Instructions to fit the Snorkel Kit S064D for the Jeep JK Wrangler

Transcription

Airflow Vector Pty Ltd
4 Collins Rd, DROMANA VIC. 3936
AUSTRALIA
Ph: +61 3 5987 3733
www.airflowvector.com
Instructions to fit the Snorkel Kit S064D
for the Jeep JK Wrangler Diesel
1.0 Introduction
Airflow Vector Pty Ltd thanks you for your purchase and the trust you put in our
products.
We strive to supply our customers with the highest quality equipment based on
the most efficient design and best styling. We are confident that you will enjoy
using our Snorkel system.
It should improve the power of your vehicle as well as reduce its fuel
consumption.
1.1 General instructions
Follow carefully the instructions listed on these
provided, do not over tighten bolts. Do not use
use mastic.
Ensure that safe work practices are followed
Snorkel. Protective ear and eye wear should be
power tools.
pages and use the template
silicone on any connections,
when installing your Airflow
worn at all times when using
1.2 Disclaimer
It is highly recommended that installation is undertaken by a qualified
mechanic or panel beater. Airflow Vector will not be held responsible for any
damage incurred through incorrect fitment of the templates and workmanship.
It is the responsibility of the fitter to ensure that particular care is taken when
assembling the Snorkel kit to the vehicle as it may cause damage to the
windscreen and or electrical components. Safe work practices must be used at
all times when undergoing installation.
We guarantee Airflow Vector’s kits against manufacturing defects as long as
proof of purchase can be established.
All models produced by Airflow Vector are verified to suit right hand drive
vehicles according to Australian specifications. Variations in vehicle
specifications may occur in other markets.
If you're in doubt about the product suitability, please forward a photograph of
the engine bay, air filter housing and of the vehicle at frontal/side position to
[email protected]
SD064DE (S064D Instructions booklet).doc
22 March 2011
\\Server\d\AirflowSnorkels\Products\Snorkels\S64D\SD064DE (S064D Instructions booklet).doc
Page 1 of 16
AUSTRALIA
Ph: +61 3 5987 3733
2.0 List of Components
S064D Kit content
Ref
Designation
Qty
Fasteners included
Leng
th
Unit
Ref
Designation
Qty
SP114
Snorkel JK
1
SP118
A Pillar bracket JK
1
SP019
Hose Clamp
60/80mm
4
SP026
Screw Plug Nylon
2
SP063
Air Ram 3.5"
1
SP024
G/Bolt M6 x 12mm Z/P
8
SP018
Hose Clamp
80/100mm
1
SP029
Screw Self Tap 10gx5/8 Z/P
3
SK020
Bolt kit
1
SP023
Washer Spring 1/4 x 1/4 Z/P
2
SP115
Under Bonnet
1
SP033
Washer 1/4 x 3/4 Z/P
2
SP116
Under Bonnet
1
SP112
Pop rivet Bulbex 4x20mm
18
SP117
Under Bonnet
1
SP025
Washer Panel 1/4 x 1.1/4 x
16g Z/P
4
SP104M
Under Bonnet
1
SP170
Plastic bag 75x125mm
1
SP015
TPR Hose 76mm
1
100
mm
SP015
TPR Hose 76mm
1
250
mm
SP120
Blocking Plate JK
1
SP119
Bracket JK
1
SP171
Plastic bag
280x380mm
1
SD064
Template
1
SD064DA
Template Air Box
1
SD064DE
Booklet
1
Page 2 of 16
Ensure that all parts listed are
included in the parcel before
starting any work.
The total expected time of
installation is around 6 - 8 hours.
22 March 2011
AUSTRALIA
Ph: +61 3 5987 3733
2.1 List of tools and additional parts required
Masking tape, clear tape, black mastic, hammer, centre punch
Assorted screw drivers, sockets and spanners, pop rivet gun
76mm hole saw, 52mm hole saw
Assorted drill set, wet / dry sand paper, ½ round file, small square file,
Zinc rich primer
It may be necessary to acquire new fixings from Chrysler to replace the
inner guard fixings if they get damaged during their removal
3.0 Detailed Instructions
3.1
3.2
Prior starting any work,
ensure that the configuration 3.3
of the air box is as shown. If it
is not, the fitting of this kit will
not be possible. Contact your
dealer for further assistance
Remove the splash panel
Remove the step
3.4
Read the templates carefully
Cut out the hole for the
aerial
3.5
