Air Fryer Chili Relleno Casserole

A slice of layered Chili Relleno Casserole on a plate with a fork, with stacked plates and a blurred background.

Air Fryer Chili Relleno Casserole is my go-to when I want all the bold flavors of chili rellenos with faster cooking and easier cleanup. The air fryer crisps the top golden while keeping everything underneath rich and cheesy with layers of seasoned beef, roasted chilies, and melted Monterey Jack. It's perfect for weeknight family dinners, casual gatherings, potlucks, Cinco de Mayo and game days because it feeds a crowd and travels well. Store leftovers in the fridge for up to 4 days or freeze for up to 2 months.

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Prep Time: 20

Cook Time: 25

Total Time: 45

Course: Main Course

Cuisine: Mexican

Keyword: Air Fryer Chili Relleno Casserole

Servings:

Calories: 654kcal

Equipment

Ingredients

8 green chilies whole, baked and peeled
1 pound ground beef
1 cup onion finely chopped
2 cups Monterey jack shredded
2 cups corn tortilla chips
1 ½ cups refried beans

For the topping:

4 eggs beaten
¼ cup flour
2 teaspoons hot sauce
½ cup whole milk
¼ teaspoon paprika
¼ teaspoon onion powder
Salt to taste

US Customary - Metric

Instructions

Grease a 9×13-inch baking dish with cooking spray.
In a large bowl, whisk together the eggs, flour, milk, hot sauce, paprika, onion powder, and salt. Set aside.
4 eggs, ¼ cup flour, 2 teaspoons hot sauce, ½ cup whole milk, ¼ teaspoon paprika, ¼ teaspoon onion powder, Salt
In a skillet over medium heat, cook the ground beef and chopped onions until the meat is browned and the onions are soft. Stir in the refried beans and mix well.
1 pound ground beef, 1 cup onion, 1 ½ cups refried beans
Layer half of the tortilla chips in the prepared baking dish, followed by half of the meat mixture, half of the chilies (laid open), and half of the shredded cheese. Repeat the layers, finishing with the chilies.
8 green chilies, 2 cups corn tortilla chips, 2 cups Monterey jack
Pour the egg mixture evenly over the top and sprinkle with the remaining cheese.
Cover with foil and bake in the air fryer at 375°F (190°C) for 25 minutes. Remove the foil during the last 5 minutes to allow the cheese to brown slightly.
Let the casserole cool for a few minutes before serving. Enjoy!

Notes

Here are my best tips for making Air Fryer Chili Relleno Casserole turn out perfect every time:

Check your dish size: Make sure your 9x13-inch baking dish actually fits in your air fryer basket before you start assembling everything, or you'll have to transfer it all to a different pan.
Whisk out the lumps: Make sure the flour is completely smooth in your egg mixture with no lumps, or you'll have pockets of dry flour in the finished casserole.
Drain the beef well: After browning the ground beef, drain off any excess grease before mixing in the refried beans so your casserole doesn't turn out greasy.
Open the chilies flat: Lay the roasted green chilies open like you're butterflying them so they cover more surface area and you get chili flavor in every bite.
Don't skip the cooling time: Let the casserole rest for 5 minutes after it comes out of the air fryer so the egg mixture sets up and you can cut clean slices instead of a soupy mess.
Flash freeze for meal prep: If you're freezing portions, place them on a baking sheet for 1 hour first before wrapping and bagging so they hold their shape and don't stick together in the freezer.

Nutrition

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