General Notes

• Read through the fitting instructions before installation of accessory. Install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or the accessory.

• Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local recycling regulations.

• It is always recommended that this accessory is fitted by a qualified Technician.

• Safely store and protect any removed vehicle components.

• Ensure all bare metal surfaces are protected using automotive bare metal primer and touch-up paint or suitable automotive rust inhibitor.

• Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.

Safety Notes:

• Check that all work practices comply with safety standards.

• Please wear appropriate clothing and use safety equipment.

Step 1

1. Position vehicle on a hoist (where possible) for access to the Front LHS inner guard area.

2. A flat level concrete surface is also suitable if a hoist is not available.

Optional:

• Jack up the front of the vehicle to allow more room under the wheel arch, secure with chassis stands.

Tools Used:

• Hoist

• Jack

• Chassis Stands

• Wheel Brace

Step 2

1. Remove wheel arch liner (A). Retain Scrivet, screws and nuts.

2. Partially separate Fender Flare (B) at rear.

Tools Used:

• Trim Clip tool

• 14 mm Socket

Step 3

1. Remove & retain 3 x10 mm airbox mounting bolts, loosen hose clamp and remove flow sensor plug.

2. Unclip the hose sensor wire from the air filter housing.

3. Cover engine inlet to prevent foreign material ingress.

Tools used:

• 10mm Socket

• Phillip's head screw driver

• Trim clip tool

Step 4

1. From under the LHS wheel arch remove the OE Duct (C) 4 clips.

2. Discard the OE duct assembly (C).

3. From under the LHS wheel arch, remove and discard the foam insert shown (D).

Tool used:

• Trim remover tool

Step 5

1. Remove foam pad (E) from the door hinge area (keep). Mark and cut the foam off as per the dimensions below.

2. Apply the EPDM tape (24) provided to the cut area.

Tool used:

• Utility knife

Step 6

1. Cut out the drilling template (22) and fit the template to the front LHS fender making sure it is aligned correctly with the door and top edges.

2. Secure the cut template with masking tape. Center Punch each hole location.

3. Using a 3 mm drill bit, drill a pilot hole in all marked locations.

4. Drill the 121 mm hole in the correct position as per the template.

5. Drill the remaining 3 holes to 14 mm with 3 mm drill bits.

IMPORTANT:

• Check scale of template is correct before cutting.

• Use 5 mm drill stopper to avoid any damages to the vehicle.

• Cut template all around.

• Align with the fender.

Tools Used:

• Scissors

• Masking Tape

• Drill

• Center Punch

• 3mm Drill Bit

• Step Drill

• 121 mm Hole Saw

• Hammer

• Drill Stopper

Step 7

1. Remove burr from all holes.

IMPORTANT:

• Treat all raw exposed edges with a rust preventative product.

Tools Used

• Deburring Tool

• Paint Brush

Step 8

Positioning of the “A” pillar bracket (2) on the vehicle:

1. Place masking tape to the LHS "A" pillar & along the belt molding area to prevent potential damage to the vehicle.

2. Install A-Pillar bracket (2) to Snorkel body (18).

3. Fit studs/grub screws (9) to upper & forward positions of the snorkel body (18). (Recommend torque. 10 N.m).

4. Fit gasket (15) to snorkel body (18).

Tools Used:

• Masking Tape

• 5 mm Allen Key

Step 9

1. Locate the snorkel body (18) on the vehicle.

2. Align the snorkel body to ensure an even gap to the door. This will determine the position of the “A” pillar bracket (2).

3. Hold the snorkel body firmly against the fender and position the top bracket on the “A” pillar.

4. Using the top bracket as a guide, mark the 2 hole positions on the “A” pillar, keeping approx.18 mm from the lower “A” pillar edge.

Important:

• Open & close the door to ensure no interference.

• Do not bolt the snorkel body in place.

• Remove the snorkel body and bracket and check that the previously marked hole locations on the “A” pillar line up with the holes in the bracket.

