I have a way of doing things which work for me. Here's what I have written up. See if it helps you any.
abbreviations:
PSP - Power Steering Pump
IC - InterCooler
UICT - Upper InterCooler Tube
LICT - Lower InterCooler Tube
SC - SuperCharger
Remove main serpentine belt. Twist 18mm bolt on alt bracket pulley clockwise with breaker bar.
Remove windshield washer reservoir. Careful with the 2 connectors, plastic may be brittle.
Remove UICT clamp nuts and SC top bolts (unless you like messing with the collar nut).
Remove UICT to PSP bracket nut (15mm) and then the stud (7mm). You'll know why when you reassemble it.
Remove UICT and SC top as 1 piece. Cover the SC inlet to keep dirt out.
Remove LICT clamp nuts at IC and LICT to PSP bracket nut and stud.
Remove IC.
## This part depends on your ability to reach and loosen nearly impossibly hard to get to bolts. If you can reach and remove the 2 with a swivel and 1/2" drive, skip this part and just remove the 2 nuts holding the plate to the water pump. ##
Remove PSP pulley with pulley puller tool.
Remove the 2 15mm bolts holding the PSP plate to the PSP bracket.
Remove the 2 nuts holding the PSP plate to the water pump.
Remove the PSP to Water pump plate.
## End of optional part. ##
Loosen psp bracket assembly (2 bolts, 1 nut/stud). Pull assembly forward to gain clearance.
Remove LICT rear clamp nuts at the intake plenum.
Remove LICT bracket holding the tube to the engine block (15mm bolt, 13mm nut/stud)
Remove LICT (carefully to avoid nicking the flange seats). You may need to loosen the bolt
holding the tube to the mounting plate. Its usually frustrating to maneuver it out, but it
can be done.
To reassemble:
Apply teflon sealant tape (or equivalent sealant) to LICT flange seats (unless you were careful and you're lucky and can reuse the existing seal tape)
Reinstall LICT loosely. (Now you see why it was necessary to remove both the nut AND the stud on the PSP bracket)
Push PSP bracket back and tighten.
## If you did the optional part:
Reinstall PSP bracket plate and tighten.
Reinstall PSP pulley
##
Reinstall LICT to PSP bracket stud and nut firmly but not too tight. Evenly tighten LICT rear clamp nuts.
Tighten LICT PSP bracket retaining stud and then the nut.
NOW tighten the LICT engine bracket firmly.
Carefully install the IC. Install LICT clamp nuts loosely.
Clean the SC top and SC inlet with solvent. Try not to scrape anything into the SC. Don't apply the copper RTV sealant just yet.
Check for dirt and clean it out. Apply tape to the UICT flange seat.
Now apply a very thin layer of copper RTV sealant to SC top.
Install UICT and SC top but do not tighten. Reinstall UCIT to PSP bracket stud, seat it, then the nut and tighten. Tighten SC top bolts (You don't need more than about 15 lbs on these)
Evenly tighten all UICT and LICT clamp nuts.
Hint: observe the amount of the stud protruding as you tighten the nuts, keep them PRECISELY the same length on both sides.
There should not be any hint of binding or misalignment. Be careful about this and you'll get a perfect seal!
Don't overtorque!
Install washer reservoir.