Cold Air Intake for Jeep Wrangler (1997-2005 ) SE Sahara Sport X Rubicon 2.5L 4.0L Engines

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Uncork the Legendary 4.0L High Output I6 and AMC 2.5L I4: Cold Air Intake for Jeep Wrangler TJ (1997-2005)

Who It’s For: Designed specifically for Jeep Wrangler TJ owners running the **AMC 2.5L I4** or the legendary **4.0L High Output I6** engine. If you’re looking to wake up your Jeep, whether it’s for better throttle response on the trail or more passing power on the highway, this is your next essential upgrade.

The Problem: The factory airbox in your Jeep Wrangler TJ, especially with the **4.0L High Output I6**, is a known bottleneck. From the restrictive paper filter to the convoluted intake tubing, it chokes your engine, limiting crucial airflow and causing it to work harder for less power. This dulls throttle response and can even contribute to heat soak, especially during those slow crawls or highway pulls. I’ve seen countless TJs come through the shop, and swapping out that stock airbox is one of the most common and effective first steps to genuine performance gains.

The Solution: We engineered this Cold Air Intake to eliminate those factory design flaws. It delivers a consistent supply of colder, denser air directly to your **AMC 2.5L I4** or **4.0L High Output I6**, optimizing combustion and delivering noticeable, real-world gains in horsepower and torque. You’ll feel the difference every time you press the pedal.

Why This is the Ultimate Upgrade

Enhanced Performance: Feel the immediate difference with improved throttle response and measurable gains in horsepower and torque, especially at mid to high RPMs. Your engine will breathe easier, and you’ll hear that satisfying, deeper growl every time you accelerate.
Built to Last: Crafted from two 3" diameter T-306 heat-resisting Premium Chrome Anodized Quality Aluminum intake pipes, paired with a high-flow, washable, and reusable Chrome Heat Shield air filter. This isn’t just a temporary fix; it’s designed for the long haul, just like your Jeep.
Straightforward Installation: This is a direct bolt-on replacement for your restrictive factory airbox. It comes with all necessary hardware including a brand new coupler, vacuum hose, mounting bracket, clamps, and basic installation instructions. Most enthusiasts can complete this upgrade in under an hour with basic hand tools. Remember to disconnect your battery to let the ECU re-learn the increased airflow for optimal tuning.

Technical Specifications

Fitment	1997-2005 Jeep Wrangler TJ
Engine Family	AMC 2.5L I4 / 4.0L High Output I6
Factory Ratings	AMC 2.5L I4: 120 HP / 140 lb-ft \| 4.0L High Output I6: 190 HP / 225 lb-ft
Part Numbers	Not specified in input data.

Compatibility & OEM Reference

Fits the Following Vehicles:

Jeep Wrangler (1997-2005) SE
Jeep Wrangler (1997-2005) Sahara
Jeep Wrangler (1997-2005) Sport
Jeep Wrangler (1997-2005) X
Jeep Wrangler (1997-2005) Rubicon

Interchange Part Numbers:

The Performance Promise

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Engine Safety Rating

Difficulty

Fitment

Make	Jeep
Engine Size	2.5L 4.0L
Year	1997 1998 1999 2000 2001 2002 2003 2004 2005

Installation & Tools

The Wrench Time

Estimated Time: 45-60 Minutes
Difficulty: 2/10 - A very straightforward bolt-on job, but requires patience when handling decades-old factory plastics and rubber under the hood.

Tools You Will Need

10mm Socket and Wrench (For battery terminals and factory air box bolts)
8mm Socket or 5/16 Nut Driver (For hose clamps)
Flathead Screwdriver (For prying stubborn vacuum hoses and releasing clips)
Silicone Spray or Soapy Water (Crucial for safely transferring the IAT sensor)
Long Socket Extension (To reach the lower air box mounting bolts)

Mechanic’s Pro Tip (The "Gotcha"):
The 1997-2005 Jeep Wrangler TJ platforms are notorious for two major headaches during intake swaps. First, the CCV (Crankcase Ventilation) plastic elbows on top of the AMC valve cover become incredibly brittle over time. If you yank the breather hose, the elbow will snap, dropping plastic into your valvetrain. Second, the factory IAT (Intake Air Temperature) sensor is wedged into a rubber grommet that turns to rock after 20 years of heat cycles. Never pull it dry. Soak it in silicone spray, gently twist, and coax it out so you don’t break the fragile sensor tip and cause a rough idle.

Phase 1: Removing the Factory Part from your 1997-2005 Jeep Wrangler 2.5L 4.0L

Disconnect the Battery: Always start by disconnecting the negative battery terminal using a 10mm wrench to prevent check engine lights and clear the ECU memory.
Unplug the IAT Sensor: Locate the Intake Air Temperature sensor plugged directly into the factory plastic intake tube. Use a small flathead screwdriver to gently push the locking tab and slide the wiring harness connector off.
Disconnect the Breather Hose: Carefully trace the CCV breather hose from the air tube to the top of the valve cover. Twist the hose gently back and forth to break the seal before pulling. Do not force it, or you will snap the factory plastic elbow.
Loosen the Throttle Body Clamp: Loosen the factory hose clamp securing the intake tube to the throttle body using an 8mm socket or a flathead screwdriver.
Remove the Factory Air Box: Remove the factory air box bolts bolted to the inner fender using a 10mm socket and a long extension. Once unbolted, pull the entire air box and intake tube assembly up and out of the engine bay as one complete unit.
Extract the IAT Sensor: With the factory tube off the Jeep, spray the base of the IAT sensor with silicone lube. Gently twist and pull to free the sensor from the hardened factory grommet. Set the sensor aside in a safe spot.

Phase 2: Installing the Cold Air Intake for Jeep Wrangler (1997-2005 ) SE Sahara Sport X Rubicon 2.5L 4.0L Engines

Install the Throttle Body Coupler: Slide the new silicone coupler onto your throttle body. Snug the hose clamps down with your 8mm socket, but do not overtighten and crush the lip of the throttle body.
Mount the Heat Shield: Drop the new metal heat shield into the engine bay, lining it up with the factory air box mounting holes. Bolt it down securely using your 10mm socket and the supplied hardware.
Transfer the IAT Sensor: Push the new supplied rubber grommet into the pre-drilled hole on the new aluminum intake tube. Apply a single drop of soapy water to the IAT sensor body, then gently push and twist the sensor into the new grommet until it seats flush.
Route the Intake Tube and Hoses: Slide the new intake tube into the throttle body coupler and into the heat shield opening. Connect the supplied CCV breather hose from the new tube directly to the valve cover elbow. Tighten all remaining hose clamps with your 8mm socket.
Plug In and Power Up: Reconnect the IAT sensor wiring harness until you hear it click. Attach the high-flow air filter to the end of the intake tube inside the heat shield and tighten its clamp. Finally, reconnect the negative battery terminal using your 10mm wrench. On the first startup, do not touch the gas pedal for 20 seconds; allow the Jeep to idle so the ECU can properly adjust to the increased airflow parameters.

Disclaimer: This is a general guide provided for the 1997-2005 Jeep Wrangler 2.5L 4.0L. Always refer to your factory service manual for exact torque specifications and safety procedures.