Tools Used:

• Machinist Scribe

Step 10

1. Remove snorkel body from vehicle. Centre punch the previously marked holes locations in the “A” pillar.

2. Using a 7.5 mm drill bit, drill the 2 holes in the “A” pillar. Debur and apply rust prevention/paint.

3. Apply a liberal amount of neutral cure silicone to the 2 holes in the “A” pillar. Fit rivet nut (11) to “A” pillar. Wipe off excess silicone.

Important:

• Use 5 mm. drill stopper to avoid any damages to the vehicle

Tools Used:

• Centre Punch

• 7.5 mm Drill Bit

• Caulking Gun

• Primer and Touch up Paint

• Nutsert Gun tool

• Drill stop

Step 11

Remove “A” pillar bracket (2) from snorkel body

1. Peel the backing tape off the Foam Pad (3) & stick to the “A” pillar bracket surface which will contact the “A” pillar.

2. Put the bracket on the “A” pillar and fix with the M5 screw (12) to the rivet nut. (Recommend torque. 5 N.m).

3. The bracket should be positioned approx.18 mm from the lower edge of the “A” pillar.

Tools used:

• Allen key

Step 12

1. Apply silicone to the outside of the snorkel body outlet flange.

2. Fit the snorkel body (18) to the vehicle and secure the snorkel body to the “A” pillar bracket (2).

3. Tighten the snorkel body at the “A” pillar & inside the inner guard using:

"A" pillar:

• M8x16 Button head screw(6), spring washer (21) and flat washer (Black) (20).

Inside inner guard:

• M8 x16 Hex bolt (10), spring washer (8) and flat washer (7), 2 x M8 nyloc Hex Nut (14) with flat washer OD 32 mm (13). (Recommended torque = 10 N.m).

• Refit foam pad from step 5.

Tip : Access is near the bonnet hinge to tighten the top nut.

Tools used:

• Ratchet Spanner 13 mm

• Allen keys

Step 13

1. Add silicone to the intermediate tube (19).

2. From under the LHS wheel arch insert the intermediate tube by sliding the intermediate tube through the engine bay side wall.

3. Push the intermediate tube (19) onto the snorkel body (18) so it clips into place.

Important:

• Be careful to avoid damage to the paint or glass.

Tip:

• Use a lever or large screw driver to clip the intermediate tube onto the snorkel body. Access is near the bonnet hinge.

Tools used:

• Neutral cure silicone

• Caulking gun

• Large flat blade screwdriver

Step 14

1. Apply a liberal amount of neutral cure silicone to the joining surfaces -i.e. to the intermediate tube (19) & both ends of the connection tube (17).

2. Insert the connection tube (17) into the intermediate tube (19).

3. Remove excess silicone.

4. Remove the cover added to the intake tube in Step 3.

5. Apply silicone to the air filter housing inlet flange & position in place.

6. Refit the airflow meter intake hose.

7. Refit the airbox, tighten bolts.

8. Refit the airflow meter wiring clip into the airbox housing and tighten the hose clamp.

9. Refit the connector.

Tools Used:

• Socket Set

• Trim Clip tool

Step 15

1. Loose fit intermediate Brackets (4) & (5) in 2 places by using M8x16 Hex bolt (10), flat washer (7) and spring washer (8).

2. Fit the intermediate bracket (4) to the vehicle bracket by reusing the original clips.

3. Tighten the bolts on both brackets.

4. Refit inner fender and wheel arch flare from step 2.

Tools Used:

• Socket Set

• Trim Clip tool

Step 16

1. Fix the Ram head (1) on top of the snorkel with 2x M5 x 10 mm screws (16).

IMPORTANT:

• Do not use silicone on this joint.

Tools Used:

• Allen key

  
  

Step 17

1. Start the engine, check for air leaks & there are no warning lights.

2. Road test to check for vibrations.

Important:

• Place the Fitting Instruction in the glove box after installation is complete.

Congratulations! you have completed installing your Genuine KIA Snorkel on your Tasman.

Thank you.