Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSMERCURY1991TRACER BASE, 4D SEDAN, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 18 (ENGINE CONTROLS - REMOVE/INSTALL/OVERHAUL)FUEL SYSTEMCHARGE AIR COOLER OUTLET 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.
- Install Teflon tape (ESE-M4G 168-B) to circumference of sealing surfaces of outlet tube. Keep tape close to inner diameter, and overlap ends by 1/4" (6 mm). DO NOT stretch tape during installation, or a leak at sealing surface may develop.
- Install outlet tube underneath power steering pump bracket assembly. See Figure. Install power steering bracket and stud retaining nut. Tighten nut to specification. See TORQUE SPECIFICATIONS TABLE (V6).CAUTION: Carefully install outlet tube to avoid damaging sealing surfaces.
- Remove bolt installed in step 5) during removal. Install power steering pump bracket-to-cylinder head bolts, and tighten to specification.
- Install power steering pump bracket brace-to-water pump retaining studs. Tighten nuts to specification. Install outlet tube on lower stud on alternator/power steering pump bracket. Install push-on nut to hold outlet tube on pump bracket. Ensure outlet tube is free to move for alignment of sealing surfaces.
- Position outlet tube clamping connector over intake elbow assembly studs. Install and tighten nuts evenly to specification. See TORQUE SPECIFICATIONS TABLE (V6). Ensure clamping connectors on outlet tube-to-intake elbow are parallel to intake elbow surface. Install nut on stud of alternator/power steering pump bracket and tighten nut to specification.
- Install outlet tube-to-cylinder block support bracket. Tighten bolt to specification. Tighten support bracket-to-front of cylinder block retaining nut and bolt to specification.
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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.