This procedure covers the removal and reinstallation of one or both cylinder heads on the 3.6L Pentastar V6 engine, including timing chain access and valve train components.

Warnings

Tools required

Parts

• Cylinder head gasket (left, right, or both) × 1 — Use OEM specification
• Cylinder head bolts (TTY - must replace) × 10 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Engine coolant × 1 — Mopar OAT Purple
• Engine oil and filter × 1 — Use OEM specification

Fluids

• Mopar OAT Coolant (Purple) — 13 qt
• Mopar 5W-20 Synthetic Blend — 6.5 qt

Preparation

1. Ensure engine is completely cold before beginning work
2. Disconnect negative battery cable and secure away from terminal
3. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
4. Drain engine coolant completely into appropriate container
5. Drain engine oil and remove oil filter
6. Remove engine cover (pull upward to release from grommets)
7. Remove air intake system from throttle body to air filter housing
8. Label and photograph all electrical connectors, vacuum lines, and hose routing before removal
9. Support vehicle on jack stands if working on components from below

Procedure

1. 1

   Remove accessories and upper engine components
   Remove the throttle body, fuel rail with injectors, and ignition coils. Disconnect all electrical connectors from the cylinder head being serviced including oxygen sensors, coolant temperature sensors, and camshaft position sensors. Remove alternator and A/C compressor mounting brackets as needed for access. Label all connectors for proper reinstallation.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)

   Sensor Bolts12 Nm (9 lb-ft)

   Mounting Bolts54 Nm (40 lb-ft)
2. 2

   Remove intake and exhaust manifolds
   Disconnect exhaust pipe from exhaust manifold. Remove intake manifold bolts in reverse of tightening sequence (outside to inside pattern). Remove intake manifold and gaskets. Remove exhaust manifold bolts and manifold from cylinder head. Inspect studs for damage.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)
3. 3

   Remove valve cover and valve train components
   Remove valve cover bolts in a crisscross pattern from outside to inside. Remove valve cover and gasket. If removing rocker arms, mark position of each component for reinstallation in original location. Use a valve spring compressor to remove rocker arms by compressing valve spring and sliding rocker arm out. Store all components in order.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
4. 4

   Access and mark timing chain
   Remove timing chain cover bolts and carefully pry cover away from engine block. Rotate crankshaft to TDC position for cylinder #1 (camshaft timing marks aligned with cylinder head surface). Use paint or permanent marker to mark timing chain links at camshaft sprocket alignment marks. Mark relationship between camshaft sprocket and camshaft. This is critical for reassembly.
   ⚠Do NOT rotate crankshaft or camshafts once timing chain is loosened. This will cause valve-to-piston contact and severe engine damage.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
5. 5

   Secure timing chain and remove camshaft sprockets
   Install timing chain wedge tools or zip-ties to prevent chain from falling into timing case. Use camshaft holding tool to prevent camshaft rotation. Remove camshaft sprocket bolts and carefully remove sprockets while keeping chain supported and in position. Wire sprockets to timing cover area to maintain chain position.
6. 6

   Remove camshafts
   Remove camshaft bearing cap bolts in reverse order of tightening sequence (loosen evenly in multiple passes from outside to inside). Carefully lift camshafts from cylinder head. Mark intake and exhaust camshafts and their orientation. Do not mix up components between cylinders or banks.
   ⚠Camshaft bearing caps are position-specific and marked with numbers. They must be reinstalled in exact original positions.
7. 7

   Remove cylinder head bolts
   Remove cylinder head bolts in reverse of tightening sequence (outside to inside pattern). Loosen each bolt gradually in multiple passes to prevent warping. Once all bolts are removed, carefully lift cylinder head from engine block using lifting points. Do not pry between head and block surfaces.
   ⚠️Cylinder head is heavy (approximately 50 lbs). Use proper lifting technique or assistance to prevent injury.
8. 8

   Inspect and clean gasket surfaces
   Remove old head gasket and thoroughly clean both cylinder head and engine block mating surfaces using plastic gasket scraper. Do not use metal scrapers that can gouge aluminum surfaces. Clean all bolt holes in block using compressed air and ensure no coolant or oil residue remains. Use straightedge and feeler gauge to check head surface for warpage across length, width, and diagonally. Maximum warpage allowed is 0.1mm (0.004 in). If beyond specification, cylinder head must be resurfaced by machine shop.
   Torque spec