22 March 2011
Page 3 of 16
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3.6
Cut around the air box
template
3.7
3.8
3.9
Centre punch all marked
holes
3.10 Cover the areas to be drilled
with masking tape
3.11 Mark the centre punch with a
felt pen on tape
3.12 Pre-drill all holes at 5mm (6
snorkel mounting holes, 2
hole saw holes)…
Page 4 of 16
Line up the template to the
guard
Tape it to the guard
3.13 … then drill the 6 fixation
holes at 10mm
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AUSTRALIA
Ph: +61 3 5987 3733
3.14 Using the hole saw, drill at
LOW SPEED two 52 mm
holes
3.15 Join the outside edges of the
holes with a marker
3.16 Cut along the lines with a
grinder
3.17 Paint ALL raw metal surfaces
with Zinc rich primer (6
snorkel fixing holes, 1 air
intake hole)
3.18 Unbolt the air box from the
engine bay and remove it
3.19 Remove the air intake
3.20 Grind the lip down to make a
flat surface
22 March 2011
Page 5 of 16
AUSTRALIA
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3.21 While holding the blocking
plate SP120 inside the air
box, drill six 4mm holes for
the rivets.
3.22 Please wear gloves
3.23 Use only NON SILICONE
BASE black mastic as
sealant
3.24 Apply sealant to the edge of
the blocking plate SP120
3.25 Rivet the blocking plate
SP120 with six rivets SP112
3.26 Grind off all the ridges inside
that face of the air box
3.27 Use the template to locate the 3.28 Pre-drill to 5mm according to
position of the drilling
the template
Page 6 of 16
22 March 2011
AUSTRALIA
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3.29 Using the hole saw, drill at
3.30 File to remove any burrs on
LOW SPEED one 76mm hole
the air box
3.31 Slide the connector SP104M
from the inside as shown and
drill four 4mm holes in the
tongues (two on each side)
for the rivets
3.33 Use only NON SILICONE
BASE black mastic as
sealant
3.34 Smear some sealant on
outside of the SP104M as
shown on the picture
3.35 Rivet the connector SP104
with four rivets SP122
3.36 This is what needs to be
achieved
22 March 2011
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AUSTRALIA
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3.37 Remove two bolts on the
lower panel and two bolts
inside the door jam.
3.38 Remove the outer scuttle
panel
3.39 Remove the main scuttle
panel
3.40 Remove the mud guard /
fender (don’t forget to
disconnect the aerial)
3.41 File to remove any burrs
3.42 Paint ALL raw metal surfaces
with Zinc rich primer (six
snorkel fixing holes, one air
intake hole)
3.43 Install the snorkel SP114
3.44 Fit washers SP025 (x4) and
bolts SP024 (x4) and
washers SP033 (x2) and
nuts SP024 (x2) to secure
the snorkel to the guard
Do not over tighten fixings to
avoid damage to the snorkel
Page 8 of 16
22 March 2011
AUSTRALIA
Ph: +61 3 5987 3733
3.45 Insert the short side of the
SP115 into the snorkel
3.46 Drill four 4mm holes (two on
the top, two from under )
3.47 Remove the SP115
inside of the SP114 as
shown on the picture
3.50 Re-insert the short side of the 3.52 Insert the SP116 about
SP115 into the snorkel
20mm onto the SP115
3.51 Rivet it in place with four
3.53 Drill four 4mm holes (two on
rivets SP112
the top, one on each side)
3.54 Remove the SP116
3.57 Re-insert the SP116 onto
the SP115
inside of the SP116 as shown 3.58 Rivet it in place with four
on the picture
rivets SP112
22 March 2011
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AUSTRALIA
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3.59 Fit the “A” pillar bracket
SP118 with the washer
SP023 and bolt SP024
3.61 Mark to contour of the “A”
pillar bracket onto the paint
3.62 Remove the mud guard /
fender
3.60 Re-assemble the mud guard /
fender temporarily
Note: This Snorkel is fitted with a second “A” pillar location to be installed
if one intends to use the Collector Pre-Cleaner instead of the Air Ram. If
required, please contact us to obtain the Bolt Kit SK220
