Complete replacement of all engine block freeze plugs (core plugs) on the 3.6L Pentastar V6 engine, requiring engine removal for proper access to all plug locations.

Warnings

Tools required

Parts

• Freeze plug kit (6 plugs - cup style) × 1 — Dorman 555-102 or OEM equivalent
• Engine oil filter × 1 — Use OEM specification
• Oil drain plug gasket × 1 — Mopar 68191349AA
• Coolant reservoir cap × 1 — Inspect and replace if damaged
• Motor mount hardware kit × 1 — Use OEM specification
• Transmission bellhousing gasket × 1 — Use OEM specification if reusing transmission
• RTV sealant (high-temp red) × 1 — Permatex 81160 or equivalent

Fluids

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

Preparation

1. Verify engine is completely cold to the touch
2. Disconnect negative battery cable and secure away from terminal
3. Raise vehicle on lift or support securely on jack stands at all four corners
4. Remove front skid plate and belly pan components
5. Drain engine coolant completely into appropriate container and capture for proper disposal
6. Drain engine oil and remove oil filter
7. Remove engine air intake system from air box to throttle body
8. Disconnect all engine electrical connectors and label for reassembly
9. Disconnect fuel lines using proper quick-disconnect tools and relieve fuel system pressure
10. Remove radiator, cooling fans, and all coolant hoses from engine
11. Disconnect exhaust system at manifold flanges
12. Remove power steering pump and secure aside without disconnecting lines
13. Remove AC compressor and secure aside without disconnecting lines
14. Support transmission with transmission jack or secure support
15. Remove transmission bellhousing bolts (if separating transmission from engine)
16. Attach engine hoist with load leveler to factory engine lift points
17. Remove engine mount bolts and carefully lift engine from vehicle
18. Mount engine on suitable engine stand for 360-degree rotation access

Procedure

1. 1

   Locate all freeze plug positions
   With engine on stand, identify all six freeze plug locations on the 3.6L block. Three plugs are on the driver side (left bank) and three on the passenger side (right bank). They are located along the lower sides of the cylinder block, between the deck surface and oil pan rail. Use inspection mirror to verify all plug locations before removal.
2. 2

   Remove driver side freeze plugs
   Starting with the driver side, use freeze plug removal tool or carefully drive a punch through the center of the first plug at an angle. Pry the plug out using the punch as a lever point, or use a specialized slide hammer freeze plug puller. Repeat for all three driver side plugs. Be careful not to damage the bore surfaces during removal.
3. 3

   Remove passenger side freeze plugs
   Rotate engine stand to access passenger side. Remove all three passenger side freeze plugs using the same method as driver side. These may be more difficult to access depending on remaining engine accessories. Take care not to push plugs into engine block.
4. 4

   Clean all freeze plug bores
   Thoroughly clean each freeze plug bore using wire brush or rotary wire wheel. Remove all rust, old sealant, and corrosion. The bore must be completely clean and dry for proper plug seating. Inspect each bore for damage, cracks, or excessive pitting. Minor surface rust is acceptable, but deep pitting may require machining or oversized plugs.
5. 5

   Measure freeze plug bore diameters
   Using calipers, measure each bore diameter to ensure standard-size replacement plugs will fit properly. Standard bores should measure approximately 38-39mm. If bores are worn beyond 0.5mm oversize, oversized plugs must be used. Verify replacement plugs match bore sizes.
6. 6

   Prepare freeze plugs for installation
   Apply thin, continuous bead of red high-temperature RTV sealant around the outer sealing surface of each freeze plug. Do not use excessive sealant as it will squeeze out during installation. Coat should be thin enough to see metal through it.
7. 7

   Install driver side freeze plugs
   Using proper size freeze plug installation tool (cup-style driver), carefully drive the first driver side plug into its bore. The plug must be driven straight and evenly. Plug should seat approximately 1-2mm below the outer surface of the block, not flush. Verify plug is fully seated around entire circumference. Repeat for remaining two driver side plugs. Allow RTV to set for 15 minutes before handling.
8. 8

   Install passenger side freeze plugs
   Rotate engine to access passenger side. Install all three passenger side freeze plugs using the same careful procedure as driver side. Ensure each plug is driven straight and seats at proper depth. Check that no RTV has squeezed into the engine interior. Wipe away excess sealant from exterior surfaces.
9. 9

   Inspect installation and cure sealant
   Visually inspect all six installed freeze plugs using inspection mirror and flashlight. Each plug should be evenly seated around its entire circumference with no gaps or high spots. Allow RTV sealant to cure for minimum 2 hours (preferably overnight) before adding coolant or reinstalling engine.
10. 10

    Reinstall engine into vehicle
    After sealant cure time, carefully lower engine back into engine bay using hoist and load leveler. Align engine to transmission (if separated) and install bellhousing bolts per factory torque specifications. Install engine mount bolts and torque to specification. Remove engine hoist.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)

    Gasket Bolts23 Nm (17 lb-ft)
11. 11

    Reconnect all engine systems
    Reinstall AC compressor and power steering pump with mounting bolts torqued to specification. Reconnect exhaust system at manifold flanges. Install all coolant hoses, radiator, and cooling fans. Reconnect all electrical connectors per labels. Reconnect fuel lines. Install air intake system. Install new oil filter and add fresh engine oil per specification.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
12. 12

    Refill coolant system
    Using vacuum refill tool if available, or traditional funnel method, refill cooling system with 13 quarts of Mopar OAT Purple coolant mixed per factory concentration specification (typically 50/50). Fill slowly to avoid air pockets. Ensure coolant reaches proper level in both reservoir and radiator. Install reservoir cap.
13. 13

    Bleed cooling system and check for leaks
    Start engine and allow to warm to operating temperature with heater on full hot. Monitor coolant level and add as needed during bleeding process. Watch carefully for any coolant leaks around all six freeze plug locations. Squeeze upper radiator hose to help purge air. Run engine through several heat cycles while monitoring for leaks. Rev engine to 2500 RPM briefly to circulate coolant.

Reassembly

1. Reinstall front skid plate and belly pan components
2. Reconnect negative battery cable
3. Verify all fluid levels are correct (coolant, oil, power steering)
4. Double-check all electrical connections are secure
5. Verify no tools or parts are left in engine bay

Verification

• Start engine and verify no coolant leaks from any freeze plug location after reaching operating temperature
• Check coolant level after first heat cycle and top off as needed
• Verify no oil leaks from reinstalled components
• Test drive vehicle and monitor temperature gauge for normal operation
• Re-inspect all freeze plug areas after 50-100 miles of driving for any seepage
• Check coolant level again after several days of operation and top off if needed

More procedures for this vehicle