   Gasket Surface Bolts23 Nm (17 lb-ft)
9. 9

   Install new cylinder head gasket and position head
   Verify engine block surface is clean and dry. Install new cylinder head gasket on engine block with all alignment dowels properly seated. Ensure gasket orientation is correct (UP marking facing cylinder head, coolant and oil passages aligned). Carefully lower cylinder head onto block, aligning with dowel pins. Do not slide head after placement as this can damage gasket.
   ⚠Head gasket has specific front/rear and up/down orientation. Installing backwards will cause immediate engine failure.
10. 10

    Install and torque cylinder head bolts
    Install NEW cylinder head bolts (TTY bolts must never be reused) hand-tight in proper sequence starting from center and working outward. Torque bolts in four stages following factory sequence: Stage 1 - torque all bolts to 30 Nm (22 lb-ft); Stage 2 - torque all bolts to 50 Nm (37 lb-ft); Stage 3 - rotate all bolts an additional 90 degrees; Stage 4 - rotate all bolts an additional 90 degrees (total 180 degrees angle torque after initial torque). Verify all bolts have been properly torqued and angled.
    ⚠️Use only NEW head bolts. Old torque-to-yield bolts will not provide proper clamping force and will cause head gasket failure.
11. 11

    Reinstall camshafts and valve train
    Lubricate camshaft journals and lobes with clean engine oil. Install camshafts in correct positions (intake and exhaust, with timing marks visible at top). Install camshaft bearing caps in original numbered positions with arrows pointing toward front of engine. Torque bearing cap bolts gradually in sequence from inside to outside in multiple passes. Install rocker arms by compressing valve springs and sliding rockers into position on their original valves and lifters.
12. 12

    Reinstall timing components and verify timing
    Position timing chain on camshaft sprockets ensuring marked chain links align with camshaft timing marks. Install camshaft sprockets onto camshafts with timing marks aligned. Install and torque camshaft sprocket bolts using camshaft holding tool. Remove timing chain wedge tools. Rotate crankshaft two complete revolutions and verify all timing marks align correctly at TDC. If timing is off, remove sprockets and repeat timing procedure.
    ⚠️Incorrect valve timing will cause immediate catastrophic engine damage when started. Triple-check all timing marks before proceeding.
13. 13

    Reinstall timing cover and valve cover
    Install new timing cover gasket and position timing cover on engine. Install and torque timing cover bolts evenly in crisscross pattern. Install new valve cover gasket on valve cover (ensure proper seating in gasket groove). Position valve cover on cylinder head and install bolts. Torque valve cover bolts in sequence from center outward.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
14. 14

    Reinstall manifolds and accessories
    Install exhaust manifold with new gasket and torque mounting bolts evenly. Install intake manifold with new gaskets, starting bolts from center and working outward. Reinstall alternator and A/C compressor mounting brackets. Reconnect all electrical connectors, vacuum lines, and coolant hoses using reference photos. Install fuel rail, injectors, ignition coils, and throttle body.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)

    Gasket Bolts23 Nm (17 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)
15. 15

    Refill fluids and prepare for startup
    Install new engine oil filter and refill engine with 6.5 quarts of Mopar 5W-20 Synthetic Blend oil. Fill cooling system with 13 quarts of Mopar OAT Purple coolant (mixture should be 50/50 coolant to distilled water). Reconnect negative battery cable. Install fuel pump fuse. Turn ignition to ON position without starting to prime fuel system (repeat 3-4 times). Check for any fuel or coolant leaks before starting engine.

Reassembly

1. Tighten all fasteners to specified torque values in proper sequence
2. Use only NEW cylinder head bolts - never reuse torque-to-yield bolts
3. Verify timing chain alignment at TDC before final assembly
4. Replace all gaskets including head gasket, valve cover, intake and exhaust manifolds
5. Ensure all electrical connectors are properly seated and locked
6. Double-check all coolant hose connections are secure before filling system

Verification

• Perform visual inspection for any disconnected hoses, wires, or loose components
• Verify oil level is correct on dipstick
• Check coolant level in overflow reservoir
• Start engine and monitor for abnormal noises, especially valve train or timing noise
• Allow engine to reach operating temperature while monitoring for leaks at head gasket, valve cover, and manifolds
• Check for coolant or oil leaks around all gasket surfaces
• Verify engine idles smoothly without misfires or rough running
• After initial startup and cooldown, re-check coolant level and top off as needed (system will need burping)
• Test drive vehicle and monitor temperature gauge, oil pressure, and overall engine performance
• Perform a final inspection after test drive for any new leaks or issues

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