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My best advice is watch what you disconnect. Then connect it back after you've ported and attached the TB. I did have to extend the TPS, but the AIC was fine. There also was the new MAF sensor. I used the one from the 3.8L from the pull-a-part yard. My 1.9L connector, connected right to the new 3.8L one.
 
If you have to add wire, try to match the gauge wire that's already there. I think it's 16 gauge if memory serves.
 
Would these 3.8 TB's work on the 2.0 Zetec. i am not a newb so dont even bitch about that!!!! i just cruise this forum from time to time.i have heard of the 3.8 tb from the T-brids would fit witch i would assume that this is what you are talking about!
 
I used a 88-91 Thunderbird TB, bored out the plenum to match the 55mm diameter. I used to have the throttle cable mounted to the firewall like 91sleeper did and others have aswell, but i went to a shop and they told me that it was a big no no! because the firewall is a part of the frame and dosen't move while the engine is constantly shifting and moving. I was having problems with spudder and little jumps so i took it to this shop that helped me out tones.

When i installled the header the EGR valve had to be bypassed so i cut the pipe short and plugged it with a big screw. There was one hose that came off a bung hole just before the EGR valve and went into the firewall near some computer boxes. i didn't think to plug it who knows if that would of done anything either, but neways i left it exposed and open. Turns out it was what was causing my check engine light to come on and the guys at the shop were saying that it controls fuel/air mixture. So they told me what they would do if they were me and showed me where they would attatch the hose to the engine. So i went and got some vacume hose and some attatchments and hooked it up and instantly i noticed a difference i think it controls the idle. The check engine light was off and idled at 900-750rmp.

So I get the guys at the shop to bypass the EGR valve right to the block and remove the whole system completely so he can fabricate a bracket to the intake manifold to hold the thottle cable. Then i had him use the throttle control arm from the stock 1.9L TB worked out great and looks super clean. check it out ...

pg 8

peace
 
wtf are you 3rd gen guys cutting and splicing the tps and iac wiring, all you need to do is feed it under the fuel rail through the intake manni, more than enough wire to plug-in.... lmfao. Im doing the swap as we speak and just had to post this. THERE IS NO NEED TO CUT/SPLICE ON A 3RD GEN. probably 2nd gen aswell. 3rd gen IAC and TPS works aswell, no need to cut and splice in the old connectors.

I love custom work, I'll post a pic of my swap as soon as my wife gets home with a return spring for me. I went under the EGR for the throttle bracket, using only 1 bolt hole and the throttle cable hole, thats it, dremeled the rest off. very simple setup, yet took me a few hours to get a good pic in my head of what to do. she sounds beautiful and I cant wait to take her for a spin.

heres a pic of the cable/linkage setup
 
Is this mod work with Automatic gearbox as well? I think that the TB has 2 cables. One for throttle cable and the other for gearbox. How to make a solution for that? Has anyone done that before? If yes, please contact me somehow. Planning to make this mode to mine Escort. :)
 
So i picked up a 3.8 TB but when i tried to install it the sensor on top hits the little port thing that comes out the just after the TB. do i use the old sensor from the 1.9 TB or is there some kind of other work around?
 
Just use your old one.
 
Not sure if anyone has figured it out yet, I just did the swap on my '97 race car and all i had to do besides making a cable bracket and boring the hole, was to swap the tps and iac from the 2.0 to the 3.8 throttle body, and it fired right up and ran excellent. Just my little advice if noone has done it yet.
 
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