This procedure involves removing the engine from the vehicle, disassembling the lower end, and replacing the connecting rod bearings on the 3.6L Pentastar V6 engine.

Warnings

Tools required

Parts

• Connecting rod bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Connecting rod bolts (complete set) × 1 — Use OEM specification - torque-to-yield, replace mandatory
• Engine oil and filter × 1 — Mopar 68191349AB filter or equivalent
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gaskets (both) × 2 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Engine coolant × 1 — Mopar OAT Purple coolant
• RTV silicone sealant (Mopar specified) × 1 — Use OEM specification

Fluids

• engine_oil — 6.5 qt
• coolant — 13 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and secure away from terminal
3. Drain engine coolant into appropriate container
4. Drain engine oil and remove oil filter
5. Remove engine cover and air intake assembly
6. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
7. Mark and photograph all electrical connectors, vacuum lines, and hose routing before disconnection
8. Support transmission with floor jack and remove bell housing bolts
9. Attach engine hoist with chains to factory lift points on cylinder heads

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all remaining electrical connections, fuel lines, coolant hoses, and exhaust connections. Remove motor mount bolts at frame. Carefully lift engine forward and up out of engine bay, ensuring transmission input shaft clears bell housing. Transfer engine to engine stand and secure using bell housing bolt holes.
   Torque spec

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

   Remove external components
   Remove alternator, A/C compressor (set aside without disconnecting lines), power steering pump, starter, and all remaining accessories. Remove both exhaust manifolds. Remove intake manifold assembly. Remove both valve covers and set aside. Remove water pump and thermostat housing. Label and store all fasteners separately by component.
   Torque spec

   Gasket Bolts23 Nm (17 lb-ft)

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

   Remove timing cover and chains
   Remove crankshaft damper using appropriate puller. Remove timing chain cover. Mark timing chain positions relative to sprockets. Remove both timing chains, guides, and tensioners. This provides access to oil pump and reduces weight during handling. Keep all timing components organized for reinstallation.
   Torque spec

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

   Remove oil pan and oil pump
   Remove oil pan bolts and carefully separate pan from block. Remove oil pump pickup tube and oil pump assembly. Clean all oil passages with brake cleaner and compressed air. Inspect oil pump for wear; replace if excessive clearance found.
   Torque spec

   Gasket Surface Bolts23 Nm (17 lb-ft)
5. 5

   Identify and mark connecting rod positions
   Rotate crankshaft to bring cylinder 1 to bottom dead center. Mark each connecting rod and cap with cylinder number using permanent marker or number stamps. Rods are numbered 1-6 from front to rear. Note the orientation of connecting rods - the oil squirt hole faces the intake side. Verify all caps are properly marked before removal.
   ⚠Connecting rod caps are NOT interchangeable between cylinders. Mixing caps will destroy bearings immediately.
6. 6

   Remove connecting rod caps and inspect journals
   Remove connecting rod cap bolts from cylinders 1 and 6 (bottom dead center position). Remove caps and keep with corresponding rods. Push pistons up into bores slightly. Inspect crankshaft rod journals for scoring, discoloration, or damage. Use micrometer to measure journal diameter at multiple points. Journals must be within 0.001 inch of specification and show no taper or out-of-round condition. Repeat for remaining cylinders in pairs, rotating crankshaft as needed.
   ⚠Discard all old connecting rod bolts. These are torque-to-yield and cannot be reused under any circumstances.
7. 7

   Remove old bearings and clean components
   Remove bearing shells from connecting rods and caps. Clean all components thoroughly with brake cleaner. Inspect connecting rod big end bores for cracks or damage. Clean crankshaft journals with lint-free cloth and brake cleaner. Ensure oil passages in crankshaft are clear by blowing compressed air through galleries. All surfaces must be completely clean and dry before measuring clearances.
   ℹ️Inspect old bearings for unusual wear patterns. Excessive wear on one edge indicates misalignment or crankshaft issues requiring professional machining.
8. 8

