aFe POWER Cold Air Intake System Installation Manual
Applicable Vehicles
| Make | Model | Year | Engine |
|---|---|---|---|
| FORD | F-150 | 2021-2024 | V6-3.5L(tt) |
| FORD | F-150 Raptor | 2021-2024 | V6-3.5L(tt) |
| FORD | EXPEDITION | 2022-2024 | V6-3.5L(tt) |
| LINCOLN | NAVIGATOR | 2022-2024 | V6-3.5L(tt) |
(Note: Does not fit F-150 Equipped with the V6-3.5L(tt) PowerBoost™)
Before You Begin
Important Safety Precautions:
- 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 951-493-7185.
- 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.
Parts List & Tools
| Label | Qty. | Description | Part Number |
|---|---|---|---|
| A | 1 | Air Filter (Black Pro 5R) For 57-10031K | 24-91149K |
| A | 1 | Air Filter (Pro DRY S) For 57-10031D | 21-91149 |
| B | 1 | Tube, Carbon Fiber | 05-5710031C1 |
| C | 1 | Housing | 05-5710010B2 |
| D | 1 | Coupler, Silicone Reducer: (3-1/2" x 3" )ID x 2-1/2"L | 05-01580 |
| E | 1 | Coupler, Silicone Bellow: 4"ID x 2-1/2"L | 05-01399 |
| F | 1 | Clamp, 044 (2-5/16" - 3-1/4") | 03-50019 |
| G | 1 | Clamp, 052 (2-13/16" - 3-3/4 ") | 03-50008 |
| H | 2 | Clamp, 064 (2-1/2"- 4-1/2 ") | 03-50006 |
| J | 1 | Insert, Vent tube | 05-01405 |
| K | 1 | Seal, Trim: 13/32" double bulb (41-1/2" Length) | 05-01534 |
| M | 2 | Retainer Clip, Push-In Style | 03-50773 |
| N | 1 | Quick Disconnect tool: 5/8" | 05-01720 |
Required Tools:
7mm, 8mm, 11mm and 13mm Nut Drivers or Ratchet and Sockets, Flat Head Screwdriver
Removal Procedure
Step 1: Unplug Temperature Sensor Harness
Locate and unplug the temperature sensor harness. This is typically found near the intake system.
Image Description: Shows the engine bay and highlights the temperature sensor harness to be unplugged.Step 2: Loosen Turbo Inlet Clamps
Loosen the two clamps connecting the factory intake tube to the turbo inlet tubes.
Image Description: Shows the engine bay with clamps connecting the intake tube to the turbo inlet tubes highlighted for loosening.Step 3: Unclip Coolant Line
Unclip the coolant line from the factory intake tube.
Image Description: Shows the coolant line attached to the factory intake tube highlighted for unclipping.Step 4: Remove Factory Air Box Components
Unclip the top of the factory air box. Then, remove the factory intake tube, air filter, and the top section of the air box from the vehicle.
Image Description: Shows the factory air box components being unclipped and removed from the vehicle.Step 5: Remove Front Scoop Rivets
Remove the two plastic rivets securing the front scoop of the housing.
Image Description: Shows the location of the two plastic rivets securing the front scoop of the housing.Step 6: Unclip Wire Harness
Unclip the wire harness from the back of the factory air box.
Image Description: Shows the wire harness attached to the back of the factory air box highlighted for unclipping.Step 7: Remove Air Box Mounting Screw
Remove the screw securing the factory air box to the fender. This screw will be reused to secure the new aFe POWER housing.
Image Description: Shows the screw securing the factory air box to the fender, which needs to be removed and saved.Installation Procedure
Step 8: Locate Driver's Side Turbo Inlet Tube
Locate the factory plastic tube feeding the driver's side turbo inlet. This connection is closer to the turbo. The installation of the plastic vent tube insert is important to prevent a check engine light. These procedures should be done with the turbo inlet tubes installed on the engine; the illustration is shown off the vehicle for better clarity.
Image Description: Shows the factory intake tube with vent fittings labeled, identifying the driver's side turbo inlet connection.Step 9: Locate Valve Cover Vent Tube
Locate the valve cover vent tube that feeds into the driver's side turbo inlet. It is not necessary to remove the engine cover.
Image Description: Close-up image showing the valve cover vent tube connecting to the driver's side turbo inlet.Step 10: Check Quick Disconnect Fitting Tab Color
Check the color of the locking tab on the quick disconnect fitting. If the locking tab is orange, proceed to steps 11 and 12. If the locking tab is blue or grey, proceed to step 13.
Image Description: Close-up image of a quick disconnect fitting showing the locking tab, which can be orange, blue, or grey.Step 11: Use Quick Disconnect Tool (Orange Tab)
If the locking tab of the quick disconnect fitting is orange, a quick disconnect tool (commonly used on AC and fuel lines) will be needed to remove it.
