SS122HP Snorkel Safari ARMAX Toyota Hilux 2005-2015 Installation Guide
- June 4, 2024
- SAFARI
Table of Contents
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)
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
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
14. Mark around the inlet snout as shown.
15. Using the body saw carefully cut off the inlet snout of the air cleaner base.
16. Using the body saw remove the corner ribs of the air cleaner housing mounting bracket as shown.
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.
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
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.
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
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.
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.
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.
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.
25. Loosely install a 110/130mm hose clamp (item 18) to the air entry
hose (item 10).
Note: Hose clamp orientation.
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).
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.
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).
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
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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) >>