Airtec Snorkel Assembly Vehicle: Toyota FJ Cruiser 4.0L Petrol, 04/2011+ Part No. 011SAT0185A. Read instructions fully before commencing fitment.

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1 Read instructions fully before commencing fitment. Estimated Fitting Time: 3hrs To provide a totally sealed intake system, it will be necessary to remove all under bonnet air-cleaner plumbing & provide a seal to all OE joints, using a neutral cure silicone. Left hand and Right hand components are determined as seated in the vehicle. Warranty 1. If any product or part of a product manufactured by TJM is found to be defective during a period of three (3) years after the date of purchase, TJM shall repair (at TJM s discretion) the defective product or part. 2. Any defect in a product distributed by TJM, but not manufactured by TJM, shall be dealt with in accordance with, and to the extent of, the warranty offered by the manufacturer of that product. 3. TJM does not warranty that the products manufactured by it comply with the laws of the place where those product are purchased or used. It is the sole responsibility of the purchaser to ascertain whether products being purchased, or the affixation of those products to any other object, comply with local laws. 4. Except to the extent described in this warranty, TJM shall not be liable for any other claims, including claims arising from incorrect fitment, product or vehicle modification, faulty design, the use of the product on any indirect special or consequential damage or injury to any person, company or other entity. 5. Modification or alteration to any product manufactured by TJM to enable fitment in conjunction with other vehicle accessories or modifications (e.g. lift kits) will void any warranty claims. File: F-2012.docx Page 1 of 15 03/10/2012

2 Bolt tensions Dia. (mm) Nm ft.lbs Dia. (inch) Nm ft.lbs All bolt tensions are as follows unless otherwise specified / / / / / Description Qty Part Number PARTS LIST Snorkel Body 1 011MB00185A Air Ram 1 011AIR0185A Upper Intermediate Tube 1 011IP10185A Lower Intermediate Tube 1 011IP20185A Upper Snorkel Bracket 1 F-2048 Intermediate Tube Bracket 1 F-2049 Hose Clamp (Black) 1 HC052B Hose Clamp 1 HC052 Template Body Guard 1 F-2012-T Cable Joiners, Heat-Shrink Tube, Automotive Twin Wire Cable 1 KIT85A BOLT KIT 8g x 20mm Screw (Black) 3 S8G20SBZ M6 x 1.0 x 16mm (Zinc) 1 BHM616Z M6 Spring Washer (Zinc) 1 WSM6ZP M6 Flat Washer (Zinc) 1 WFM6ZP M8 x 1.25 x 16mm Hex Head Bolt (Zinc) 5 BHM816Z M8 x 1.25 x 16mm S/Steel Button Head Socket Screw (Black) 2 SBHM816D M8 Spring Washer (Zinc) 5 WSM832Z M8 S/Steel Spring Washer (Black) 2 WSM83D 5/16 x Ø7/8 Flat Washer (Zinc) 1 W51678Z 5/16 x Ø1-1/4 Flat Washer (Zinc) 4 WF ZPG M8 x Ø17mm S/Steel Flat Washer (Black) 2 WFM817D File: F-2012.docx Page 2 of 15 03/10/2012

3 1. To ensure that the correct template has been supplied, position the Outer Guard template over the snorkel body, ensuring that the hole positions match. 2. Position the vehicle on a hoist so as to allow access to the RHS plastic wheel arch liner. It is suggested, but not required, that you remove the RHS front wheel so as to allow complete access to the wheel arch/body guard cavity. 3. Remove (& retain) the fasteners (4) that are securing the grille to the vehicle. 4. Remove (& retain) the grille from the vehicle & carefully set it aside. 5. Remove (& retain) the indicated fasteners (2) that are securing the centre section of the bumper. File: F-2012.docx Page 3 of 15 03/10/2012

4 6. Remove (& retain) the indicated fasteners (4) from the underside of the RHS end of the bumper. 7. Remove (& retain) the fasteners (2) from the RHS outside edge of the bumper. 8. Release the RHS of the bumper from the vehicle, so as to allow access below the headlight. 9. Remove (& retain) the indicated fastener securing the front of the guard flare, then detach the guard flare from the plastic retainer bracket. File: F-2012.docx Page 4 of 15 03/10/2012

5 STEP 11 STEP Disconnect the harness connector from the indicated sensor, then unclip the sensor wiring from the air-cleaner unit. 11. Retaining the hose clamp, disconnect the outlet hose from the air-cleaner unit, making sure to cover the end of the outlet hose, so that no foreign matter can enter the system during the installation process. 12. Where present, unclip any attached hoses/wiring from the top section of the aircleaner unit. 13. Disconnect the clips around the air-cleaner unit, then remove (& retain) the top section of the air-cleaner unit. 14. Remove (& retain) the filter element from the air-cleaner unit base. 15. Where present, unclip any attached hoses/wiring from the air-cleaner unit base. STEP Remove (& retain) the fasteners (3) securing the air-cleaner unit base, then remove (& retain) the air-cleaner unit base from the vehicle. File: F-2012.docx Page 5 of 15 03/10/2012

