This procedure covers removal and replacement of both cylinder head gaskets on the 3.6L V6 Pentastar engine, including removal of intake/exhaust manifolds, camshafts, and cylinder heads.

Warnings

Tools required

Parts

• Cylinder head gasket - left × 1 — Mopar 68105599AC or equivalent
• Cylinder head gasket - right × 1 — Mopar 68105599AC or equivalent
• Cylinder head bolt set (24 total) × 1 — Replace all head bolts - TTY type
• Valve cover gasket - left × 1 — Use OEM specification
• Valve cover gasket - right × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Upper and lower manifold gaskets
• Exhaust manifold gaskets × 2 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Camshaft position sensor O-rings × 4 — 4 required
• Spark plugs × 6 — Champion RC12YC or equivalent
• Engine coolant × 1 — Mopar OAT Purple
• Engine oil and filter × 1 — Mopar 5W-20

Fluids

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

Preparation

1. Ensure engine is completely cold (minimum 2 hours after last operation)
2. Disconnect negative battery cable and secure away from terminal
3. Drain engine coolant completely into suitable container using radiator petcock and block drain plugs
4. Drain engine oil and remove oil filter
5. Remove engine cover and air intake system completely
6. Remove serpentine belt and tensioner
7. Tag and photograph all electrical connectors, vacuum lines, and fuel lines for reassembly reference
8. Relieve fuel system pressure by removing fuel pump relay and cranking engine
9. Place vehicle on level surface with wheels chocked
10. Support engine with fixture or hoist as motor mounts will be disturbed

Procedure

1. 1

   Remove upper intake manifold and ignition components
   Disconnect throttle body electrical connector and all vacuum lines from upper intake manifold. Remove ignition coils by disconnecting electrical connectors and removing mounting bolts. Remove spark plugs and label cylinder positions. Remove upper intake manifold mounting bolts in reverse of tightening sequence (outside to inside) and lift manifold away. Remove PCV hoses and valve.
2. 2

   Remove lower intake manifold
   Disconnect fuel rail and all fuel injector electrical connectors. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors attached. Disconnect coolant temperature sensor and any remaining sensors on lower manifold. Remove lower intake manifold bolts working from outside to inside. Carefully lift lower manifold and remove all gasket material from cylinder head surfaces.
   ⚠Fuel system may still contain residual pressure. Have shop towels ready to catch fuel spillage.
3. 3

   Remove exhaust manifolds
   From underneath vehicle, disconnect exhaust pipes from both exhaust manifolds at the flange connections. Remove heat shields from exhaust manifolds. Working from the top, remove exhaust manifold mounting nuts from both left and right manifolds. Carefully remove manifolds and set aside. Inspect manifold studs for damage.
   ⚠Exhaust studs are prone to breaking on this engine. Apply penetrating oil 24 hours before removal if possible.
4. 4

   Remove valve covers and accessory brackets
   Disconnect all ignition coil harness connectors and remove harness from valve covers. Remove valve cover bolts from both left and right covers. Carefully break valve cover seal and remove covers. Remove any accessory brackets attached to cylinder heads including alternator bracket, AC compressor bracket (if head-mounted), and ground straps. Tag all bracket bolt locations.
5. 5

   Remove timing chain cover
   Remove crankshaft vibration damper using appropriate puller tool. Remove all timing chain cover bolts noting different lengths and locations. Carefully separate timing chain cover from engine block. You may need to gently tap with plastic mallet. Remove cover gasket completely and clean mating surfaces.
6. 6

   Set engine to TDC and mark timing chain
   Rotate engine clockwise using crankshaft bolt until cylinder #1 is at Top Dead Center (TDC) on compression stroke. Verify timing marks on camshaft sprockets align with marks on cylinder heads. Use paint marker or permanent marker to mark timing chain position on both left and right camshaft sprockets. Take detailed photographs of timing mark alignment for reference.
   ⚠️Incorrect timing chain alignment will cause catastrophic engine damage. Triple-check all timing marks before proceeding.
7. 7

   Remove camshafts
   Using camshaft holding tool, secure camshaft and remove camshaft sprocket bolts from all four camshafts (both intake and exhaust on each head). Mark sprockets left/right and intake/exhaust. Remove camshaft position sensors. Loosen camshaft bearing cap bolts in reverse of tightening sequence (outside to inside, multiple passes). Remove bearing caps keeping them in order. Carefully lift camshafts out and store in clean area with journals protected.
   ⚠Camshaft bearing caps must be installed in exact original positions. Mark each cap with cylinder head side and position number.
8. 8

   Remove cylinder head bolts and heads
   Remove cylinder head bolts from both heads in proper reverse sequence (consult service manual diagram - typically outside to inside pattern). Cylinder head bolts must be loosened gradually in multiple passes to prevent head warping. Once all bolts are removed, carefully break cylinder head seal using plastic pry points only (never between mating surfaces). Lift cylinder heads straight up and place on clean padded surface with combustion chambers facing up. Remove and discard old head gaskets.
   ⚠️Never pry between head and block mating surfaces as this will cause damage requiring machining.
9. 9

