Airflow Vector S002D User manual

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
SD002DE (S002D Instructions booklet).doc 21 March 2011 Page 1 of 16
\\Server\d\AirflowSnorkels\Products\Snorkels\S002D\SD002DE (S002D Instructions booklet).doc
Instructions to fit the Snorkel Kit S002D
for the Jeep Grand Cherokee WJ / WG Diesel
1.0 Introduction
Airflow Vector Pty Ltd thanks you for your purchase and the trust you put in our
products.
We strive to supply our customers with the highest quality equipment based on
the most efficient design and best styling. We are confident that you will enjoy
using our Snorkel system.
It should improve the power of your vehicle as well as reduce its fuel
consumption.
1.1 General instructions
Follow carefully the instructions listed on these pages and use the template
provided, do not over tighten bolts. Do not use silicone on any connections,
use mastic.
Ensure that safe work practices are followed when installing your Airflow
Snorkel. Protective ear and eye wear should be worn at all times when using
power tools.
1.2 Disclaimer
It is highly recommended that installation is undertaken by a qualified
mechanic or panel beater. Airflow Vector will not be held responsible for any
damage incurred through incorrect fitment of the templates and workmanship.
It is the responsibility of the fitter to ensure that particular care is taken when
assembling the Snorkel kit to the vehicle as it may cause damage to the
windscreen and or electrical components. Safe work practices must be used at
all times when undergoing installation.
We guarantee Airflow Vector’s kits against manufacturing defects as long as
proof of purchase can be established.
All models produced by Airflow Vector are verified to suit right hand drive
vehicles according to Australian specifications. Variations in vehicle
specifications may occur in other markets.
If you're in doubt about the product suitability, please forward a photograph of
the engine bay, air filter housing and of the vehicle at frontal/side position to
[email protected]

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
Page 2 of 16 21 March 2011 SD002DE (S002D Instructions booklet).doc
2.0 List of Components
S002D Kit content
Ref Designation
Qty Length Unit
SP198 Snorkel Jeep
WJ 1
SP063 Air Ram 3.5" 1
SK145 Bolt kit 1
SP013 TPR Hose
90mm 1 100 mm
SP018 Hose clamp
80/100mm 3
SP205 Relocation
bracket 1
SP209 Air box plug 1
SP210 Air box
connector 1
SD002D Template 1
SD002DE Booklet in
English 1
Fasteners included
Ref Designation Qty
SP043 A Pillar bracket 1
SP026 Screw Plug Nylon 2
SP029 Screw Self Tap 10gx5/8
Z/P 4
SP023 Washer Spring 1/4 x 1/4
Z/P 1
SP025 Washer Panel 1/4 x
1.1/4 x 16g Z/P 5
SP024 G/Bolt M6 x 12mm Z/P 3
SP027 Flange Nut M6 Z/P 7
SP022 Stud M6 x 25mm Z/P 5
SP112 Pop rivet Bulbex 8
SP170 Plastic bag 75x125mm 1
Ensure that all parts listed are
included in the parcel before
starting any work.
The total expected time of
installation is around 5 hours.

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
SD002DE (S002D Instructions booklet).doc 21 March 2011 Page 3 of 16
2.1 List of tools and additional parts required
Masking tape, clear tape, black mastic, hammer, centre punch
Assorted screw drivers, sockets and spanners, pop rivet gun
90mm hole saw
Assorted drill set, wet / dry sand paper, ½ round file, small square file,
Zinc rich primer
3.0 Detailed Instructions
3.1 Prior starting any work,
ensure that the configuration
of the air box is as shown. If it
is not, the fitting of this kit will
not be possible. Contact your
dealer for further assistance
3.2 Disconnect the air outlet
from the air box
3.3 De-assemble the air box and
remove it from the engine bay 3.4 Protect the air intake by placing a rag inside

