Well I got board the other day and came up with a cold air mod that so far has impressed me.Since I'm running the AFE induction kit I decided to wrap the intake tube with header wrap,hey it's good for keeping heat in so it should work great for keeping heat out right?

The next thing I did will only work if you have relocated your windshield washer bottle.I purchased a APC universal expandable ducting and ran it through the hole left behind in the wheel well for the washer bottle.I secured it (via zip-tie) to the unibody just under my ARB bumber to catch cold air while driving down the road.Next I ran it up close to my cone filter(about 2" from the filter) and secured it to the AC line close by.The next 3 pics show all 3 angles of it on my KJ.

I've been driving around for 2 days with this done and have felt a noticeable increase in power going down the highway(60-80 mph),it's unreal the change it's done.It's not no 40 HP increase or nothing but you can feel it has more get up and go a highway speeds.Don't ask about mpg increase because I did not do it for milage,I did it to help give a little more get up and go for my overwieght hog.

PS expandable piping is not a good choice for air intake piping. Smoother is better, because every single one of those grooves creates "dirty" air (turbulent) that greatly slows down the incoming air charge. Try mandrel bent exhaust pipe or some other heat resistant, smooth, sturdy tubing.

the intake tube needs to be in a high pressure area, and where you have it is very low pressure. (Almost a vacuum, really) The air will hit your bumper and be canted down nearly completely missing your hose. Since there is no suction on the other end from the engine, pulling air into the hose, chances are that since there is no high pressure forcing air up that tube and around your filter, it isnt doing you a whole lot of good. The air around the intake hose may actually have a venturi effect sucking air out of the hose!

A better place to mount that would be in the grill or somewhat out in front where the air is forced into it. This will force air up the tube and down onto your filter.

If you wish to test this, go buy a portable anemometer (wind speed device) and mount it in front of the exit of your intake pipe, and ride around. Check the windspeed of the air from that hose before and after mounting in high pressure area. You will see a pretty astounding difference.

And the header tape is a really good idea that works. A lot of people dont do it because of the looks, but the practice is sound and does keep that air cool. A metal air intake is just asinine. (but on that same point, air goes into the engine so quickly that its impossible to heat it up more than a degree or two, but that is another subject)

PS expandable piping is not a good choice for air intake piping. Smoother is better, because every single one of those grooves creates "dirty" air (turbulent) that greatly slows down the incoming air charge. Try mandrel bent exhaust pipe or some other heat resistant, smooth, sturdy tubing.

when you trick it (resistor) it doesnt make anything better. but on the 02 and 03s the sensor is on the manifold and 04+ put it on the intake tube. so why not let it read the actual temp instead of 116 degrees or more. i improved my mileage hands down from 15.5 to 17 per tank.

It's programmed differently then the '04+ KJ's though. Also, did you do the sensor relocation and additional cold air at the same time?

Btw Savage, i used the flex pipe from autozone for 15 bucks. it is great and serves its purpose.

As far as a write up:

Buy and 04 intake sensor for 25 bucks (you cant use old one)

Find a drill bit that will cut into your pipe i think its 5/8

Cut the hole as near the filter as you can. put the sensor in and either glue it in or use some aquarium sealent.

Unplug the sensor pig tail at the manifold and cut the wire about 2 inches back.

Crimp some wires long enough to go around the enging and attach the sensor pig tail. you will need to cut the existing sensor you bought cause they dont mate perfectly. cutting plastic will make this work you will see what i mean.

Doing this changed a best temperture on my scan guage from 116 to pretty much acual temperture. now i took the resistor off when i did this so i dont know if that alone made my mileage better or not. i am not going to argue about that but doing this mod on my buddys saturn raised mileage also.