aFe POWER Bronco 2021+ BladeRunner Cold Side Charge Pipe Kit Instruction Manual

aFe POWER Bronco 2021+ BladeRunner Cold Side Charge Pipe Kit

Product Information

• Instruction Manual P/N: 46-20589-B
• Make: Ford
• Model: Bronco
• Year: 2021+

Installation will require the following tools:

• 8mm socket
• 10mm socket
• 15mm socket
• 5mm allen wrench
• 3/16 Allen wrench
• T30 Torx socket
• 6 extension
• ratchet
• pick
• flat head screwdriver
• thread sealant

Warranty Information available at https://afepower.com/contact#warranty

Note: Legal in California for use on race vehicles only. The use of this device on vehicles used on public streets or highways is strictly prohibited in California and other states that have adopted California emission regulations.

Product Usage Instructions

1. Park the vehicle on level ground and engage the parking brake.
2. Disconnect the negative battery cable.
3. Unclip the wire harness from the factory hot side charge pipe on the passenger side of the vehicle in two places.
4. Disconnect the bypass valve actuator connector on the hot side charge pipe by sliding the security tab back, then pressing the tab down and pulling it off the sensor.
5. Disconnect the bypass valve hose on the factory air intake tube by squeezing the ribbed features and pulling upwards on it.
6. Loosen the clamp securing the passenger side hot charge pipe coupling to the turbo.
7. Loosen the clamp securing the passenger side hot charge pipe coupling to the driver side hot charge pipe.
8. Remove the three screws securing the hot side charge pipe to the engine.
9. Release the factory retaining clip securing the hot side chargepipe connection together by sliding the clip back to lock it in theopen position.
10. Remove the passenger side and y-merge portion of the hot side charge pipe from the vehicle.
11. Underneath the vehicle, loosen the two rearward screws securing the skid plate, then remove the four remaining screws from the skidplate and remove it from the vehicle.
12. Release the factory retaining clip from the intercooler connection for the cold side charge pipe on the passenger side of the vehicle and disconnect it from the intercooler.
13. Loosen the two clamps securing the air intake tube from the airbox to the driver’s side turbo.
14. Remove the screw securing the driver’s side air intake tube to the cold side charge pipe.
15. Remove the driver’s side air intake tube from the vehicle.
16. Unclip the wire harness from the factory cold side charge pipe.
17. Disconnect the MAP sensor from the cold side charge pipe.
18. Disconnect the crankcase breather tube from the cold side charge pipe by pressing the white button in and pulling it off.
19. Remove the bolt and nut securing the cold side charge pipe to the bracket on the engine.

• Please read the entire instruction manual before proceeding.
• Ensure all components listed are present.
• If you are missing any of the components, call customer support at 951-493-7100.
• Ensure you have all the necessary tools before proceeding.
• Do not attempt to work on your vehicle when the engine is hot.
• Disconnect the negative battery terminal before proceeding.
• Retain factory parts for future use.

Installation will require the following tools:

• 8mm socket, 10mm socket,15mm socket, 5mm allen wrench, 3/16” allen wrench, T30 Torx socket, 6” extension, ratchet, pick, flat head screwdriver, & thread sealant
• Warranty Information is available at https://afepower.com/contact#warranty.

Note: Legal in California for use on race vehicles only. The use of this device on vehicles used on public streets or highways is strictly prohibited in California and other states that have adopted California emission regulations.

Installation

1. Park the vehicle on level ground and engage the parking brake.

2. Disconnect the negative battery cable.

3. Unclip the wire harness from the factory hot side charge pipe on the passenger side of the vehicle in two places 1.

4. Disconnect the bypass valve actuator connector on the hot side charge pipe 2 .by sliding the security tab back then pressing the tab down and pulling it off the sensor.

5. Disconnect the bypass valve hose on the factory air intake tube 3 by squeezing the ribbed features and pulling upwards on it.

6. Loosen the clamp securing the passenger side hot charge pipe coupling to the turbo 4

7. Loosen the clamp securing the passenger side hot charge pipe coupling to the driver side hot charge pipe 5.

8. Remove the three screws securing the hot side charge pipe to the engine 6.

9. Release the factory retaining clip securing the hot side charge pipe connection together by sliding the clip back to lock it in the open position 7.

10. Remove the passenger side and y-merge portion of the hot side charge pipe from the vehicle.

11. Underneath the vehicle loosen the two rearward screws securing the skid plate then remove the four remaining screws from the skid plate and remove it from Vehicle 8.

12. Release the factory retaining clip from the intercooler connection for the cold side charge pipe on the passenger side of vehicle 9 and disconnect it from the intercooler.

13. Loosen the two clamps securing the air intake tube from the air box to the driver’s side turbo 10.

14. Remove the screw securing the driver’s side air intake tube to the cold side charge pipe 11.

15. Remove the driver’s side air intake tube from the vehicle.

16. Unclip the wire harness from the factory cold side charge pipe 12.

17. Disconnect the MAP sensor from the cold side charge pipe 13.

18. Disconnect the crankcase breather tube from the cold side charge pipe by pressing the white button in and pulling it off 14.

