aFe POWER Explorer ST BladeRunner Hot Side Charge Pipe Kit Instruction Manual

: September 6, 2024
: aFe POWER

Table of Contents

Explorer ST BladeRunner Hot Side Charge Pipe Kit
Product Information
Specifications:
- Product Usage Instructions
Installation Tools Required:
Warranty Information:
Emissions Disclaimer:
- Frequently Asked Questions (FAQ)
Q: Can this product be used on a Ford Aviator?
Q: What is the procedure for disconnecting the negative battery

Explorer ST BladeRunner Hot Side Charge Pipe Kit

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Product Information

Specifications:

Make: Ford
Model: Explorer ST
Year: 20-21
Engine: V6-3.0L (tt)
Part Numbers: 05-61315B, 05-61316B, 05-61275, 05-60940,
05-61318, 05-61319, 03-50655, 03-50656, 03-50241, 03-50177,
03-50029

Product Usage Instructions

Installation Tools Required:

7mm, 8mm, 10mm, 13mm sockets
5mm allen, 3/16 allen
Extensions, ratchet
Plastic panel popper, flat screwdriver, pick
Teflon tape

Warranty Information:

Warranty information can be found at here.

Emissions Disclaimer:

This product is not currently CARB exempt and is not available
for purchase in California or for use on any vehicle registered
with the California Department of Motor Vehicles.

Frequently Asked Questions (FAQ)

Q: Can this product be used on a Ford Aviator?

A: Yes, this product is compatible with the Ford Aviator model
year 20-21 with a V6-3.0L (tt) engine.

Q: What is the procedure for disconnecting the negative battery

cable?

A: To disconnect the negative battery cable, follow these
steps:

Refer to Figure A for Steps 1-3.
Remove the screws securing the factory strut tower brace onto
the vehicle and remove the brace.
Loosen the two clamps securing the passenger side turbo inlet
tube into the vehicle and remove it.

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BladeRunner Hot Side Charge Pipe Kit

Instruction Manual P/N: 46-20658-B

Make: Ford

Model: Explorer ST Year: 20-21

Engine: V6-3.0L (tt)

Make: Ford

Model: Explorer

Year: 20-21

Engine: V6-3.0L (tt)

Make: Ford

Model: Aviator

Year: 20-21

Engine: V6-3.0L (tt)

· Please read the entire instruction manual before proceeding.
· Ensure all components listed are present. · For technical support please call 951-493-7185. · Ensure you have all necessary tools before proceeding. · Do not attempt to work on your vehicle when the engine is hot. · Retain factory parts for future use.

Label Qty. UoM Description A 1 Ea. Tube, DS Hot Side: 46-2065X-B B 1 Ea. Tube, PS Hot Side: 46-2065X-B C 1 Ea. Coupling, Silicone Rdr Elbow 2.25″ x 1.50″ 45 Deg D 1 Ea. Coupling, Silicone Straight: 2.30″ x1.85″ x3.50″L E 1 Ea. Coupling, Silicone Elbow: 2.25″ x 40 Deg F 1 Ea. Coupling, Silicone Hump: 2.50″ x 3″L G 2 Ea. Clamp, SmartSeal, 032 (1.94″ 2.31″) H 6 Ea. Clamp, SmartSeal, 044 (2.50″ 3.06″) J 5 Ea. Screw, Socket Head Cap: M6x1.0x20, S/S K 5 Ea. Washer, M6 (12mm OD x 6.4mm ID) M 2 Ea. Plug, Hex Hd Socket: 1/8″ NPT (Zn Plt)

Part Number 05-61315B 05-61316B 05-61275 05-60940 05-61318 05-61319 03-50655 03-50656 03-50241 03-50177 03-50029

Installation will require the following tools:
7mm, 8mm, 10mm, 13mm sockets , 5mm allen, 3/16″ allen, extensions, ratchet, plastic pannel popper, flat screwdriver, pick, teflon tape.
Warranty Information available at https://afepower.com/contact#warranty

Emissions Disclaimer: This product is not currently CARB exempt and is not available for purchase in California or for use on any vehicle registered with the California Department of Motor Vehicles.

