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
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
In case that you are not entirely familiar with this system, here are some basic details. As you can see, ducting runs from the front kidneys to provide cold airflow to the airbox, which is located just behind the driver-side headlamp. The airbox contains a standard, flat paper filter that provides a barrier for dirt and debris attempting to enter your engine. Before the throttle body, a mass airflow (MAF) housing with sensor is in place to measure the volume of air entering the engine. This volume dictates the correct amount of fuel that is injected into the engine.
Below is a shot of the MAF housing, courtesy of realoem.com.
Stock E46 MAF housing
As you can see, the MAF housing is connected to the throttle body with a rubber inlet hose. This hose is prone to failure and cracking
