Safari - Snorkels

SS40HFM Mitsubishi Pajero NS Series V8/V9 - 3.2 Litre Turbo Diesel (MANUAL TRANS ONLY)

Parts List

ITEM	IMAGE	DESCRIPTION	PART NO	QTY
1		BODY - SNORKEL	570-133-000	1
2		3½" AIR RAM ASSEMBLY	000-135-650	1
3		DUCT - INNER (REAR)	570-124-000	1
4		DUCT - INNER (FRONT)	570-124-200	1
5		DUCT - AIR CLEANER ENTRY (SS35HF)	565-123-000	1
6		BRACKET - UPPER MOUNTING	570-032-000	1
7		BOLT - HEX 6mm x 1.0mm x 14mm (SEMS)	000-002-100	3
8		INSERT - PLASTIC	000-960	3
9		SCREW - S/T 4.2mm x 16mm	000-951-300	4
10		STUD - S/S 8mm x 1.25mm x 25mm O/L	000-110	3
11		WASHER - BODY 8mm x 30mm	000-311	3
12		NUT - NYLOC 8mm x 1.25	000-205	3
13		HOSE - RUBBER 90mm ID x 40mm	000-807-157	1
14		HOSE - RUBBER 90mm ID x 70mm	000-807-275	1
15		CLAMP - HOSE 80/100mm	000-909	4
16		CABLE - TIE 8mm x 500mm	000-987-550	1
17		POP RIVET - 4.8mm x 21mm	000-958-400	1
18		FIXTURE - HOLESAW CENTRE	565-017-100	1
19		POP RIVET - 4mm x 12mm	000-958	2
20		BRACKET - AIR CLEANER RELOCATION	565-031-000	1
21		BRACKET - AIR CLEANER RELOCATION	565-031-100	1
22		WASHER - BODY 8mm x 24mm x 3mm	000-335	3
23		BOLT - HEX 6mm x 1.0mm x20mm (SEMS)	000-003-100	3
24		TEMPLATE	570-017-000	1
25		HOSE CLAMP - SIZE 56 (BLACK)	000-914/B	1
26		WASHER BOTTLE	570-098-000	1
27		SPACER - 25mm OD x 8.5mm ID x 12mm	570-992-000	2
28		WASHER - FLAT 8mm	000-302	2
29		WASHER - STAR 8mm	000-305	2
30		BOLT - HEX 8mm x 1.25mm x 30mm	000-014	2
31		CUSHIOIN CLAMP 32/15	000-967	1
32		CABLE TIE 2.5mm x 100mm	000-987-100	10
33		STRAIGHT CONNECTOR 5.0mm	000-979	1
34		WINDSCREEN WASHER TUBING 4mmID x 1500mm	000-826-150	1
35		LOOM - Washer Motor Extension	570-083-000	1
36		PLATE - Indicator Blank Off	570-704-000	1

Installation Guide

Fitment to:

Right Hand Side

Fitting Time:

240 min on models with guard mounted indicator lights
210 min on models with mirrors that have integrated indicator lights

Special Tools:

102 mm diameter hole saw
step drill
air body saw
loctite (thread lock)
Sikaflex 227 (adhesive sealant)
Pop-Rivet Gun
Touch-up Paint

Prior to commencing the installation, it is the installer's responsibility to verify that all components and particularly the template (Item 24) are correct.

Remove:

RHS Front mud flap
RHS inner guard liner
RHS Guard mounted indicator (if fitted)
Air intake ducting (remove and discard)

Air cleaner assembly
Air cleaner housing mounting bracket
Front Grille
Winsdcreen washer bottle assembly

OPTION: Models with Guard mounted Indicator lights - the indicator light is to be relocated. Remove the pre-stamped indicator cut-out from the snorkel body template (Item 24). Cover the existing indicator light mounting hole with masking tape.

Tape the template (Item 24) to the rear and upper edges of the right hand side guard. With the template correctly positioned on the guard, use a felt tip pen to mark all hole positions (and the new indicator lamp hole profile if required), then remove the template.

Drill a pilot hole for each marked hole position.

Use a 102mm hole saw to drill the snorkel body outlet hole.

OPTION: Models with Mirrors that have integrated Indicator lights - Use a step drill to drill the three mounting hole positions to 16mm.

OPTION: Models with Guard mounted Indicator lights - Use a step drill to drill the two mounting hole positions to 16mm. File the lower mounting hole to 16mm diameter and carefully cut and file the new indicator hole as shown.

