Cold Air Intake Kit for 1991-2001 Jeep Cherokee XJ 4.0L I6

The factory airbox on the 1991-2001 Jeep Cherokee XJ is a restrictive pancake-style plastic housing that chokes AMC's legendary 4.0L inline-six with a flat panel filter and a narrow, ribbed rubber intake tube designed for silence, not airflow. This engine is one of the most durable powerplants ever built — but it breathes through a straw from the factory.

Flashark's cold air intake kit replaces the factory airbox with a mandrel-bent black powder-coated aluminum intake tube, a high-flow dry conical filter, and a formed steel heat shield. The result is a straighter, larger-diameter airflow path that uncorks the 4.0L's natural induction growl and improves throttle response where it matters — in the 1,500-3,500 RPM range where you actually drive an XJ on the street and trail. Expect 3-8 WHP on a healthy stock engine; the real gain is the sharper pedal feel and the unmistakable inline-six intake note.

Installation is straightforward with basic hand tools — unbolt the factory airbox, mount the heat shield bracket to existing fender points, connect the intake tube with the supplied silicone couplers and clamps, and transfer your IAT sensor. No cutting, no drilling, no ECU reprogramming. Plan 45-75 minutes, depending on the condition of your XJ's original hardware. For a 30-year-old Jeep, budget extra time for rusty bolts and brittle vacuum lines.

Key Features

Mandrel-Bent Black Powder-Coated Aluminum Intake Tube — High-quality aluminum tubing with a durable black powder-coated finish. Larger inner diameter than the restrictive factory ribbed rubber plumbing for reduced airflow restriction. The black powder coat resists the heat and grime of an XJ engine bay.

High-Flow Dry Conical Air Filter — Washable and reusable dry media filter with a large surface area. No filter oil required — no risk of MAF sensor contamination, cleaner maintenance, and consistent filtration across the service interval. Clean every 15,000-20,000 miles under normal conditions (more often if you off-road regularly).

Formed Steel Heat Shield — Shields the filter from the hottest radiant engine heat coming off the exhaust manifold and cylinder head. Not a substitute for a true fender-well cold air routing, but a meaningful improvement over an exposed filter sitting in the engine bay. Uses existing mounting points — no drilling.

Silicone Couplers & Stainless Steel Clamps — Multi-ply reinforced silicone couplers with stainless steel T-bolt clamps. Flexible enough to absorb engine movement (the 4.0L is not a smooth engine) and resistant to under-hood heat and oil vapor.

Throttle Response Improvement — The combination of a straight, larger-diameter intake path and a high-flow filter reduces intake restriction. On a stock 4.0L, you'll notice sharper pedal response in the 1,500-3,500 RPM range — exactly where you drive on the street and trail.

4.0L Inline-Six Induction Sound — The open-element dry filter unleashes the deep, distinctive intake growl that the factory airbox was designed to suppress. Loudest under load and at wide-open throttle. If you've ever wanted your XJ to sound like the tractor motor it actually is, this is how.

Zero Cutting, Zero Drilling, Zero Tuning — The heat shield bracket uses existing mounting points in the engine bay. The intake tube connects to the factory throttle body with the supplied coupler. The IAT sensor (91-95 in manifold; 96-01 in airbox) transfers to the provided bung. No permanent modifications. No ECU flash required.

Cleaner Engine Bay — Removes the bulky factory airbox and resonator assembly, freeing up space on the driver's side of the engine bay. Easier access to the distributor (91-99), ignition coil (00-01), and throttle body for maintenance.

Reusable Filter — Lower Long-Term Cost — The dry filter is washable and reusable. No disposable paper filters to buy for every oil change. Clean it, dry it, put it back. One filter lasts the life of the vehicle.

Specifications

Brand: Flashark
SKU: FLIS25092
Material: Aluminum piping
Tubing Finish: Black powder-coated
Filter Type: Dry
Filter Color: Red
Filter Shape: Conical
Filter Reusability: Washable and reusable
Heat Shield Material: Formed steel
Coupler Material: Multi-ply reinforced silicone
Clamp Type: Stainless steel T-bolt
Installation: Bolt-on — no cutting, no drilling, no permanent modification
Weight (Shipping): Approximately 8-10 lbs

Package Includes

1× Aluminum Intake Tube
1× Dry Conical Air Filter
1× Formed Steel Heat Shield
2× Multi-Ply Reinforced Silicone Couplers
4× Stainless Steel T-Bolt Clamps
1× Mounting Hardware Kit (brackets, bolts, washers)
1× Installation Instructions