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How to Replace Coolant Overflow Tank 99-06 Chevy Silverado

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How to Replace Coolant Overflow Tank 99-06 Chevy Silverado

Created on: 2014-06-04

How to repair, install, fix, change or replace a broken, damaged, split or leaking radiator coolant overflow bottle on 00, 01, 02, 03, 04, 05, 06, Chevy Suburban.

  1. step 1 :Removing the Air Intake Box
    • Loosen the air intake hose clamp with a flat blade screwdriver
    • Separate the intake hose from the air box
    • Lift the air box up and out
  2. step 2 :Removing the Coolant Bottle
    • Have a drain pan ready
    • Clamp the coolant hose with vise grip pliers
    • Loosen the hose clamp with needle nose pliers
    • Pull the hose free
    • Remove the two 10mm nuts from the coolant bottle bracket
    • Loosen the lower hose clamp with needle nose pliers
    • Clamp the lower coolant hose with vise grip pliers
    • Pull the coolant bottle aside
    • Tip the coolant bottle to pool coolant away from the hose
    • Pull off the lower coolant hose
    • Disconnect the wiring harness from the coolant bottle
  3. step 3 :Installing the New Coolant Bottle
    • Connect the wiring harness to the new coolant bottle
    • Push the lower hose onto the coolant bottle
    • Push the coolant bottle into place using the locating tab
    • Remove the vise grip pliers from the lower hose
    • Push on the lower hose clamp with pliers
    • Fasten the two 10mm nuts onto the coolant bottle bracket
    • Push the upper hose onto the coolant bottle
    • Remove the vise grip pliers from the lower hose
  4. step 4 :Reinstalling the Air Box
    • Put the air box into place, using the locating tabs, starting at the back
    • Push the intake hose into air box
    • Tighten the intake hose clamp
  5. step 5 :Refilling the Coolant
    • Twist off the coolant bottle cap
    • Add coolant to the cool fill line
    • Twist on the coolant bottle cap

Tools needed for replacement

  • General Tools

    Drain Pan

  • Pliers, Cutters & misc Wrenches

    Needle nose pliers

    Vise Grip Pliers

  • Ratchets & Related

    Ratchet

  • Screwdrivers & Related

    Flat Blade Screwdriver

  • Sockets - Metric

    10mm Socket

Installation Video
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Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.

Hi, I'm Mike from 1A Auto. I hope this how-to video helps you out, and next time you need parts for your vehicle, think of 1AAuto.com. Thanks.

In this video, we're going to show you how to replace the radiator overflow bottle on this 2002 Chevy Suburban. It's the same part and similar process on these Suburbans from 2000 to 2004. The items you'll need are a new radiator overflow bottle from 1AAuto.com, flat blade screwdriver, 10mm socket and ratchet, pliers, two pairs of locking pliers, and a drip pan.

Start off by loosening up this hose clamp. Then, just pull this hose free from the air box. Lift up the air box and just push it towards the engine to free it from the side. Then, lift up that hose and lift your air box up and out.

Clamp on to this hose with locking pliers and make sure you have a drip pan below it. Then just push these teeth together on the hose clamp and pull the hose free. Then remove these two 10mm nuts. We'll just fast forward as Don does that. Now, push the teeth together on this hose clamp. Slide it down the hose. Then clamp onto this hose with locking pliers and pull the hose free. It's a good idea to tip the tank back so it makes less of a mess. Then just pry that hose off with a flat blade screw driver until you can get a good enough grip on it, and pull it off. Just lift up on the tab on this harness and pull it free. And your radiator overflow bottle is disconnected.

On the left, is the old radiator overflow bottle. On the right, is the new one from 1A Auto. You can see they're identical, and they'll fit exactly the same. Take your new overflow bottle and reconnect the harness. Then, push that lower hose into place. Now push this tab into this slot. Push the bottle down. Then remove those locking pliers and slide that hose clamp back into place. We'll just fast forward as Don replaces those two 10mm nuts and tightens them up. Now push the teeth together on this hose clamp again and push the hose back into place. Then just remove the locking pliers.

You want to push these three tabs down into these three holes. Pull back the air hose and push the back end of the air box down in first. Then just push the box straight down into place and make sure you push those tabs in, push the hose back onto the front, and then tighten up that hose clamp.

Obviously you'll want to refill your radiator fluid. There are cold and warm fill lines. Obviously our engine's cold right now, so fill up to the cold line. You should after you refill it, the first few times you drive your vehicle just check it and make sure that it's at the proper level.

We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    General Tools

  • Drain Pan

  • Pliers, Cutters & misc Wrenches

  • Needle nose pliers
  • Vise Grip Pliers

  • Ratchets & Related

  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 10mm Socket

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