Cold Air Intake for Ford Explorer Sport (2013-2019) 3.5L V6 Turbo Engine

The Wrench Time: 2013-2019 Ford Explorer 3.5L

• Estimated Time: 45-60 Minutes
• Difficulty: 3/10 - This is a straightforward driveway bolt-on, but requires patience with the brittle 3.5TT EcoBoost factory plastic clips and delicate sensors.

Tools You Will Need

• 10mm deep socket and ratchet (Battery terminal, factory airbox mount)
• 8mm and 7mm sockets (OEM worm gear clamps)
• T20 Torx bit (IAT sensor transfer)
• Panel popper tool (Push-pins on the factory air scoop)
• Silicone spray (To lubricate aftermarket silicone couplers)

Phase 1: Removing the Factory Part

1. Disconnect the Battery: Always start by disconnecting the negative battery terminal using a 10mm socket to prevent check engine lights and allow the ECU to reset its airflow learned values.
2. Remove the Fresh Air Scoop: Use your panel popper tool to pry up the two plastic push-pins securing the factory fresh air intake scoop to the radiator support. Lift the scoop out and set it aside.
3. Unplug the IAT Sensor: Locate the Intake Air Temperature (IAT) sensor on the side of the main factory intake tube. Press the release tab on the wiring harness and pull the plug straight back. Tuck the wire harness out of the way.
4. Disconnect the PCV Hose: Locate the hard plastic PCV line tapping into the intake tube. Depress the locking tab fully and slide the fitting off the intake port. Be extremely gentle with this EcoBoost-specific plastic.
5. Loosen the Clamps & Remove the Airbox: Use your 8mm or 7mm socket to loosen the worm gear clamps securing the factory corrugated tube to the twin turbo inlet pipes. Next, use your 10mm socket to remove the single retaining bolt securing the lower airbox to the driver’s side fender well. Pull the entire factory intake assembly firmly upward to pop it out of the lower rubber mounting grommets.

Phase 2: Installing the Cold Air Intake for Ford Explorer Sport

1. Transfer the IAT Sensor: Using your T20 Torx bit, remove the factory fasteners holding the IAT sensor in the OEM tube. Gently twist and pull the sensor out. Do not touch the delicate internal sensor tip. Slide the sensor into the port on your new intake tube and secure it using the supplied aftermarket hardware.
2. Install the Heat Shield: Drop the new airbox or heat shield into place, ensuring the bottom pegs seat fully into the factory rubber floor grommets. Bolt it down to the fender well using your 10mm socket and the original factory bolt.
3. Mount the Silicone Couplers: Slide the new silicone couplers over the factory turbo inlet pipes. If the fit is excessively tight, spray a tiny amount of silicone spray on the inside lip. Slip the provided hose clamps over the couplers but keep them loose.
4. Install the Intake Tube: Guide the new Cold Air Intake tube through the heat shield and into the silicone couplers. Once seated properly, use an 8mm socket to tighten all hose clamps. Snug them down so the tube won’t pull out under boost, but do not overtighten and crush the factory plastic inlets.
5. Connect Hardware and Filter: Push the factory PCV hose onto the new tube’s aluminum port until you hear a definitive click. Plug the wiring harness back into the IAT sensor. Finally, slide the high-flow air filter onto the tube inside the heat shield and lock it down tightly with an 8mm socket.
6. Perform the Relearn Startup: Reconnect the negative battery terminal using your 10mm socket. Start the engine. Do not touch the gas pedal for at least 20 seconds. Let the vehicle idle so the ECU can calibrate to the increased airflow of the 3.5L Twin Turbo without throwing a check engine code.

Disclaimer: This is a general guide provided for the 2013-2019 Ford Explorer 3.5L. Always refer to your factory service manual for exact torque specifications and safety procedures.