SAFARI SS86HP ARMAX Snorkel Installation Guide
- June 4, 2024
- SAFARI
Table of Contents
SAFARI SS86HP ARMAX Snorkel
Parts List
| ITEM | PART NO | DESCRIPTION | QTY |
|---|---|---|---|
| 1 | 385-133-600 | BODY – SNORKEL (SS86HP) | 1 |
| 2 | 000-135-960 | 4″ AIR RAM ASSEMBLY | 1 |
| 3 | 385-032-600 | BRACKET-UPPER MOUNTING | 1 |
| 4 | 000-002-100 | BOLT – HEX – 6mm x 1.0 x 14mm (SEMS) | 2 |
| 5 | 000-951-300 | SCREW – S/T – 4.2mm x 16mm – S/S | 3 |
| 6 | 000-960 | INSERT – PLASTIC | 3 |
| 7 | 000-110 | STUD – 8mm x 1.25 x 25mm – S/S | 6 |
| 8 | 000-311-300 | WASHER – BODY – 8mm x 30mm – S/S | 6 |
| 9 | 000-205-300 | NUT – NYLOC – 8mm x 1.25mm – S/S | 6 |
| 10 | 385-024-600 | HOSE – AIR ENTRY (Flanged) | 1 |
| 11 | 385-025-600 | PLATE – HOSE SUPPORT (Main) | 1 |
| 12 | 385-025-650 | PLATE – HOSE SUPPORT (Lower) | 1 |
| 13 | 000-958-150 | POP RIVET – 4mm x 13mm | 12 |
| 14 | 000-1020-300 | BOLT – B/H 5.0mm x 0.8 x 12mm | 3 |
| --- | --- | --- | --- |
| 15 | 000-320-350 | WASHER – BODY 5mm x 15mm | 6 |
| 16 | 000-221-300 | NUT – NYLOC – 5.0mm x 0.8mm | 3 |
| 17 | 000-1911 | CLAMP – HOSE – 100/120mm | 1 |
| 18 | 000-1931/B | CLAMP – HOSE – SIZE 64 (BLACK) | 1 |
| 19 | 370-704-000 | PLATE – BLANK-OFF (A-PILLAR) | 1 |
| 20 | 370-435-200 | RUBBER GASKET | 1 |
| 21 | 385-217-600 | TEMPLATE – AIR CLEANER | 1 |
| 22 | 385-017-600 | TEMPLATE – GUARD PANEL | 1 |
Installation Guide
Installation Guide
| Fitment to: Special Tools:
· Right Hand Side · Body Saw (Reciprocating) · Files / Grinder
· Step Drill and Metric Drill Bits · Masking Tape Fitting Time: · Loctite 243 (Thread Lock) · Touch-up Paint
· Pop Rivet Gun · Sikaflex 227 Adhesive Sealant
· 180 min
· +30 min (Factory Raise Air Intake)
Prior to commencing the installation, it is the installer’s responsibility to verify that all components and particularly the guard panel template (Item 22) are correct.
1|
Remove the following in accordance with the factory service manual:
· Air Cleaner Assembly
· RHS Mud Flap
· Inner Guard Liner
· RHS Guard Mounted Indicator Lamp
Standard Toyota Air Intake Vehicle
Remove and discard the standard Air Entry Duct and Air Entry Flange.
Factory Toyota Raised Air Intake Vehicle:
Remove and discard the Factory Toyota Raise Air Intake components (shown). The
two A-pillar mounting bolt assemblies must be retained.
Remove and discard the perforated section from the guard panel template (item
22) as shown.
Align the guard panel template (Item 22) to the upper and rear edges of the
right-hand guard panel as shown (Use the side indicator hole as a guide only
).
Tape the
template to the guard with masking tape. Mark all hole positions and the cut-
out section with a felt tip pen. Remove the template.
