SS 660HF
Installation Guide

ITEM
IMAGE
DESCRIPTION
PART NO.
QTY
1
BODY - SNORKEL (SS660HF) 525-133-000 1
2
3 ½" AIR RAM ASSEMBLY 000-135-650 1
3
BRACKET - UPPER MOUNTING 525-032-000 1
4
BOLT - HEX - 6mm x 1.0 x 14mm (SEMS) 000-002-100 5
5
SCREW - S/T - 4.2mm x 16mm 000-951-300 3
6
INSERT - PLASTIC 000-960 3
7
STUD - S/S - 8mm x 1.25 x 25mm O/L 000-110 8
8
WASHER - BODY - 8mm x 45mm 000-352 8
9
NUT - NYLOC - 8mm x 1.25 000-205 10
10
HOSE - AIR ENTRY 525-024-200 1
11
ADAPTOR - AIR CLEANER 525-023-200 1
12
POP RIVET - 4.8mm x 12mm 000-958-300 3
13
CLAMP - HOSE - 80/100mm 000-909 2
14
BOTTLE - RADIATOR OVERFLOW 525-098-000 1
15
BOLT - HEX - 8mm x 1.25 x 20mm 000-012 2
16
WASHER - FLAT - 8mm 000-302 4
17
CLAMP - HOSE - SIZE 56 (BLACK) 000-914/B 1
18
TEMPLATE - SNORKEL BODY 525-017-000 1

Installation Guide
1
Fitment to:
  • Right Hand Side

Fitting Time:

  • 180min

Special Tools:

  • 95mm hole saw
  • 102mm hole saw
  • step drill
  • pop-rivet gun
  • loctite (thread lock)
  • Sikaflex 227 (adhesive sealant)
  • touch-up paint
Prior to commencing the installation, it is the installer's responsibility to verify that all components and particularly the template (Item 19) are correct.
2 Remove:
  • Remove the following in accordance with the factory service manual.
  • RHS Mud flap (If fitted to vehicle)
  • RHS Inner guard liner
  • RHS Flare (If fitted to vehicle)
  • Air cleaner assembly
3 Remove and discard air cleaner entry duct and radiator overflow bottle (retain overflow bottle cap and coolant).
4 Tape the template (Item 19) to the rear, upper edges and front of the right hand side guard as shown. With the template correctly aligned on the guard, use a felt tip pen to mark all hole positions.

Remove the Template.
5 Drill a pilot hole for each marked hole position. Using the 95mm hole saw, drill the main hole square to the guard surface. (holesaw cutting on both top and bottom surfaces of the guard). Using the step drill, drill the 8 mounting hole positions to 16mm. Deburr and paint holes to prevent rust.
Use the overflow bottle front mounting hole as a centering guide for drilling the inner guard hole. Use the 102mm hole saw to drill the inner guard hole and internal panel. Deburr holes then gently tap the two sharp edges created using a piece of timber and a hammer as shown to prevent any damage occuring to the air entry hose when installed. Paint holes to prevent rust.
6 Fasten the Upper Mounting Bracket (Item 3) to the Snorkel Body (Item 1) and secure with 3 x 6mm Hex Bolts (Item 4). Apply loctite to all 8 mounting studs (Item 7) and install studs into the snorkel body (Item 1) mounting inserts.
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 three upper mounting bracket hole positions on the A-Pillar.
7 Remove the snorkel body (Item 1) from the vehicle. Remove the upper mounting bracket (Item 3) from the snorkel body.
8 Drill an 8mm diameter hole for each marked hole position on the A-Pillar panel.

NB: Extreme care must be taken when drilling the 3 A-Pillar mounting hole positions. Ensure that the drill bit is just long enough to drill through the thickness of the A-Pillar panel and no further.

Deburr and paint the holes.

Install the plastic inserts (Item 6) into the newly drilled A-Pillar holes.
9 Secure the upper mounting bracket (Item 3) to the A-Pillar using 3 x self tapping screws (Item 5).
Using a sharp knife trim 3 of the front air cleaner housing ribs to approximately 12mm in length, as shown. This will ensure that the air cleaner adaptor sits flat against the air cleaner housing.
10 Position and align the air cleaner adaptor (Item 12) over the air cleaner inlet snout and mark the 3 hole positions.

Remove the air cleaner adaptor and drill the 3 marked hole positions to 5mm.
11 Apply a liberal amount of sikaflex sealant to the air cleaner adaptor flange and around the external surface of the air cleaner inlet snout. Secure the air cleaner adaptor to the air cleaner housing using 3 pop rivets (Item 13). Clean up any excessive sealant to produce a neat finish.
12 Install the radiator overflow bottle (Item 15) and secure using 8mm x 20mm Hex Bolts (Item 16), 8mm Flat washers (Item 17), 8mm Nyloc Nuts (Item 10) and 6mm x 14mm Hex Bolts (Item 4) as shown.
13 Connect the radiator overflow hose to the new radiator overflow bottle (Item 15). Remove the radiator over flow hose from the radiator filler neck and trim approximately 150mm off the hose as shown.

Refill the overflow bottle with the previously drained coolant and seal bottle with genuine radiator overflow bottle cap.

IMPORTANT: Only refill the radiator overflow bottle to half capacity.
14 Install the air entry hose (Item 11) through the inner guard hole. Position a 80/100mm hose clamp at each end of the hose.

With the air entry hose correctly positioned install the air cleaner housing and fasten using standard mounting bolts.

15 With the hose loosely positioned, carefully guide the snorkel body outlet snout into the air entry hose and install the snorkel body to the guard.

Align the snorkel body to the upper mounting bracket and the guard. When correctly aligned, fasten the snorkel body to the guard with body washers (Item 8 & 9) and Nyloc nuts (Item 10).

NB: Use 4 x body washer (Item 8) on the top 4 mounting stud positions. Use 4 x body washer (Item 9) on the bottom 4 mounting stud positions.

Fasten the snorkel body to the upper mounting bracket with 6mm x 14mm hex bolts (Item 4).
16 Ensure that the air entry hose is correctly positioned onto the snorkel body snout and air cleaner adaptor. Orientate the 80/100mm hose clamps (Item 14) into position and tighten.
17 Install the genuine air cleaner element, air cleaner housing lid and connect the air mass sensor wiring plug.
18 Install RHS inner guard liner, RHS Flare (If fitted to vehicle), and any other items that may have been removed during the snorkel installation process.
19 Loosely install the black hose clamp (Item 18) to the base of the air ram assembly (Item 2). Install the Air ram assembly onto the snorkel body.

Align the air ram assembly and tighten the black hose clamp (Item 18).
20 It is the installer’s responsibility to ensure that all connections are water tight.