Pipercross Toyota GR86 OEM+ Intake Kit

Pipercross Performance Intake System
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Pipercross Toyota GR86 OEM+ Intake System
The Pipercross OEM+ Intake System has been designed and engineered to directly replace the OEM panel air filter and corresponding intake hose on the Toyota GR86 with the 2.4L boxer engine

PRODUCT HIGHLIGHTS

• Pipercross Plus premium, hybrid multi-density replacement high flow panel filter
• 4 Ply silicone intake hose for optimal internal airflow/thermal characteristics and proper engine decoupling
• Stainless steel hardware for long-term corrosion protection
• Designed, prototyped and iteratively refined using latest 3D scanning and CAD technology
• Flow tested to confirm 56.23% maximum, 23.08% average airflow restriction decrease vs. full OE intake system
• Dyno tested +13.9 WHP/+13.04 ft.-lbs. WTQ maximum power gain

OEM INTAKE ASSESSMENT
The OEM intake system on the Toyota GR86 2.4L engine has several hallmark features that exemplify the simplistic and functionally focused engineering expected of Toyota vehicles. While this intake design ethos serves the 2.4L boxer engine well in almost all scenarios, it also presents several opportunities to enhance the performance of the engine, through select intake modifications.

For an introductory “OEM+” intake kit, the Pipercross engineering team identified the OE intake filtration media type/total surface area and the convoluted intake hose as areas of potential OE system performance improvement. Alternatively, the OE airbox and cold-air ducting were deemed critical to maintain in the introductory Pipercross OEM+ kit - based on specific part size/functionality and Pipercross engineers’ experience with overall performance intake design across a multitude of chassis/engines.

Filtration media/surface area was to be improved via Pipercross’ premium Plus panel filter, produced in-house at Pipercross. The OE intake hose was to be reproduced as a silicone intake hose, to maintain proper flexibility and retain the heat-resistant properties of the OE hose, to create an introductory performance intake kit that provides meaningful engine performance improvement with no impacts to the long-term functionality/durability of the 2.4L boxer engine.

PLUS PANEL FILTER
The heart of the GR86 OEM+ Intake is Pipercross’ flagship panel filter; the Pipercross Plus. This filter features a hybrid, bespoke filtration multi-laminate foam to achieve the optimal balance between increased flow and air filtration. Additionally, the Plus filter range feature an industry-first, CNC-laser cut, 0.9mm thick stainless steel backing frame that increases effective airflow 22.1% over typical mesh backing frames. Plus filters are the performance bedrock for the entire Pipercross OEM+ Intake, with all other components meticulously designed to leverage this remarkable airflow performance

INTAKE HOSE
The Pipercross intake hose compliments the performance features of the Plus panel filter, further bolstering the overall performance of the Pipercross OEM+ kit. The thick-walled, 4ply silicone construction of the Pipercross hose has both more heat resistant and more flexible than alternative aluminium hard pipe options. The thermal resistance of this part is crucial in the GR86 application, to manage intake air temperatures during aggressive vehicle operation. The OE intake hose also features this type of heat-resistant polymer construction but the flow-destabilising flexible convolutions  in the OE are eliminated with the Pipercross part. Similarly, the Pipercross hose mimics the flexible characteristics of the OE hose, ensuring parts do not contact or bind during significant engine movement. Unlike the OE hose, the exterior of Pipercross part is finished in a smooth, gloss black with a prominently featured white logo - adding a level of “OEM+” aesthetic to any GR86 engine bay.

RESEARCH AND DEVELOPMENT
All Pipercross products are designed in-house, utilising the latest 3D-printing, 3D-scanning, CAD, CFD, airflow testing and performance testing product development technologies. The set of Pipercross GR86 Intake Kits saw several design stages/iterations, maximize improvable performance aspects, while maintaining required design criteria. Bench airflow testing was conducted on the full OEM intake system and multiple Pipercross prototype intake design iterations, using Pipercross’ in-house, custom designed and built airflow test apparatus inside a controlled environment. Performance testing of the OEM and final OEM+/open cone Pipercross intake designs was completed at a third party, independent, environmentally regulated Dynojet dynamometer cell; to ensure unbiased, final performance gain data was captured.

AIRFLOW TESTING DATA
Two intake configurations were tested on Pipercross’ in-house, custom built stationary airflow test apparatus to acquire final performance data for the Pipercross kit. To develop an initial performance benchmark, the full OE intake system (complete OE airbox, filter and intake hose) were flow tested to a maximum airflow value of 759 CFM. The Pipercross OEM+ intake system was then tested, to gauge the resulting airflow and performance increase.

The graph below summarizes the results of this testing and serves to confirm the performance benefit of the Pipercross intake kit. In addition to the 56.23% maximum/23.08% average decrease in airflow restriction, the Pipercross intake can also support airflow values up to 774 CFM (to the OE kit’s maximum 759 CFM), thus verifying the “introductory” airflow upgrades targeted by the Pipercross OEM+ kit.

PERFORMANCE TESTING DATA
As detailed above, the final configuration of the Pipercross OEM+ Intake Kit were tested on an unmodified 2023 Toyota GR86, to acquire data on the actual performance gained by the Pipercross kit. This testing was conducted utilising a third-party, independent Dynojet dynamometer within a temperature and airflow-controlled test cell. To ensure the data captured only quantifies the performance of the Pipercross intake; only the intake systems were changed between tests. Additionally, all tests were conducted on the same day, within the same cell and the vehicle was allowed to cool between testing sets.The data graphed shows the average of three runs for both the complete OE intake system, as well as Pipercross OEM+ Intake system. A maxium increase of +13.96WHP & + 13.04ft-lbs WTQ were achieved @ 5600RPM, as the data confirms, the Pipercross intake provides meaningful performance improvements throughout the engine speed range, particularly considering the simplicity of the Pipercross kit. Additionally (and not clearly demonstrated in the data provided) is the consistency at which both the OE and Pipercross intakes performed. Each intake configuration posted data within ~5% for all three testing runs, indicating that both the OE and Pipercross OEM+ intake configurations are markedly resistant to the adverse effects of high engine bay temperatures - which would be expected given that the most beneficial OE intake components have been reused within the Pipercross kit.

Manufacturer:

PIPERCROSS

Manufacturer Part Number:

PK451

Quantity Per Package:

1

Filter type:

Long-life Filter