Instructions to fit the Snorkel Kit S080 for the Nissan Terrano II

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1 Instructions to fit the Snorkel Kit S080 for the Nissan Terrano II Airflow Vector Pty Ltd 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 pages and use the template provided, do not over tighten bolts. Do not use silicone on any connections, use mastic. Ensure that safe work practices are followed when installing your Airflow Snorkel. Protective ear and eye wear should be worn at all times when using power tools. 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 info@airflowvector.com SD080E (S080 Instructions booklet).doc 22 March 2011 Page 1 of 16 \\Server\d\AirflowSnorkels\Products\Snorkels\S80\SD080E (S080 Instructions booklet).doc

2 2.0 List of Components S080 Kit content Ref Designation Qty Length Unit SP094M Snorkel Terrano II (Co-fit) SP064 Air Ram 3.0" 1 SK035 Bolt kit for S080 1 SP090C SP019 SP142 SP015 SP015 Under Bonnet for S080 Hose Clamp 60/80mm Hose Clamp 70/90mm TPR Hose 76mm TPR Hose 76mm SP104 Connector 1 SP137A SP161 SP162 SP171 Elbow 76OD/65-76OD/30 Blocking plate 60x130mm Blocking plate 50x50mm Plastic bag 280x380mm SD080 Template mm mm Fasteners enclosed Ref Designation Qty SP160 A Pillar bracket S080 1 SP023 Washer Spring 1/4 x 1/4 Z/P 1 SP026 Screw Plug Nylon 2 SP024 G/Bolt M6 x 12mm Z/P 2 SP033 Washer 1/4 x 3/4 Z/P 4 SP029 Screw Self Tap 10gx5/8 Z/P 3 SP022 Stud M6 x 25mm Z/P 3 SP027 Flange Nut M6 Z/P 3 SP112 Pop rivet Bulbex 4x20mm 13 SP170 Plastic bag 75x125mm 1 Ensure that all parts listed are included in the parcel before starting any work. The total expected time of installation is around 2 hours. SD080E Booklet Page 2 of March 2011 SD080E (S080 Instructions booklet).doc

3 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, grinder Assorted drill set, wet / dry sand paper, ½ round file, small square file, Zinc rich primer Note: This snorkel is designed for another vehicle and adapted to fit this one. Although, all care is taken to achieve a good fit, no guarantees are given in regard of final aspect of installation 3.0 Detailed Instructions 3.1 Prior starting any work, ensure that the configuration 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 3.2 Remove the splash panel and the mud flap 3.3 Unbolt the air box from the engine bay 3.4 and remove it SD080E (S080 Instructions booklet).doc 22 March 2011 Page 3 of 16

4 3.5 Remove the factory under bonnet and discard it 3.6 Read the template carefully 3.7 Cut out the hole for the indicator 3.8 Cut out the template along the guard line 3.9 Line up the template to the guard 3.10 Tape it to the guard 3.11 Centre punch all marked holes 3.12 Although there is a bolt location at the back of the snorkel, it is not used. The template is correct 3.13 Cover the areas to be drilled with masking tape 3.14 Mark the centre punch with a felt pen on tape Page 4 of March 2011 SD080E (S080 Instructions booklet).doc

5 3.15 Pre-drill all holes at 5mm (4 snorkel mounting holes, 1 hole saw hole) 3.16 Then drill the four fixation holes at 10mm 3.17 Using the hole saw, drill at LOW SPEED a 76mm hole 3.18 File to suit snorkel tube and to remove any burr 3.19 Using the elbow SP137A as a template, mark the amount of material that needs to be removed as shown here SD080E (S080 Instructions booklet).doc 22 March 2011 Page 5 of 16

6 3.21 Grind the excess material 3.22 File to remove any burrs 3.23 Screw the 3 studs SP022 with chemical locking compound; at least 20mm must protrude 3.24 Leave these positions empty 3.25 Peel the rubber away from the windscreen 3.26 Fit temporarily the snorkel SP094M to allow the marking of the A pillar 3.27 Fit the A pillar bracket SP160 with the washer SP023 and bolt SP024 Do not over tighten fixings to avoid damage to the snorkel 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 SK235 Page 6 of March 2011 SD080E (S080 Instructions booklet).doc

