Tools and Materials Needed

Before diving into the installation, gather everything you’ll need. A clean, organized workspace saves time and prevents frustration. For this job, you will require:

  • AFE Power Stage 2 Pro Dry S Intake Kit (ensure it includes the filter, intake tube, hardware, and installation instructions)
  • Socket set with metric and standard sizes (usually 10mm, 13mm, and 8mm are needed)
  • Ratchet and a set of extensions (including a 6-inch and a flex-head extension for tight spots)
  • Flathead screwdriver (medium size) for prying hose clamps
  • Phillips screwdriver for any plastic fasteners
  • Torque wrench capable of low torque settings (for intake tube clamps and sensor bolts)
  • Shop towels or clean rags
  • Safety glasses and gloves
  • Small pick or trim tool (optional, helpful for removing electrical connectors)

Having a flashlight or work light is also recommended – the engine bay of the Silverado can be dark, especially near the back of the turbo inlet.

Preparation and Safety

Park the Silverado on a level surface and allow the engine to cool completely. A hot engine increases the risk of burns and makes plastic components brittle. Disconnect the negative battery terminal using a 10mm socket. This prevents accidentally triggering any sensors or starting the engine during the swap. Note: disconnecting the battery will reset your radio presets and driver memory settings, so plan accordingly.

Open the hood and inspect the stock intake area. Remove any loose debris or leaves that might fall into the intake opening. If the truck has a recently driven engine, the turbo and exhaust manifold stay hot for a while – use caution.

Removing the Stock Intake System

The factory intake on the Silverado 2.7 Turbo is a closed, resonance-tuned assembly. Removing it is straightforward but attention to detail prevents broken clips and stripped bolts.

Step 1: Disconnect Sensors and Hoses

Locate the mass air flow (MAF) sensor on the intake tube. Depress the connector tab and pull gently. Use a small pick to release the locking tab if necessary. Also disconnect the turbo inlet air temperature sensor (if equipped) and any crankcase ventilation hose attached to the intake duct. Label the small hose connections with tape if needed.

Step 2: Loosen Clamps and Ducts

Using the flathead screwdriver, loosen the two hose clamps on the factory intake tube – one at the turbo inlet, the other at the air filter housing. Do not remove them entirely; just loosen enough to slide the tube off. Next, remove the three 10mm bolts holding the air filter housing to the inner fender. There may also be a bolt on the top of the housing near the battery. Keep these bolts safe.

Step 3: Remove the Factory Assembly

Twist the intake tube slightly to break the silicone seal at the turbo inlet, then pull the entire assembly – filter housing and tube together – out of the engine bay. Be careful not to drop anything into the open turbo inlet. Cover the turbo opening with a clean shop towel to prevent debris entry during the rest of the install.

If the factory intake has a vacuum reservoir attached, unclip it and set aside – you will reuse it with the AFE kit. Clean the mounting area with a shop towel to remove any oil or dirt.

Installing the AFE Power Stage 2 Pro Dry S Intake

Now the exciting part. The AFE intake is designed to bolt directly onto the factory turbo inlet without modifications. Follow the kit’s instructions closely, but here are the key steps with extra detail.

Step 1: Prepare the Filter and Heat Shield (if included)

Some AFE Stage 2 kits come with a heat shield that replaces the factory air box. If your kit includes one, install it first. The heat shield usually mounts using existing holes in the inner fender and the stock air box mounting points. Use the provided nuts and bolts; do not overtighten. The shield acts as a barrier to hot engine air, improving intake air temperature.

Step 2: Install the Intake Tube

Slide the AFE silicone coupler (with hose clamp) onto the turbo inlet. Then attach the new intake tube to the coupler. Ensure the mark on the tube aligns with the clamp location. Tighten the clamp at the turbo to the torque specified in the manual (usually 5–7 ft-lb). Do not overtighten – silicone can distort. A snug, even clamp is adequate.

Step 3: Reconnect Sensors and Hoses

Plug the MAF sensor into the AFE intake tube; it should click firmly. The AFE tube may have a dedicated bung for the sensor – ensure the O-ring is seated properly. Reconnect the crankcase vent hose to the tube’s molded nipple. If your kit includes a fitting for the turbo inlet temperature sensor, install that now.

Step 4: Install the Dry S Filter

AFE’s Pro Dry S filter is pre-oiled from the factory – do not wash or oil it before installation. Gently position the filter onto the intake tube’s flange. Use the provided clamp and tighten evenly. The filter should sit level and be free from binding against the heat shield or fender. Check that the filter is not touching metal surfaces, as vibration can wear a hole over time.

Step 5: Finalize Mounting and Routing

If you have a heat shield, secure it with the remaining fasteners. Route the intake tube so it has no sharp bends or contact with moving parts (e.g., fan shroud, belt). Leave a 1/2-inch gap between the tube and any hot surfaces. Reinstall any brackets or supports that came with the kit.