6 17. Remove (& retain) the plastic trim moulding (& respective fasteners) from the top of the RHS guard. GUARD FLARE 18. Remove (& retain) the mud-flap (& respective fasteners) from the vehicle. 19. Release the guard flare (retaining the fasteners) from the wheel arch so as to gain access to the wheel arch liner fasteners. STEP Remove (& retain) the wheel arch liner (& respective fasteners) from the vehicle. 21. Temporarily secure the guard flare back into position on the guard with a fastener so as to prevent any damage during the installation. File: F-2012.docx Page 6 of 15 03/10/2012

7 22. Remove (& discard) the air-cleaner intake moulding (& respective fasteners) from the inner guard. INTAKE MOULDING 23. Disconnect the RHS indicator lead harness, then remove (& retain) the RHS indicator from vehicle. 24. Remove (& discard) the rubber backing gasket from the RHS indicator. STAGGER JOINS 25. Crimp the supplied terminal cable joiners onto the ends of the supplied twin wire extension cable in a staggered position, so as to allow fitment of the heat-shrink tubing. 26. Cut the RHS indicator lead at a suitable distance back from the harness connector, then slide the heat-shrink tubing over each wire end. 27. Join the extension cable into each end of the RHS indicator lead so as to extend the reach of the indicator. 28. Slide the heat-shrink tubing over the join positions, then apply heat to the heat-shrink tubing so as to seal the joins. File: F-2012.docx Page 7 of 15 03/10/2012

8 29. Trim the supplied outer guard template to shape, along the noted edges on the template. 30. Accurately aligning the template with the indicator opening & the rear edge of the RHS body guard, tape it in place (as shown). 31. Centre-punch the Ø14mm (4) & Ø98mm (1) hole positions onto the body guard. 32. Remove (& discard) the template from the vehicle, then drill Ø3mm pilot holes at all of the previously centre-punched positions. 33. Drill the Ø14mm & Ø98mm hole positions out to size. 34. De-burr the holes/edges, then thoroughly clean the area/surface of any swarf/debris. 35. Detach the intake socket from the air-cleaner unit base, then remove the foam tape from the outer diameter of the intake socket. File: F-2012.docx Page 8 of 15 03/10/2012

9 36. Clean the outside diameter of the air-cleaner unit base connection & the inside diameter of the intake socket. 37. Apply a thin coating of a neutral cure silicone to the inside surface of the intake socket & the external surface of air-cleaner unit base connection. 38. Re-assemble the air-cleaner unit base connection & intake socket, then wipe off any excess silicone. 39. Aligning the upper intermediate tube inlet (011IP10185A) with the previously drilled Ø98mm hole, position the upper intermediate tube in the top rear corner of RHS body guard cavity. 40. Position the lower intermediate tube inlet (011IP20185A) over the upper intermediate tube outlet, as shown. File: F-2012.docx Page 9 of 15 03/10/2012

10 STEP 41.2 STEP Ensuring that the lower intermediate tube outlet is aligned with the hole that the aircleaner intake moulding was removed from (step 22), loosely secure the lower intermediate tube bracket in place, using the fasteners listed below: M8 x 1.25 x 16mm hex screw (1), M8 spring washer (1) & 5/16 x Ø7/8 flat washer (1) M6 x 1.0 x 16mm hex screw (1), M6 spring washer (1) & M6 x Ø12.5mm flat washer (1). 42. Check the clearances from the upper intermediate tube to the rear inner panel & the aerial assembly. As required, trim the upper intermediate tube so as to achieve an appropriate fit. 43. To avoid damaging the area when positioning the snorkel body/snorkel bracket, mask the RHS windscreen pillar. 44. Aligning the captive nuts in the snorkel body with the Ø14mm holes drilled in step 33 & with the snorkel body outlet positioned inside the upper intermediate tube inlet, place the snorkel body in position, on the vehicle. 45. Loosely secure the snorkel body to the vehicle, using M8 x 1.25 x 16mm hex screws (4), M8 spring washers (4) & 5/16 x Ø1-1/4 flat washers (4). 46. Check the clearances between the snorkel body outlet & upper intermediate tube inlet. As required, trim the mouldings & slot the respective holes to achieve an appropriate fit. File: F-2012.docx Page 10 of 15 03/10/2012