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
Page 4 of 16 21 March 2011 SD002DE (S002D Instructions booklet).doc
3.5 Remove the air intake and
discard it 3.6 Remove the splash guard and store it with its fasteners
3.7 Unfasten the plenum
chamber mounting plate
(keep the screws)
3.8 Disconnect the hoses and
remove it from the engine
bay
3.9 Remove all the elements from
the mounting plate 3.10 Mark the holding tag as shown…

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
SD002DE (S002D Instructions booklet).doc 21 March 2011 Page 5 of 16
3.11 … and cut if off 3.12 Increase the size of the two
holes to 6.5 mm and
elongate the bottom one
3.13 Mark the mounting bracket as
shown…
3.14 Part to keep
3.15 … and cut it off
3.16 Cover the raw edge with zinc
rich paint
3.17 Grind away the ribs inside the
air box… 3.18 … to achieve this result.

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
Page 6 of 16 21 March 2011 SD002DE (S002D Instructions booklet).doc
3.19 Using the air box connector
SP210 as a template drill a
5mm the pilot hole in the air
box
3.20 Using the 90mm hole saw,
drill at SLOW speed a 90mm
hole in the air box
3.21 To ensure proper fitting, place
temporarily the SP210 from
the inside of the air box.
3.22 Trim as required
3.23 Using a 4mm bit, drill 4 holes
through the air box and the
SP210
3.24 Remove the SP210 and
apply some mastic as shown 3.25 Re-install it inside the air box

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
SD002DE (S002D Instructions booklet).doc 21 March 2011 Page 7 of 16
3.26 Pop rivet it in place 3.27 Remove the excess mastic
for a smooth finish
3.28 Insert the air box plug SP209
flush in the unused air intake 3.29 Using a 4mm bit, drill on three sides, about 120° apart
around the air intake and
through the SP209
3.30 Apply some mastic inside the
air intake 3.31 Insert the air box plug SP209 and rivet it in place
3.32 Let the air box cure while
installing the snorkel

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
Page 8 of 16 21 March 2011 SD002DE (S002D Instructions booklet).doc
3.33 Cut around the template
following the guard lines 3.34 Line up the template to the edge of guard
3.35 Following a left to right
sequence, tape it to the
guard
3.36 Centre punch all marked
holes 3.37 Using a 5mm bit, pre-drill all holes (5 snorkel mounting
holes, 1 hole saw hole)
3.38 When pre-drilling the snorkel
hole, ensure that the hole
goes through the inside panel
as well.
3.39 Cover with masking tape
3.40 Using a 10mm bit, drill the 5
fixation holes (not the
snorkel hole)

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
SD002DE (S002D Instructions booklet).doc 21 March 2011 Page 9 of 16
3.41 Using the 90mm hole saw,
drill at LOW SPEED the
snorkel hole
3.42 Continue through the inside
panels
3.43 This is what needs to be
achieved 3.44 File the edge of the hole to remove any bur.
3.45 Paint ALL raw metal surfaces
with Zinc rich primer (5
snorkel fixing holes, 1 air
intake hole including inside
panels)
3.46 Peel off the door rubber seal

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
Page 10 of 16 21 March 2011 SD002DE (S002D Instructions booklet).doc
3.47 Fit the five studs SP022
(20mm must protrude) and
secure them with a locking
compound
3.48 Fit the “A” pillar bracket
SP043 with the washer
SP023 and bolt SP024
Do not over tighten fixings to
avoid damage to the snorkel
Note: This Snorkel is fitted with a second “A” pillar location to be installed
if one intends to use the Collector Pre-Cleaner instead of the Air Ram. If
required, please contact us to obtain the Bolt Kit SK203
3.49 Pre fit the snorkel to the
guard to allow the marking of
the “A” pillar bracket
3.50 Mark two holes of the “A”
pillar bracket onto the paint
3.51 Remove the snorkel
3.52 Centre punch the 2 holes
3.53 Using a 4mm bit, pre-drill the
two holes