Deburr and paint all holes to prevent rust.

Remove the combined windscreen washer motor and RHS indicator wiring loom from its retaining clips. Note that on models with mirrors that have integrated Indicator lights, the indicator wiring component of the combined loom is not used.

Position the holesaw centre fixture (Item 18) into the hole in the inner guard . Mark the two fixture mounting hole positions and drill these out to 4mm diameter.

Secure the fixture into position with two pop-rivets (Item 19).

Enlarge the diameter of the exisiting hole with a 102mm hole saw.

Deburr and paint hole perimiter to prevent rust.

OPTION: Models with Mirrors that have integrated Indicator lights - Pass the windscreen washer motor wiring loom under the RHS headlight to the front of the vehicle.

OPTION: Models with Guard mounted Indicator lights - Pass the side indicator wiring loom through the hole in the inner guard as shown. Connect the washer motor extension loom (Item 35) to the standard washer motor plug and pass the extension loom (Item 35) under the RHS headlight to the front of the vehicle. Secure the extension loom (Item 35) with cable ties (Item 32).

Use an air body saw to remove the standard washer bottle mounting bracket located between the inner and outer guards. Deburr and paint the exposed metal edges to prevent rust.

Mark a position that is 25mm back from the front air cleaner mounting bracket hole and drill a pilot hole. Use a step drill to drill a 16mm diameter hole.

Place a spacer washer (Item 22) over each of the air cleaner relocation bracket mounting holes as shown.

Install the air cleaner relocation brackets (Items 20 & 21) and secure with 6mm x 20mm hex bolts (Item 23)

Install the standard air cleaner housing mounting bracket onto the air cleaner relocation mounting brackets (Items 20 & 21) and secure with the standard mounting hardware.

Apply loctite to all three studs (Item 10) and install the studs into the snorkel body (Item 1) mounting inserts.

Install the upper mounting bracket (Item 6) and secure with 6mm x 14mm hex bolts (Item 7).

Place a strip of masking tape along the A-Pillar panel.

Carefully install the snorkel body onto the guard. With the snorkel body correctly positioned, mark the position of the upper mounting bracket on the A-Pillar.

Remove the snorkel body from the vehicle and remove the upper mounting bracket (Item 6) from the snorkel body (Item 1).

Align the upper mounting bracket (Item 6) back onto the A-Pillar and mark the position of the three upper mounting bracket mounting holes.

Drill an 8mm diameter hole for each marked hole position on the 'A' pillar panel (deburr and paint the holes).

Install the plastic inserts (Item 8) into the newly drilled A-Pillar holes.

Install the upper mounting bracket to the A-Pillar and secure with 4.2mm x 16mm self tapping screws (Item 9).

Measure and mark 35mm in from the oval end and 20mm in from the round end of the front inner duct (Item 4).

Measure and mark 35mm in from the oval end of the rear inner duct (Item 3).

Install the front inner duct (Item 4) through the enlarged hole in the inner guard into the engine bay.

Install the joiner hose (Item 13) and ensure that the hose only extends 20mm over the end of the front inner duct. When installed correctly, there will be 20mm of hose left exposed.

Secure the hose to the front inner duct with a 80/100mm hose clamp (Item 15).

Secure the front inner duct loosely with a cable tie (Item 16).

Drill a 5mm diameter hole that is 55mm down from the air cleaner filter element recess and between the first and second ribs inside the air cleaner housing as shown.

Loosely install the air cleaner entry duct (Item 5) onto the air cleaner housing and install the assembly into position inside the engine bay. Fasten the aircleaner housing with the standard mounting bolts.

Install the end of the air cleaner entry duct into the joiner hose (Item 13).

Mark the hole position onto the mounting pad of the air cleaner entry duct (Item 5).

Remove the air cleaner housing and air cleaner entry duct assembly from the engine bay and drill a 5mm hole into the air cleaner entry duct (Item 5) at the position marked in the previous step.

Apply a generous amount of Sikaflex sealant to the air cleaner housing inlet and to the end and mounting pad of the air cleaner entry duct (Item 5) Install the duct back into the air cleaner.

Secure the duct into position with a 4.8mm x 21mm pop-rivet (Item 17).

Ensure that a water-tight connection between the air cleaner entry duct and the air cleaner housing is achieved. Apply more sealant and/or clean excess sealant away to produce a neat finish.

