do88 Intake with Intercooler, BMW M2 M3 M4 G80 G82 G87 (S58)

Enhance the performance of your S58 engine with do88's intake with intercooler!

Background

The S58 engine, introduced with the G80/82 M3/M4 2021+, has proven to be a true gem of an engine, capable of high power output with fantastic character. However, there are some weaknesses that need to be addressed, both for performance and reliability. The S58 is equipped with a water-to-air intercooler that is connected to a heat exchanger located at the front. The front heat exchanger cools 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 Original Components

The intercooler is integrated into the S58's intake manifold, making it a complex and compact design that requires precision in design and execution from us as an aftermarket manufacturer. This design, combining the intercooler with the intake manifold, is effective; however, its performance is compromised because the Tube&Fin core is only clamped to its plastic tanks. This mounting of the tanks has proven to be a significant vulnerability, with many cases where the end tanks "popped" off the core at only slightly higher boost pressures than original.

Owners of tuned S58 engines often encounter the problem of rapid heat soak in the charge air cooling system, especially during track driving. High intake temperatures can cause the ECU to reduce power output, or even put the car into limp mode. Furthermore, the factory-installed direct injection system, with its obvious advantages, is not well suited for insane power levels or the use of ethanol/flex fuel. To inject more fuel, many modify the standard intake by drilling holes for additional low-pressure injectors. As is often the case, original components can become limiting factors when striving for high power levels, especially concerning airflow. The factory-fitted (OE) intake manifold is one such component, which not only restricts airflow but also poses a significant risk of cracking under high boost pressures due to its plastic construction.

do88's Solution

Bar&Plate Core

Our intake with intercooler features a Bar&Plate air-to-water core, which contains densely stacked cooling fins, offering great heat transfer. The core is a full 127 mm (5”) thick, maximizing its efficiency. Our core is an incredible 62 percent larger than the original! Both air and water fin specifications have been carefully evaluated to achieve the ideal balance between optimal cooling and airflow.

Innovatively Designed Cast End Tanks

The charge 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 from cast aluminum. CNC machining would have been a viable option, but it would only have added a "bling factor" and a higher price without increasing 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.

Key features

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 included, which 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 (short) 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 outlet tank is a block with three ports. 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.

Advanced Heat Management

Included with the intercooler is a thick, heat-dissipating spacer, whose purpose is to insulate the intake 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 connection as it comes 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.