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Another update on our E46 expansion tank project! Last time we showed off some images of our prototype unit, noting the numerous precise features we built into our design. This time we are installing the tank in our test vehicle to confirm fitment with the stock shroud and all coolant connection points. In addition, we will check out clearance between the tank and the belt-drive system to ensure appropriate fitment.

Removing the Stock BMW E46 Expansion Tank

Stock BMW E46 expansion tank installed

First we need to remove the stock tank from our test vehicle. As you can see in the image above, the stock fan shroud is the first component to come out before we tackle the expansion

This is a pretty cool post, something a bit out of the ordinary for our projects. We typically utilize our existing silicone boots in our intercooler kits, intake systems, etc. For this project, we decided to manufacture the first portion of our intake system from a wire-reinforced silicone hose. This would facilitate an easier installation, and it would also provide a smooth airflow transition from the small turbocharger compressor inlet to our intake's large pipe diameter. Since we like to show you what goes into developing our prototypes, check out the process for creating our silicone turbo inlet hose below!

Printing Our Fixture

The hose we have in mind will follow the path of the stock induction hose, which is actually a plastic piece on the stock ST. Before beginning our silicone project, we needed a fixture that would serve as a base for the silicone layers that will be applied. After making a model in Solidworks, we fired up the 3D printer and watched

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

We are pretty pumped about our new BMW performance parts! Our prototype radiator looks and fits great, so now let's make sure it performs as well as we intended. As we noted previously, we've made a variety of improvements over the stock core to improve heat transfer and efficiency. Let's take a look at the specs!

Core Improvements

BMW E46 radiator coolant surface area comparison

Our first comparison is coolant surface area, which is a measure of the area of the coolant tubes within the core. Greater tube area results in increased heat transfer as well

Now that we had a ton of information and data points for the stock intake system, it was time to begin creating our own design.

Piping Fabrication

We're starting our intake system at the turbocharger and working to the airbox. We intend to place our box in the same location as the stock unit so we can take advantage of the stock cold-air duct.

We switched on the band saw, fired up the welder, and started tackling the route for our prototype pipe. Our first length runs from the turbocharger around to the rear of the valve cover.

Prototype Fiesta ST parts

Big news for our E46 followers! Our aluminum prototype of the BMW E46 expansion tank is complete. Gone are the days of roadside tows and antifreeze puddles messing up your driveway. Enjoy the images of our awesome prototype below!

First Prototype Images

Mishimoto prototype BMW performance parts

Mishimoto prototype E46 expansion tank

We designed five different CNC-machined pieces to attach

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

Mishimoto BMW E46 Non-M Performance Aluminum Radiator!

It's been a while since our last update. Don't worry, we have not abandoned our E46 aluminum radiator project. In fact, this may be the most exciting update yet. We are getting closer to bringing you guys a much-needed reliable and efficient radiator solution. Our line of BMW performance parts is growing!

Prototype Images

The wait is over! Check out a couple shots of our prototype radiator!

Mishimoto prototype E46 radiator

Automotive passion has evolved over the years, and is still very much alive and well. A lot of this is a result of automakers continually bringing us the best in technology, innovation, and performance. Some will complain that modern automobiles are numb, boring, and full of complicated electronics and gizmos. Whatever your take on this is, one thing is certain. People still love cars, and the impulse to modify vehicles is as strong as it has ever been.

Take the Fiesta ST for example. A compact hatchback, front-wheel drive, economical vehicle. A few bolt-on modifications can turn this into a tire-shredding, corner-carving autocross monster. It is all in how you approach new technology. You can embrace it and take advantage of what we have available in today's age, or you can curse electronic fuel injection, discredit independent rear suspension, and continue to rip around your hometown streets in your SBF-powered Cougar. Not that there is anything wrong with this. The key here is acceptance,

Interested in purchasing this awesome oil cooler system? Check out our product page for more details!

Mishimoto Ford Fiesta ST Oil Cooler Kit

Testing time! It's always fun to see the results when you make changes to your vehicle, whether bolting on a new wheel and tire combo, or installing a  new set of  dampers. In this case, we are expecting our Fiesta ST oil cooler setup to drop fluid temperatures by a substantial margin during our on-road testing.

Testing Setup and Conditions

Testing the stock Fiesta ST oil cooler is relatively simple. Only one temperature and pressure will need to be monitored, so we can utilize our sandwich plate sensor adapter shown below.

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After removing both catch cans for data collection in our previous post, we discussed the idea of relocating the bracket that holds the PCV catch can to a different area in the engine bay. We mentioned earlier that we were toying with the idea because the current location of the Fiesta ST catch can raised some concerns. One of them being that the current location for the catch can would interfere with right-hand drive (RHD) applications of the Fiesta ST, and we want this catch can to be all inclusive. In addition, it came to our attention later on that it would also interfere with some aftermarket intakes.  We try to take common Fiesta ST parts upgrades into consideration so that the products we make will fit all Fiesta STs. The consensus was that because there was a bit more room further forward in the engine bay to relocate the catch can, that would be the way to go.

Bracket and Hose Setup

With this new location in mind our engineers began fabricating a