Install the air cleaner and air cleaner entry duct assembly back into the engine bay and secure into position with the standard air cleaner housing mounting bolts.

Leave the joiner hose clamp (Item 15) loose for now.

Install the duct joiner hose (Item 14) onto the front inner duct (Item 4).

Loosely install the two 80/100mm hose clamps (Item 15) onto the joiner hose (Item 14).

Install the rear inner duct (Item 3) and ensure that the duct opening is located centrally inside the outer guard panel 102mm diameter hole.

Ensure that the joiner hose (Item 14) is installed centrally over the front and rear inner ducts (Items 3 & 4) - use the previously marked lines as a guide.

Apply a generous amount of Sikaflex sealant to the outer surface of the snorkel body outlet snout (Item 1) as well as to the internal surface of the rear inner duct entry (Item 3) to ensure a watertight seal. Carefully guide the snorkel body outlet snout into the inner duct and install the snorkel body to the guard panel.

Align the snorkel body to the upper mounting bracket and the guard.

OPTION: Models with Mirrors that have integrated Indicator lights - When correctly aligned, fasten the snorkel body to the guard with body washers (Item 11) and Nyloc nuts (Item 12) on each of the three mounting studs (Item 10).

OPTION: Models with Guard mounted Indicator lights - When correctly aligned, fasten the snorkel body to the guard with body washers (Item 11) and Nyloc nuts (Item 12) on the two mounting studs (Item 10) that pass through the drilled holes on the guard. Do not install washer or nut to the stud that passes through the standard indicator hole. Install side indicator into relocated hole and connect wiring harness.

Fasten the snorkel body to the upper mounting bracket with two hex bolts (Item 7).

OPTION: Models with Mirrors that have integrated Indicator lights - Ignore this step

OPTION: Models with Guard mounted Indicator lights - Apply a small amount of Sikaflex sealant to the outer edge of the blank-off plate (Item 32) and install into the standard indicator hole in the guard from inside the wheel well.

Secure the blank-off plate with a washer (Item 11) and Nyloc nut (Item 12).

Ensure that the inner duct is hard up against the shoulder on the snorkel outlet snout and secure to the inner duct to the snorkel body with a 4.2mm x 16mm self tapping screw (Item 10) through the pre-drilled hole in the rear inner duct as shown.

Ensure that the joiner hose (Item 14) is installed centrally over the front and rear inner ducts (Items 3 & 4) and tighten the two 80/100mm hose clamps (Item 15).

Tighten the cable tie (Item 16) that was used previously to secure the front inner duct (Item 4).

Ensure that the air cleaner entry duct (Item 5) and the front inner duct (Item 4) are positioned correctly and tighten the 80/100mm hose clamp (Item 15) over the joiner hose (Item 13) as shown.

Install the standard air filter element and air cleaner lid and related wiring.

Remove the standard windscreen washer bottle filler lid.

Remove the standard washer motor and grommet from the standard windcsreen washer bottle.

Install the standard windscreen washer bottle filler lid. Install the grommet and washer motor onto the new washer bottle (Item 26) and secure with a cushion clamp (Item 31) and 6mm x 14mm hex bolt (Item 7).

Connect the extension hose (Item 34) to the standard washer hose with a straight connector (Item 33).

Route the windcsreen washer extension hose (Item 34) along the outside of the inner ducts and support with cable ties (Item 32) as shown.

Pass the extension hose under the headlight assembly and connect to the new windscreen washer bottle (Item 26).

Connect the washer motor electrical connector.

Install the new washer bottle assembly to the radiator support panel using a 12mm thick spacer (Item 27) at each of the two mounting points and secure with 8mm x 30mm hex bolts (Item 30), 8mm star washers (Item 29) and 8mm flat washers (Item 28).

Fill the washer bottle (Item 26) with washer fluid and check for leaks and correct windscreen washer system operation.

Install the front grille, inner guard liner and any other items that may have been removed during the snorkel installation process. Check operation of the indicators.

Loosely install the black hose clamp (Item 25) to the base of the air ram (Item 2) and install the air ram onto the snorkel body.

Align the air ram and tighten the black hose clamp (Item 25).

It is the installer's responsibility to ensure that all connections are watertight.

Please note: all model fitments are verified to suit right hand drive Australian specification vehicle releases. Dates refer to Australian vehicle release dates. Variations in engine size and air filter housing specifications may apply in other markets. If in doubt as to product suitability please forward a photograph of engine bay and body at ¾ frontal position.