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Interested in picking up our E46 intake system? Check out our product page for more information!

Mishimoto BMW E46 Performance Air Intake

Final Intake Images

With successful testing data acquired from our first prototype, it was time to make a final prototype and perform our last test fit before producing a batch of final intake systems. Check out a shot of the shroud, intake hose, and filter!

Mishimoto E46 air intake shroud, intake hose, and air filter

The airbox is constructed of powder-coated steel, and we line the edges with weather stripping to prevent any vibrations or damage. The silicone coupler is a four-ply unit designed specifically for this kit.

The air filter shown above is the Mishimoto Oiled Air Filter. These filters are completely serviceable and can provide a lifetime of service if appropriately cleaned and maintained.

We also designed an internal CNC-machined connector that will allow the silicone intake hose to mate properly with our air filter. This setup can be seen

Interested in picking up this aluminum E36 expansion tank? Check out our product page linked below!

BMW E36 Aluminum Coolant Expansion Tank!

The time has come and the anticipation is over. Our final prototype unit has been constructed, and we are ready to check fitment! On to the pictures!

Final Expansion Tank Images

Mishimoto expansion tank prototype

Mishimoto expansion tank prototype

Mishimoto expansion tank prototype

Check out a closer look at the lower coolant hose fitting and our threaded fluid level sensor bung on the base of the tank.

Mishimoto expansion tank prototype fittings

We also stamped our Mishimoto "M" logo into the side of the tank. Although not super visible once installed, this is a nice subtle inclusion to identify this tank as another awesome Mishimoto component.

Mishimoto expansion tank logo

Now the cool part! Check out the fill neck and dipstick we have designed for this tank.

Mishimoto expansion tank top

This part of the tank deserves some extra conversation. The

Interested in picking up our E46 intake system? Check out our product page for more information!

Mishimoto BMW E46 Performance Air Intake

After completing our initial prototype it was time to strap this E46 to the dyno and make a few pulls. We would be evaluating power output, monitoring vital engine sensors such as AFR, and collecting sound clips for comparison against the stock intake system.

Dyno Testing

E46 on dyno for intake testing

E46 on dyno for intake testing

E46 on dyno for intake testing

Time to make some pulls! Check out the dyno video below.

Initial Impressions

The video shows the changes our setup made in  intake noise. This is likely a result of our open-element filter residing within the engine bay. Although closing the hood seals off the airbox portion of the intake, it is still more audible than the stock unit. The stock airbox is designed in a way to reduce noise and create a more drivable experience for non-enthusiasts. That said, this creates a numbness among car

Quick project update! As noted in our last post, we had finished collecting data points and dimensional information for the stock tank and were setting our sights on creating a tank of our own.

After pulling our engineers out from under shop vehicles, we set them behind the computer to get this project moving. Check out some of our initial 3D models!

Mishimoto expansion tank, 3D model

Mishimoto expansion tank, 3D model

Mishimoto expansion tank, 3D model

Mishimoto expansion tank, 3D model

Mishimoto expansion tank, 3D model

And here's a shot showing our fill-neck design and upper hose connection!

Mishimoto expansion tank, 3D model

Below is a shot showing the quick-connect fittings located on the base of the expansion tank. As noted in our first post, these attach to the plastic plate on the radiator fan shroud. One of the ports will be capped on manual models.

Mishimoto expansion tank, 3D model

Our tank is being designed to function with all stock connection points and will not require any

Interested in picking up this aluminum E36 expansion tank? Check out our product page linked below!

BMW E36 Aluminum Coolant Expansion Tank!

Time to break open the stock tank and see what lies within. If you follow some of our other development projects, you would know that we recently split an E46 3-series expansion tank and found quite a complex system including both internal and external features. Although this added some complexity and difficulty to the project, it seemed like our engineers enjoyed the challenge.

Stock Expansion Tank Internals

First, before we slice this guy in half, a look inside the tank from the cap.

Stock expansion tank, internal design

We can see from this shot that the tank does indeed feature a unique internal chamber. A tube appears to run the full length of the tank. Let's get to the band saw so we can split this component for evaluation.

Stock expansion tank, internal design

Stock expansion tank, internal design

Stock expansion tank, internal design

The internal

Interested in picking up our E36 fan shroud? Check out the full details on this kit on our product page!

Mishimoto BMW E36 Performance Fan Shroud Kit!

Our final prototype is complete and looks fantastic. The fan mount is constructed from 1/8" steel that has been cut to a specific shape allowing for additional airflow through the radiator core at speed. Additionally, the mount is powder coated black to provide a durable finish. As noted in our last post, we tested this unit extensively with our 16" fan to ensure that coolant temperatures were properly regulated during both idle and all driving conditions.

Check out a few shots of the mount!

Final prototype of fan mount

Final prototype of fan mount

This shroud has been designed to function with the stock expansion tank as well as the aluminum expansion tank we have been working to develop. Check out the mounting system our engineering team designed to secure the tank properly in the stock location.

Final prototype of expansion tank mount

Interested in purchasing our 2015 WRX top-mount intercooler kit? Check out more details on our product page linked below!

Mishimoto Subaru WRX Performance Top-Mount Intercooler and Charge-Pipe System

As noted in our previous post, we decided to design a shroud that would channel airflow more efficiently through the core of our intercooler. Because our cooler features a larger footprint, the stock air shroud directs flow to only a portion of the core. Opening up this airflow to the entire core should result in even greater temperature reductions than we saw during our first round of testing.

Stock Intercooler Shroud

First, let's take a look at the stock shroud as Steve removes it from our test vehicle. Here is what you will see under the hood of your WRX.

Stock intercooler shroud

The stock setup features a large center scoop that directs airflow through the intercooler core. This rubber unit flexes to seal against the intercooler. Next, we removed the hood insulation, destroying several

Interested in purchasing our E46 aluminum radiator? Check out our product page linked below!

Mishimoto BMW E46 Non-M Performance Aluminum Radiator!

3D Modeling

After some serious 3D modeling work in Solidworks, our first prototype unit is complete. Let's check out a few of the renders!

Mishimoto E46 3-series aluminum radiator 3D model

Mishimoto E46 3-series aluminum radiator 3D model

As you can see, the rear of the radiator features a variety of complex pieces. The quick-disconnect fittings have been replicated and will be CNC-machined. All stock mounting points have been included in our design so that this radiator drops into place just like the stock unit.

Take a look at the front side of the radiator.

Mishimoto E46 3-series aluminum radiator 3D model, front view

Mishimoto E46 3-series aluminum radiator 3D model, front view

Mishimoto E46 3-series aluminum radiator 3D model, front view

Although you can't see much of the core in these shots, we did spend a great deal of time designing this

Interested in picking up our 2015 WRX FMIC kit? Check out more details on our product page linked below!

Mishimoto Subaru WRX Front-Mount Intercooler Kit

Time for the fun part of development, product testing! Since this is an intercooler, we would certainly need to put the WRX on the dyno for some pulls and data collection. It would be interesting to see how the installation of a front-mount system has an impact on turbo spool, intake temperatures, and perhaps even power output.

Testing Preparation

The first step toward data collection is to prepare our sensor bungs and install our pressure and temperature sensors. We installed our bungs within the inlet and outlet intercooler couplers.

Sensor bungs installed for dyno testing

Sensor bungs installed for dyno testing

Sensor bungs installed for dyno testing

Dyno Testing

Once complete we strapped the WRX to the dyno and started making our pulls! Check out the images and video from our tests!

Front-mount intercooler dyno testing

Front-mount