19. Remove the bolt and nut securing the cold side charge pipe to the bracket on the engine 15.

20. Loosen the clamp securing the cold side charge pipe to the throttle body 16.

21. Remove the cold side charge pipe from the vehicle. Note: The retaining clip at the intercooler side of the charge pipe will need to be removed for reuse with the aFe charge pipe.

22. Lift the two metal retainers up enough to slide the retaining clip out of the factory charge pipe and remove the clip 17.

23. Install the factory retaining clip onto the supplied aFe intercooler adaptor with the opening of the clip at the notch in the adaptor 18
    Note: Be sure to lubricate the O-ring with grease to prevent it from tearing during installation.

24. Install the supplied 66mm inner diameter x 5mm width O-ring into the groove on the inside of the aFe intercooler adaptor 19

25. Remove the MAP sensor from the factory cold side charge pipe 20
    Note: Be sure to lubricate the O-ring with grease to prevent it from tearing during installation.

26. Install the factory MAP sensor onto the supplied aFe upper cold side charge pipe using the supplied M6x1.0x20mm screw and M6 washer 21.
    Note: Be sure to use thread sealant on the plug or sensor to prevent any leaking.

27. If you are not using any aftermarket sensors, install the 1/8” NPT plug 22 into the threaded fitting on the aFe upper cold side charge pipe.

28. Install the supplied M6x1 clip nut onto the mounting bracket on the aFe upper cold side charge pipe 23. Note: Be sure to thoroughly clean all oil residue off of the connections before installing any of the aFe couplings onto the vehicle.

29. Install one of the supplied aFe silicone hump couplings 2.75″x 4”L and one supplied 3″ – 3.25″ spring-loaded T-Bolt clamp onto the throttle body 24, do not tighten the clamp yet.
    Note: Be sure to lubricate the O-ring with grease to prevent it from tearing during installation.

30. Install the aFe intercooler adaptor onto the intercooler on the passenger side of the vehicle. Line up the notch on the adaptor with the notch on the intercooler, and ensure the retaining clip snaps into the intercooler all of the way around 25.

31. Install the supplied aFe silicone elbow coupling 2.75″x 90Deg and one 3″ – 3.25″ spring-loaded T-Bolt clamp onto the adaptor from the previous step 26, do not tighten the clamp yet.

32. Install one M6x1 clip nut onto the factory lower cold side charge pipe mounting bracket on the engine 27.

33. Install the aFe upper cold side charge pipe into vehicle 28 along with one 3″ – 3.25″ spring-loaded T-Bolt clamp, do not tighten the clamp yet.

34. Install one aFe silicone hump coupling 2.75″x 4”L and one 3″ – 3.25″ spring-loaded T-Bolt clamp onto the bottom of the aFe upper cold side charge pipe 29, do not tighten the clamp yet.

35. Install the supplied aFe lower cold side charge pipe into vehicle 30, connecting it to the coupling from the previous step and the intercooler coupling from Step 31, along with one 3″ – 3.25″ spring-loaded T-Bolt clamp on each end, do not tighten the clamps yet.

36. Install one M6x1x20 screw with one M6 washer into the vehicle connecting the aFe lower cold side charge pipe to the factory mounting bracket on the engine 31, do not tighten this screw yet.

37. Reinstall the driver’s side air intake tube into vehicle 32, do not tighten the clamps yet.

38. Reinstall the passenger side and y-merge portion of the hot side charge pipe into vehicle 33, do not tighten the clamps yet.

39. Adjust all of the charge pipes so they are not touching anything and lined up with the mounting holes on the vehicle.

40. Ensure the aFe cold side charge pipes are not touching anything and tighten the lower mounting bracket screw 34.

41. Secure the aFe upper cold side charge pipe to the air intake tube with one M6x1x20 screw and M6 washer 35.

42. Secure the passenger side and y-merge charge pipe to vehicle 36.

43. Tighten all of the clamps on the aFe cold side charge pipes, factory hot side charge pipes, and the air intake tube.

44. Reinstall the skid plate onto the vehicle.

45. Reconnect the bypass valve actuator connector on the hot side charge pipe 37, be sure to lock the security tab.

46. Reconnect the bypass valve recirculation hose to the air intake tube 38 to ensure it snaps into place.

47. Connect the crankcase breather hose to the aFe cold side charge pipe 39, and ensure the clip snaps into place.

48. Reconnect the MAP sensor connector and lock the security tab 40.

49. Reconnect the negative battery cable.

50. Install is now complete.

Note: Be sure to check all connections after 50-100 miles

This Page Was Left Intentionally Blank

• 252 Granite Street Corona, CA 92879
• TEL: 951.493.7100
• TECH: 951.493.7100 x23
• E-Mail:[email protected].

References

• Contact US/FAQ | aFe POWER

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