SS122HP Snorkel Safari ARMAX Toyota Hilux 2005-2015 Installation Guide

June 4, 2024
SAFARI

Snorkel Safari ARMAX LOGO 2 SS122HP
SAFARI ARMAX SNORKEL
To Suit: TOYOTA HILUX (KUN26R Series)
3.0L Turbo Diesel D-4D (1KD-FTV Engine)
Built: 03/2005 – 06/2015 (Pre & Post Facelift Models)SS122HP Snorkel Safari
ARMAX Toyota Hilux 2005 2015

Parts List

ITEM PART NO. DESCRIPTION QTY
1 320-133-600 BODY – SNORKEL (SS122HP) 1
2 000-135-960 4″ AIR RAM ASSEMBLY 1
3 320-032-600 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
10 320-024-600 HOSE – AIR ENTRY 1
11 320-025-600 PLATE – HOSE SUPPORT 1
12 000-958-175 POP RIVET- 4.0mm x 17mm 12
13 000-300-350 WASHER – BODY – 4.0mm x 12mm S/S 13
14 320-967-600 PLATE – INNER GUARD SUPPORT 1
15 000-1020-300 BOLT – B/H CAP SCREW 5.0mm x 0.8 x 12mm S/S 9
16 000-320-350 WASHER – BODY 5.0mm x 15mm S/S 18
17 000-221-300 NUT – NYLOC 5.0mm x 0.8mm S/S 9
18 000-1912 CLAMP – HOSE – 110/130mm 1
19 000-1931/B CLAMP – HOSE – SIZE 64 (BLACK) 1
20 320-217-600 TEMPLATE – AIR CLEANER HOUSING 1
21 320-017-700 TEMPLATE – INNER GUARD PANEL 1
22 320-017-600 TEMPLATE – GUARD PANEL 1
23 320-016-600 INFILL – FOAM (Snorkel Body) Pre-Facelift Models Only 1

Installation Guide

Fitment to:
• Right Hand Side
Fitting Time:
• 210min| Special Tools:
---|---
• Body Saw (Reciprocating)
• 90 deg Drill
• Step Drill
• 4.5mm, 5.5mm Drill Bits
• Files| • Pop Rivet Gun
• Sikaflex 227 Adhesive Sealant
• Loctite 243 (thread lock)
• Masking Tape
• Touch-up paint

Prior to commencing the installation, it is the installer’s responsibility to verify that all components and particularly the template (Item 22) are correct.

1. Remove the following in accordance with the factory service manual:

  • Air Cleaner Assembly
  • RHS Mud Flap
  • RHS Guard Liner
  • RH Guard mounted indicator (if fitted to the vehicle)

2. Remove and discard

  • Air intake ducting

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove and
discard

3. Align the guard panel template(Item 22) with the upper and rear edges of the RHS guard panel as shown.
Tape the template to the guard panel with masking tape.
Mark all hole positions and the cut-out section with a felt tip pen.
Remove the template.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the
template

4. Drill a pilot hole for each of the marked hole positions.
Use a step drill to drill the six 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 3.
Deburr and paint all holes.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 1

NEW ZEALAND INSTALLATIONS ONLY :
Safari has 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
5a. Pre & Post Facelift Models:
Install the upper mounting bracket (Item 3) to the snorkel body (Item 1) with hex bolts (Item 4).
Apply Loctite 243 to each of the stainless steel mounting studs (Item 7) and install the studs finger-tight into the snorkel body (Item 1) mounting inserts as shown.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 2

5b. Pre-Facelift Models Only
Built: 03/2005 – 07/2011:
Remove the self-adhesive backing from the foam infill (item 23).
Install the foam infill over the front mounting stud and align the foam infill piece to the front of the snorkel body.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 3

6. 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 on the vehicle, accurately mark the position of the upper mounting bracket (Item 3) onto the masking tape.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 4

7. Remove the snorkel body (Item 1) from the vehicle and remove the upper mounting bracket (Item 3) from the snorkel body.
Position the upper mounting bracket (Item 3) onto the A-pillar and align the bracket with the marked bracket outline. Mark the three mounting hole positions with a felt tip pen.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 5

8. Drill a pilot hole at each of the three marked hole positions.
Drill each hole position to 8mm diameter with a step drill or 8mm drill bit.
Deburr and paint holes.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 6

9. 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).

