View Full Version : AEV 2nd gen snorkel install
Jeep'ers
09-02-2013, 01:56 PM
I received my AEV gen2 snorkel on Thursday from Jeep konnection, great guys to deal with and highly recommend them!! Too bad they are no longer vendors on this site!But, Thursday night the snorkel was on and functioning... A very easy job to do (If you have the balls to cut a big arse hole in your hood) and the instructions we clear and relatively easy to follow (I printed out two sets to make sure I had the right size stencil and to reread everything)... So here is the story of how I did it and ill include pictures of each stage.
As handy tips and tricks watch the AEV gen 1 installs on YouTube before you attempt this as it is quite scary if you haven't already done one before, this being my second snorkel install onto a jeep. There isnt much difference in the installs between gen 1 and 2.
here is a link to the AEV gen2 install instructions:
http://aev-conversions.com/isheets/aev_jk_snorkel.pdf
http://img.tapatalk.com/d/13/02/09/6ytyveju.jpg
http://img.tapatalk.com/d/13/02/09/5u8urypa.jpg
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Jeep'ers
09-02-2013, 02:13 PM
I first made sure that I had all the bits I needed to glue, cut, insulate, cover etc etc so here is a list of things
Sikaflex 227
http://img.tapatalk.com/d/13/02/09/ame9ajyn.jpg
Heat resistant black paint
http://img.tapatalk.com/d/13/02/09/edy5used.jpg
18volt drill which meant it wouldn't kick out on me like a power drill would as I could set the clutch on it.. Learned that one out the hard way with my previous jeep as the power drill kicked out on two of us holding the damn thing and it cut the aircon pipe.. I also had a small angle grinder with a cutting wheel... A dremel or a drill nibbler would do the job too
You need a hole saw drill bit I think it was a 45mm hole saw bit (it is specified in the instructions)
http://img.tapatalk.com/d/13/02/09/a5uzupab.jpg
And tape to stop paint chopping when cutting and to stop over spray, I used the blue stuff from bunnings
http://img.tapatalk.com/d/13/02/09/te3a6eda.jpg
You'll also need a 12mm spanner or long reach socket and the right sized allan key. You'll need a T40 torx bit to get the body pannel bolts out...
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Jeep'ers
09-02-2013, 02:21 PM
To start make sure you read through your instructions at least twice before starting and have watched the videos on YouTube to give you a good idea...
On the back page of the instructions is the cut out stencil you'll need to use to cut the holes and mark up the drill spots. You need to make sure this has been printed to size. At the bottom of the same page is a square with measurements next to it... Make sure it measures the exact length as this means the cut out is the right size!! It should measure a square one inch which is 25.4mm.. If it is the right size cut it out!!
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Jeep'ers
09-02-2013, 02:34 PM
Prepare your car now first move the hood about 150mm away from the body and cover everything with a blanket or towel etc i propped up the hood with four old towels
http://img.tapatalk.com/d/13/02/09/a4ypy8u3.jpg
I then taped off the entire area where the cut is going to be with tape
http://img.tapatalk.com/d/13/02/09/ugyja2a8.jpg
And then measure exactly what the instructions say to measure from the angle where the latch is to the start of the stencil.
http://img.tapatalk.com/d/13/02/09/a6ujuta7.jpg
I had a conversation with another jeeper who was going to install his but he seemed to think the cut would be too short however I found the cut slightly bigger however the black guard is going to cover this eventually as seen in previous pic..
Tape the stencil in place measure it a few times!! If in the correct spot use a sharp punch to mark the where the pilot hole needs to be drilled on the stencil... Drill the holes through both panels.. On the new 3.6s you'll find that the heat shield clip might cause you grief, don't worry it will be cut off anyway..
http://img.tapatalk.com/d/13/02/09/5eje5e3u.jpg
Once the two 45mm holes have been cut through both panels get the grinder and start the cuts..
http://img.tapatalk.com/d/13/02/09/y2ady5u4.jpg
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Jeep'ers
09-02-2013, 02:43 PM
http://img.tapatalk.com/d/13/02/09/qabuqeja.jpg
Once the hole is cut you'll need to cut the under panel of the hood slightly bigger... Following the instructions use your finger as a guide to make a line to make a cut just above the first fold
http://img.tapatalk.com/d/13/02/09/ugajy4a6.jpg
When done and painted it should look like this..
http://img.tapatalk.com/d/13/02/09/ezezyvyv.jpg
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Jeep'ers
09-02-2013, 02:56 PM
While waiting for the paint you need to remove the air box... On the 3.6 there are a few bolts to remove. The first is next to the factory "snorkel" on the left hand side along where the power steering fluid bottle is and then remove the bolts for the air intake long the radiator
http://img.tapatalk.com/d/13/02/09/aruhaqem.jpg
http://img.tapatalk.com/d/13/02/09/yhy6e3yr.jpg
Then loosen the the clamps on the engine and the air box and move the inlet pipe..
http://img.tapatalk.com/d/13/02/09/3aju5e3u.jpg
http://img.tapatalk.com/d/13/02/09/e2ery9y2.jpg
http://img.tapatalk.com/d/13/02/09/a7yzu6ed.jpg
Once the intake pipe and the inlet pipe, and all three bolts removed and kept somewhere safe, remove the air box..
