Safari Snorkel SS1066HF User manual

Installation Guide –Safari SS1066HF Page - 1 of 12
SS1066HF
Jeep JK Wrangler Left Hand Drive
CRDI4 2.8Litre-I4 Diesel Engine and
EGHV6 3.8Litre V6 Gasoline Engine
6/10/2009
ITEM
PART NO
DESCRIPTION
QTY
1
956-133-000
BODY - SNORKEL (SS1065HF)
1
2
000-135-800
3 1/2" AIR RAM ASSEMBLY
1
3
956-032-000
BRACKET - UPPER MOUNTING
1
4
000-002-100
BOLT - HEX - 6mm x 1.0 x 14mm (SEMS)
3
5
956-992-000
SPACER - PLASTIC 8.7mmID x 18mm x 4.5mm
2
6
000-110
STUD - S/S - 8mm x 1.25 x 25mm
3
7
000-311-300
WASHER - BODY - 8mm x 30mm - S/S
3
8
000-205-300
NUT - NYLOC - 8mm x 1.25mm - S/S
3
9
956-024-250
HOSE - AIR ENTRY
1
10
000-909
CLAMP - HOSE - 80/100mm
1
11
000-910
CLAMP - HOSE - 90/110mm
1
12
956-123-200
DUCT - AIR ENTRY (SS1066HF)
1
13
000-958-450
POP RIVET - ALUMINIUM - 4.8mm x 21mm
9
14
000-226
CLIP - SPIRE - 4.8 x 2.5/3.7mm
3
15
000-951-550
SCREW - S/T - 4.8mm x 16mm (BLACK)
3
16
000-914/B
CLAMP - HOSE - No. 56 (BLACK)
1
17
956-017-000
TEMPLATE - OUTER FENDER
1
18
956-017-200
TEMPLATE - INNER FENDER
1
19
956-017-300
TEMPLATE - FENDER LINER (FRONT)
1
20
956-017-400
TEMPLATE - FENDER LINER (REAR)
1
21
956-017-500
TEMPLATE - AIR CLEANER HOUSING
1
22
000-987-178
TIE STRAP - NYLON - 4.8mm x 178mm
1
23
000-268
NUT - TUBE - FENDER LINER
1
24
000-441-200
SLEEVE - AIR RAM
1
Manufactured by Safari Automotive Pty Ltd
73 Merrindale Drive, South Croydon Victoria 3136 Australia Tel: [phone] Fax: [phone]
www.safarisnorkel.com ABN 75 803 294 474

Installation Guide –Safari SS1066HF Page - 2 of 12
SS1066HF
Jeep JK Wrangler Left Hand Drive
CRDI4 2.8Litre-I4 Diesel Engine and
EGHV6 3.8Litre V6 Gasoline Engine
Installation Guide
Fitment to:
Right Hand Side
Fitting Time:
210 min
Special Tools:
Air Body Saw (Reciprocating)
Step Drill
T40 Torx Bit
Pop-Rivet Gun (Swivel Head)
Touch-up Paint
Sikaflex 227 (adhesive sealant)
Loctite 243 (thread lock)
Loctite 406 Instant Adhesive
Clip Removing Tool
12"/18" Adjustable Wrench
Prep Wash
Masking Tape
Prior to commencing the installation, it is the installer's responsibility to verify that all
components and particularly the template (Item 17) are correct.
1
Jack the vehicle up and remove the right hand front wheel.
2
Remove the RHS inner
fender liner. (The 3 rear
plastic pop rivets must be
removed as shown).

Installation Guide –Safari SS1066HF Page - 3 of 12
3
Remove the following in accordance with the factory service manual:
Radio antenna
Air cleaner assembly
4
Remove and discard the:
Air intake from the
air cleaner housing
"Sport" sticker from
the RHS fender.
(Use prep wash to
remove any sticky
residue from the
sticker).
5
Tape the outer fender
template (Item 17) to the
rear and upper edges of the
right hand fender. Use a felt
tip pen to mark the 3 hole
positions and the required
fender panel and flare cut
out area.
Remove the template.
6
Position the inner fender
template (Item 18) over the
2 flare clips. Using a felt tip
pen, mark the required
fender panel area which
needs to be removed.

