"I ran into a simular problem
"I ran into a simular problem with the new 3.0 L engine I installed. I bought a new 160 degree thermostat and it would decide to go to 210 or 190 degrees at different times (whenever). The manuel test for air leaks by removing the hose along the spark plugs to the thermostat housing and install a clear hose. It states to do this only in the lake or etc (not with a water hose). Just run at idle and at different rpms to see if any air is going threw the system. Also, another test to see if the impeller is working properly, is to disconnect the hose at the thermostat housing (again in the lake or etc.) place the hose level with the inlet where it attaches (must be pointing up vertical). Start the engine and the water should stream up 4 to 6 inches (the engine must be shut down quickly). I also checked exhaust flapper valve (make sure it is not stuck closed), spark plugs for water leak (clean spotless plug may indicate warped or leaking head). My problem was the brand new thermostat, I did not believe it (cause it was new). I just removed it from the housing and the engine never overheated so it proved to be the cause."