3.63 Using the “A” pillar bracket as 3.65 Pre-drill at 4mm the two
a template, mark the centre of
holes
the two holes
3.66 Drill the two holes for the “A”
3.64 Centre punch the 2 holes
pillar position at 7mm
3.67 File the holes with a square
file to suit nylon plugs SP026
Page 10 of 16
3.68 Paint the two holes with Zinc
rich primer
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AUSTRALIA
Ph: +61 3 5987 3733
3.69 Once the paint is dry, fit the
two square plugs SP026
3.70 Mount the bracket SP118
with the screws SP029
3.71 Re-assemble the mud guard / 3.72 Re-assemble the outer
fender
scuttle panel
3.73 It may be necessary to pull on 3.74 Secure the snorkel to the
the snorkel to assemble the
bracket with the washer
panel
SP023 and the bolt SP024
22 March 2011
Page 11 of 16
AUSTRALIA
Ph: +61 3 5987 3733
3.75 Re-assemble the scuttle
panel
3.76 Re-fit the windscreen wipers
3.78 Smear some sealant inside
both ends of the TPR hose
SP015 x 100mm long
3.79 Slide a hose clamp SP019
on one end
3.80 Connect it to the under
bonnet SP116
3.81 Tighten the hose clamp
3.82 Slide a hose clamp SP019 to
the other end of the TPR
hose SP015
3.83 Insert the tube SP117
through the engine bay and
connect it to the hose
3.84 Do not tighten the clamp yet
3.85 Attach the bracket SP119 to
this location
3.86 Secure the tube to the
bracket with the washer
SP023 and bolt SP024
3.87 Now tighten the hose clamp
SP019 under the guard
Page 12 of 16
22 March 2011
AUSTRALIA
Ph: +61 3 5987 3733
3.88 Re-fit the air box
3.89 Slide the clamps SP019 at
each end of the hose SP015
3.90 Smear some sealant inside
both ends of the TPR hose
SP015
3.91 Connect the TPR hose to
the air box
3.92 Tighten the hose clamp
SP019
3.93 Connect the TPR hose
SP015 to the tube SP117
3.94 Tighten the clamp SP019
3.95 Re-install the air cleaner
3.96 Close the air box
3.97 Re-install the splash panel
3.98
Re-fit the step
22 March 2011
Page 13 of 16
AUSTRALIA
Ph: +61 3 5987 3733
Slide the hose clamp SP018 3.101 Drill the hose clamp next to
the worm drive
on the air ram SP063 then
slide it on the snorkel SP114
3.100 Ensure that the top of the
snorkel matches the top of
the slot cut in the Air Ram
3.99
3.102 Secure the Air Ram with the
self tapping screw SP029
Note: The Air Ram is also
available in Fluro, green or
blue
Important note: Do not turn the Air Ram away from the direction of
travel because it will lessen the positive pressure necessary for proper
operation. In extreme situation, at speed above 25km/h (15m/h) a
vacuum may be generated causing irreversible engine damage
Page 14 of 16
22 March 2011
AUSTRALIA
Ph: +61 3 5987 3733
4.0 Optional pre-cleaner (not included in this kit)
4.1
Remove the Air Ram SP063
4.2
Install Pre-cleaner filter sock
SP065B
4.3
Air sock should neatly fit into
the top of the snorkel body
4.4
4.5
Re-install the Air ram SP063
Tighten the hose clamp
SP018
Screw the self tapper SP029
through the hose clamp
4.6
4.7
Polish with silicone cleaner
22 March 2011
Page 15 of 16
AUSTRALIA
Ph: +61 3 5987 3733
5.0 Improvement program
We strive to produce documentation and kits free of mistakes, however,
should you discover any error or omission, please let us know by quoting
the initials shown in the box below.
Furthermore, if you think that a step of this procedure could be improved,
please send us at [email protected] your suggestions indicating
the procedure name, its release date, the step details and the photo if
necessary.
We appreciate your support.
This kit has been carefully packed by
Date
Initials
Note: The content of this manual may be modified from time to time to
ensure that improvements brought to our kits are described accurately.
Before starting the installation, try to obtain the latest version of the
instruction manual from our web site www.airflowvector.com
Page 16 of 16
22 March 2011

Instructions to fit the Snorkel Kit S064D for the Jeep JK Wrangler

Transcription

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