Supercharger Kit Installation Instructions Triumph TR4 & TR4A PART# 150-138 440 Rutherford St. Goleta, CA 93117 1-800-642-8295 • FAX 805-692-2525 • www.MossMotors.com Tools required: • TR4 Shop manual • Wire cutters, strippers and crimpers • Strap wrench • Side cutters (dikes) • Thread sealer or Teflon tape • 1/4", 3/8", & 1/2" ratchets • Masking tape • 3" and 6" extensions for above ratchets • Drill motor • Combination wrenches and sockets in the following sizes: • 1/4" drill bit • 7mm, 8mm, 10mm, 12mm, 13mm, 17mm • Phillips screwdrivers • 1/4", 5/16", 3/8", 7/16", 1/2", 9/16", 5/8", 11/16", • Flat-blade screwdrivers 3/4", 15/16", 1-1/8" • Torque wrench up to 65 ft-lbs • 9/16" swivel socket or universal joint • 3/16" Allen wrench • 13/16" spark plug socket • Hack saw or cut-off wheel Figures may vary from actual components. empty or by draining the fuel tank before beginning supercharger installation. Never smoke or work You must have a shop manual to complete this around open flames. install. These instructions focus on the installation of this supercharger system and not disassembly of If your car is + (positive) ground (earth), we will be the stock engine. Refer to the shop manual for more converting it to – (negative) ground (earth) during detail on disassembly or components having to do this install. You must follow the extra steps in the with a stock vehicle, i.e. torque specs, wiring, hose/ back of these instructions on how to rewire various cable routing, etc... Read and understand these components to work with – (negative) ground (earth). instructions before picking up a tool. If you do not feel 100% confident in your ability to install this kit, Note: Your engine should be in good mechanical pay a professional to do it for you. Moss Motors may condition and should have a recent tune up. It be able to recommend a shop in your area. should have good compression in all cylinders. Your distributor should also be in good condition. Vehicle shown in most of the illustrations is a TR3 We sent our distributor out to be checked. We with a steering rack conversion and an electric had 10 degrees of mechanical advance for every fan conversion. Although the pictures do not look 1000rpm, with total mechanical advance of 28 identical to your vehicle, they are more than adequate degrees coming in by 3000-3200 rpm. Your engine for this install. Focus on the parts that look similar to mounts should be in good condition. Replace your car, rather than the differences. them if they are not. Excessive engine rock can cause damage to you, your vehicle, or the During installation, we will be changing fuel lines. supercharger. Also, after installation, the fuel tank will need to always be refilled with 91 octane fuel. So, empty the fuel tank either by running the car close to Part # 150-138 -1- Modified 02/18 Installation Instructions 1. Use a timing light to check total timing advance. Rev 9. Remove the intake manifold with the carburetors your engine until the timing stops moving. This is your attached. Set aside the intake manifold attachment total advance. All of your advance should be in before clamps and nuts for later reuse. If necessary, replace 3500rpm. Take note of the total timing number and the intake/exhaust manifold gasket. This would RPM it was achieved at. Then rotate your distributor require removing and replacing the exhaust manifold to achieve 30 degrees total advance. On our car, this as well. A new gasket set is provided. Figure 9. was achieved at ~1 degree base timing. 2. Disconnect both battery cables. NOTE: Before installing this kit, your car will need to be or be converted to a negative ground. 3. Place the vehicle on jack stands to allow access to the underside of the car. 4. Remove the hood and the radiator shroud, referring to the shop manual. Removal of the hood is not necessary but will make working on the car easier. Figure 4. Figure 9 10. Remove the accelerator pedal return spring. Do not skip this step. If left in place the return spring could cause the throttle to stick. Figure 10. Figure 4 5. Drain the cooling system. Remove the radiator by disconnecting the top and bottom hoses. Release the bolts on either side at the base of the unit and release the tie rods at the top. 6. Remove the cooling fan using a 7/16" socket. 