Complete teardown, inspection, machining, and rebuild of the 3.6L Pentastar V6 engine including short block, cylinder heads, valve train, and timing system.

Warnings

Tools required

Parts

• Complete engine gasket set (includes head gaskets, intake/exhaust manifold gaskets) × 1 — Use OEM specification
• Main bearing set (standard or oversized as measured) × 1 — Use OEM specification
• Rod bearing set (standard or oversized as measured) × 1 — Use OEM specification
• Piston ring set (6 cylinder) × 1 — Use OEM specification
• Timing chain kit (includes primary chain, guides, tensioners) × 1 — Use OEM specification
• Secondary timing chains (left and right) × 2 — Use OEM specification
• Oil pump assembly × 1 — Use OEM specification
• Water pump × 1 — Use OEM specification
• Thermostat housing assembly × 1 — Use OEM specification
• Connecting rod bolts (new torque-to-yield) × 6 — Use OEM specification
• Main bearing cap bolts (new torque-to-yield) × 1 — Use OEM specification
• Cylinder head bolts (new torque-to-yield) × 2 — Use OEM specification
• Harmonic balancer bolt (new) × 1 — Use OEM specification
• Valve stem seals (set of 24) × 1 — Use OEM specification
• Camshaft position sensors × 4 — Use OEM specification
• Crankshaft position sensor × 1 — Use OEM specification
• Oil filter × 1 — Mopar 5083285AA or equivalent
• Spark plugs (set of 6) × 1 — Use OEM specification
• Intake manifold gaskets × 2 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Engine assembly lube × 1 — Use OEM specification
• RTV silicone sealant (Mopar specified) × 2 — Use OEM specification

Fluids

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

Preparation

1. Ensure engine is removed from vehicle and mounted securely on engine stand
2. Drain all remaining coolant and oil from engine block
3. Clean exterior of engine to prevent contamination during disassembly
4. Organize clean workspace with labeled containers for bolts and small parts
5. Have all machine shop services scheduled (hot tank cleaning, cylinder boring/honing, valve job, deck surfacing as needed)
6. Review factory service manual torque sequences for head bolts and main caps
7. Photograph or document timing chain orientation before disassembly

Procedure

1. 1

   Remove external components and accessories
   Remove alternator, A/C compressor (if still attached), power steering pump, all wiring harnesses, fuel rail and injectors, ignition coils, and throttle body. Label all connectors and photograph positions for reassembly reference. Remove intake manifold by loosening bolts in reverse of tightening sequence.
2. 2

   Remove valve covers and exhaust manifolds
   Unbolt and remove left and right valve covers, noting locations of any wiring harness brackets. Remove exhaust manifolds and set aside. Inspect valve train for obvious wear or damage while visible.
3. 3

   Remove cylinder heads
   Remove cylinder head bolts in reverse of factory torque sequence (work from outside toward center). Carefully lift cylinder heads off block using appropriate lifting points. Place heads on clean surface with combustion chambers facing up. Do not lay heads on valve faces. Send heads to machine shop for inspection, valve job, and surfacing as needed.
4. 4

   Remove timing components and front cover
   Remove harmonic balancer using puller tool. Remove front timing cover bolts and separate cover from block. Mark timing chain orientation with paint before removal. Remove primary timing chain tensioner, then primary chain. Remove secondary chain tensioners and secondary chains from both banks. Remove camshaft sprockets and crankshaft sprocket.
   Torque spec

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

   Remove oil pan and oil pump
   Flip engine on stand to access oil pan. Remove oil pan bolts and carefully separate pan from block. Remove oil pump pickup tube and oil pump assembly mounting bolts. Extract oil pump and inspect for wear or damage.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)
6. 6

   Remove pistons and connecting rods
   Rotate crankshaft to position each piston at bottom dead center. Use ridge reamer to remove any ridge at top of cylinder bores. Mark connecting rod caps and rods with cylinder number and orientation. Remove rod cap bolts and caps. Push piston and rod assemblies out top of block. Keep caps with their respective rods.
7. 7

   Remove crankshaft and main bearings
   Remove main bearing cap bolts in sequence (start from outer caps and work toward center). Carefully mark each main cap with position and orientation. Lift crankshaft from block and place on clean protected surface. Remove main bearings and keep organized by position.
8. 8

   Inspect and measure engine block
   Clean block thoroughly and send to machine shop for hot tank cleaning. Measure cylinder bore diameter at top, middle, and bottom in two perpendicular directions. Check for taper and out-of-round (maximum 0.002 inch). Measure deck surface flatness with straightedge and feeler gauge (maximum 0.004 inch warpage). Check main bearing bores for alignment and proper diameter. Determine if boring/honing is required.
9. 9

   Inspect crankshaft and connecting rods
   Measure crankshaft main and rod journals with micrometer for out-of-round, taper, and wear. Check for scoring or damage. Measure crankshaft end play (should be 0.004-0.012 inch). Inspect connecting rods for bend, twist, and proper sizing. Send crankshaft for grinding if journals are worn beyond specification. Connecting rods should be checked for straightness and resized if necessary.
10. 10

    Inspect and measure pistons
    Measure piston diameter at skirt perpendicular to pin bore. Check piston-to-bore clearance (specification typically 0.0008-0.0018 inch for this engine). Inspect ring grooves for wear or damage. Measure ring end gap by placing rings in cylinder bore (typical specification 0.009-0.019 inch for top ring). If pistons or bores are worn, replace pistons and have block bored/honed to next oversize.
11. 11

