Increase the performance of your S58 engine with the do88 intercooler manifold!
Background
The S58 engine, introduced with the 2021+ G80/82 M3/M4, has proven to be a real gem of an engine, capable of high performance with great character. However, there are some weak points that need to be addressed for both performance and reliability. The S58 is equipped with a water-to-air intercooler coupled with a front-positioned heat exchanger (water cooler mesh). The heat exchanger serves to cool the water circulating through the intercooler, which in turn helps to dissipate the heat from the charge air before it enters the engine.
Challenges with the factory components
The intercooler is integrated into the intake pipe of the S58, making it a complicated and tight construction and requiring precision in design and execution from us as an aftermarket manufacturer. This design, which connects the intercooler to the intake pipe, is effective; however, its performance is compromised by the tube-and-fin intercooler mesh, which is connected to the thermoplastic tanks by crimping. These crimped connections have proven to be a significant weak point, with numerous failure cases occurring at just slightly above factory levels of boost.
Owners of tuned S58 engines often face the problem of rapid heat buildup in the intercooler system, especially when the vehicle is used for track days. Increased intake air temperatures can cause the ECU to reduce power or even put the car into limp mode.
Additionally, the factory-installed direct injection system, despite its obvious advantages, is not well suited for insane horsepower applications or ethanol flex-fuel use. To be able to inject more fuel, many resort to drilling holes for port fuel injectors in the stock intake manifold.
As is often the case, factory components can become limiting factors when striving for high performance levels, especially in terms of airflow. The stock (OE) intake manifold is one such component that not only restricts airflow, but also presents a significant risk of cracking under high boost levels, due to its plastic construction.
The do88 solution
Bar&Plate Intercooler Core
Our manifold features a Bar&Plate design air-water core that includes densely stacked cooling fins for great heat transfer. The core is exactly 127mm (5 inches) thick, maximizing its effectiveness for this specific application. Remarkably, our core is 62 percent larger than stock! Both the air and water fin characteristics were carefully evaluated to achieve the ideal balance between optimal cooling and airflow.
Innovatively designed cast end tanks
The charge air and cooling water are evenly distributed throughout the network through carefully designed cast end tanks. The development of these end tanks involved an extensive process including 3D scanning, several design iterations followed by Computational Fluid Dynamics (CFD) analysis and 3D printing before the final prototype was reached. We opted for cast end tanks rather than CNC machining. Casting allows for complex shapes that better fulfill the desired function. For us, maximum performance trumps the bling factor!
Key Features
Versatile Manifold Design: From Fuel Injection to Performance Modifications
Our manifold outlet tank is pre-configured to support auxiliary port fuel injection. A custom fuel rail with female AN-8 threads is included, which is easy to install on the outlet tank. We designed it for compatibility with Injector Dynamics ID1050x-34-14 or Bosch EV14 (short) fuel injectors. If you choose not to use port fuel injection, we provide injector plugs. Additionally, each cylinder barrel on the outlet tank is equipped with a 1/8” NPT port suitable for nitrous oxide or methanol injection – a commonly used performance modification for the S58 engine (plugs are included).
Additional Gauge & Vacuum Ports
Integrated into the side of the collector inlet tank, do88 has built a 3-port pad directly into the casting. This feature provides the flexibility to measure additional parameters or serve as an additional vacuum source. Should you not wish to use these three 1/8” NPT ports, blanking plugs are provided in the included hardware kit.
Advanced Thermal Management
Included with the intake manifold is a special thermal barrier spacer, designed to isolate the aluminum intake pipe from conductive heat transfer from the cylinder head. This barrier effectively lowers intake air temperatures (IAT's), improves intercooler efficiency and helps minimize the problem of heat buildup. Unlike the OE plastic intake manifold, the do88 manifold is made from aluminum, which can withstand higher boost pressures. The thermal barrier spacer reduces the conductive heat transfer otherwise typical of aluminum components. The spacer features a robust seal achieved by custom-made, high-spec FKM silicone o-rings. These o-rings are installed in precisely machined grooves for a secure fit. This approach provides a significantly better seal compared to the methods used by other competitors, who often rely on less reliable sealants.
Product details:
- Utilizes a high performance, bar&plate, air-to-water intercooler core, 127mm (5 inches) thick.
- Maintains low intake air temperatures and shows improvement over the OE intercooler. 28.5°C compared to OEM 33°C. Exact numbers can be found in the charts below the product images.
- More air for your engine, less back pressure and better airflow! Airflow at 0.05 bar / 0.73 psi pressure drop: 511 CFM (422 CFM), 21% higher! See diagram below product images.
- Designed in SolidWorks using Computational Fluid Dynamics (CFD).
- Easy access to the screw-on oil filter for quick oil changes - no need to remove the distributor every time you change the oil.
- Integrated sensor pad with three 1/8″ NPT connections for measuring additional parameters (sealing plugs are included).
- Fuel rails for additional top feed injection are included.
- Fuel injection plugs for each cylinder barrel are included.
- Individual 1/8″ NPT ports on the top of each cylinder barrel for nitrous oxide or methanol injection (plugs included).
- Plug and play design, see installation instructions.
- All necessary brackets for various components, such as wiring harnesses, are included.
- Thermal barrier spacers are included, designed to isolate the aluminum intake pipe from conductive heat transfer from the cylinder head.
- Custom made high quality FKM silicone O-rings are included for both the thermal barrier spacer and the inlet tube (12 total).
Suitable for the following models:
BMW G87 M2
Engine: S58
Years of manufacture: 2023 – 202X
BMW G80 M3 / M3 Competition / M3 CS
Engine: S58
Years of manufacture: 2020 – 202X
BMW G82 M4 / M4 Competition / M4 CSL
Engine: S58
Years: 2020 – 202X