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Jeep'ers
09-02-2013, 03:01 PM
I don't have pictures of the air box bit but basically in the 3.6 you have to remove the pop rivets in the oEM snorkel and squirt a fair amount of silicone into the intake when inserting the snorkel. Once in, there are marked holes in the snorkel needing to be drilled out and new pop rivets put in.. Then go nuts with the sikaflex everywhere there is a crease on the intake inside and out seal it and let it dry for a short while!!
http://img.tapatalk.com/d/13/02/09/e6use7eh.jpg
http://img.tapatalk.com/d/13/02/09/pe2ejuna.jpg
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Jeep'ers
09-02-2013, 03:08 PM
Now remove the bolts holding the panels onto the body and then remove the two too bolts above the mirror..
http://img.tapatalk.com/d/13/02/09/uzaje6a3.jpg
http://img.tapatalk.com/d/13/02/09/8a4e5etu.jpg
Once the sikaflex has has formed a set layer, apply the brackets to the snorkel but I noticed the washers were too small and kept falling through so I bought these..
http://img.tapatalk.com/d/13/02/09/yry7ujur.jpg
http://img.tapatalk.com/d/13/02/09/2abyhyby.jpg
http://img.tapatalk.com/d/13/02/09/matyju2y.jpg
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Jeep'ers
09-02-2013, 03:14 PM
Fit the snorkel to the car and push the air box back into its sitting holes.. I also sealed the one of two drain holes in the air box and tighten up all bolts..
http://img.tapatalk.com/d/13/02/09/adate8az.jpg
http://img.tapatalk.com/d/13/02/09/e6u6ybaz.jpg
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Jeep'ers
09-02-2013, 03:17 PM
Drop the hood and then using the sticky tape adjust the black cover to where you would like it and then drill and pop rivet it in place and final touch up paint here and ther and she's all done!!
I have a pop riveter attachment for my drill seeings how im building a trailer as well and this makes pop riveting soooo much easier... 70 bucks from bunnings (I dont know the technical name for it but it stops me having to squeeze)
http://img.tapatalk.com/d/13/02/09/yneraset.jpg
http://img.tapatalk.com/d/13/02/09/e3uzu7yn.jpg
http://img.tapatalk.com/d/13/02/09/qeqaja5e.jpg
And you are done..
http://img.tapatalk.com/d/13/02/09/paju4a2e.jpg
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4WD4FUN
09-02-2013, 03:58 PM
Nice install and description:D, where did you get the AEV Gen 2 snorkel or did you import direct from O/Seas.
Jeep'ers
09-02-2013, 08:51 PM
Nice install and description:D, where did you get the AEV Gen 2 snorkel or did you import direct from O/Seas.
From jeep konnection but I preordered months ago...
DBOR may have them, I know CRDstu was bringing some in and not sure if Wooders might be bringing some in...
You wont need to cut if you have the AEV heat reduction hood, that is on the cards for me but only when she who must be obayed gives me the go ahead
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4wd man
11-02-2013, 10:08 AM
Well done Jeep'ers. Nice work and very good write up. Here's a few pics of mine:
Jeep'ers
11-02-2013, 10:20 AM
Nice work mate looks well done!! Have you noticed a marked difference in power in yours?
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4wd man
11-02-2013, 10:20 AM
More pics attached. Overall it wasn't hard but it took me quite a while to get it done. I started off drilling the holes with a hole saw but then decided to do the whole lot with a dremmel which I found to be easier to handle and more precise with the cut...
Jeep'ers
11-02-2013, 10:21 AM
A good way to test for leaks is to attach a piece of paper to the snorkel ram and if it stays there under idle its correctly sealed
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4wd man
11-02-2013, 10:43 AM
Nice work mate looks well done!! Have you noticed a marked difference in power in yours?
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Thanks mate. I did notice an increase in power but I can't prove it! The interesting thing about that is when I had a TJM snorkel installed on the Suzuki Jimny I could feel a DECREASE in power and at high revs the snorkel gets very noisy sucking in air. The opening at the top of the TJM snorkel is only 2 3/4" while for the AEV it's 4" but then again you can't compare the air intake requirements of a 1.3L engine with a 3.6L. It will be interesting to find out if those who had an AEV Gen1 (3" opening) installed on their 3.6L notice an increase and hopefully not a decrease in power...