Image Description: Close-up image of an orange locking tab on a quick disconnect fitting, illustrating the need for a special tool.Step 12: Disconnect Fitting with Orange Tab
For the fitting with the orange locking tab, slide the provided 5/8" quick disconnect tool over the fitting and push it inside. Rotate the tool and pull the fitting simultaneously to disconnect it.
Image Description: Image demonstrating the use of the quick disconnect tool on the orange locking tab to detach the fitting.Step 13: Disconnect Fitting with Grey/Blue Tab
If the locking tab is grey or blue, apply pressure against the exposed tail of the fitting and pull the vent fitting off the turbo inlet tube. It is not necessary to disconnect at the valve cover end. Be careful, as there is a sensor and wire harness on this vent tube; do not damage or remove these components.
Image Description: Image illustrating how to disconnect a vent fitting with a grey or blue locking tab by applying pressure and pulling.Step 14: Install Vent Fitting onto aFe Intake Tube
Insert the vent fitting onto the aFe POWER intake tube. Ensure the slash cut faces the turbo. It should not be a loose fit and is direction-dependent; it must not rotate once installed.
Image Description: Shows the aFe POWER intake tube with the vent fitting inserted, indicating the correct orientation with the slash cut facing the turbo.Step 15: Reconnect Vent Fitting
Reconnect the vent fitting to its designated port. It will snap into place without needing to release the plastic clip. Pull up slightly to confirm the connection is secure.
Image Description: Image showing the vent fitting being reconnected, with an arrow pointing to the connection point, indicating it will snap into place.Step 16: Complete Vent Tube Installation
The installation of the vent tube is now complete. Any diagnostic trouble codes (DTCs) can be cleared with a code reader or by disconnecting the vehicle's battery. Note that disconnecting the battery will reset radio presets.
Image Description: Visual confirmation that the vent tube installation is complete.Step 17: Install Seal Trim
Install the longer seal trim onto the top edge of the aFe POWER housing.
Image Description: Shows the seal trim being installed onto the top edge of the aFe POWER housing.Step 18: Transfer Factory Grommet and Sleeve
Transfer the factory grommet and sleeve from the original air box to the new aFe POWER housing.
Image Description: Illustrates the process of transferring the factory grommet and sleeve from the old air box to the new housing.Step 19: Install aFe POWER Housing
Install the aFe POWER housing into the truck by pushing it into the factory mounting grommets.
Image Description: Shows the aFe POWER housing being positioned and installed into the vehicle's engine bay, aligning with factory mounting grommets.Step 20: Secure Housing with Factory Screw
Secure the aFe POWER housing using the factory screw that was removed in Step 7.
Image Description: Shows the location where the factory screw is used to secure the aFe POWER housing.Step 21: Secure Front of Housing
Secure the front of the housing using the two provided plastic rivets.
Image Description: Shows the two plastic rivets being used to secure the front of the aFe POWER housing.Step 22: Install aFe POWER Air Filter
Remove the filter clamp from the aFe POWER air filter. Slide the air filter into the aFe POWER housing from the top opening. Guide the filter flange through the round opening in the housing and snap it into place. Place the filter clamp onto the filter flange, but do not tighten it at this time.
Image Description: Shows the aFe POWER air filter being slid into the housing and secured with its clamp.Step 23: Transfer Temperature Sensor
Remove the temperature sensor from the factory intake tube. Transfer it to the fitting onto the aFe POWER intake tube. Turn it clockwise until the tab locks it into place.
Image Description: Shows the temperature sensor being removed from the factory tube and transferred to the aFe POWER intake tube, with an indication of turning it clockwise to lock.Step 24: Install Bellow Coupler
Install the bellow coupler onto the driver side turbo inlet. Place the larger clamps on it but do not tighten them yet.
Image Description: Shows the bellow coupler being installed onto the driver side turbo inlet with clamps.Step 25: Install Reducer Coupler
Install the reducer coupler on the other turbo inlet. Place the clamps on it but do not tighten them at this time.
Image Description: Shows the reducer coupler being installed onto the other turbo inlet with clamps.Step 26: Install aFe POWER Intake Tube
Install the aFe POWER intake tube into the filter flange and connect it to the two couplers (bellow and reducer).
Image Description: Shows the main aFe POWER intake tube being connected to the air filter and the turbo inlet couplers.Step 27: Align and Tighten Clamps
Align the intake tube and filter assembly, then tighten all clamps securely.
Image Description: Shows the complete intake tube and filter assembly in place, with all clamps ready for final tightening.Step 28: Reconnect Temperature Sensor Harness
Reconnect the temperature sensor harness to its port on the intake tube.
Image Description: Shows the temperature sensor harness being reconnected to the intake system.Step 29: Secure Harness Clip
Secure the harness clip into the designated hole on the aFe POWER housing.
Image Description: Shows the harness clip being secured into the housing.Step 30: Final Verification
Verify that all clamps and connections are secured properly. Your installation is now complete. Thank you for choosing aFe POWER!
Image Description: Final overview of the installed aFe POWER Cold Air Intake System in the engine bay, confirming all connections are secure.
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