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
SD002DE (S002D Instructions booklet).doc 21 March 2011 Page 11 of 16
3.54 Using a 7mm bit, drill the two
holes for the “A” pillar position 3.55 File the holes with a square file to suit nylon plugs SP026
3.56 Fit the two square plugs
SP026 (you may need to trim
the bottom part of the plugs
to allow their insertion)
3.57 Secure the “A” Pillar bracket
SP043 with the screws
SP029
3.58 Refit the rubber seal and
mark the location of the
bracket on the rubber seal
3.59 Using a scalpel, cut the
rubber seal along the marks

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
Page 12 of 16 21 March 2011 SD002DE (S002D Instructions booklet).doc
3.60 Refit the rubber seal 3.61 Secure the snorkel with
washers SP025 (x5) and
nuts SP027 (x5) to the guard
Do not over tighten fixings to
avoid damage to the snorkel
3.62 Secure the snorkel on the “A”
pillar bracket with bolt SP024
fitted with spring washer
SP023
Do not over tighten fixings to
avoid damage to the snorkel
3.63 Secure the relocation
bracket SP205 with the top
screw retrieved from step
3.8
3.64 Mark the base of the bracket
3.65 Remove the bracket SP205
3.66 Punch the location 3.67 Using a 5mm bit, drill the
location

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
SD002DE (S002D Instructions booklet).doc 21 March 2011 Page 13 of 16
3.68 Secure the plenum chamber
on the bracket SP205 using
the bolts SP024 (x2) and the
nuts SP027 (x2)
3.69 Using the self tapper screw
SP029, secure the base of
the bracket to the engine
bay
3.70 Install the plate modified in
step 3.13 under the bracket
SP205 and secure it together
with the regulator
3.71 Resecure the solenoid to the
plate and reconnect all the
hoses
3.72 Please wear gloves
3.73 Use only NON SILICONE
BASE black mastic as sealant
3.74 Smear sealant inside both
ends of the hose SP013
3.75 Slide one hose clamp SP018
at each end
3.76 Connect the TPR hose to
the snorkel SP198

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
Page 14 of 16 21 March 2011 SD002DE (S002D Instructions booklet).doc
3.77 Re-secure the air box inside
the engine bay 3.78 Tighten the two hose clamps SP018
3.79 Re-install the air filter inside
the air box 3.80 Close the air box
3.81 Re-connect the top hose to
the air box and secure the
hose clamp
3.82 Refit the splash guard

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
SD002DE (S002D Instructions booklet).doc 21 March 2011 Page 15 of 16
3.83 Slide the hose clamp SP018
on the air ram SP063 then
slide it on the snorkel SP198
3.84 Ensure that the top of the
snorkel matches the top of
the slot cut in the Air Ram
3.85 Drill the hose clamp next to
the worm drive
3.86 Secure the Air Ram with the
self tapping screw SP029
Important note: Do not turn the Air Ram away from the direction of
travel because it will lessen the positive pressure necessary for proper
operation. In extreme situation, at speed above 25km/h (15m/h) a
vacuum may be generated causing irreversible engine damage
Note: The content of this manual may be modified from time to time to
ensure that improvements brought to our kits are described accurately.
Before starting the installation, try to obtain the latest version of the
instruction manual from our web site www.airflowvector.com

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: [phone]
www.airflowvector.com
Page 16 of 16 21 March 2011 SD002DE (S002D Instructions booklet).doc
3.87 Polish with silicone cleaner
4.0 Improvement program
We strive to produce documentation and kits free of mistakes, however,
should you discover any error or omission, please let us know by quoting
the initials shown in the box below.
Furthermore, if you think that a step of this procedure could be improved,
please send us at [email protected] your suggestions indicating
the procedure name, its release date, the step details and the photo if
necessary.
We appreciate your support.
This kit has been carefully packed by
Date Initials