11 47. Orientating the snorkel bracket as shown, loosely secure it to the top of the snorkel body, using M8 x 1.25 x 16mm stainless button screws (2), M8 x Ø17mm stainless flat washers (2) & M8 stainless spring washers (2). 48. Using the holes in the snorkel bracket as a template, mark the three hole positions onto the windscreen pillar. 49. Remove (& retain) the snorkel body, upper intermediate tube, lower intermediate tube (& respective fasteners) from the vehicle. 50. Remove (& retain) the snorkel bracket (& respective fasteners) from the snorkel body. 51. Drill Ø2mm holes at the positions previously marked in step Thoroughly clean the pillar & RHS body guard area/surface of any swarf/debris, then treat all previously exposed raw surfaces with a rust preventative. 53. Apply a liberal amount of neutral cure silicone onto the inside face of the upper intermediate tube inlet (as shown) & also the outside face of the upper intermediate tube outlet. 54. Reposition the upper intermediate tube, as per step 39. HOSE CLAMP 55. Apply a liberal coating of a neutral cure silicone to the inside face of the lower intermediate tube inlet. 56. With the hose clamp in place, carefully re-fit the lower intermediate tube to the upper intermediate tube (as per step 40), then loosely secure the lower intermediate tube in place (as per step 41). 57. Clean any excess neutral cure silicone from the connection points. File: F-2012.docx Page 11 of 15 03/10/2012

12 58. Ensuring that the rubber backing gasket has been removed from the RHS indicator, clip the RHS indicator into the snorkel body recess, ensuring that the connector for the harness faces towards the front of vehicle. 59. Pass the RHS indicator wiring harness through the existing indicator hole in the guard & attach it to the RHS indicator. Check the operation of the indicator & ensure that it is functioning correctly. 60. Apply a liberal coating of a neutral cure silicone around the external face of the snorkel body outlet. 61. Apply loctite 271 threadlocker compound (or an equivalent) to the captive nuts in the snorkel body, then carefully re-fit the snorkel body back to the vehicle, utilising the fasteners from step 45 (finger tighten only). 62. Clean any excess neutral cure silicone from the connection points. File: F-2012.docx Page 12 of 15 03/10/2012

13 63. Apply a liberal amount of a neutral cure silicone onto the outside face of the air-cleaner unit base intake socket & also the inside face of the lower intermediate tube outlet. 64. Ensuring that the lower intermediate tube outlet is positioned over the intake socket of the air-cleaner unit base, re-fit the air-cleaner unit base back into its original position & loosely secure it in place, using the fasteners from step Clean any excess neutral cure silicone from the connection points. 66. Loosely secure the snorkel bracket to the snorkel body, using the fasteners from step Secure the snorkel bracket to the vehicle, through the holes drilled in step 51, using 8g x 20mm screws (3). 68. Check the clearances from the intermediate tubes to the inner guard panel, the air-cleaner unit base & also the connection points of the snorkel body, then fully tighten the previously installed fasteners & hose clamp to their respective torque settings, listed on page 2. File: F-2012.docx Page 13 of 15 03/10/2012

14 69. Position the air-ram on the snorkel body, so that the fasteners securing the mesh are horizontal to each other. 70. Secure the air-ram in place, using the black hose clamp supplied. To prevent possible chaffing/damage, position the hose clamp so that the worm drive is positioned at the rear of the snorkel body & ensure that there is sufficient clearance for the door to open. 71. Re-fit the filter element to the air-cleaner unit base. 72. Re-fit the top section of the air-cleaner unit. 73. Uncover the outlet hose, then reconnect it to the air-cleaner unit, using the hose clamp retained in step Re-connect the previously removed harness connector (step 10). 75. Re-connect any hoses/wiring that was removed during the removal of the air-cleaner unit. 76. Secure the RHS indicator harness to the aerial harness / bracket so as to prevent any instances of chafing from occurring. File: F-2012.docx Page 14 of 15 03/10/2012

15 77. Re-fit the plastic trim moulding removed in step 17, as per its original installation. 78. Release the guard flare & fastener from step 21, then re-fit the wheel arch line to the vehicle, using the fasteners from step Re-fit the guard flare & mud-flap to the vehicle, as per their original installation. 80. Re-fit the bumper to the vehicle, as per its original installation. 81. Re-fit the front grill to the vehicle, as per its original installation. Where applicable, re-fit the RHS front wheel & tighten to the applicable torque settings. 82. Ensure that all of the relevant wiring looms are connected & check that the associated systems are functioning correctly. 83. Ensure that all of the fasteners are fully tightened to the appropriate torque settings & that, as a results of fitting the product, no vehicle components are crushed or will chafe. File: F-2012.docx Page 15 of 15 03/10/2012