do88 Charge Cooler Manifold, BMW M2 M3 M4 G80 G82 G87 (S58)

Enhance your S58 engine’s performance with the do88 Charge Cooler Manifold!

Background
The S58 engine, introduced with the G80/82 M3/M4 2021+, 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 S58 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.

Challenges with the factory components

The charge air cooler is integrated into the intake manifold on the S58, making it an intricate and dense construction, demanding accuracy in the design and execution by us as an aftermarket producer. This design that merges the intercooler with the intake manifold is effective; however, its performance is compromised by the tube-and-fin core that is attached to the thermoplastic tanks through crimping. These crimped connections have emerged as a significant vulnerability, with numerous instances of failure occurring with boost just a bit beyond the factory level.

Owners of tuned S58 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.

Additionally, the factory installed direct injection system, with its obvious benefits, is not well suited for insane horsepower applications or ethanol flex fuel usage. To be able to inject more fuel, many turn to modifying the stock intake by drilling holes for port fuel injectors.

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 127 mm (5 inches) thick, maximizing its effectiveness for this specific application. Our core is remarkably 62 percent larger than stock! 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!