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Enthusiast groups' feedback plays a massive role in our product development process. Not only is it a great way to bounce ideas off our potential customers, but it also allows us to see exactly what our customers want and need for their vehicles. This project is no different. Due to a substantial amount of demand via forums and social media, we decided it was time to get the ball rolling on this coolant expansion project.

Stock Expansion Tank

In typical BMW fashion, this tank was quite unique and featured some very interesting components, both internally and externally. First, a look at the exterior of the tank. Many of you are very familiar with this, based on the rate of failure reported for this plastic tank.

Stock E46 3-series coolant expansion tank

Stock E46 3-series coolant expansion tank

Stock E46 3-series coolant expansion tank

Stock E46 3-series coolant expansion tank

So, there are five - yes, five - unique fittings located on this tank, excluding the fill-neck connection. Check

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

BMW E36 Aluminum Coolant Expansion Tank!

Historically, BMW vehicles have been plagued with rather frequent cooling system failures. A majority of these failures are a result of the use of plastic components in a high-temperature application. Although failure isn't immediate, over time the frequent heat cycling of these plastic components results in increased fragility, fatigue, and eventual failure.

A few components we see failing on E36 models include the radiator end tanks, radiator expansion tank, and the mechanical fan. We already offer two aluminum radiator options, and we have an electric-fan conversion kit in the works. An expansion tank is our last stop for product development on the E36 (for now). We have had numerous requests for this component on both the 36 and 46 chassis, because folks are not pleased about having to replace this unit over and over again. They would prefer an

Interested in purchasing our WRX or STi catch can system? Check out more details on our product pages linked below!

Subaru WRX Baffled Oil Catch Can System

Subaru STi Baffled Oil Catch Can System

After completing the fabrication of our brackets for this kit and assembling the STI-specific lines, it was time to tackle the WRX. As you may be aware, the stock CCV lines are slightly different on the WRX, which necessitates a separate set of WRX-specific catch can lines.

The Test Subject

After reaching out to local contacts, we found a willing vehicle donor just one state away. We have borrowed this particular vehicle on several occasions for a variety of test fittings. A big "thank you" to the owner for lending his vehicle and his time for the sake of awesome new product development!

2011 WRX test-fit vehicle

This vehicle is kept super clean; check out the engine bay!

2011 WRX test-fit vehicle engine bay

This owner also has our cold-air intake setup installed!

Mishimoto intake installed

WRX

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

Front-mount intercooler installed

In the last portion of this series we completed the fabrication of our prototype intercooler core and tanks, as well as our new bumper beam. We now had everything in place to construct a piping kit that would route air from the turbocharger to the intercooler and back to the engine.

Hot-Side Piping

We started our piping with the hot-side of the intercooler system. The stock compressor housing uses a two-bolt flange connection, similar to what you would see on a 2008-2014 WRX. As you probably know, the FA20 turbocharger is on the lower front area of the engine, essentially right below the drive belt system. Because of this, our piping for the hot-side would be significantly shorter compared to the traditional turbo location featured on the EJ engine.

We started by 3D printing the flange that connects to

Interested in purchasing our 2015 STi intake system? Check out more details on our product page linked below!

Mishimoto Subaru STI Performance Air Intake

As noted earlier in this article series, we would be tackling a race intake system to go along with our bolt-on unit. So what makes the race system different? For this particular system we are using a larger-diameter intake pipe with a larger MAF housing. This means greater intake flow, but it also means it will no longer function with the factory tune. This system is meant specifically for drivers who want aggressive professional tunes so they can take advantage of airflow modifications such as larger turbochargers and high boost pressures.

Because the 15' model shares the EJ from the previous generation, we would be using the same intake pipe and filter as we did with our 2008-2014 kit. This unit is shown below.

So, all we truly needed was to design an airbox that would accommodate this pipe and function with the body of the new 15'

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

Crash Beam Fabrication

After an unsuccessful test fit of our existing bumper beam on the 15', we started from scratch to create a beam specific for the 15' chassis. First we hacked off the end tanks of our cooler so we were left with a bare core. This would provide some freedom to design our crash beam and later work on the end tank direction. Next we cut out some new mounting plates and fit them into position.

Intercooler crash beam mounting plates

Intercooler crash beam mounting plates

Next we fabricated a beam for mounting the cooler. The beam would run parallel across the front of the vehicle and attach to each mounting plate.

Intercooler crash beam fabrication

Intercooler crash beam fabrication

Intercooler crash beam fabrication

We then added the connector legs to attach this beam to the mounting plates. After a few tweaks, this guy

Interested in purchasing our WRX or STi catch can system? Check out more details on our product pages linked below!

Subaru WRX Baffled Oil Catch Can System

Subaru STi Baffled Oil Catch Can System

Mishimoto 2010 STI

After developing a highly successful, direct-fit catch can setup for the 2015 WRX we turned our attention to the previous generation. Our next target would be the 2008-2014 WRX and STI. At this point, Mishimoto still owned a 2010 STI, and this project would be our last for our shop vehicle.

Catch Can Selection

As with our 2015 WRX project, we would be using a dual catch can system to address both the PCV line and the crankcase breather line. One of the main differences would be the inclusion of a three-port breather catch can to replace the two-port unit used on the FA20 engine. The EJ engine features a breather line for each valve cover, which necessitates a dual-in, single-out catch can for that system. The PCV line would still use a standard dual-port catch can for the EJ.