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

Boost your B58's performance with do88's intake manifold with intercooler!

Background

The B58 engine, introduced in the F-series a few years ago, 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/air intercooler, paired with a heat exchanger in the front. The heat exchanger, which is simply a front-mounted water cooler, helps to cool down the coolant circulating through the intercooler, which in turn transfers heat from the supercharged intake air. This is a conventional and effective solution. On the B58, the intercooler itself is integrated with the intake manifold, 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 particularly 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 which has its obvious limitations with more aggressive tuning or flexfuel optimization. To circumvent 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, but soon become a limiting factor at higher power outputs – especially regarding airflow. The intake manifold is one such part where the flow is simply insufficient. In addition, the plastic casting runs a high risk of cracking when boost pressure increases.

Bar&Plate Core

Our intake manifold features a Bar&Plate type water/air core, which 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 the density and specification of the cooling fins on both the air and water sides have allowed us to achieve the perfect balance between flow and cooling!

Innovative Design – Cast End Tanks

The boost air and coolant are evenly distributed across the core via meticulously 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 all part of the process before we reached the final design. The tanks are made of cast aluminum. CNC machining would have been a viable alternative, 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 cannot achieve in some cases.

Compatibility with the Engine Cover

A key 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 whole is based on the details, and we are proud to have succeeded with this goal! To date, do88 is the only manufacturer (to our knowledge) of intake manifolds with intercoolers for the B58 that offers full compatibility – the obvious choice for the enthusiast who values visual impression as highly as pure performance!

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 (female) connections is available for separate purchase and can be 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 oxide injection, which are often used on these engines.

Measurement and Vacuum Ports

Integrated into the inlet tank is a block with three outlets. This provides the ability to read additional parameters and gives 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, two 1/8” BSPT outlets are found. These are strategically placed and serve dual purposes. By having the tank internally divided in the middle, dual temperature sensors can be connected, thereby allowing the delta of the water's inlet and outlet from the intercooler to be read. 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 Thermal Management

Included with the intercooler is a thick, heat-dissipating spacer, whose purpose is to insulate the intake manifold from the cylinder head and thereby 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 rely on.

Key features

• Bar&Plate water/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: 873 CFM (595 CFM), 47% higher! See diagram under product images.
• Lower inlet temperature under identical conditions: 26°C compared to original 41°C. Exact figures can be found 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 manifold does not need to be removed during oil changes.
• Integrated sensor block with three 1/8” NPT outlets for measuring additional parameters.
• Fuel rail available for purchase as an accessory (not included) for extra low-pressure injectors fed through the intake manifold.
• Plugs to close the extra injector ports are included.
• Each intake runner is prepared with 1/8” NPT ports for nitrous oxide or methanol injection.
• Two 1/8” BSPT outlets 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 manifold.
• Specially manufactured FKM-silicone O-ring seals are included. 12 pieces in total.
• Plug and Play! No modifications required during installation.