Final Checks and System Integration

Double-check all connections before reconnecting the battery:

  • Ensure all hose clamps are tight (but not crushing the tube).
  • Verify sensor connectors are fully seated and locked.
  • Look for any loose bolts or tools left in the engine bay.
  • Rotate the engine by hand (using a socket on the crank pulley) to ensure the belt and fan do not contact the intake tube.

Reconnect the negative battery terminal. Start the engine – it may idle a bit rough for 10–20 seconds as the ECU re-learns the new airflow. Listen for any whistles or hisses that indicate a vacuum leak. If you hear a constant hiss, shut off the engine and tighten the clamps near the turbo inlet. A slight induction noise is normal – the AFE intake is designed to let you hear the turbo spool and the blow-off valve.

Test drive: Take the truck for a short run with moderate acceleration. Watch the boost gauge (if equipped) or listen for surging. The new intake should allow the turbo to reach peak boost more quickly. Pay attention to the gearbox shift quality – the extra airflow may initially cause a slightly different shift pattern until the ECU adapts. This typically normalizes within 50–100 miles.

Performance Expectations and Tuning

The AFE Stage 2 Pro Dry S intake is a high-flow, closed-box design that increases volumetric efficiency. On a Silverado 2.7 Turbo, you can expect gains of 15–20 horsepower and 20–25 lb-ft of torque at the wheels, per AFE’s dyno testing. The real-world benefit is a more responsive throttle and quicker spool. The dry filter provides 99.5% filtration efficiency without the mess of oiled filters.

Note: These gains assume a stock engine. If you have added a performance intercooler, exhaust, or tune, the intake will work synergistically. For maximum benefit, consider a custom or off-the-shelf tune (e.g., from HP Tuners or Trifecta Performance) to adjust fuel and timing tables for the increased airflow.

The intake is also compatible with aftermarket blow-off valves and charge pipes – many Silverado owners pair it with a turbosmart BOV adapter for improved throttle response and sound.

Maintenance and Filter Care

The Pro Dry S filter is reusable and washable. AFE recommends cleaning every 25,000 to 30,000 miles under normal driving conditions, or more often if you drive on dusty roads. To clean:

  1. Remove the filter from the intake tube.
  2. Tap loose dirt from the outside (do not use compressed air – it can damage the cotton/polyester media).
  3. Use AFE’s dry filter cleaner or mild soapy water (dish soap is safe). Gently massage the cleaning solution into the pleats from the inside out.
  4. Rinse with low-pressure water from the inside out until the water runs clear.
  5. Allow the filter to air dry completely (overnight). Re-oiling is not required for the dry system – just reinstall.

Check the silicone couplers and clamps for tightness at every oil change. Vibration and heat cycling can cause slight loosening over the first few thousand miles.

Troubleshooting Common Issues

  • Engine Check Light (CEL): A P0101 or P0102 code may appear if the MAF sensor is not properly seated or the intake tube has a leak. Check that the sensor O-ring is in place and the connector is locked. Reset the code with a scanner after repairs.
  • Excessive induction noise under light throttle: This is normal; the open-element or semi-open nature of the Stage 2 lets you hear the intake. If you prefer a quieter cabin, consider the Stage 1 or a closed box version.
  • Filter collapsing or deformation: Most AFE filters are sturdy, but if you overtighten the clamp, you can crush the inner support mesh. Loosen and reform the filter with your hands.
  • Boost leaks: If you notice a drop in peak boost (compared to before), check the clamp at the turbo inlet – it’s the most common leak point.

Why Choose AFE Power Stage 2 Pro Dry S?

AFE Power (Advanced Flow Engineering) has been a leading aftermarket manufacturer for over 20 years. The Stage 2 Pro Dry S intake uses high-flow silicone and aircraft-grade aluminum components. Unlike oiled cotton filters (which can cause MAF fouling if over-oiled), the dry filter eliminates that risk while still flowing more than the restrictive factory box. Independent tests on the 2.7L L3B engine show the AFE can reduce intake restriction by 30–40% across the rev range.

For comparison, the factory intake is optimized for noise dampening and cost, not peak airflow. The AFE system is designed to lower intake air temperatures by pulling cold air from behind the headlight area, rather than drawing heated engine bay air like some competing intakes.

Conclusion

Installing the AFE Power Stage 2 Pro Dry S intake on your Silverado 2.7 Turbo is a rewarding weekend project that delivers measurable performance gains. The step-by-step process is simple enough for a confident DIYer with basic tools, yet the results are professional-grade. After the install, you’ll enjoy quicker spool, a more responsive throttle, and a satisfying induction sound that doesn’t drone on the highway. While the intake alone is a great upgrade, pairing it with a tune and a cat-back exhaust will unlock the full potential of the highly capable 2.7L turbo engine.

For genuine AFE products and install tips, visit the official AFE Power website or the Silverado / GMC Sierra enthusiast forums where owners share their experiences and dyno results.