Do88 MERA intake manifold, BMW F-Series engine (B58)

Description

Improve the performance of your B58 engine with the MERA do88 charge cooling manifold!
Context
The B58 engine, introduced with the F series, has proven to be a true gem, capable of high performance with excellent character. However, a few weaknesses need to be addressed, both in terms of performance and reliability. The B58 features an air-to-water charge cooler coupled to a front-mounted heat exchanger (water radiator). This heat exchanger cools the water circulating through the charge air cooler, which helps dissipate heat from the charge air before it enters the engine. The charge air cooler is integrated into the intake manifold on the B58, making it a complex and dense construction that requires precision in design and execution from us as an aftermarket manufacturer.

Challenges with factory components
Owners of tuned B58 engines often encounter the problem of the charge air cooling system overheating rapidly, 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. Dynamic street driving can also cause similar issues.

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 blends such as ethanol. To inject more fuel, many opt for installing ported fuel injectors between the intake manifold and cylinder head. The drawback of this solution is that it positions the injectors at an awkward angle. As a result, fuel hits the walls of the intake ports, which can lead to fuel buildup.

As is often the case, factory components can become limiting factors when aiming for high power levels, particularly 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 boost pressures due to its plastic construction.

The do88 solution
This high-performance charge cooler is part of our MERA range! MERA, as in "more," means more cooling, better airflow, more performance. Simply put, MERA!

Garrett Motorsport Core
Our MERA manifold features a Bar&Plate design air-to-water core, crafted by the renowned Garrett Motorsport, which sets the industry standard for quality and performance. Its construction incorporates thin, densely stacked cooling fins, providing exceptionally efficient heat transfer. The core is precisely 102 mm (4 inches) thick, maximizing its efficiency for this specific application. The characteristics of the air and water fins have been meticulously evaluated to achieve the ideal balance between optimal cooling and airflow.

Innovative molded end tanks
Charge air and cooling water are evenly distributed across the core by carefully designed, molded 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 molded end tanks rather than CNC machining. Molding allows for complex shapes that better serve the intended function. For us, maximum performance trumps aesthetics!

Compatibility with the engine cover
One goal during the development of our do88 manifold was to maintain compatibility with the standard engine cover. It goes without saying that many enthusiasts prefer to preserve the original appearance of their engine bay whenever possible. With this in mind, we invested considerable effort in designing an air-charged intercooler that not only delivers a massive performance improvement but also allows the engine cover to be used. We successfully met the challenge of fitting our manifold under the engine cover.

Furthermore, with some modifications, it's possible to integrate our auxiliary fuel rail. To do this, the soundproofing material under the engine cover and hood must be removed. Additionally, the standard engine cover mounting pins must be replaced with longer ones, which we include in our kit. Note that installing the engine cover in this elevated position brings it much closer to the hood; a slight adjustment or reshaping of the hood support structure can be performed to increase clearance. We have verified this compatibility exclusively on BMW 340i F30/F31 models.

The devil is in the details, and to this day, this unique feature sets the do88 kit apart from the competition. High-performance builds tend to be created by enthusiasts who place as much importance on aesthetics as on pure, uncompromising performance.

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, which easily mounts to the outlet tank. We designed it to be compatible with Injector Dynamics ID1050x-34-14 (ID1050x-34-14-14) or Bosch EV14 Compact (K) fuel injectors. If you choose not to use port fuel injection, we provide injector caps for your convenience. Additionally, each cylinder on the outlet tank is equipped with a 1/8″ NPT port, suitable for nitrous or methanol injection – a power modification commonly used for the B58 engine (sealing caps are included).

Additional Measurement & Suction Ports
Integrated into the side of the manifold inlet reservoir, do88 has incorporated a 3-port mounting bracket directly into the molded part. This feature offers the flexibility to measure additional parameters or serve as an additional suction 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 (IAT), 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, otherwise typical of aluminum components. The spacer features a robust seal, achieved using custom-made FKM-silicone 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.

Plugs and caps included for customizing the collector
If you wish to close the crankcase vacuum connection to the manifold outlet, a plug is included specifically for this purpose. Additionally, a cap is provided to close the fuel tank vent line connection to the manifold inlet. These ports are commonly blocked for higher outlets, so we include them.

Product Details:
Utilizes a motorsport-grade, Bar&Plate type air-to-water intercooler core from Garrett, 102 mm (4″) thick. 11 rows of water cooling, OE 6 rows.
Lower intake air temperature under identical conditions: 23°C compared to the OEM 40°C. Exact figures can be found in the diagrams below the product images.
More air for your engine, less backpressure, and better airflow! Airflow at 0,1 bar / 1,45 psi pressure drop: 874 CFM (615 CFM), 42% more! See the diagram below the product photos.
Maximum power gain of 5 horsepower! Measured on a car with bootmod3 Stage 2+ optimization (BMW 340i 2017).
Power gain in the middle of the highest range of 18 horsepower!
Maximum torque gain of 28 Nm!
Designed in SolidWorks using computational fluid dynamics (CFD).
Easy access to the screw-on 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).
Fuel rail included (included in the MERA version) for auxiliary fuel injection via top port.
Injector caps for each cylinder runner are included.
Individual 1/8″ NPT ports on top of each cylinder runner for nitrous or methanol injection (sealing plugs are included).
Plug-and-play design, requiring no modifications for installation.
Included are all the essential supports needed for various components, such as wiring harnesses and the engine cover.
Can be installed with the OE engine cover. It even fits with modification when used with the auxiliary fuel injection rail via port (Only confirmed on BMW 340i F30/F31).
Thermal barrier spacer included, designed to isolate the aluminum intake manifold from conductive heat transfer from the cylinder head.
Custom-made FKM-silicone O-rings included for both the heat barrier spacer and the intake manifold (12 pcs total).

Compatibilities:

BMW 1′ M140i M140iX (F20 F21)
Engine: B58 Gen 1
Model years: 09/2015 –

BMW 2′ M240i M240iX (F22 F23)
Engine: B58 Gen 1
Model years: 09/2015 –

BMW 3′ 340i 340iX (F30 F31 F34)
Engine: B58 Gen 1
Model years: 10/2014 –

BMW 4′ 440i 440iX (F32 F33 F36)
Engine: B58 Gen 1
Model years: 03/2015 –

BMW 5 Series 540i 540iX (G30 G31)
Engine: B58 Gen 1
Model years: 10/2015 –

BMW 6 Series 640i 640iX (G32)
Engine: B58 Gen 1
Model years: 09/2016 –

BMW 7 Series 740i 740iX (G11 G12)
Engine: B58 Gen 1
Model years: 10/2014 –

BMW X3 M40iX (G01)
Engine: B58 Gen 1
Model years: 10/2016 –

BMW X4 M40iX (G02)
Engine: B58 Gen 1
Model years: 03/2017 –

OE Ref / Replaces

11618603913

In stock at the factory, delivery time approximately 7 working days from the time of order.