do88 Intake with Intercooler MERA, BMW G-Serie (B58) / Toyota GR Supra A90

MERA performance for your B58 with do88's intake and intercooler!

Background

The B58 engine, introduced in the F-series a few years back, has proven to be a true gem with great tuning potential and a pleasant character. However, there are a number of weak points that should be addressed, both regarding performance and durability. The B58 engine is equipped with a water-to-air intercooler, paired with a heat exchanger in the front. The heat exchanger, which is simply a front-mounted water radiator, helps cool down the coolant circulating through the intercooler, which in turn transfers heat from the supercharged intake air. This is a conventional and efficient solution. On the B58, the intercooler itself is integrated with the intake, making the entire design space-efficient, but also more complicated. This places high demands on an aftermarket manufacturer like us. It requires finesse – both in thought and execution!

Challenges with the Original Components

Owners of cars with a tuned B58 engine often face the problem of heat soak in the intercooler system. This is especially common during track driving but also occurs during spirited driving on public roads. As a consequence, the ECU reduces power to protect the engine, and sometimes the car can even enter limp-home mode.

The engine is equipped with direct injection, which definitely has its advantages regarding engine operation and efficiency, but has its obvious limitations with harder tuning or flexfuel optimization. To get around this, many install a spacer for low-pressure injectors between the intake manifold and the cylinder head. The disadvantage of this solution is that the injectors end up at an unfavorable angle. Fuel hits the intake runners, and the risk of unwanted fuel accumulation increases. It is not a good solution.

As in many other cases, the original components are designed for the manufacturer's specified power output, but soon become a limiting factor at higher power outputs – especially regarding airflow. The intake is one such part where the flow is simply insufficient. In addition, the plastic casting runs a high risk of cracking as boost pressure increases.

do88's solution: This intake with intercooler is part of our MERA range. More cooling, more flow, more power. Simply MERA!

Core from Garrett Motorsport

Our water-to-air cores are of the Bar&Plate type, manufactured by the reputable Garrett Motorsport, which has long set the standard for both performance and quality in automotive applications. The core is constructed with very thin and incredibly fine, tightly packed cooling fins that ensure exceptional heat transfer! The core measures 102 mm (4”) in thickness and is as generously sized as possible. In-depth evaluations of density and specification of the cooling fins on both the air and water sides mean that we have achieved the perfect balance between flow and cooling!

Innovative Design – Cast End Tanks

The charge air and coolant are evenly distributed over the core via carefully designed, cast end tanks. The finished product is the result of extensive design studies. Evaluation, revisions, analysis using Computational Fluid Dynamics (CFD), and several 3D prints were put into action before we reached the final design. The tanks are made of cast aluminum. CNC machining would have been a viable option, but it would only have added a "bling" factor and a higher price with no increased performance. For us, it's about achieving performance in the most efficient way – from several aspects. Casting also allows for shapes that CNC machining, in some cases, cannot achieve.

Compatibility with the Engine Cover

An important premise during this development was to guarantee fitment with the original engine cover. This is a key feature and a must for many enthusiasts who want the engine bay to look original. This requirement made the development significantly more difficult, but also the result more rewarding. We even managed to integrate our fuel rail under the engine cover, which means that even in its most comprehensive version, this kit can look original if desired. The overall integrity is based on the details, and we are proud to have succeeded with this goal! To date, do88 is the only manufacturer (as far as we know) of intake with intercooler for B58 that offers full compatibility – the obvious choice for the enthusiast who values visual impression as highly as pure performance!

Key features

• Core from the renowned Garrett Motorsport.
• Bar&Plate water-to-air core, 102 mm thickness.
• 11 cooling water rows vs original, 6 rows.
• More oxygen to your engine, less back pressure and better flow!
• Airflow at 0.1 bar / 1.45 psi pressure drop: 874 CFM (595 CFM), 47% higher! See diagram under product images.
• Lower inlet temperature under identical conditions: 23°C compared to original 41°C. Exact figures are in the diagrams under the product images.
• Peak power increase of 5 hp! Measured on a car with bootmod3 Stage 2+ (BMW 340i 2017).
• Highest power increase in the mid-range of 18 hp!
• Highest torque increase of 28 Nm!
• Designed in SolidWorks with Computational Fluid Dynamics (CFD).
• Allows access to the oil filter. The intake does not need to be removed during oil changes.
• Integrated sensor block with three 1/8” NPT ports for measuring additional parameters.
• Included fuel rail for extra low-pressure injectors fed through the intake. Plugs to close these ports are included.
• Each intake runner is prepared with 1/8” NPT ports for nitrous or methanol injection.
• Two 1/8” BSPT ports on the rear water tank for easy bleeding and the possibility to mount separate temperature sensors.
• Supplied complete with all accessories, brackets, and components needed for all given parts.
• Compatible with original and aftermarket engine covers (with original mounting points).
• Even the extra fuel rail works with the cover with only minor modifications.
• Heat-dissipating spacer counteracts heat transfer from the cylinder head to the intake.
• Specially manufactured FKM-silicone O-ring seals are included. 12 pieces in total.
• Plug and Play! No modifications required during installation.

Outlet Tank Design – Prepared for Low-Pressure Injectors

Our outlet tank is prepared and adapted for additional low-pressure injectors. A unique, custom-designed fuel rail with AN8 connections (female) is included and easily mounted on the intercooler's outlet tank. The product is designed for Injector Dynamics ID1050x-34-14 (ID1050x-34-14-14) or Bosch EV14 Compact (K) fuel injectors. If you do not wish to use any additional injectors, plugs are included to easily seal these openings. In addition, each runner is equipped with 1/8” NPT ports for methanol or nitrous injection, which are often used on these engines.

Measurement and Vacuum Ports

Integrated into the inlet tank is a block with three ports. This allows for reading additional parameters and provides access to extra vacuum ports. Plugs in suitable 1/8” NPT are included and provide a secure seal if these ports are not used.

On top of the rear water tank, there are two 1/8” BSPT ports. These are strategically placed and serve dual purposes. Since the tank is divided in the middle internally, two temperature sensors can be connected, thereby reading the delta of the water's inlet and outlet from the intercooler. Furthermore, the ports facilitate bleeding the system, as they are located at the highest point of the system. Suitable plugs are included when these functions are not used.

Advanced Heat Management

The intercooler comes with a thick, heat-dissipating spacer, whose purpose is to insulate the intake from the cylinder head and thus counteract heat transfer from the engine. This gasket effectively lowers the inlet temperature and increases the intercooler's efficiency by minimizing heat soak. The intercooler is made of aluminum and is therefore superior in terms of strength. However, aluminum has the disadvantage of higher conductivity. This spacer eliminates the mentioned heat transfer.

The spacer guarantees a secure joint as it is supplied with specially manufactured FKM-silicone O-rings, which rest in precision-milled grooves. While some competitors rely on gasket sealant and other less secure sealing methods, this provides a seal you can trust.

Included Plugs for Intake Modification

At high power outputs, it is desirable to limit the number of potential failure points. The connection for crankcase ventilation and for tank ventilation (EVAP), both of which connect to respective tanks on the intercooler, can therefore be completely closed with our included blanking plugs.