4wd man
11-02-2013, 10:54 AM
A good way to test for leaks is to attach a piece of paper to the snorkel ram and if it stays there under idle its correctly sealed
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Ah, just a word of caution, I've read somewhere that blocking the air ram is not a good idea to test for leaks since it could have the opposite effect by blowing a seal, squashing the intake tubing and engine warning lights going off, etc. Not sure if that's true but I personally won't risk it but even the guys at the 4wd training centre recommended the plastic bag over air ram test for leaks...
Wrangler_Scott
11-02-2013, 11:14 AM
I'd like to get one of these Snorkels but don't have the guts to take to my new Jeep with an angle grinder. Where would be a good place in Sydney to it to and have it installed?
Jeep'ers
12-02-2013, 11:11 AM
I'd like to get one of these Snorkels but don't have the guts to take to my new Jeep with an angle grinder. Where would be a good place in Sydney to it to and have it installed?
I'll do it for ya and help you out....
Jeep'ers
12-02-2013, 11:12 AM
Ah, just a word of caution, I've read somewhere that blocking the air ram is not a good idea to test for leaks since it could have the opposite effect by blowing a seal, squashing the intake tubing and engine warning lights going off, etc. Not sure if that's true but I personally won't risk it but even the guys at the 4wd training centre recommended the plastic bag over air ram test for leaks...
Don't like the plastic bag idea but having a sheet of paper on there for a second or two means there's no leaks:p:hammer:
LeighP
26-11-2014, 01:21 PM
Just fitted my Gen II AEV snorkel.....thought I'd throw in a few comments/pics.
I used a 1 3/4" (44mm) hole saw.....bought a decent quality one, and it shows...made short work of cutting 4 layers of hood steel.
http://i104.photobucket.com/albums/m195/TA76400/Wrangler/snorkelc_zpsc37e5fa6.jpg (http://s104.photobucket.com/user/TA76400/media/Wrangler/snorkelc_zpsc37e5fa6.jpg.html)
Cut out the shape using an air driven disc cutter (one of my handier tool purchases), both inside and outside profiles. Ground the edges to remove the burrs.
http://i104.photobucket.com/albums/m195/TA76400/Wrangler/snorkelf_zps959cf93e.jpg (http://s104.photobucket.com/user/TA76400/media/Wrangler/snorkelf_zps959cf93e.jpg.html)
Daniel from Trax Industries (who supplied the snorkel and price matched for me) also suggested using electrical split conduit to edge the inner cut and retain the hood soundproofing.
http://i104.photobucket.com/albums/m195/TA76400/Wrangler/snorkelj_zpsfdd8408f.jpg (http://s104.photobucket.com/user/TA76400/media/Wrangler/snorkelj_zpsfdd8408f.jpg.html)
When fitting he outside trim, I painted the edges and up under the trim piece Satin Black....so no body colour would show when the hood was closed.
http://i104.photobucket.com/albums/m195/TA76400/Wrangler/snorkelk_zps71fa224f.jpg (http://s104.photobucket.com/user/TA76400/media/Wrangler/snorkelk_zps71fa224f.jpg.html)
http://i104.photobucket.com/albums/m195/TA76400/Wrangler/snorkell_zps96f9114b.jpg (http://s104.photobucket.com/user/TA76400/media/Wrangler/snorkell_zps96f9114b.jpg.html)
Looks good, fits properly.
http://i104.photobucket.com/albums/m195/TA76400/Wrangler/snorkelo_zps07995fea.jpg (http://s104.photobucket.com/user/TA76400/media/Wrangler/snorkelo_zps07995fea.jpg.html)
Couple of points I found....
1. I had to trim about 3/16" more steel off the rear vertical cutout than the stencil suggested....the cutout would hit the snorkel while closing, even with the snorkel pushed as far forward as possible.
2. The antenna.....I figured that I was destined to listen to the antenna whacking the top of the snorkel intake on a regular basis, so I zip tied the antenna whip to the top of the snorkel.
http://i104.photobucket.com/albums/m195/TA76400/Wrangler/snorkelm_zps89fdf49f.jpg (http://s104.photobucket.com/user/TA76400/media/Wrangler/snorkelm_zps89fdf49f.jpg.html)
Dizzyh
27-11-2014, 06:27 AM
2. The antenna.....I figured that I was destined to listen to the antenna whacking the top of the snorkel intake on a regular basis, so I zip tied the antenna whip to the top of the snorkel.
http://i104.photobucket.com/albums/m195/TA76400/Wrangler/snorkelm_zps89fdf49f.jpg (http://s104.photobucket.com/user/TA76400/media/Wrangler/snorkelm_zps89fdf49f.jpg.html)
Neat trick!
Looks good ;)
LeighP
27-11-2014, 01:12 PM
Thanks. :)
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