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How to Replace Radiator Overflow Bottle 02-05 Mercury Mountaineer

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How to Replace Radiator Overflow Bottle 02-05 Mercury Mountaineer

Created on: 2014-10-13

How to repair, install, fix, change or replace a broken, damaged, split or leaking radiator coolant overflow bottle on 02, 03, 04, 05 Ford Explorer or Mercury Mountaineer.

  1. step 1 :Removing the Air Filter Box
    • Unclip the air box cover
    • Pull out the air filter by hand
    • Lift the air filter box up and out
  2. step 2 :Removing the Coolant Bottle
    • Slide back the coolant bottle hose clamps with pliers
    • Clamp the lower coolant bottle hose with vise-grip pliers
    • Pull the upper hose off the coolant bottle
    • Remove the three 10mm bolts from the coolant bottle
    • Pry the lower hose off the coolant bottle with a flat blade screwdriver
    • Pull the coolant bottle up and out
  3. step 3 :Installing the Coolant Bottle
    • Push the lower hose onto the coolant bottle
    • Remove the vise grip pliers from the lower hose
    • Lower the coolant bottle into place
    • Push the upper hose onto the coolant bottle
    • Insert the three 10mm bolts into the coolant bottle
    • Tighten the hose clamps with pliers
  4. step 4 :Installing the Air Box
    • Lower the air box into place using the locating tabs
    • Put the air filter into the air box
    • Clip on the air box cover
  5. step 5 :Filling the Coolant
    • Twist off the coolant bottle cap
    • Add coolant to the cold fill line
    • Twist on the coolant cap
    • Run the engine briefly
    • Allow it to cool down
    • Check the coolant level
    • Add coolant as necessary

Tools needed for replacement

  • Pliers, Cutters & misc Wrenches

    Slip-Joint 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 2003 Mercury Mountaineer. It's the same part and similar process on these Mountaineers from 2002 to 2005. The items you'll need for this are a new radiator overflow bottle form 1AAuto.com, a 10 millimeter socket and ratchet, a pair of pliers, and locking pliers.

Start off by lifting up on these clips and pulling them back. Then slide the top of your air intake box off. Pull out the air filter. Then lift up on the bottom of your air intake box, maneuver it free, and lift it up and out.

Take a pair of pliers and slide this hose clamp back. Do the same thing to this hose clamp. Then just put a pair of locking pliers on this large hose and just clamp it on. This will keep the hose from leaking. Now just pull this hose free and you're going to need to twist it while you pull and eventually, it will pull free. Remove these three 10 millimeter bolts. We'll fast forward as Mike does that. Using a flat blade screwdriver just pry at this hose and loosen it up. Then just twist the bottle until it pulls free from the hose.

On the right is the old radiator overflow bottle; on the left is the new one from 1A Auto. You can see they're identical and they'll fit exactly the same. Take your new radiator overflow bottle and reconnect that large hose. Then remove the locking pliers, and push the bottle back down into place, and replace the smaller hose. Now replace those three 10 millimeter bolts by hand. Once you have each of them started just tighten them up with your socket and ratchet. Using a pair of pliers just slide those hose clamps back into place.

On the lower part of your air intake box, you want to push those two legs into those two holes. Just feed it down into place. Then push those two back clips into the side of the vehicle, and then push the two legs on the bottom down into the holes. Make sure it's all the way down. Then replace your air filter. Then replace the top of the air intake box and just slide those tabs back into the side. Then reclip the top of the air intake box down.

Now you want to fill your radiator overflow bottle. We have our coolant. Just remove the cap. You want to fill it to the cold fill line. Whenever you open your radiator overflow bottle you want to make sure that your engine is cool. We're just going to fill it up to that line, replace the cap. Then you want to start your vehicle. Let it run for a little while. Let it cool down. Check it. Refill it back up to that line. Do that a couple more times.

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:

    Pliers, Cutters & misc Wrenches

  • Slip-Joint Pliers

  • Ratchets & Related

  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 10mm Socket


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