7 3.28 Mark the A pillar bracket position 3.29 Remove the snorkel 3.30 Centre punch the 2 holes 3.31 Drill the two 4mm holes for the A pillar position 3.32 Unscrew and remove the windscreen moulding 3.33 Re-drill the same holes at 7mm 3.34 File the holes with a square file to suit nylon plugs SP Paint ALL raw metal surfaces with Zinc rich primer (4 snorkel fixing holes, 1 air intake hole, 1 inner guard hole, 2 A pillar holes) SD080E (S080 Instructions booklet).doc 22 March 2011 Page 7 of 16

8 3.36 Once the paint is dry, fit the 2 square plugs SP Refit the windscreen moulding 3.38 Mount the bracket SP160 with the screws SP Reset the rubber lining in its groove 3.40 Please wear gloves 3.41 Use only NON SILICONE BASE black mastic as sealant 3.42 Smear some sealant on outside of the SP090C as shown on the picture 3.43 Slide on a hose clamp SP Install the snorkel SP094M connecting it to the SP090C through the guard 3.45 Fit washers SP033 and nuts SP027 (x3) and washer SP033 and bolt SP024 at the front location to secure the snorkel Do not over tighten fixings to avoid damage to the snorkel Page 8 of March 2011 SD080E (S080 Instructions booklet).doc

9 3.46 Smear some sealant on both side of the SP015 (400mm) 3.47 Slide one hose clamp SP019 at each end 3.48 Connect one end to the long side of the SP137A and tighten the hose clamp 3.49 Connect the other end to the SP090C and tighten the hose clamp 3.50 Slide the short side of the SP137A through the inner guard 3.51 Mark the position where the connector SP104 will be installed 3.52 Grind off the old air intake SP File to remove any burrs SD080E (S080 Instructions booklet).doc 22 March 2011 Page 9 of 16

10 3.54 While holding the blocking plate SP161 (60x130mm) in place, drill five 4mm holes through the box and the plate 3.55 Using the hole saw, drill at LOW SPEED a 76mm hole 3.56 While holding the blocking plate SP162 (50x50mm) in place, drill four 4mm holes through the box and the plate 3.57 While holding the connector SP104 in place, inside the air box, drill four 4mm holes through the box and the lips 3.58 Smear some sealant on the edge of the tube 3.59 Slide it inside the air box 3.60 Rivet it in place Page 10 of March 2011 SD080E (S080 Instructions booklet).doc

11 3.61 Smear some sealant on the blocking plate SP161 and SP Slide them inside the air box 3.63 Rivet them in place 3.64 Resecure the air box in the engine bay 3.65 Smear some sealant on both side of the SP015 (250mm) 3.66 Slide one hose clamp SP019 at each end 3.67 Connect one end to the elbow SP137A 3.68 Tighten the hose clamp SP Connect the other end to the air box 3.70 Tighten the hose clamp SP019 and close the air box SD080E (S080 Instructions booklet).doc 22 March 2011 Page 11 of 16

12 3.71 Refit the plash panel and the mud flap 3.72 Secure the snorkel SP094M to the A pillar bracket SP160 with the washer SP023 and bolt SP024 Do not over tighten fixings to avoid damage to the snorkel 3.73 Slide the hose clamp SP142 on the air ram SP064 then slide it on the snorkel SP Ensure that the top of the snorkel matches the top of the slot cut in the Air Ram 3.75 Tighten the hose clamp 3.76 Drill the hose clamp next to the worm drive Page 12 of March 2011 SD080E (S080 Instructions booklet).doc

13 3.77 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 SD080E (S080 Instructions booklet).doc 22 March 2011 Page 13 of 16

14 4.0 Optional pre-cleaner (not included in this kit) 4.1 Remove the Air Ram SP Install Pre-cleaner filter sock SP065A 4.3 Air sock should neatly fit into the top of the snorkel body 4.4 Re-install the Air ram SP Tighten the hose clamp SP142 Screw the self tapper SP029 through the hose clamp Page 14 of March 2011 SD080E (S080 Instructions booklet).doc

15 4.6 Polish with silicone cleaner 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 overleaf. Furthermore, if you think that a step of this procedure could be improved, please send us at info@airflowvector.com your suggestions indicating the procedure name, its release date, the step details and the photo if necessary. We appreciate your support. SD080E (S080 Instructions booklet).doc 22 March 2011 Page 15 of 16

16 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 Page 16 of March 2011 SD080E (S080 Instructions booklet).doc

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