Discovery II Safari Snorkel
Fits: Discovery Series II | '99 - '04
(#1) 1-Body/Snorkel; (#2) 1-3 Air Ram Assembly; (#3) 1-Upper Mounting Bracket; (#4) 6-S/S 8mm x 1.25mm x 25mm O/L; (#5) 6-8mm x 30mm Body Washers; (#6) 6-8mm x 1.25mm Nyloc Nuts; (#7) 3-6mm x 1.0mm x 14mm (SEMS) Hex Bolts; (#8) 5-4mm x 16mm Pop Rivets; (#9) 1-Air Entry Adaptor; (#10) 1-Inner Template; (#11) 1-Template; (#12) 1-Size 48 Hose Clamp
Fitment to: Left hand side
Fitting time: Approx. 120 minutes
Special Tools: 70mm Hole-saw; Air hacksaw; Step drill; Pop rivet gun; Sensor safe silicone sealant
Remove left hand front wheel arch liner and air entry duct.
Tape the template to the upper rear corner of the left hand guard. Using a felt tip pen mark the hole positions on the guard, remove template.
Drill a 4.5mm pilot hole for each hole position. Using the step drill, drill the 6 snorkel mounting holes to 16mm, drill the two main holes to 70mm with the hole-saw. Mark a straight line top and bottom between the two holes, cut away the remaining piece of panel between the two holes using the air hacksaw.
Deburr and paint all holes.
Place the inner template over the air entry duct-mounting studs. Using a felt top pen mark the hole position, remove template and drill a 4.5mm hole, deburr and paint hole.
Bolt upper mounting bracket to the snorkel body, screw the 6 mounting studs into the snorkel body inserts, position air entry adaptor into position in the inner guard, carefully position the snorkel body onto the guard, guiding the snorkel snout into the air entry adaptor. Fasten snorkel body to the guard with a couple of nuts and washers. Ensure that all mounting studs have adequate clearance to mounting holes. (Filing of holes to gain clearance may be necessary).
Holding the air adaptor in position, mark the hole position through the inner guard onto the adaptor, remove snorkel body, air entry adaptor from vehicle. Drill the hole position marked on the air entry adaptor to 4.5mm.<
Apply a liberal amount of sensor safe silicone sealant to the sealing surface of the air entry adaptor, install the air entry adaptor into position and secure using pop rivet supplied.
Apply a liberal amount of sensor safe silicone sealant around the end of the snorkel snout and air entry adaptor inlet. Carefully position the snorkel body onto the guard, guiding the snorkel snout into the air entry adaptor. Using necessary hardware secure the snorkel body to the guard. Apply more sealant if required to ensure the snorkel snout to inner guard has a watertight seal.
Line the upper mounting bracket up with the inside edge of the plastic A pillar molding (to achieve bracket to molding edge alignment, the top of the snorkel body may need to be pushed towards the A pillar) mark the 4 hole positions on the A pillar molding, remove bracket and drill a 4.5mm hole for each hole position.
Refasten upper mounting bracket onto the snorkel body, fasten upper mounting bracket to the A pillar using pop rivets supplied.
Install air ram assembly to snorkel body and fasten. Refit wheel arch liner. Refit air entry duct.
N.B Sealing of air ducting joints and air cleaner housing.
Sealing of ALL air ducting joints, air cleaner housing entry snout and cleaner housing drains is at the owner/installer discretion.
Failure to use a sensor safe silicone sealant will cause sensor contamination.