Cherokee Coolant leaks - Troubleshooting & Tips

Cherokee Coolant leaks underneath the manifolds
The 4.0L Inline 6 MPI "Power Tech HO" engine may develop coolant leaks when the engine core plugs become corroded. Corrosion is often caused by running the engine without anti-freeze or corrosion inhibitors in the cooling system.

Access to the front core plug is possible without removing the manifold. Remove the core plug by locating the weaker corroded part and puncturing it with a center punch or a screwdriver. The core plug is made of fairly soft material, but be very careful not to push the plug into the engine block, if this happens the manifold will have to be removed to recover it. Once the core plug is pierced with the screwdriver lever it out until an edge is exposed and then use a Mole grip to remove it. http://en.wikipedia.org/wiki/Mole_grip

Refit using a socket that fits the new core plug loosely, 32 mm or similar. Ensure that the core plug is square on the engine block, add sufficient socket extension bars so that they are free of the manifold and the push it using a large piece of wood as a lever. Once the core plug is engaged feel it to check that it is square, if so drive it in with a shorter extension and a hammer (be sure to use a solid steel hammer, not a sand filled or lead "dead blow" type, as the impact of these hammer types is not sufficient to drive in the frost plug), if not use use a smaller socket to drive one side rather than the other to square it up. Stop when the core plug flange is flush with the engine block. Refill the cooling system with rust inhibitor and anti-freeze.

Frost plug sizes are 2", except certain 1987 Renix models which have both 2" aswell as 1" frost plugs.

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