DO88 intake manifold for BMW M2 M3 M4 G80 G82 G87 S58 engine

Description

Description
Improve the performance of your S58 engine with the do88 Charge Cooler Manifold!
Context
The S58 engine, introduced with the G80/82 M3/M4 models in 2021+, has proven to be a true gem, capable of high performance with great character. However, there are a few weaknesses that require attention, both in terms of performance and reliability. The S58 is equipped with an air-to-water charge cooler coupled to a front-mounted heat exchanger (water radiator). The heat exchanger cools the water circulating through the charge cooler, which in turn helps dissipate heat from the charge air before it enters the engine.

Problems with factory components

The charge cooler is integrated into the intake manifold on the S58, making it a complex and dense construction that demands precision in design and execution from us as an aftermarket manufacturer. This design, which fuses the intercooler with the intake manifold, is effective; however, its performance is compromised by the finned tube core that is crimped to the thermoplastic tanks. These crimped connections have emerged as a significant vulnerability, with numerous failures occurring at pressures only slightly above the factory level.

Owners of tuned S58 engines often encounter the problem of rapid thermal saturation in the charge air cooling system, especially when the vehicle is used for track days. High intake air temperatures can cause the ECU to reduce power or even put the car into limp mode.

Furthermore, the factory-installed direct injection system, despite its obvious advantages, is not well-suited to high-power applications or the use of flex-fuel ethanol. To inject more fuel, many choose to modify the original intake by drilling additional holes for fuel injectors.

As is often the case, factory components can become limiting factors when you're aiming for high power levels, especially in terms of airflow. The factory (OE) intake manifold is one such component, which not only restricts airflow but also presents a significant risk of cracking under high pressure levels due to its plastic construction.

The do88 solution
Bar & Plate Core
Our manifold features a Bar&Plate design air-water core, incorporating densely stacked cooling fins for excellent heat transfer. The core is precisely 127 mm (5 inches) thick, maximizing its efficiency for this specific application. Our core is a remarkable 62 percent larger than the original! The characteristics of the air and water fins have been carefully evaluated to achieve the ideal balance between optimal cooling and airflow.

Innovative cast end tanks
Charge air and cooling water are distributed evenly throughout the core by meticulously designed, cast end tanks. Developing 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 final prototype. We opted for cast end tanks rather than CNC machining. Casting allows for complex shapes that better serve the intended function. For us, maximum performance takes precedence over aesthetics!

Key features
Versatile manifold design: From fuel injection to power modifications
Our manifold outlet tank is pre-configured to accommodate auxiliary port fuel injection. A custom-designed fuel rail with AN-8 female threads is included, making it easy to install on the outlet tank. We designed it to be compatible with Injector Dynamics ID1050x-34-14 (ID1050x-34-14-14) or Bosch EV14 (short) fuel injectors. If you choose not to use the fuel port injection, we provide injector blanking plugs for your convenience. Additionally, each cylinder port on the outlet tank is equipped with a 1/8″ NPT port, suitable for nitrate or methanol injection – a power modification commonly used for the S58 engine (sealing plugs are included).

Additional measurement and vacuum ports
Integrated into the side of the manifold outlet tank, do88 has incorporated a 3-port pad directly into the casting. This feature offers the flexibility to measure additional parameters or serve as an additional vacuum source. If you choose not to use these three 1/8″ NPT ports, sealing plugs are provided in the included hardware kit.

Advanced thermal management
Included with the intake manifold is a special thermal barrier spacer, designed to isolate the aluminum intake manifold from conductive heat transfer from the cylinder head. This barrier effectively lowers intake air temperatures (IATs), improves charge air cooler efficiency, and helps minimize the problem of thermal saturation. Unlike the OE plastic intake manifold, the do88 manifold is made of aluminum, capable of withstanding higher boost pressures. The thermal barrier spacer reduces conductive heat transfer, typically associated with aluminum components. The spacer features a robust seal, achieved through custom-made, high-specification silicone-FKM O-rings. These O-rings are installed in precision-machined grooves for a secure fit. This approach provides a significantly better seal compared to competitor methods, which often rely on less reliable sealants.

Product details:
Uses a Bar&Plate air-to-water intercooler core, 127 mm (5″) thick.
Maintains low intake air temperatures and shows an improvement over the original charge cooler. 28,5°C compared to OEM 33°C. Exact figures are available in the diagrams below the product images.
More air for your engine, less back pressure, and better airflow! Airflow at a pressure drop of 0,05 bar / 0,73 psi: 511 CFM (422 CFM), 21% higher! See the diagram below the product images.
Designed in SolidWorks using computational fluid dynamics (CFD).
Easy access to the removable oil filter for quick oil changes – no need to remove the manifold for every oil change.
Integrated sensor pad with three 1/8″ NPT ports for measuring additional parameters (sealing plugs are included).
The fuel rail is included for top auxiliary port injection.
Fuel injector caps for each cylinder port are included.
Individual 1/8″ NPT ports on top of each cylinder conduit for nitrate or methanol injection (sealing plugs are included).
Plug-and-play design, see installation instructions.
All essential supports needed for various components, such as cable harnesses, are included.
The thermal barrier spacer is included, designed to isolate the aluminum intake manifold from conductive heat transfer from the cylinder head.
High specification custom-made silicone-FKM O-rings are included for both the heat barrier spacer and the intake manifold (12 pieces total).

Suitable for
BMW M2 (G87)
Engine: S58
Model years: 2023 – 202X

BMW M3 / M3 Competition / M3 CS (G80)
Engine: S58
Model years: 2020 – 202X

BMW M4 / M4 Competition / M4 CSL (G82)
Engine: S58
Model years: 2020 – 202X

In stock