I can change a t-stat in like 10 minutes as long as the coolant isn't hot. Here is the easiest way I know!!!
1. Remove upper radiator hose
2. Remove serpentine belt (18mm bolt on the tensioner)
3. Remove tensioner (18mm bolt)
4. Disconnect the temp switch (slide the connector up and off)
5. Remove bypass hose going to water pump from housing
6. Remove two bolts (13mm and 10mm if I recall)
7. Remove housing pull old t-stat out
8. Scrape gasket off housing and intake manifold
9. Put new t-stat in housing
10. Put new gasket on (or make one from gaket material)
11. Take the two mounting bolts and stick them through the
holes of the gasket
12. Start threading the bolts back in, then line up the gasket
perfect and tighten the bolts down.
13. Replace bypass hose
14. Reconnect temp switch
15. Replace upper radiator hose
16. Loosen bleeder screw on housing (13mm)
17. Fill radiator with coolant, when it starts bubbling from the
bleeder screw, tighten the screw up.
18. Replace tensioner.
19. Replace serpentine belt.
20. Loosen bleeder screw again, start engine, when coolant
over flows, tighten bleeder again. That way all air is out of
your cooling system.
You don't even need to mess with the SC pulley to change a t-stat.
To change the SC pulley do as follows:
1. Using 18mm socket, remove tension from the belt and slide
belt off SC pulley.
2. Remove the pulley retaining nut
3. Using a 3-jaw puller remove the pulley
4. Take new pulley and line it up on the shaft
5. Take a flat surface such as a book or block of wood and
place it on the front of the pulley and GENTLY tap the pulley
onto the shaft of the blower.
6. Once its on enough to get the nut to start threading, put the
nut back on and use a big breaker bar (I prefer a 2-foot) to
tighten the nut, which then applies even pressure to the
center of the pulley which will slide the pulley on evenly.
7. Tighten nut but not too tight, make sure the pulley can spin
so that its not hitting the blower. You don't need to torque
the nut down very tight, just make sure its not gonna come
loose.
8. Apply pressure on the tensioner an re-install the belt.
9. Start engine and listen to make sure blower isn't grinding
and pulley isn't moving front to back
10. Enjoy your new horse power!
Good luck, shouldn't be too hard. I just changed my t-stat the other night. You can use Permatex Blue on the t-stat gasket for added sealant.