do88 Charge Cooler Manifold, BMW G-Serie (B58) / Toyota GR Supra A90

Enhance your B58 engine’s performance with the do88 Charge Cooler Manifold!

Background
The B58 engine, introduced with the F-series a few years back, has proven to be a real gem of an engine, capable of high outputs with great character. However, there are a few week points that needs addressing, both for performance and reliability. The B58 comes equipped with a water-to-air charge cooler that is coupled a with front-positioned heat exchanger (water radiator). The heat exchanger serves to cool the water circulating through the charge air cooler, which in turn helps dissipate heat from the charge air before it enters the engine. The charge air cooler is integrated into the intake manifold on the B58, making it an intricate and dense construction, demanding accuracy in the design and execution by us as an aftermarket producer.

Challenges with the factory components
Owners of tuned B58 engines often confront the issue of rapid heat soak in the charge air cooling system, particularly when the vehicle is used for track days. Elevated intake air temperatures may prompt the ECU to decrease the power output, or even switch the car into limp-home mode. Regular spirited street driving can also cause similar issues.

Additionally, the factory installed direct injection system, with its obvious benefits, is not well suited for high horsepower applications or ethanol flex fuel usage. To be able to inject more fuel, many turn to installing port fuel injector spacers between the intake manifold and the cylinder head. The downside with this solution is that it positions the injectors in a funny angle. As a result, the fuel hits the walls of the intake runners, leading to potential fuel puddling.

As is often the case, factory components can become limiting factors when you strive for high power levels, particularly in terms of airflow. The factory (OE) intake manifold is such a component, that not only restricts airflow but also poses a significant risk of cracking under high boost levels, due to its plastic construction.

The do88 solution

Bar&Plate core
Our manifold features a Bar&Plate design air-water core, which incorporates densely stacked cooling fins, offering great heat transfer. The core is precisely 102 mm (4 inches) thick, maximizing its effectiveness for this specific application. Both the air and water fins´ characteristics have undergone careful evaluation to achieve the ideal balance between optimal cooling and airflow.

Innovatively designed cast end tanks
The charge air and cooling water are evenly distributed across the core through carefully designed, cast end tanks. The development of these end tanks involved a comprehensive process, including 3D-scanning, multiple design iterations followed by Computational Fluid Dynamics (CFD) analysis and 3D-printing, before arriving at the finalized prototype. We opted for cast end tanks over CNC-machining. Casting allows complex shapes that better serves the desired function. To us, maximum performance supersedes the bling factor!

Engine Cover Compatibility
A key objective during the development of our do88 Charge Air Cooler, was ensuring its compatibility with the standard engine cover. It goes without saying, enthusiasts prefer to maintain the original appearance of their engine bay if possible. With this in mind, we invested significant effort to design a charge air cooler that not only makes a massive performance upgrade, but also fits beneath the engine cover. We even managed the challenging task of accommodating our auxiliary fuel rail under the engine cover. The devil is in the detail and to date, this unique feature sets the do88 kit apart from the competition. High performance builds tend to be made by enthusiasts that value the appearance equally as high as the sheer performance without compromise.