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 7

10. Un-clip the wiring loom, and bonnet release cable, and remove the M6 earth bolt from the inner guard panel.
Align the inner guard template (item 21) to the earth bolt hole, wiring loom, and bonnet cable clip holes. With the template correctly aligned install the earth bolt and tape the template to the inner guard with masking tape as shown.
Mark all nine hole positions and the main inner guard hole.
Remove the template.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 8

11. Drill a pilot hole for each of the marked hole positions (use the 90 deg drill to drill the two upper holes), and drill each hole to 5.5mm.
Using the body saw cut the main hole in the inner guard panel as marked.
Trial fit the inner guard support plate (item 14), if necessary re-drill any of the mounting holes or file the main hole to suit the plate.
De-burr and paint all holes.
Hint: Either use a long series 5.5mm drill bit to drill holes or drill as many holes as possible, install the support plate and drill from the inner guard side, and drill through the support plate and through the inner guard panel using a 90 deg drill.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 9

12. Apply Sikaflex 227 adhesive sealant to the inner guard support plate (item 14) and install the plate to the inner guard panel, secure to the inner guard panel with 5mm x 12mm Button Head bolts (item 15), 5mm x 15mm body washers (item 16) and 5.0mm nylon nuts (item 17) as shown.
Clean up any excess Sikaflex 227 adhesive sealant to ensure a neat finish.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 10

13. Drill out the three pop rivets holding the cyclonic 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 cyclonic deflector.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 11

14. Mark around the inlet snout as shown.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 12

15.  Using the body saw carefully cut off the inlet snout of the air cleaner base.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 13

16. Using the body saw remove the corner ribs of the air cleaner housing mounting bracket as shown.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 14

17. Apply masking tape to the inside of the air cleaner housing, and align the air cleaner housing template (item 20) to the two upper pop rivet holes (install two pop rivets) and the top edge of the air cleaner housing as shown.
With the template correctly aligned, tape to the air cleaner housing with masking tape.
Mark all eleven hole positions and the air cleaner housing the main hole.
Remove the template.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 15

18. Drill a pilot hole for each marked hole position, using the 4.5mm drill bit, drill the eleven holes.
Using the body saw cut the main hole in the air cleaner housing

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 16

19. Using a file or die grinder clean up the cut hole in the air cleaner.
Neatly remove the marked air cleaner ribs as shown.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 17

20. Trial fit the air entry hose (item 10), install the support plate (item 11) and all eleven pop rivets (item 12), if necessary re-drill any holes that are not correctly align

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 18

21.  Apply Sikaflex 227 adhesive sealant to the air entry hose (item10) sealing flange, install the hose to the air cleaner housing install the support plate (item 11), pop rivets (item 12), and note the orientation of the three lower pop rivets with body washers (item 13) installed, install a body washer to the remaining eight pop rivets.
With all of the pop rivets and body washers installed, secure the pop rivets using the pop rivet gun.
Clean up any excess Sikaflex 227 adhesive sealant to ensure a neat finish.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 19

22. Install a pop rivet (item 12) with a body washer (item 13) through the hole in the air cleaner housing as shown, and install a second body washer to the pop rivet, using the pop rivet gun secures the pop rivet with body washers installed.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 20

23. INSTALLER OPTION :
The air cleaner housing base 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.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 21

24. Install the air cleaner base with the air entry hose installed, through the hole in the inner guard panel.
Hint: Squash and tape the end of the air entry hose for easier installation of the air cleaner housing.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 22

25. Loosely install a 110/130mm hose clamp (item 18) to the air entry hose (item 10).
Note: Hose clamp orientation.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 23

26. Carefully install the snorkel body (Item 1) to the guard panel, guide the snorkel body snout into the air entry hose (item 10), and align the snorkel body to the guard panel and upper mounting bracket.
When correctly aligned, fasten the snorkel body to the guard panel with body washers (Item 8) and nylon nuts (Item 9).
Fasten the snorkel body to the upper mounting bracket with hex bolts (Item 4).

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 24

27. Align the air entry hose (item 10) for best fitment (Ensure the air entry hose is installed hard up against the shoulder of the snorkel body outlet), correctly position the 110/130mm hose clamp (item 18), tighten the hose clamp.

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 25

28. Loosely install the black hose clamp (Item 19) to the base of the air ram assembly (item 2).
Install the air ram onto the snorkel body (item 1).
Align the air ram assembly and tighten the black hose clamp (item 19).

SS122HP Snorkel Safari ARMAX Toyota Hilux 2005 2015 - Remove the template -
FIG 26

29. Install the guard-mounted indicator (if fitted to the vehicle), guard liner, mud flap, air cleaner element, air cleaner lid, reconnect sensor wiring, and any other items that may have been removed during the snorkel installation process.
30. 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

Documents / Resources

| SAFARI SS122HP Snorkel Safari ARMAX Toyota Hilux 2005-2015 [pdf] Installation Guide
SS122HP, Snorkel Safari ARMAX Toyota Hilux 2005-2015, Snorkel Safari ARMAX, Safari ARMAX, Snorkel Safari, Safari
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References

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

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