Factory Toyota Raised Air Intake Vehicle only:
The factory front captive mounting nut assembly must be removed. The assembly
is spot welded to the guard panel in two places. Drill a pilot hole in the
centre of each spot welds and drill out the spot welds using a 6.5mm drill bit
or spot weld drill bit. Use a small pry bar or flat blade screwdriver to break
the spot welds from the guard panel, remove and discard the captive mounting
nut assembly. Deburr holes.
Drill a pilot hole for each of the marked hole positions.
Use a step drill to drill the 6 mounting holes to 16mm diameter. Drill 2 or 3,
10mm diameter holes in the cut-out section for a start/stop point for the body
saw, using the body saw cut the main hole in the guard panel as marked from
the template cut-out in step 4. Deburr and paint holes.
NEW ZEALAND INSTALLATIONS ONLY:
Safari have developed 2 methods of Snorkel A pillar attachment, for the
conventional method please proceed with the current document alternatively
please see the link below for further instructions.
www.safari4x4.co.nz/apillarmounting.
Install the upper mounting bracket (Item 3) to the snorkel body (Item 1) with
hex bolts (Item 4). Apply Loctite 243 to only five of the six stainless steel
mounting studs (Item 7) and install the five studs finger-tight into the
snorkel body (item 1) mounting inserts, excluding the front mounting insert as
shown. N.B: Do Not Install the front mounting stud into the snorkel body
mounting insert.
Place a strip of masking tape along the A-Pillar panel. Carefully install the
snorkel body (Item 1) to the guard panel. With the snorkel body correctly
positioned, mark the outline of the upper mounting bracket (Item 3) onto the
masking tape. (If upgrading from an SS86HF to an SS86HP, remove the 3 plastic
inserts from the A-pillar first, before applying the strip of masking tape to
the A-pillar).
Remove the snorkel body
(Item 1) from the vehicle, remove the upper mounting bracket (Item 3) from the
snorkel body. Position the upper mounting bracket onto the A-Pillar and align
the bracket with the marked bracket outline. Mark the three mounting hole
positions with a felt tip pen. (If upgrading from a SS86HF to a SS86HP, mark
the centres of the existing A-pillar holes onto the masking tape, the slots in
the bracket are there to allow for slight differences from the previously
fitted snorkel, depending on where the previously fitted snorkel was
positioned on the A-pillar will determine whether or not the bracket may need
to be modified by the installer).
Drill a pilot hole for each of the three marked hole positions in the centre
of each marked slot. Drill each pilot hole to 8mm diameter with a step drill
or 8mm drill bit. Deburr and paint holes. (If upgrading from an SS86HF to an
SS86HP, you will need to work out the required bracket position, if required
modified the bracket to suit, Do not drill any additional holes in the
A-pillar).
Install the plastic inserts
(Item 6) into the 8mm diameter holes in the A-pillar. Secure the upper
mounting bracket (Item 3) to the A-pillar with three self-tapping screws (Item
5).
Factory Toyota Raised Air Intake Vehicle only:
Install the A-pillar blank-off plate (item 19) and rubber gasket (Item 20) to
the A-pillar, secure with the standard Toyota bolt assemblies removed and
retained in step 2b.
Using a 4.5mm drill bit, drill out the 3 pop rivets retaining the pre-spinner
section of the air cleaner inlet snout to the air cleaner base (hold the back
of the pop rivets with a pair of pliers to prevent them from spinning whilst
drilling out the pop rivets). Remove and discard the pre-spinner section
.
Using a 4.5mm drill bit, drill out the four pop rivets retaining air deflector
in the air cleaner base (hold the back of the pop rivets with a pair of pliers
to prevent them from spinning whilst drilling out the pop rivets). Remove and
discard the air deflector.
Using the body saw cut-off the 3 tabs which retained the pre-spinner section
to the air cleaner base inlet. 
Using a paint pen, mark a cut line around the base of the inlet snout. Using
the body saw carefully cut around the base of the inlet snout and remove the
inlet snout from the air cleaner base.
Using the body saw, neatly cut-off the remaining sections of the three tabs
removed in step 13, use a grinder, file, or sharp knife to clean up the three
tabs flush to the air cleaner base. 
