aFe

BladeRunner intercoolers. aFe's largest category with us. An intercooler cools the air coming out of the turbo before it enters the engine, and cooler charge air is denser and helps keep exhaust gas temperatures in check. BladeRunner GT Series intercoolers are built to replace the factory unit in the stock location, with a larger core than stock. You can buy the intercooler alone or as a kit with matching tubes.

Intercooler kits with tubes. Complete kits that pair a BladeRunner intercooler with aluminum hot and cold side tubes, couplings, and clamps. Tubes come in finishes such as black or red.

Shop aFe Intercoolers

Charge pipe kits. Aluminum hot side and cold side charge pipes that replace factory piping, including 2-1/2 in. hot side pipes for select applications. They're a common upgrade when factory pipes or boots leak, or when you're adding boost.

Coupling and clamp kits. Replacement couplings and clamps for BladeRunner tubes, including kits that connect aFe tubes to a factory intercooler. These are worth replacing during any intercooler service, since worn boots are a common source of boost leaks.

BladeRunner turbochargers. Drop-in replacement and upgrade turbos that bolt into the factory location. aFe turbos typically use billet compressor wheels and revised turbine housings to improve airflow and spool over stock. aFe Turbochargers

Turbo inlets. Vehicle-specific inlet tubes that replace the factory intake path in front of the turbo compressor to reduce restriction. aFe Turbo Inlets

Turbo upgrade components. Individual parts for upgrading an aFe or factory turbo. aFe Turbo Upgrade Components

Intercooler only, kit, or charge pipes?

Choose the intercooler only if your factory tubes and boots are in good shape and you want a larger core without changing the rest of the system.

Choose a kit with tubes if your factory boots leak, you're adding boost, or you want the whole charge path replaced at once. This is typically the most complete fix on trucks with known boot problems.

Choose charge pipes or a coupling kit if the core is fine and the problem is a leaking boot, cracked pipe, or worn clamp.

• Match the exact vehicle. aFe intercoolers and turbos are built for specific years, engines, and body styles. A part for one generation will often not fit the next, even on the same truck model.
• Size the turbo to your goals. A turbo close to stock size typically spools faster and suits towing. A larger turbo typically supports more peak power but spools later and usually needs tuning and fuel system work.
• Build the system together. A larger turbo makes more heat, so pairing it with a larger intercooler and leak-free charge pipes helps keep EGT and intake temperatures under control.
• Plan for tuning. An intercooler or charge pipe upgrade typically works with factory calibration. Turbo upgrades commonly need tuning, and larger turbos typically need upgraded fueling as well.

Installation notes

• Clean before you install. If you're replacing a failed turbo, clean oil and debris out of the intercooler and charge pipes, or replace them. Debris left in the system can damage a new turbo.
• Prime the turbo. Pre-lube a new turbo and crank with fuel disabled to build oil pressure before first start. Replace suspect oil feed and drain lines.
• Seat couplings and torque clamps. Push couplings fully onto the pipe beads and torque clamps evenly. Most boost leaks after an install come from a coupling that slipped or a loose clamp.
• Pressure-test the charge system before the first drive, and recheck clamps after the first heat cycle.
• Break in gently. Vary load for the first few hundred miles and let the engine idle briefly after hard pulls.

Common problems aFe parts address

• Blown intercooler boots. Factory boots on many diesel trucks split or slip under boost, causing low boost, black smoke, and power loss.
• High EGT when towing. A small or heat-soaked factory intercooler raises intake temperature, which raises EGT under sustained load.
• Leaking or cracked charge pipes that cause underboost codes and inconsistent power.
• A tired factory turbo on a high-mileage truck, where a drop-in BladeRunner turbo can replace it in the stock location.