   Install new bearings and check clearances with Plastigage
   Install new bearing shells in rod and cap, ensuring bearing tangs seat properly in notches. Do not oil bearings yet. Place strip of Plastigage across crankshaft journal parallel to crankshaft centerline. Install cap with new bolts and torque to 20 ft-lbs plus 90 degrees. Remove cap carefully without rotating crankshaft. Measure flattened Plastigage width using scale on package. Clearance should be 0.0008-0.0018 inches. Repeat for all six cylinders. Remove all Plastigage residue completely.
   ⚠Do not rotate crankshaft with Plastigage installed. This will give false readings and contaminate bearings.
9. 9

   Final connecting rod bearing installation
   Once clearances are verified, remove bearings and apply thin coat of assembly lube or clean engine oil to bearing surfaces and crankshaft journals. Reinstall bearings in rods and caps. Install connecting rod caps to correct cylinder ensuring orientation marks align. Install new connecting rod bolts and hand-tighten. Verify rod can move freely on journal before final torque.
   ℹ️Connecting rods should have slight side-to-side play on crankshaft journal. Binding indicates misalignment or contamination.
10. 10

    Torque connecting rod bolts
    Using torque-angle method, tighten connecting rod bolts to 20 ft-lbs initial torque in even increments. Then rotate each bolt an additional 90 degrees using angle gauge or torque-angle adapter. Verify all six connecting rods are properly torqued. Rotate crankshaft by hand to ensure smooth rotation with no binding or tight spots.
    ⚠Rod bolts require angle torque method. Torque wrench final reading will exceed initial 20 ft-lbs - this is normal for torque-to-yield fasteners.
11. 11

    Reinstall oil pump and oil pan
    Install oil pump with new gasket or O-ring as specified. Prime oil pump by filling with clean engine oil. Install pickup tube with new O-ring. Clean oil pan and block mating surfaces thoroughly. Apply thin bead of RTV sealant where timing cover meets block. Install new oil pan gasket and install pan. Torque oil pan bolts to specification in cross-pattern sequence starting from center.
    Torque spec

    Gasket Surface Bolts23 Nm (17 lb-ft)
12. 12

    Reinstall timing components
    Install timing chains, guides, and tensioners according to timing marks recorded during disassembly. Verify camshaft and crankshaft timing marks align properly. Install new timing cover gasket and timing cover. Install crankshaft damper to specified torque. Verify crankshaft rotates freely through two complete revolutions.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
13. 13

    Reinstall valve train and external components
    Install valve covers with new gaskets. Reinstall intake manifold with new gaskets. Reinstall exhaust manifolds with new gaskets. Reinstall all accessories including alternator, A/C compressor, power steering pump, and starter. Reconnect all electrical connectors and sensors using photographs from disassembly.
    Torque spec

    Gasket Bolts23 Nm (17 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)
14. 14

    Reinstall engine in vehicle
    Using engine hoist, carefully lower engine into engine bay, aligning transmission input shaft with clutch disc or torque converter. Install bell housing bolts and motor mount bolts. Reconnect all coolant hoses, fuel lines, vacuum lines, and remaining electrical connections. Remove transmission support jack.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
15. 15

    Fill fluids and prime oil system
    Install new oil filter. Fill engine with 6.5 quarts of Mopar 5W-20 synthetic blend oil. Fill cooling system with Mopar OAT Purple coolant (13 quarts total including reservoir). Using oil pump priming tool through distributor hole or by cranking engine without spark plugs, prime oil system until oil pressure gauge shows pressure. Reinstall spark plugs and coils. Reconnect battery.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

Reassembly

1. Torque all fasteners to specified values using torque wrench
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Double-check that all fluid levels are correct before starting engine
4. Verify no tools or parts are left in engine bay before first start

Verification

• Start engine and verify immediate oil pressure within 2-3 seconds
• Check for any fluid leaks around oil pan, timing cover, and valve covers
• Allow engine to warm to operating temperature and verify cooling system operation
• Listen for unusual noises such as knocking or ticking that could indicate bearing issues
• Perform test drive and monitor oil pressure gauge under various loads
• Re-check oil level after test drive and top off if necessary
• Inspect for leaks again after test drive with vehicle on lift
• Monitor oil consumption and condition for first 500 miles to verify proper break-in

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