    Reassemble short block - Install main bearings and crankshaft
    After block returns from machine shop, install new main bearings in block and caps (ensure oil holes align). Lubricate bearings thoroughly with assembly lube. Carefully lower crankshaft into block. Lubricate upper bearing surfaces. Install main caps in correct position and orientation. Install NEW main cap bolts and torque in sequence per factory specification (typically 15 ft-lb initial, then 55 ft-lb, then additional 60-degree turn). Verify crankshaft rotates freely. Measure endplay with dial indicator.
12. 12

    Install piston rings and piston assemblies
    Install piston rings on pistons with ring expander tool, ensuring gaps are staggered 120 degrees apart. Oil ring expander goes in first, then lower and upper oil ring rails, then second compression ring (dot faces up), then top compression ring (mark faces up). Lubricate cylinder walls with engine oil. Lubricate piston and rings thoroughly. Install rod bearings and lubricate. Compress rings with ring compressor and carefully tap piston into bore with wooden hammer handle. Ensure orientation mark on piston crown faces forward. Install rod cap with NEW bolts, torque to specification (typically 15 ft-lb plus 90-degree turn). Repeat for all six cylinders.
13. 13

    Install oil pump and oil pan
    Install new oil pump with fresh assembly lube packed into gears. Torque oil pump mounting bolts to specification. Install pickup tube with new O-ring. Clean oil pan and block mating surfaces completely. Apply thin bead of RTV sealant per factory pattern. Install oil pan and torque bolts to specification in cross-pattern sequence.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
14. 14

    Install timing components
    Install crankshaft sprocket ensuring keyway aligns. Apply assembly lube to timing chain guides and install. Position crankshaft at TDC cylinder #1. Install primary timing chain with marks aligned per factory specification. Install and tension primary chain tensioner. Install camshaft sprockets (if removed during head work) with marks aligned. Install secondary timing chains with colored links aligned to camshaft timing marks. Install secondary tensioners. Rotate crankshaft two complete revolutions and verify all timing marks realign correctly.
15. 15

    Install front cover and water pump
    Clean front cover and block mating surfaces thoroughly. Apply RTV sealant to corners where rubber gaskets meet. Install new front cover gasket. Install front cover and torque bolts to specification in sequence. Install new water pump with fresh gasket, torque mounting bolts to specification. Install harmonic balancer using NEW bolt, torque to specification plus angle per factory procedure.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)
16. 16

    Prepare and install cylinder heads
    After heads return from machine shop with completed valve job and new valve stem seals, thoroughly clean head and block mating surfaces. Inspect head bolt holes in block and clean/chase threads if needed. Position new head gaskets on block (check for TOP marking and orientation). Carefully lower cylinder heads onto block. Install NEW head bolts finger tight. Torque head bolts in factory sequence: typically 25 ft-lb, then 55 ft-lb, then 55 ft-lb again, then additional 90-degree turn. Follow exact factory procedure as this is critical.
    Torque spec

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

    Install camshaft position sensors and valve train components
    Install new camshaft position sensors on both cylinder heads at intake and exhaust cam positions. Torque sensor mounting bolts to specification. Verify valve lash is within specification (this engine uses hydraulic lifters, check for proper lifter operation). Install valve covers with new gaskets, torque bolts evenly to specification.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
18. 18

    Install intake and exhaust manifolds
    Install exhaust manifolds with new gaskets, torque bolts to specification starting from center and working outward. Install intake manifold with new gaskets, following factory torque sequence (typically 9 ft-lb in sequence). Install fuel rail and injectors. Install throttle body with new gasket. Reconnect all vacuum lines and electrical connectors.
    Torque spec

    Gasket Bolts23 Nm (17 lb-ft)
19. 19

    Install accessories and external components
    Install alternator, A/C compressor, power steering pump. Torque mounting bolts to specification. Install all wiring harnesses and connectors, referencing photographs from disassembly. Install ignition coils and new spark plugs. Install crankshaft position sensor and torque to specification. Install all remaining sensors and electrical connectors.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)
20. 20

    Perform final inspection and prepare for installation
    Rotate engine by hand multiple complete revolutions to ensure no binding or interference. Verify all bolts are torqued to specification. Check that no tools or parts are left in engine. Install new oil filter. Engine is now ready for installation back into vehicle. After installation into vehicle, fill with proper oil and coolant before attempting to start.

Reassembly

1. After engine is reinstalled in vehicle, fill cooling system with 13 quarts Mopar OAT purple coolant mixed 50/50 with distilled water
2. Fill engine with 6.5 quarts Mopar 5W-20 synthetic blend oil
3. Reconnect battery, fuel lines, and all remaining connections
4. Prime oil system by cranking engine without starting (disable ignition or fuel) until oil pressure gauge shows pressure
5. Check all connections for leaks before starting engine

Verification

• Perform initial start and run engine only until operating temperature is reached, monitoring for leaks, unusual noises, or warning lights
• Check for oil leaks at pan, front cover, valve covers, and all gasket surfaces
• Check for coolant leaks at water pump, thermostat housing, and head gaskets
• Verify oil pressure is within normal range (typically 25-110 psi depending on RPM and temperature)
• After initial warm-up and cool-down, recheck all fluid levels and inspect for leaks
• Perform break-in procedure: avoid sustained high RPM or heavy loads for first 500 miles, vary engine speed, change oil and filter at 500 miles
• After break-in period, perform compression test to verify all cylinders are within 10% of each other and meet specification
• Monitor oil consumption and check for smoke from exhaust during break-in period

More procedures for this vehicle