7. Use a screwdriver to remove the inlet fuel line from the carburetor. Then remove the fuel line to the mechanical fuel pump and then remove the Figure 10 mechanical fuel pump. 11. Disconnect the two wires at the back of the 8. Disconnect the choke cable. Remove the throttle generator. Loosen all of the generator bolts and linkage at the firewall-mounted throttle linkage cross the generator link bolt. Remove the belt. Remove tube. Then remove the hose from the distributor’s the generator link and the generator. The generator vacuum advance diaphragm. hardware will not be reused. Figure 11. Part # 150-138 -2- Modified 02/18 Figure 4 Installation Instructions Figure 11 Figure 12 13. Use a strap wrench and a 3/4" combination wrench to remove the water pump pulley nut. Use a pulley puller if necessary. Then use a 9/16" socket and a 3/8" extension to remove the water pump mounting nuts. 14. Clean the gasket surfaces. Install a new water pump gasket and the provided water pump from the kit. Install the new water pump pulley, securing it into place with locknut that comes with the pump. Figure 14. 12. Use a 3/4 inch combination wrench and a 7/8" combination wrench to remove the generator mounting pedestal from the front engine plate. Use a 1/2 inch socket or combination wrench to remove the generator mounting bracket from the engine block. Figure 12. Figure 14 Part # 150-138 -3- Modified 02/18 Installation Instructions 15. Use two 7/16" combination wrenches to loosen the 16. Install the six bolts through the rear side of the crank six fan hub extension retaining bolts. Use a 1-1/8" pulley. Slide the crank hub pulley over the bolts and socket to break the crank bolt loose. Rotate the into the recess on the front side of the crank pulley. crank until the timing mark on the crank pulley lines Slide the crank pulley/crank hub assembly over the up with the timing cover pointer. Remove the fan hub end of the crank shaft. NOTE: The timing tab will extension. Remove the crank pulley bolt, the crank have to be bent as necessary to clear the crank hub pulley and the two plates that make up the crank pulley. You should try to have at least 1/8" of pulley. It is critical that you align the timing mark with clearance between the timing tab and the crank the pulley before you remove the pulley. If you do pulley. Make sure the timing mark on the pulley not align the marks you may not be able to set your is aligned with the tab on the timing cover. If not, timing when this install is complete. Figure 15. remove the pulley from the hub and re-clock it so that it is. Again, this is critical for setting ignition timing. Figure 16. Figure 16 Figure 15 17. Reinstall the fan hub extension using the provided nuts and lock washers. Torque the nuts to 10 ft-lbs. Then install the crank pulley bolt. Part # 150-138 -4- Modified 02/18 Installation Instructions 18. Bolt the tensioner plate assembly to the engine. For the 5/16" upper bolt, there will be the bolt, a lock washer, a flat washer, the tensioner plate and a washer on the back side of the idler plate followed by the water pump. For the 7/16" lower bolt, there will the bolt, then a flat washer, then the tensioner plate, the tensioner plate standoff (tall spacer), then the engine plate, a flat washer, a lock washer and a nut. Torque the 5/16" upper bolt to 17 ft-lbs. Torque the 7/16" lower bolt to 55 ft-lbs. Figure 18. Figure 18 cont. 19. Some kits have the 4 rib serpentine belt pulley and fan installed. If your kit does, skip this step. Loosen the 7/8 inch or 22 millimeter nut on the provided alternator. Install the provided alternator fan and alternator pulley onto the provided alternator. Then install the alternator nut. Tighten the nut to 45 ft-lb. You will need to hold the fan from turning while tightening the nut. We have had good luck holding the fan with a carefully positioned rag and using an impact to tighten the pulley. Figure 19. Figure 18 Figure 19 Part # 150-138 -5- Modified 02/18 Installation Instructions 20. Mount the alternator bracket to the block with the bolts finger tight. Then insert the 4" long upper mounting bolt through the tensioner plate and the alternator mounting bracket. This will allow you to align the hole in the alternator bracket to the hole in the tensioner plate bracket. Push the alternator bracket forward so that the tube at the top of the alternator bracket is flush with the backside of the tensioner plate. Then tighten the three mounting bolts to 17 ft-lbs. The 4" long alternator mounting bolt should still slide freely with the bolts tightened. Now remove the bolt so that the alternator can be Figure 21 mounted into place using it.