolant hose would be so difficult to remove. It was quite securely fastened to the t-stat housing, even with the clamp loosened and removed. Really had to work it to get it off.

It's quite crowded back there where the t-stat is. No special tools required, but it helps to have skinny wrists and good eyesight.

The temperature sensor also seemed tricky. Not much room for maneuvering tools around it - I'm hoping I put it in tight enough.

I'm sure the tight work spaces could be alleviated by removing surrounding stuff - I wasn't feeling that adventurous.

I did not drain the coolant before hand. Collected the spillage as best I could, and topped off with fresh Prestone 50/50 "compatible with everything" coolant. I had the original coolant replaced at 50k, the shop used the green stuff rather than Dexcool. I think this should be fine.

So far so good. The car is acting normally. Just got back from using the scanner at Advance to clear the code, so far so good. Gonna drive it about 180 miles this afternoon, should know by the end of the trip if it's truly fixed or not.

jeff

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