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HOMESERVICE MANUALSMERCURY1991TRACER BASE, 4D SEDAN, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 18 (ENGINE CONTROLS - REMOVE/INSTALL/OVERHAUL)FUEL SYSTEMCHARGE AIR COOLER INLET TUBEINSTALLATION (3.8L SC)
1991 Mercury Tracer Base, 4D Sedan, Automatic

Installation (3.8L SC)

1991 Mercury Tracer Base, 4D Sedan, AutomaticSECTION Installation (3.8L SC)
WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 1994 Mercury Tracer, 1994 Mercury Topaz, 1994 Mercury Sable, 1994 Mercury Grand Marquis, and 1994 Mercury Cougar. However, it is still accessible from the selected car via links, so may be relevant.
  1. Ensure all sealing surfaces are clean. Install Teflon tape (ESE-M4G168-B) to circumference of sealing surfaces of charge air cooler inlet tube. Apply tape 1/8" (3 mm) from inner diameter, and overlap ends by 1/4" (6 mm). Apply Anti-Seize Compound (ESE-M12A-4A) to sealing surface and threads of supercharger outlet adapter collar.
    CAUTION: DO NOT stretch Teflon tape during installation.
  2. Position inlet tube and install stud into alternator/power steering pump bracket. DO NOT damage sealing surfaces of inlet tube. Install push-on nut on stud enough to hold inlet tube. Ensure inlet tube is free to move for alignment of sealing surfaces.
  3. Hand tighten supercharger outlet adapter collar on inlet tube. Install and slightly tighten nuts attaching inlet and outlet tubes to charge air cooler. Ensure tubes are free to move at sealing areas.
  4. Using adapter, tighten supercharger outlet adapter collar to specification. See TORQUE SPECIFICATIONS TABLE (V6). Wait at least 10 minutes, and retighten adapter collar to specification.
    CAUTION: Supercharger outlet adapter collar must be retightened after 10 minutes, as Teflon tape will form to sealing surfaces.
  5. Tighten nuts attaching inlet and outlet tubes to charge air cooler to specification. Ensure clamping connectors on inlet and outlet tubes at charge air cooler are tightened evenly to specification. See TORQUE SPECIFICATIONS TABLE (V6). Tighten nut attaching inlet tube to alternator/power steering bracket to specification. Start engine and check for leaks.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.