Remove and discard the perforated inner section from the air cleaner template
(item 21) as shown. 
Align the air cleaner template (item 21) to the side of the outer air cleaner
mounting bracket and under the main shoulder of the air cleaner base as shown,
tape the template to the air cleaner base with masking tape. Mark all eight
hole positions and the required air cleaner base cut-out. Remove the template
.
Using a 4.5mm drill bit, drill all eight marked hole positions. Using the body
saw, cut the new air cleaner entry hole as marked from the template in step
17. Deburr all eight holes and the air inlet hole.
Carefully bend the main hose support plate (item 11) to the external diameter of the air entry hose flange. Trial fit the plate to hose and check the bend.
Hint: Bend the support plate to a diameter of approximately 350mm
.
Install the air entry hose
(Item 10) onto the air cleaner base. Position the hose support plate (Item 11)
onto the air entry hose flange and install the eight pop rivets (Item 13) from
the inside of the air cleaner base through the air entry hose and support
plate. When all the pop rivets are installed and the hose aligned correctly,
mark or drill the four lower mounting holes as shown.
Apply a liberal amount of adhesive sealant to the flange of the air entry hose
(Item 10), and apply an additional amount of sealant to the corner section of
the air entry hose flange. Install the air entry hose (Item 10) onto the air
cleaner base. Position the hose support plates (Items 11 & 12) onto the air
entry hose flange. Install all twelve pop rivets (Item 13) from the inside of
the air cleaner base through the air entry hose and clamping plates. With all
the pop rivets installed and the hose aligned correctly, fasten the pop rivets
using a pop rivet gun. Clean up any excess sealant to ensure a neat finish
.
Install a 5mm body washer (item 15) to each of the 5.0 x 12mm button head
bolts (item 14), install the bolts with washers installed through the three
holes in the air cleaner base, secure the bolts with 5.0mm body washer (item
15) and 5.0mm nyloc nut (item 16). 
INSTALLER OPTION
The air cleaner housing base dust cap contains a drain valve as shown. The
drain valve can permit water to enter the air intake. Safari advises that the
drain valve should be sealed to ensure a watertight installation.
The installer should also check the condition of both the Air Cleaner Lid Seal
and the Dust Cap Seal, if necessary, these items should be replaced if they
are in a poor serviceable condition. The end of the air entry hose (item 10)
must be squashed inwards and taped to hold in position as shown.
N.B: it is critical the hose is
taped the way shown in the photo, for installation purposes.
With the hose taped, install the air cleaner base assembly into position,
guiding the air entry hose through the hole in the inner guard panel, with the
air cleaner base correctly installed fasten with the standard mounting bolts.
Remove the tape.
Loosely install the 100/120mm hose clamp (item 17) loosely over the air entry
hose (Item 10).
Note the
orientation of the hose clamp.
Carefully install the snorkel body (Item 1) to the guard panel, guide the
snorkel body outlet into the air entry hose (item 10), align the snorkel body
to guard panel and upper mounting bracket. When correctly aligned, install the
front mounting stud (item 7) finger tight into the snorkel body mounting
insert (do not apply loctite to the mounting stud). Fasten the snorkel body to
the guard panel with body washers (item 8) and nyloc nuts (item 9). Fasten the
snorkel body to the upper mounting bracket with hex bolts (Item 4).
Ensure the air entry hose is correctly installed onto the snorkel body outlet
and tighten the 100/120mm hose clamp (item 17).
Install the black hose clamp (Item 18) loosely to the base of the air ram
assembly (Item 2). Install the air ram assembly onto the snorkel body. Align
the air ram and tighten the black hose clamp (Item 18).
Install the standard air filter element, air cleaner lid, side indicator, guard liner, mud flap, and any additional components that may have been removed during the snorkel installation process.
N.B:
It is the installer’s responsibility to ensure that all connections are
watertight.
Copyright Safari 4×4 Engineering Pty Ltd Melbourne Victoria Australia – www.safari4x4.com.au
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>