How to Install an Airaid Cold Air Intake SynthaMax Dry Filter in your 1997-2006 Wrangler TJ with 4.0

1997-06 Jeep Wrangler 4.0L I6 

Full color instructions can be viewed on our web site at Airaid.com. Use the Product Search function to find your part number, and click View Details. 

1. Disconnect negative battery cable. Remove factory valve cover breather hose from intake tube and discard. Retain plastic valve cover fitting for later use.

2. Loosen hose clamps on both ends of factory intake tube. Remove intake tube from engine. 

3. 2005-06 Vehicles: Disconnect the electrical connector to the air temp sensor on the backside of the factory intake tube and remove sensor. Retain sensor for later use.

4. Remove factory air filter from airbox. 

5. Using a 5/16” socket, remove the three nuts and bolts mounting the factory air filter housing to inner fender. Remove air filter housing. 

6. Using a 7/16” socket, remove the factory radiator mount bolt. Retain bolt for later use. 

7. Using a flat blade screwdriver, push locking tabs inward to remove the fuse panel from the mounting bracket. Position panel out of the way to access the bolt underneath.

8. Using a 10mm socket, remove one bolt from the inner fender as shown above. Retain bolt for later use. 

9. Using a 13mm socket, remove the radiator rod support bolt on the passenger side. Retain bolt for later use. 

10. Using the supplied hardware, assemble the Airaid Cool Air Dam assembly as shown above.

11. Using the supplied thin grommet, position it over the passenger side radiator support rod as shown above.

12. Carefully slide the Airaid Cool Air Dam assembly over the passenger side radiator support rod. Be careful not to scratch the paint. Insert the rubber grommet into the panel for final positioning of the assembly.

13. Align the mounting holes in the Airaid Cool Air Dam with the factory holes in the inner fender. Using the original bolts from step 7, mount the Airaid Cool Air Dam to the inner fender. 

14. Using the supplied ¼ x 20 nut, bolt and washers, mount the front of the Airaid Cool Air Dam to the inner fender.

15. Using the original bolt from step 5, mount the Airaid Cool Air Dam to the passenger side radiator mount.

16. Remove one valve cover bolt on the passenger side nearest to the oil fill cap. Use this bolt to mount the supplied mounting bracket to the engine as shown above. Leave bolt loose until final assembly

17. For 1997-2004 Vehicles Only: Install the supplied rubber grommet with out the hole into the Airaid intake tube. 

18. For 2005-06 Vehicles: Install the supplied rubber grommet with the hole. Next, install the factory air temp sensor retained from step 3 into the grommet.

19. Install the supplied rubber hose on the factory plastic valve cover breather fitting.

20. Install the urethane hump hose and two #72 hose clamps on end of the Airaid Cool Air Dam. Leave hose clamps loose until final assembly.

21. Install reducer coupler on throttle body with two #44 hose clamps. Leave hose clamps loose until final assembly.

22. Install Airaid intake tube by connecting both ends into the urethane hump hose and reducer. 

23. Mount the Airaid intake tube to the valve cover bracket using the supplied ¼” bolt and washer as shown above.

24. Make final adjustments to the intake tube for correct position. Tighten all four hose clamps and bracket bolt

25. For 2005-06 Vehicles: Re-connect the air temp sensor on the backside of intake tube.

26. Connect the other end of the valve cover hose to the intake tube. Secure both ends of the hose using the supplied black speed clamps. 

27. Install the Airaid Premium Filter on the Cool Air Dam assembly. Secure the filter using the supplied hose clamp. 

28. Install the weather strip on the edge of the Cool Air Dam assembly as shown above. Reconnect negative battery cable. Double-check your work to be certain that all nuts, bolts, and clamps are securely fastened. 


Thank you for purchasing the Airaid Intake System. Contact Airaid @ (800) 498-6951 8:00 AM - 5:00 PM MST weekdays for questions regarding fit or instructions that are not clear to you. Your Airaid Intake System was carefully inspected and packaged. Check that no parts are missing, or were damaged during shipping. If any parts are missing, contact Airaid. The air filter element is protected from direct exposure to water and debris; care should be taken not to drive through deep water. WATER INGESTION IS THE DRIVERS RESPONSIBILITY! The air filter is reusable and should be cleaned periodically. 

700-456 Airaid Oiled Media
702-456 Airaid SynthaMax Dry Media - Black
701-456 Airaid SynthaMax Dry Media - Red
703-456 Airaid SynthaMax Dry Media - Blue 

Synthamax Air Filters do not require oil. Service air filter as needed by cleaning with common nonpetroleum all-purpose household cleaner and water. Simple Green®, Formula 409® or equivalent works great. Apply cleaner to outside of air filter and allow to soak. Then flush filter clean from the inside out with a garden hose and repeat steps if necessary. Do not apply high pressure water or air to clean filter. Allow filter to air dry and reinstall.