Installation Guide –Safari SS1066HF Page - 4 of 12
7
Use an air body saw to
remove the marked area of
the inner fender panel,
outer fender panel and
flare.
Drill pilot holes for the three
marked mounting hole
positions. Use a step drill to
drill the 3 mounting hole
positions to 16mm.
De burr and paint all the
exposed metal surfaces to
prevent rust.
8
Using a 12" or 18"
adjustable wrench or
specialized panel beating
equipment, bend the lower
"A" Pillar reinforcement
panel inwards (Be sure to
bend the panel far enough
inwards).
This process is critical to
ensure that adequate
clearance is achieved for
the fitment of the air entry
hose (Item 9).
Prepare the surface and
paint to prevent the panel
from rusting.

Installation Guide –Safari SS1066HF Page - 5 of 12
9
Remove the two stock bolts
from the 'A' Pillar and install
the two plastic spacers
(Item 5) into the two
'A' Pillar bolt reliefs.
Apply Loctite 243 to the two
stock 'A' Pillar bolts and
install the upper mounting
bracket (Item 3) onto the
'A' Pillar.
Fasten bolts in accordance
with the factory service
manual.
10
Apply Loctite 243 to each of
the stainless steel mounting
studs (Item 6) and install
the studs finger tight into
the snorkel body inserts.
11
Measure 65mm down from
the top of the snorkel body
and mark the
circumference.
Slide the air ram sleeve
(Item 24) over the top of the
snorkel body (Item 1) and
align the bottom of the
sleeve with the 65mm mark.
Lift the edges of the sleeve
(Item 24) and apply several
small dabs of Loctite 406
Instant Adhesive or similar
to secure the sleeve in
position.

Installation Guide –Safari SS1066HF Page - 6 of 12
12
Install the snorkel body onto
the fender panel.
Align the snorkel body to
the upper mounting bracket
and fender panel. When
correctly aligned, fasten the
snorkel body to the fender
panel with body washers
(Item 7) and nyloc nut (Item
8).
Fasten the snorkel body to
the upper mounting bracket
with hex bolts (Item 4).
13
Unclip the wiring harness
from its mounting position.
Mark 80mm down (3.2")
from the top of the air
cleaner housing mounting
bracket as shown.
Use an air body saw to cut
away the required section
of the air cleaner housing
mounting bracket as shown.
Ensure that the wiring
harness is clear of the saw
blade whilst cutting.

Installation Guide –Safari SS1066HF Page - 7 of 12
14
Mark the lower section of
the plastic aircleaner
housing mounting bracket
as shown.
Use an air body saw to cut
away the required section
of the air cleaner housing
mounting bracket.
15
Mark the small section of
the fender flare support
bracket as shown.
Use an air body saw to cut
the marked section off.
Ensure that the wiring loom
is clear of the saw blade
whilst cutting.
Hint: It is easier to work
from underneath inside the
wheel well.
16
Use a grinder to remove the
intake snout from the air
cleaner base.
Hint: Remove the four lid
retaining clips to make it
easier to handle the air
cleaner base.

Installation Guide –Safari SS1066HF Page - 8 of 12
17
Position the air cleaner
base template (Item 21) to
the underside of the air
cleaner base, locate the
template over the two air
cleaner base mounting pins
as shown and mark the
required profile.
Use an air body saw to cut
away the marked section of
the air cleaner base and
discard the centre cut
piece.
Use a fine file to smooth
any rough edges in the air
cleaner base part of the cut.
18
Position the air entry duct
(Item 12) over the air
cleaner base and press
down firmly.
With the air entry duct
correctly positioned onto
the air cleaner base, mark
the nine hole positions onto
the air cleaner base.
Drill the marked hole
positions on the air cleaner
base with a 5mm (13/64")
drill.
19
Install the air entry duct
(Item 12) up through the air
cleaner housing mounting
bracket trimmed previously.
Install a 90/110 hose clamp
(Item 11) at the front end
and a 80/100 hose clamp
(Item 10) at the rear end of
the air entry hose (Item 9).
Install the air entry hose to
the snorkel body outlet and
the air entry duct.
Do not tighten the hose
clamps yet.

