Thermostat Removal & Instalation

Not sure if this belongs here as this is my first post but I hope this will help someone.

I am level 3 tech at a dealership in VA. I was tasked with a thermostat replacement today on a 124. I was taken back at the complexity of the job and was looking to the internet for a possible shortcut to beat flat rate times. After searching I came up empty handed and did not even see a R&R procedure for the average person. I hope this helps someone.

This was not an easy job as I did evac the A/C system to remove the compressor. Book time was 5.2 hours not including Diag, Fill & Bleed, and Road Test. Im sure you could become proficient but it took every bit of 5.2 as I followed the procedure to a T to understand the process.

The repair procedure directly from Mopar is as follows:

07 - Cooling / Engine / THERMOSTAT / Removal and Installation
THERMOSTAT
REMOVAL

1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle (Refer to 04 - Vehicle Quick Reference/Hoisting/Standard Procedure) .
3. Remove the front belly pan (Refer to 13 - Frame and Bumpers/Under Body Protection/BELLY PAN/Removal and Installation) .
4. Drain the cooling system (Refer to 07 - Cooling/Standard Procedure) .
5. Remove the oil vapor separator (Refer to 09 - Engine/Lubrication/SEPARATOR, Oil/Removal and Installation) .
6. Remove the air cleaner body (Refer to 09 - Engine/Air Intake System/BODY, Air Cleaner/Removal and Installation) .
7. Remove the PCM mounting bracket.
8. Remove the A/C compressor (Refer to 24 - Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C/Removal and Installation) .
9. Remove the GENERATOR(Refer to 08 - Electrical/Charging/GENERATOR/Removal and Installation) .
10. Remove the A/C compressor mounting bracket.
11. Remove the accessory drive belt tensioner (Refer to 07 - Cooling/Accessory Drive/TENSIONER, Belt/Removal and Installation) .
12. Remove the vacuum pipe between heat exchanger outlet pipe and air filter.
13. Remove the engine oil recovery pipe (Refer to 09 - Engine/Lubrication/SEPARATOR, Oil/Removal and Installation) .
14. Remove the throttle body (Refer to 14 - Fuel System/Fuel Injection/THROTTLE BODY/Removal and Installation) .
15. Remove the pipe from solenoid valve to airbox (Refer to 25 - Emissions Control/Evaporative Emissions/SOLENOID, Evaporative Emissions Purge/Removal and Installation) .
16. Remove the cowl panel cover (Refer to 23 - Body/Exterior/COVER, Cowl Panel/Removal and Installation) .
17. Remove the vacuum pump (Refer to 09 - Engine/Cylinder Head/PUMP, Vacuum/Removal and Installation) .
    
    
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18. Disconnect the Camshaft Position (CMP) sensor wire harness connector (1).
19. Disconnect the coolant temperature sensor wire harness connector (2).
    
    
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20. Remove the coolant outlet duplex pipe screw (1) from cylinder head.
21. Remove the coolant outlet duplex pipe nut (2) from intake chamber.
    
    
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22. Remove the coolant outlet duplex pipe screw (1) from intake chamber.
23. Release the retaining clips (2) of the engine compartment wiring to coolant outlet duplex pipe from thermostat.
    
    
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24. Remove the spring clamp and the hose (1) from the thermostat.
25. Remove the nut (2a) and rigid pipe (2b) from thermostat.
    
    
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26. 1. Remove the bolt (1) and coolant tube from the thermostat.
    
    
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27. Remove the bolts (1a), thermostat (1b), and the seal (1c)

Install is the opposite of removal, plus recharge of the A/C system, and coolant fill/bleed.

I would recommend torturing your local technician before undertaking this repair haha.