Outlet Tube

REMOVAL
1. Remove two nuts retaining outlet tube to intake elbow assembly.

2. Raise vehicle on a hoist.

3. Remove bolt retaining outlet tube to cylinder block front upper support bracket.

4. Loosen but do not remove support bracket at front of cylinder block.

NOTE:
The bracket must be close to the front face of the cylinder block to allow the bracket to pivot during outlet tube reinstallation.

5. Remove nut and push-on nut retaining outlet tube to alternator-power steering pump bracket.

NOTE:
The outlet tube does not have to be removed from the vehicle if just resealing the tube.

6. Remove upper intercooler tube stud from the alternator-power steering pump bracket.

7. Remove power steering pump drive belt.

8. Disconnect spark plug wires from coil. Note location of plug wires for proper reinstallation.

9. Remove power steering pump bracket brace to water pump retaining stud nuts.

10. Remove two power steering pump bracket to cylinder head retaining bolts and one stud nut.

TIP:
Install a 10 x 1.5mm x 170mm bolt (6.5 inch) long into the top hole in the power steering pump bracket. Thread the bolt into the cylinder head approximately five turns.

11. Remove power steering pump filler cap.

12. Slide power steering pump bracket assembly forward on the stud and bolt that was installed.

13. Remove outlet tube by pulling underneath the power steering pump bracket assembly and up through the engine compartment.

IMPORTANT:
- Use extreme care during removal and installation of the intercooler tubes so as not to scratch, nick or contaminate the sealing surfaces.

- It may be necessary to pivot the outlet tube clamping connector to gain clearance during removal.

INSTALLATION
1. Clean and inspect the sealing surfaces of the supercharger outlet adapter, intake elbow, intercooler and tubes.

NOTE:
Make sure there are no foreign particles on the sealing surfaces of the tubes. It is important that the intercooler tubes seal completely. Any air leak will cause poor operation and performance.

2. Install gasket sealant tape ESE-M4G168-B or equivalent (from Kit No. E9PE-6F091-AA) circumferentially to the spherical seal surfaces of the intercooler tubes (4 places). Install the tape approximately 3mm (1/8 inch) from the inner diameter of the tubes. Overlap the tape ends approximately 6mm (1/4 inch).

IMPORTANT:
- Do not stretch the tape during installation or the seal may leak.

- During installation, a slight wrinkling will occur on the tape edge at the inner diameter.

- For proper alignment of the system to ensure proper sealing of the intercooler tubes. The system must be tightened in sequence and to the specification for that step.

3. Guide the outlet tube down through the engine compartment and underneath the power steering pump bracket assembly.

CAUTION:
Use extreme care during installation of the intercooler tubes so as not to scratch, nick or contaminate the sealing surfaces.

NOTE:
It may be necessary to rotate the lower outlet tube clamping connector to gain clearance while installing the outlet tube.

4. Slide power steering pump bracket assembly into position.

5. Install power steering pump bracket retaining stud nut.
Tighten to 40-55 Nm (30-40 ft lb).

6. Remove bolt installed in Step 11 of removal procedure.

7. Install power steering pump bracket to cylinder head bolts.
Tighten to 40-55 Nm (30-40 ft lb).

8. Install power steering pump bracket brace to water pump retaining stud nuts.
Tighten to 20-30 Nm (15-22 ft lb).

9. Install outlet tube over lower stud on alternator-power steering pump bracket.

10. Install push-on nut onto stud, tight enough to retain tube against the alternator-power steering pump bracket surface but free enough to allow tube movement to ensure seating of spherical seat on outlet tube to intake elbow assembly.

11. Install outlet tube clamping connector over studs on the intake elbow assembly and secure with two nuts.
Tighten both nuts to 20-30 Nm (15-22 ft lb).

NOTE:
The clamping connector should be installed so it is visually parallel to the stud mounting face of the intake elbow assembly.

12. Install nut to the stud on alternator-power steering pump bracket.
Tighten to 40-55 Nm (30-40 ft lb).

13. Install bolt to secure outlet tube to cylinder block support bracket.
Tighten to 40-55 Nm (30-40 ft lb).

14. Tighten support bracket to front of cylinder block retaining nut to 20-30 Nm (15-22 ft lb) and bolt to 70-95 Nm (52-70 ft lb).