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.