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Page 3

1 3

2 3

REMOVAL

Figure A
Refer to Figure A for Steps 1-3
Step 1: Disconnect the negative battery cable 1. Step 2: Remove the screws securing the factory strut tower brace onto the vehicle 2, and remove the brace. Step 3: Loosen the two clamps securing the passenger side turbo inlet tube into the vehicle, then remove it
3.

Page 4

REMOVAL
6 5
4
6
Figure B
Refer to Figure B for Steps 4-6
Step 4: Loosen the clamp securing the driver side turbo inlet tube to the intake air box, then disconnect it 4. Step 5: Disconnect the air intake temperature sensor harness from the sensor on the intake air box 5. Step 6: Unclip the air intake sensor wire harness from the mounting screw and intake air box lid 6
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8 9

REMOVAL
7

Figure C
Refer to Figure C for Steps 7-9
Step 7: Remove the nut securing the intake air box into the vehicle 7. Step 8: Lift upwards on the factory intake air box to disconnect it from the lower mounting grommets 8. Step 9: Disconnect the intake air scoop from the bottom half of the factory air box by firmly pulling the
connection apart 9.
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14 10
13

REMOVAL
TAP

12
10 11
Figure D
Refer to Figure D for Steps 10-15
Step 10: Disconnect the intercooler pressure line from the intercooler by releasing the security tab and disconnecting it 10.
Step 11: Remove the screw securing the coolant reservoir to the vehicle 11. Step 12: Place a plastic pry tool between the reservoir and the fan shroud mount, and gently tap the coolant
reservoir towards the passenger side to disconnect it from the vehicle 12. Step 13: Loosen the clamp securing the factory cold side charge pipe to the intercooler 13. Step 14: Lift the coolant reservoir and remove the nut securing the factory cold side charge pipe mounting
bracket to the vehicle 14. Step 15: Loosen the clamp securing the factory cold side charge pipe to the throttle body, then remove the
charge pipe from the vehicle.
Page 7

REMOVAL
17 15
16 16
Figure E
Refer to Figure E for Steps 16-18
Step 16: Remove the screw securing the ground strap onto the vehicle 15. Step 17: Disconnect the EVAP hose from the turbo inlet tube. It should have an orange tag on it 16. Step 18: Loosen the clamp securing the driver’s side hot charge pipe onto the turbo 17.
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REMOVAL

22

21

20

19

18

Figure F
Refer to Figure F for Steps 19-24
Step 19: Release the security tab on the electrical connector for the bypass control valve by sliding it back then disconnect it 18.
Step 20: Remove the screws securing the bypass control valve onto the driver’s hot side charge pipe 19 and remove it from the vehicle. Disconnect the bypass control valve hose from the hot side charge pipe.
Step 21: Remove the screw securing the driver’s side hot charge pipe to the intake mount 20. Step 22: Loosen the clamp securing the hot side charge pipe merge coupling to the driver’s side hot charge
pipe and disconnect 21. Step 23: Disconnect the driver’s side hot charge pipe from the turbo and remove the pipe from the vehicle. Step 24: Loosen the clamp securing the driver’s side hot charge pipe coupling to the merge tube and
remove the coupling from the vehicle 22.
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26 25
23

REMOVAL
24

Figure G
Refer to Figure G for Steps 25-28
Step 25: Disconnect the middle ECU harness connector from the ECU 23. Step 26: Disconnect the clip securing the harness to the passenger side hot charge pipe 24. Step 27: Disconnect the electrical connector shown above 25. Step 28: Disconnect the clip securing the harness from above to the ECU mounting bracket and lay the
entire harness over the engine 26.
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28 27

REMOVAL

29

Figure H

30

Refer to Figure H for Steps 29-33
Step 29: Remove the screw securing the passenger side hot charge pipe onto the engine 27. Step 30: Loosen the clamp securing the passenger side hot charge pipe coupling to the turbo 28. Step 31: Loosen the clamp securing the passenger side hot charge pipe coupling to the merge tube 29. Step 32: Remove the passenger side hot charge pipe from the vehicle. Step 33: Loosen the clamp securing the hot side merge tube to the intercooler and remove it from the
vehicle 30.

