How to Replace the Radiator on a 1999 Mercury Cougar V6

Written by dan ferrell
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Replacing the radiator in your 1999 Mercury Cougar V6 is not much different than installing a new one in other cars. Most cooling systems follow the same basic configuration, but access to it may get complicated by the arrangement of components and space in the engine compartment. Fortunately, your Cougar model provides fairly good access so grab your toolbox. You will not only save your Mercury engine from overheating disaster but can also save your driving budget.

Skill level:
Moderately Easy

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Things you need

  • Wrench set
  • Large drain pan
  • 18-inch hose
  • Ratchet
  • Socket set
  • Rib joint pliers
  • Line wrench
  • Floor jack
  • Jack stands (4)
  • Short ratchet extension
  • Flexible wire
  • Antifreeze
  • Distilled water

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Instructions

    Removing the Old Radiator

  1. 1

    Disconnect the negative (black) battery cable with a wrench.

  2. 2

    Place a large drain pan under the passenger's side of the radiator and install an 18-inch hose over the radiator drain valve. Point the hose into the drain pan, then open the coolant reservoir cap and radiator valve to drain the coolant from the radiator. When finished, cover the pan to keep the coolant clean and remove the hose from the radiator valve.

  3. 3

    Unfasten the front air intake components with a ratchet and socket to gain better access to the radiator. There will be two mounting bolts for these components next to the bonnet latch on the driver's side.

  4. 4

    Unplug the cooling fan electrical connector and remove the wiring harness from the holding clip so that you can move the harness out of the way.

  5. 5

    Unfasten the fan's ground cable from the passenger's side fender with a ratchet and socket. Unfasten the fan shroud with the ratchet and socket and move the fan assembly out of the engine compartment.

  6. 6

    Squeeze the tabs on the upper radiator hose clamp with a pair of rib joint pliers and slide the clamp away from the radiator. Disconnect the upper hose from the radiator. Disconnect the overflow hose from the radiator neck if you have a 2.5L engine model.

  7. 7

    Detach the upper transmission cooler line from the radiator with a backup wrench on the radiator connector and a line wrench on the retaining nut if your Cougar model has an automatic transmission.

  8. 8

    Raise the front of your Cougar with a floor jack, support it on two jack stands and detach the lower transmission cooler line from the radiator with a backup wrench on the radiator connector and the line wrench on the retaining nut if your Cougar model has an automatic transmission.

  9. 9

    Squeeze the tabs on the lower radiator hose clamp with the rib joint pliers, slide the clamp away from the radiator and disconnect the lower hose from the radiator.

  10. 10

    Support the radiator and condenser with a jack stand on each side, then remove the radiator lower supports and the condenser mounting bolts from the bottom of the radiator with a ratchet, short ratchet extension and socket.

  11. 11

    Secure the condenser to the front subframe of your Cougar with flexible wire, remove the two jack stands from under the radiator and remove the radiator out from the bottom of the engine compartment.

    Installing the New Radiator

  1. 1

    Position the new radiator through the bottom of the engine compartment and hold the radiator and condenser in place with two jack stands.

  2. 2

    Replace the lower supports and the condenser mounting bolts onto the bottom of the radiator with the ratchet, short ratchet extension and socket. Untie and remove the flexible wire from the condenser and remove the two jack stands.

  3. 3

    Reconnect the lower hose to the radiator fitting and secure it with the clamp and the rib joint pliers.

  4. 4

    Reconnect the lower transmission cooler line to the radiator with the backup wrench and line wrench if your Cougar model has an automatic transmission then lower your Cougar off the jack stands.

  5. 5

    Reattach the upper transmission cooler line to the radiator with the backup wrench and line wrench if your Cougar model has an automatic transmission.

  6. 6

    Reconnect the upper hose to the radiator fitting then secure it with the clamp and the rib joint pliers. Reattach the overflow hose to the radiator neck if you have a 2.5L engine model.

  7. 7

    Position the fan assembly in place, tighten the mounting bolts and fasten the fan's ground cable to the passenger's side fender with the ratchet and socket.

  8. 8

    Plug in the cooling fan electrical connector and secure the wiring harness with the holding clip.

  9. 9

    Replace the front air intake components you removed with the ratchet and socket.

  10. 10

    Refill the radiator with the coolant through the coolant reservoir up to the "Max" mark and leave the reservoir cap off. Start the engine and let it idle. Once the thermostat opens, you will see the coolant level drop. Add the rest of the coolant and make sure the level reaches the "Max" mark. If necessary, add a 50/50 mixture of new antifreeze and distilled water then turn off the engine.

  11. 11

    Reconnect the negative (black) battery cable with the wrench and close the bonnet.

Tips and warnings

  • Always wait for the engine to cool down before removing the radiator or coolant reservoir caps. Hot coolant under pressure may spray out and burn you.

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