Installation Guide –Safari SS1066HF Page - 9 of 12
20
Reposition the wiring loom
to the upper holes.
Apply a thick coating of
adhesive sealant to the air
entry duct (Item 12)
surfaces that will be mating
with the bottom of the air
cleaner base.
21
Reinstall the four air cleaner
lid retaining clips to the
aircleaner base and apply
lubricant to the rubber air
cleaner mounting bushes.
Apply a generous coating of
adhesive sealant to the
underside surfaces of the
air cleaner base that will be
mating with the air entry
duct (Item 12).
Install the air cleaner base
and install all nine pop
rivets before securing with
the pop rivet gun.
To make the mounting pins
watertight, completely seal
the holes in the three
mounting pins with
adhesive sealant.
Wipe away and smooth out
any excess adhesive
sealant.
22
Adjust the position of the air
entry hose (Item 9) installed
earlier for a relaxed fit.
Tighten the hose clamps
(Items 10 & 11) at each end
of the air entry hose (Item
9).
Reinstall the air filter
element, air cleaner
housing top and connect
sensor plugs.

Installation Guide –Safari SS1066HF Page - 10 of 12
23
Mark and cut the inner
fender liner as shown.
24
Align the front inner fender
liner template (Item 19) to
the engine bay side of the
front section of the plastic
fender liner as shown.
Retain with masking tape.
Mark the outline of the
noted section of the fender
liner to be cut and the hole
position shown.
Use an air body saw to cut
the marked section out from
the front section of the
plastic fender liner.
Drill the marked hole
position with a 5mm
(13/64") drill.
25
Align the rear inner fender
liner template (Item 20) to
the front wheel side of the
plastic fender liner as
shown. Retain with masking
tape.
Mark the outline but do not
cut yet.

Installation Guide –Safari SS1066HF Page - 11 of 12
26
Extend the cutting path as
shown. Maintain
approximately a 15mm
(9/16") below the corner
ridge shown.
Use an air body saw to cut
the marked section out from
the rear section of the
plastic fender liner.
27
Trail fit the rear plastic inner
fender liner and mark areas
shown for additional
trimming.
Trim marked areas to
achieve a neat fit and finish.
28
Trial fit the front section of
the fender liner and if
required, make further
trimming adjustments for a
neat fit.
Install the front section of
the fender liner and secure
with the stock clips.
Drill a 5mm (13/64") hole
into the shocker tower and
with a small file, elongate
the hole for the plastic tie
strap. Deburr and paint the
hole to prevent rust.
Install the plastic tie strap
(Item 22) as shown.

Installation Guide –Safari SS1066HF Page - 12 of 12
29
Install 3 spire clips (Item 14)
to the three rear fender liner
holes.
Install the rear section of
the inner fender liner.
Secure in place with stock
clips and the tube nut (Item
23).
30
Install three self tapping
screws (Item 15) through
the fender flare and into the
three spire clips (Item 14).
31
Refit the right front wheel, radio antenna and any other components that may have been
removed during the installation process.
32
Loosely install the black
hose clamp (Item 16) to the
base of the air ram
assembly (Item 2). Install
the air ram assembly onto
the snorkel body. Align the
air ram assembly and
tighten the black hose
clamp (Item 16).
It is the installer's responsibility to ensure that all connections are watertight.
For an on-line colour copy of these instructions, please see:
www.safarisnorkel.com/guides/JEEP/ss1066hf/ss1066hf_guide.htm
Manufactured by Safari Automotive Pty Ltd
73 Merrindale Drive, South Croydon Victoria 3136 Australia Tel: [phone] Fax: [phone]
www.safarisnorkel.com ABN 75 803 294 474