S-Model Supercharger & 70mm TB 'How-To'
 

Note: Before beginning it is recommended that you read the SC OD Pulley install 'How-To' for pulley removal and the Spark plug wire installation 'How-To' articles. You will need the Supercharger Reseal Kit E9SZ-19577-A which is available from your local Ford parts department or any Gasket Maker (requires 6-12 hours set-up time). You will need about 4 hours to complete the removal and installation of the supercharger, throttle body, and inlet plenum. S-Model supercharger and 70mm BBK Throttle Body can be purchased through MN12 Performance.
 

1. Designate a clean area to set the parts down after removal from the car.
2. Disconnect the connector to the Mass AirFlow (MAF) sensor and loosen the clamp at the Throttle Body.  Remove the air tube assembly from the Throttle Body (TB) and pull the air intake system out. Disconnect the #1,#2,#3 plug wires from the distributor.
3. Disconnect all (accelerator, speed sensor, & AOD) linkages from the TB bracket. Next, remove the 2 bolts that attach the TB bracket to the inlet plenum assembly.
4. Disconnect fuel charging wiring connectors at the throttle position sensor (TPS) and idle air control (IAC) from the TB.
5. Remove the supercharger belt & pulley (see SC OD pulley installation article)
6. Remove all vacuum hoses that connect to the inlet plenum. (Hint: Mark the location of all vacuum hoses that are connected to the inlet plenum before removal).  Loosen supercharger bypass hose clamps that connect the inlet plenum to the outlet plenum.
7. Remove the supercharger outlet plenum collar nut with the spanner nut wrench and remove the 2 nuts that connect the upper intercooler tube assembly to the intercooler.

Hint: If you never cleaned the Intercooler out or flushed the radiator this is the best time. Use mineral spirits or a can of brake fluid to clean the Intercooler out and radiator flush to clean the radiator out. This is also the best time to mount a intercooler fan behind the intercooler.

8. If your SC is equipped with a Exhaust Gas Recirculation (EGR) valve you need to remove the two bolts that connect the EGR valve to the inlet plenum along with the bolt that connects the EGR transducer. You will have to remove the passenger side cowl vent screens to access the EGR. You will need a 3/8" flex head ratchet to reach the 2 bolts that hold the EGR to the inlet plenum. If your SC is equipped with the coolant lines that run through the TB you will need to block the lines off.

9. Finally, remove the three bolts that hold the supercharger down to the intake. Remove the supercharger, intake plenum, & throttle body together from the car. Clean as much oil and dirt from the engine as possible using brake cleaner or engine cleaner and compressed air. With the supercharger out check all vacuum hoses for signs of cracking and check valve covers for oil leaks. With the stock supercharger out of the car check all vacuum fittings on the inlet plenum and swap any fittings over to the S-Model that are different. Remove the 4 bolts that hold the SC top on the supercharger and remove the SC top. Clean and inspect sealing surfaces. Remove the 4 retaining nuts from the stock TB and separate the TB from the inlet plenum. With the TB off remove the IAC and TP sensors. (Note: Be careful the screws are very hard to get off so use a bench and a good phillips head screw driver to remove the screws. Install both IAC and TP sensors on the new BBK TB. Tighten the IAC bolts to 6-9 lb-ft and the TPS phillip screws to 6-9 lb-ft. Check all nuts and bolts that connect the intake plenum to the supercharger and torque to proper specifications. )
   
   
10. Check the TP voltage after you install the TPS on the TB. To check voltage connect the TPS connector to the TPS and using a paper clip insert one end into the the back of the harnesses CENTER wire in the 3 wire harness. Turn the ignition to ON with the engine off and check the voltage using a volt meter. At idle the voltage should be between (see chart). To adjust the voltage turn the idle stop screw down until correct voltage range is achieved. If correct voltage cannot be set then remove the TPS and using a drill bit or chain saw file round the brass holes that the screws go through to hold the TPS down to the TB. This will provide you adjustibility when setting the base voltage.
    

Passenger Car Engine	Engine	1993 Service Part	Voltage at Idle
Thunderbird/Cougar	V6 3.8L EFI	F2SZ-B	.66-1.22
Thunderbird	V6 3.8L SC	F2SZ-C	.70-1.31
Thunderbird/Cougar	V8 (4.6L) EFI	F2SZ-A	.65-1.26
Thunderbird/Cougar	V8 (5.0L) HO	F2SZ-C	.70-1.31

Installation is the reverse of removal.