   Inspect and clean all mating surfaces
   Thoroughly inspect cylinder head surfaces and engine block deck for warpage using precision straight edge and feeler gauge. Maximum allowable warpage is 0.002 inch. If beyond specification, heads must be machined flat at professional machine shop. Clean all gasket surfaces on block and heads using plastic scraper only - no metal tools. Wipe surfaces with brake cleaner and lint-free cloth. Inspect cylinder bores for scoring or damage. Clean all bolt holes in block using compressed air and thread chaser. Ensure no coolant or oil in head bolt holes.
   ⚠Any fluid in cylinder head bolt holes will cause hydraulic lock and incorrect torque values or cracked block.
10. 10

    Install new head gaskets and position cylinder heads
    Place new head gaskets on engine block ensuring they are oriented correctly (UP marks facing up, coolant holes aligned). Gaskets are not interchangeable left-to-right - verify correct gasket for each side. Do NOT use any sealant on head gaskets. Carefully position cylinder heads onto block, aligning dowel pins and ensuring gasket does not shift. Insert new cylinder head bolts finger-tight in all positions.
    ⚠️Head gaskets have specific front-to-back and top-to-bottom orientation. Installing backwards will cause immediate failure.
11. 11

    Torque cylinder head bolts
    Using proper tightening sequence (consult service manual diagram - typically center outward pattern), torque all cylinder head bolts in four steps: Step 1 - torque all bolts to 25 lb-ft in sequence. Step 2 - torque all bolts to 75 lb-ft in sequence. Step 3 - torque all bolts an additional 90 degrees (1/4 turn) in sequence using angle gauge. Step 4 - torque all bolts an additional 90 degrees (1/4 turn) in sequence. Verify each bolt has been torqued properly before proceeding.
    ⚠️Cylinder head bolt torque procedure must be followed exactly. Do not skip steps or change sequence.
    Torque spec

    Cylinder Head Bolts101 Nm (75 lb-ft)
12. 12

    Install camshafts and bearing caps
    Lubricate camshaft journals and lobes with engine assembly lube. Install camshafts into correct positions (intake and exhaust) ensuring timing marks are visible. Install bearing caps in exact original positions. Tighten camshaft bearing cap bolts in proper sequence (inside to outside, multiple passes) to specification. Install camshaft position sensors with new O-rings. Install camshaft sprockets aligning timing marks with marks made during disassembly. Install and torque sprocket bolts while holding camshafts with holding tool.
    Torque spec

    Camshaft Cap Bolts19 Nm (14 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)
13. 13

    Verify timing and install timing cover
    Manually rotate engine two complete revolutions clockwise and verify all timing marks realign perfectly at TDC. Chain should have no slack. If timing is off, disassemble and correct before proceeding. Install new timing chain cover gasket. Install timing cover and torque all bolts to specification working in cross pattern. Install crankshaft vibration damper and torque to specification.
    ⚠️If timing marks do not realign after two revolutions, timing is incorrect. Do not proceed.
    Torque spec

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

    Install valve covers
    Install new valve cover gaskets into valve cover grooves ensuring they are fully seated. Install valve covers and torque bolts in sequence (center outward) to specification. Do not overtighten as this will distort covers and cause oil leaks. Reconnect all ignition coil harnesses and secure to valve covers.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
15. 15

    Install exhaust and intake manifolds
    Install exhaust manifolds with new gaskets and torque nuts to specification in sequence (center outward pattern). Reconnect exhaust pipes to manifolds. Install lower intake manifold with new gaskets and torque bolts to specification in proper sequence (center outward). Install fuel rail and injectors, reconnecting all electrical connectors. Install upper intake manifold with new gasket and torque bolts to specification. Install new spark plugs torqued to specification. Reconnect all vacuum lines, PCV system, throttle body, and sensors per photographs taken during disassembly.
    Torque spec

    Exhaust Manifold Nuts39 Nm (29 lb-ft)

    Intake Manifold Bolts28 Nm (21 lb-ft)
16. 16

    Install accessories and fill fluids
    Reinstall all accessory brackets, alternator, AC compressor, and serpentine belt system. Install new oil filter and fill engine with 6.5 quarts Mopar 5W-20 oil. Fill cooling system with Mopar OAT coolant using vacuum fill method if available, or fill radiator and allow air to burp through system with heater on full hot. Reconnect negative battery cable.

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify all hose clamps are tight and coolant hoses properly connected
3. Ensure no tools or rags are left in engine compartment
4. Verify oil drain plug is tight and oil level is correct on dipstick
5. Check that all mounting bolts for accessories are properly torqued

Verification

• With ignition off, crank engine for 10 seconds to build oil pressure. Check for oil leaks around valve covers and timing cover
• Start engine and listen for abnormal noises. Engine should start immediately and run smoothly
• Verify no coolant or oil leaks from cylinder heads, intake manifold, or exhaust manifolds after 5 minutes of running
• Allow engine to reach full operating temperature and check for leaks again under pressure
• Check cooling system operation and verify no air bubbles in coolant overflow tank
• Perform test drive and verify normal operation, no overheating, and proper power delivery
• Recheck cylinder head bolt torque after first heat cycle (optional but recommended for critical applications)
• Monitor coolant level for first 100 miles and top off as air purges from system
• Change engine oil after 500 miles of break-in period

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