Since there are those of us who are getting the recently released snorkels from ARB, and for many, this may be their 1st attempt at cutting rather larger holes in the fender of an otherwise perfectly good truck, I figured I'd give a synopsis with photos of an install.
I've previously installed 4 other snorkels, with each of them having their own challenges. Overall, the 5th Generation Safari Snorkel from ARB was simple, with good instructions.
My take on the 2 difficult places:
1. Inner fender well lining. Have extra expandable fittings...even brand new I broke about 3. (OEM Part No. 90189-06065 List is $1.03 each.)
2. The rubber air tubing between the snorkel body and the air box was a bugger to put together...not impossible by any means, but patience and a few choice words were involved.
So...on with the show.
Remove the factory air box. Easy. Two bolts inside; one outside on the firewall side.
This is the interior of my air box after one four hour trip to Grand Falls, on the Navajo Reservation in Northern Arizona. As can be seen...there's quite a bit of sand in the system. (Plus, I've already had the opportunity to ford 34" of water, which was the pucker factor of the year, as the truck had 300 miles on it at the time.) Thus, I consider a snorkel a necessary addition.
Remove fender inner liner. Helps if your girlfriend likes doing the parts that frustrate you.
If you want, fill the lower drain and upper inspection holes in the air box with silicone.
Remove factory fender air-thingy.
Cut/file 25mm off of alignment notch. It will basically be the same length as the shorter ones on the air intake.
Now the fun begins.
Line up the template with the rear of the fender where it meets the door, and the top by the hood. Line it up again.
Line it up again...
Once you're satisfied, tape it in place.
Check alignment 2 more times....
Mark your cut and drill holes. I used a white paint pen...graphite truck.
Once you're satisfied, remove the template and make sure the marks are visible.
Put the template back on, and make sure one last time the holes all line up.
Put a piece of tape along the fender flare, as to not get pieces of metal stuck in it.
Begin to cut! I used a dremel with a heavy cut off wheel. Went through 4 disks, but it worked just fine.
Fender holes are drilled to 16mm with a step bit. I put tape where I'm supposed to stop. A punch is used to center the point of drilling, pilot holes could be used as well.
File and paint all the nice holes you've made!
Install the studs in the snorkel body with some blue Loctite.
Install the A-Pillar bracket onto the snorkel body; hand tight. Put some tape on the A-Pillar itself so you can mark the bracket location.
Carefully place the snorkel body onto the fender. Helps if someone can hold it while you mark the bracket location on the A-Pillar.
You'll take the bracket off the snorkel body to make the final locating marks.
I always put it on a second time and re-check. Drill some pilot holes, then out to 6mm using the step drill. File and paint the holes. I use silicone in these A-Pillar holes on snorkels before putting the plastic inserts in.
Install the A-Pillar bracket.
Now the part I found most difficult...your experience may vary.
Place the rubber airbox connector through the factory fender hole; this requires some effort, as the part that needs to be on the inside of the engine bay is slightly larger than the hole in the inner fender. Put the appropriate (smaller of the silver) hose clamps around the rubber connector where you can reach the adjustment. (This was close for me, as I've got a second battery right in the vicinity.)
Once that's on, I wrist-tightened it on the airbox, but left the airbox itself unbolted.
Install the larger of the silver hose clamps on the snorkel side of the rubber air tube, with the adjustment towards the rear; pointing down.
Next, and you're likely gonna need two people for this...install the body of the snorkel onto the fender; sliding the snorkel body fitting inside the rubber air tube. It's okay to curse a few times; maybe even take a short break...yeah, this was kindof a pain. I used some light grease to help it along.
Once you've finally gotten it in all the way, hand tighten the fender washers and nyloc nuts on the studs; make sure the A-Pillar bracket lines up.
Tighten the hose clamp on the snorkel side and the stud bolts, along with the A-Pillar bolts.
Re-attach the airbox and tighten the engine-bay hose clamp.
Attach the Ram Air head...if you want. I prefer a pre-cleaner...
