Safari Snorkel Install Part 1
Safari Snorkel SS135HFD
Modified for 2005+ Toyota Tacoma 1GRFE 4.0 Liter-V6
DETAILED PARTS LIST
ITEM - DESCRIPTION - QTY - PART NO.
1 BODY-SNORKEL - 1 - 315-133-500
2 1/2" AIR RAM ASSEMBLY - 1 - 000-135-650
3 BRACKET-UPPER MOUNTING - 1 - 315-032-500
4 BOLT-HEX 6mm x 1.0mm x 14mm - 3 - 000-002-100
5 SCREW - S/T 4.2mm x 13mm - 3 - 000-951
6 BODY CLIP - PLASTIC - 3 - 000-960
7 HOSE-AIR ENTRY - 1 - 315-024-500
8 STUD - S/S 8mm x 1.25mm x 25mm O/L - 1 - 000-110
9 WASHER-BODY 8mm x 30mm - 5 - 000-311
10 NUT-NYLOC 8mm x 1.25mm - 5 - 000-205
11 CLAMP-HOSE 70/90mm - 2 - 000-908
12 TEMPLATE - 1 - 315-017-500
13 HOSE CLAMP-SIZE 56 (BLACK) - 1 - 000-914/B
14 JOINER - STEEL - 70mm O.D x 40 - 1 - 315-025-400
15 POP RIVET - 5.0mm x 12mm - 3 - 000-958-300
16 HOSE - RUBBER - 70mm ID x 25mm - 1 - 000-804-100
17 SLEEVE - AIR INLET (SS) - 1 - 315-025-500
PARTS NOT INCLUDED IN THE SS135HFD KIT:
3 foot section of 3 inch Exhaust Pipe (1)
3x3 inch Heavy Duty Rubber Plumbing connector (1)
3 inch hose clamps (2)
4 inch hose clamp (1)
Black Silicone Sealant (RTV)
Silicone spray lubricant
Primer
Touch up paint
NOTE: These parts are all available at your hardware store or auto shop.
Fitment To: Passenger Side Fender / A-Pillar
Fitting Time: 8 Hours (Depending on Skill Level)
Special Tools:
• 92mm hole saw
• 3/8 Drill with assorted drill bits
• Hack saw/air hack saw
• Round file
• Tube bender
Prior to commencing the installation, it is the Installer's responsibility to verify that all components and particularly the template placement (Item 14) are correct!
Ensure you have all parts and tools accounted for before you begin work!
STEP 1
Open hood. Remove the OEM air intake duct from inner fender/engine intake using a screwdriver and 10mm socket/ratchet. Leave intake air filter in place.
STEP 2
Remove the RHS inner fender liner and the engine air intake duct from engine bay in accordance with the factory service manual.
There are 6 plastic inserts and 2 10mm screws retaining the fender well liner to the inner fender well and fender flare.
From the inside of the engine compartment, remove the plastic inserts carefully using a flat tip screwdriver, popping them out toward the tire. Using a 10mm socket, remove the screws from the edge of the flare and remove the last 2 plastic clips hidden under them.
Fold the liner back out of your way as shown (this will all be re-installed in reverse order later).
STEP 3
Hold the snorkel up to the fender where you want the snorkel to mount, paying special attention to the indentation in the snorkel for the antenna.
Attach the studs and then mark them with paint.
CAREFULLY (have a buddy help out if possible) hold the snorkel back up where you just had it and lightly touch the painted studs to the sheet metal.
Pay close attention to the antenna indentation mentioned earlier as well as the rake of the snorkel at the windshield and the level appearance of the snorkel on the fender.
Using the stud marks you have chosen, align your template and firmly tape it on.
Mark all holes and cut-outs with a black marker.
This will mark the location for attaching the template to drill the 5 holes and the use of the 92mm hole saw.
NOTE: This is all necessary as this template is cut out to fit the contours of a HILUX fender and not a TACOMA (see picture for detail).
STEP 4
Using a spring loaded punch, mark the exact location for drilling your 6 pilot holes.
STEP 5
Using a small drill bit, drill pilot holes.
Drill the 5 snorkel mounting stud hole positions to 16mm.
Using the 92mm holesaw, drill the main hole.
Enlarge the main hole with hacksaw as per template cut away section.
Test fit snorkel to fender.
Use round file to adjust any mounting stud holes that are not true for smooth fit (this is not a cause for alarm as studs may protrude slightly irregularly).
De-burr and paint all holes. Allow sufficient drying time.