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31 32

INSTALL
31

Figure I
Refer to Figure I for Steps 34-35
Note: Be sure to use thread sealant on the plugs or sensors to prevent any leaking
Step 34: If you are not using any aftermarket sensors, install the supplied 1/8″ NPT plugs into the threaded fittings on the aFe POWER driver’s and passenger side hot charge pipes 31
Step 35: Install the supplied aFe POWER silicone hump coupling, 2.50″x 3″L, 32 and one of the supplied 044 SmartSeal clamps onto the end of the aFe POWER passenger side hot charge pipe, do not tighten the clamp yet.
Note: Be sure to thoroughly clean all oil residue off of the connections before installing any of the aFe couplings onto the vehicle.
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INSTALL
33
35
34
36
Figure J
Refer to Figure J for Steps 36-39
Step 36: Install the supplied aFe POWER silicone reducer elbow coupling 2.25″x 1.50″ x 45 Deg and one of the supplied 032 SmartSeal clamps onto the passenger side turbo 33, do not tighten the clamp yet.
Step 37: Install your aFe POWER passenger side hot charge pipe along with one of the supplied 044 SmartSeal clamps on each end 34. Install it by connecting to the turbo coupling then to the intercooler, do not tighten the clamps yet.
Step 38: Adjust the couplings as needed and secure the charge pipe with one supplied M6 x 1 x 20 screw and M6 washer 35, then tighten all of the clamps for the passenger side hot charge pipe..
Step 39: Install the supplied aFe POWER silicone elbow coupling 2.25″x 40 Deg along with one 044 SmartSeal clamp onto the lower tube of the passenger side hot merge tube 36, do not tighten the clamps yet.
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38 37
38

INSTALL
39

Figure K
Refer to Figure K for Step 40-42
Step 40: Install the supplied aFe POWER silicone reducer coupling 2.30″ x1.85″ x3.50″L and one supplied 032 SmartSeal clamp onto the driver’s side turbo 37, do not tighten the clamp yet.
Step 41: Install your aFe POWER driver’s side hot charge pipe along with one supplied 044 SmartSeal clamp on each end 38. Install it by connecting to the turbo coupling then to the lower coupling on the passenger side hot merge tube, do not tighten the clamps yet.
Step 42: Adjust the couplings as needed and secure the charge pipe with one supplied M6 x 1 x 20 screw and M6 washer 39, then tighten all of the clamps for the driver’s side hot charge pipe.
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INSTALL
38
41 40
Figure L
Refer to Figure L for Step 43-44
Step 43: Install the bypass control valve with three of the supplied M6 x 1 x 20 screw and M6 washers and reconect the electrical connector and secure the security tab 40.
Step 44: Install the bypass hose onto your aFe POWER driver’s side hot charge pipe 41.
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INSTALL
43 45
44 42
Figure M
Refer to Figure M for Steps 45-50
Step 45: Reinstall the cold side charge pipe into the vehicle, adjust the couplings and tighten the clamps. Step 46: Secure the cold side charge pipe with the factory nut. Step 47: Reconnect the intercooler pressure line to the intercooler and secure the security tab 42. Step 48: Secure the ground strap back into place 43. Step 49: Reinstall the coolant reservior into its mounting tab and secure it using the factory screw 44. Step 50: Reconnect the EVAP hose to the turbo inlet tube 45.
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47
46
47 50

51
49 50
48

INSTALL

Figure N
Refer to Figure N for Steps 51-58
Step 51: Reinstall the passenger side turbo inlet tube into the vehicle 46. Step 52: Reconnect the electrical connections on the ECU harness and secure them to the aFe POWER
charge pipe and the ECU mounting bracket 47. Step 53: Reinstall the intake air box to the intake air scoop and secure it into the vehicle 48. Step 54: Reconnect the electrical harness to the intake air temperature sensor and secure the harness back
to the air box 49. Step 55: Secure the air intake tubes to the air box 50. Step 56: Reinstall the strut brace into the vehicle 51. Step 57: Reconnect the negative battery cable. Step 58: Install is now complete.
NOTE: Check all clamps, and connectors are secure after 100-200 miles
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Corona, CA 92879 https://afepower.com/contact