Throw on your roof tent and get ready to go camping in the Altar-Pinacate deserts of Mexico; it's just that easy!
-H-
I've previously installed 4 other snorkels, with each of them having their own challenges. Overall, the 5th Generation Safari Snorkel from ARB was simple, with good instructions.
My take on the 2 difficult places:
1. Inner fender well lining. Have extra expandable fittings...even brand new I broke about 3. (OEM Part No. 90189-06065 List is $1.03 each.)
2. The rubber air tubing between the snorkel body and the air box was a bugger to put together...not impossible by any means, but patience and a few choice words were involved.
So...on with the show.
Remove the factory air box. Easy. Two bolts inside; one outside on the firewall side.
This is the interior of my air box after one four hour trip to Grand Falls, on the Navajo Reservation in Northern Arizona. As can be seen...there's quite a bit of sand in the system. (Plus, I've already had the opportunity to ford 34" of water, which was the pucker factor of the year, as the truck had 300 miles on it at the time.) Thus, I consider a snorkel a necessary addition.
Remove fender inner liner. Helps if your girlfriend likes doing the parts that frustrate you.
If you want, fill the lower drain and upper inspection holes in the air box with silicone.
Remove factory fender air-thingy.
Cut/file 25mm off of alignment notch. It will basically be the same length as the shorter ones on the air intake.
Now the fun begins.
Line up the template with the rear of the fender where it meets the door, and the top by the hood. Line it up again.
Line it up again...
Once you're satisfied, tape it in place.
Check alignment 2 more times....
Mark your cut and drill holes. I used a white paint pen...graphite truck.
Once you're satisfied, remove the template and make sure the marks are visible.
Put the template back on, and make sure one last time the holes all line up.
Put a piece of tape along the fender flare, as to not get pieces of metal stuck in it.
Begin to cut! I used a dremel with a heavy cut off wheel. Went through 4 disks, but it worked just fine.
Fender holes are drilled to 16mm with a step bit. I put tape where I'm supposed to stop. A punch is used to center the point of drilling, pilot holes could be used as well.
File and paint all the nice holes you've made!
Install the studs in the snorkel body with some blue Loctite.
Install the A-Pillar bracket onto the snorkel body; hand tight. Put some tape on the A-Pillar itself so you can mark the bracket location.
Carefully place the snorkel body onto the fender. Helps if someone can hold it while you mark the bracket location on the A-Pillar.
You'll take the bracket off the snorkel body to make the final locating marks.
I always put it on a second time and re-check. Drill some pilot holes, then out to 6mm using the step drill. File and paint the holes. I use silicone in these A-Pillar holes on snorkels before putting the plastic inserts in.
Install the A-Pillar bracket.
Now the part I found most difficult...your experience may vary.
Place the rubber airbox connector through the factory fender hole; this requires some effort, as the part that needs to be on the inside of the engine bay is slightly larger than the hole in the inner fender. Put the appropriate (smaller of the silver) hose clamps around the rubber connector where you can reach the adjustment. (This was close for me, as I've got a second battery right in the vicinity.)
Once that's on, I wrist-tightened it on the airbox, but left the airbox itself unbolted.
Install the larger of the silver hose clamps on the snorkel side of the rubber air tube, with the adjustment towards the rear; pointing down.
Next, and you're likely gonna need two people for this...install the body of the snorkel onto the fender; sliding the snorkel body fitting inside the rubber air tube. It's okay to curse a few times; maybe even take a short break...yeah, this was kindof a pain. I used some light grease to help it along.
Once you've finally gotten it in all the way, hand tighten the fender washers and nyloc nuts on the studs; make sure the A-Pillar bracket lines up.
Tighten the hose clamp on the snorkel side and the stud bolts, along with the A-Pillar bolts.
Re-attach the airbox and tighten the engine-bay hose clamp.
Attach the Ram Air head...if you want. I prefer a pre-cleaner...
Throw on your roof tent and get ready to go camping in the Altar-Pinacate deserts of Mexico; it's just that easy!
-H-
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