Discovery I Safari Snorkel
Fits: Discovery I | '94 - '98
(#1) 1-Body/Snorkel; (#2) 1-3 Air Ram Assembly; (#3) 1-Bracket/Upper Mounting; (#4) 3-6mm x 1.0 x 12mm Hex Bolts; (#5) 6-6mm Flat Washers; (#6) 3-6mm Star Washers; (#7) 3-6mm x 1.0 x 16mm Hex Bolts; (#8) 3-6mm x 16mm Flat Washers; (# 9) 3-6mm Nyloc Nuts; (# 10) 6-8mm x 1.25 x 25mm O/L Studs; (# 11) 6-8mm x 30mm Body Washers; (# 12) 6-8mm Nyloc Nuts; (# 13) 12-4mm x 12mm Pop Rivets; (# 14) 4-4.2mm x 13mm S/T Screws; (# 15) 2-60/80mm Hose Clamps; (# 16) 1-70mm Plug; (# 17) 1-400mm Rubber Edging; (# 18) 1-Rear Mounting Air Cleaner Bracket; (#19) 1-Mounting Air Cleaner Bracket; (#20) 1-Air Cleaner Entry Adaptor; (#21) 1-Connecting Duct; (#22) 1-Template; (#23) 2-Plastic Body Clips; (#24) 1-Switch Relocation Bracket; (#25) 3-4.8mm x 21mm Pop Rivet; (# 26) 1-Size 48 Hose Clamp
Fitment to: Left hand side
Fitting time: Approximately 120 minutes
Suits: TDI/V8 with or without ABS
Special Tools: 86mm hole-saw; 89mm hole-saw; Pop rivet gun; Air hacksaw; Unibit step drill
Remove the left front guard liner and air cleaner assembly. On petrol vehicles the air flow meter and rubber duct from the inlet manifold must also be removed.
Locate the template on the upper rear corner of the guard and mark the hole positions using a felt pen. Remove the template and drill a 4mm pilot hole for each position. Open the 6 mounting holes to 16mm using a step drill. Drill the main hole to 86mm using a hole-saw. Deburr all holes to leave a clean edge.
To locate the inner hole, measure back from the headlight support panel 450mm, then down from the bottom edge of the guard flange 60mm. This hole should be located in the center of the round bulge in the side of the engine bay. Drill a 4mm pilot hole, then open the hole out using a 89mm hole saw. Deburr to leave a clean edge.
Paint all holes using a suitable touch up paint.
Insert the mounting studs into the back of the snorkel. Bolt the upper mounting bracket to the top of the snorkel. Position the snorkel body on the vehicle and secure using 8mm nyloc nuts and body washers supplied. Mark holes for A pillar bracket remove bracket and drill holes. Deburr and paint holes. Use the 4mm pop rivets to fasten bracket to A pillar. Position the air ram on the top of the snorkel body and tighten the clamp.
Remove the air cleaner lid, mounting plugs and filter element from the air cleaner assembly. Locate the adaptor casting on the lower left hand side front corner of the air cleaner body and mark the main hole position using a scriber. Remove front three ribs from air cleaner body to obtain flat surface. Use an air hacksaw to cut out the hole. Smear silicone sealant on the sealing surface of the adaptor casting then fasten it to the cleaner body using 4mm pop rivets.
Cut off the 2 locating pins on the front of the air cleaner body. Locate the large mounting bracket on the front face of the body and fasten in place with 4mm pop rivets.
Remove air filter inlet by removing flange clip inside air filter housing and pull out air inlet extension.
Use the 70mm blank off plug to fill the original intake hole. The plug should be sealed in place using silicone and fastened using 2 4.2mm x 13mm S/T Screws. The drain holes in the bottom of the air cleaner body should also be sealed using silicone.
Position the air cleaner body in the vehicle. The pins on the front mounting bracket locate in the original mounting bushes. When in the correct position, the pins should push approximately 1mm through the bushes.
Mark the new rear mounting hole position through the large hole in the bottom of the air cleaner onto the inner guard. Remove the air cleaner and drill the hole to 12.5mm.
Refit the mounting plugs into the air cleaner body then relocate the air cleaner body into the vehicle. Fit the rear-mounting bracket to the second mounting plug. Mark the 3, bracket-mounting hole positions on the inner guard. Remove the air cleaner body from the vehicle and drill the 3 holes to 7mm. Bolt the rear bracket in place using the 6mm flat washer, 6mm x 1.0 x 16mm hex bolt, 6mm x 16mm flat washer and 6mm nyloc nut.
Fit the rubber edging around the inner hole. Smear silicone to the inside of connecting duct at both ends. Slide the long end of the connecting duct onto the snorkel snout and secure with a 60/80 clamp.
Re-assemble the air cleaner, then position it in the vehicle. Fasten the end of the connecting duct to the adaptor casting using a 60/80 clamp.
N.B.: PETROL VEHICLES
The rubber duct between the air flow meter and inlet manifold will have to be shortened as shown in diagram.
Using bracket supplied in kit to relocate bonnet switch as shown in diagram, mark holes with a felt pen and drill 2 x 8mm holes. Fit nylon inserts and mount bracket. Reposition ABS brake pipe to clear mounting bracket.
Refit guard liner and use 3 large headed pop rivets supplied to fasten liner.