DO88 Performance Intercooler for BMW F8X M2C / M3 / M4 S55 Engine

Description

do88 performance intercooler designed for easy installation in your BMW M2 / M3 / M4 F8X

The S55 turbo engine found in the BMW M2C/M3/M4 F8X uses a top-mounted, water-cooled intercooler rather than a conventional air-cooled one. This OE intercooler has a tube-and-fin core with tightly fitted plastic end tanks. This design has its drawbacks, as it is prone to cracking and leaking coolant into the engine or boost pressure from the tank seals.

Our mission when we began developing this new performance intercooler was to eliminate the weaknesses of the OE intercooler and, of course, to deliver a significant performance increase. Throughout all the testing we conducted during the development of our entire BMW F8X M2C/M3/M4 product range, we clearly saw how maximum power is directly related to intake air temperature (IAT).
To obtain an accurate 3D model of the available space for designing our intercooler, we performed a detailed 3D scan of our M3 Competition engine bay. Using Solidworks CAD software, we tested several design concepts for our intercooler piping based on the model generated by the 3D scan.

The final design was decided after several CFD simulations in our Solidworks flow simulation software. With this software, we can simulate airflow and measure pressure drop and air distribution across the intercooler core. We decided against including internal air guides because several of our simulations showed they did more harm than good. Contrary to what many claim, the airflow is perfectly distributed across the intercooler core with our tank design, which lacks internal air guides. However, in many cases, these guides cause turbulence and disturbances in the airflow.

Our final design resulted in a bar-and-plate intercooler core with TIG-welded aluminum end tanks. This provides peace of mind for any high-boost optimization. We managed to use a massive intercooler core that is 85% larger than the OEM core and reduce (by 16%) the boost air pressure drop, while maintaining a plug-and-play installation without modifications. Reducing the boost air pressure drop across the intercooler has several advantages, such as the turbos needing to work less to reach the target boost pressure, lower temperatures, and improved throttle response. We have the equipment to calculate the pressure drop in our CFD software and also conduct real-world testing on our SF-1020 SuperFlow test bench. On the coolant side, we have switched to a dual-pass flow structure which allows the coolant to pass through the intercooler core twice before exiting the intercooler instead of the OE single-pass structure.

We use a high-density, offset cooling fin on both the air and water sides. Extensive testing was conducted to find the optimal balance between the air and water fins for maximum heat transfer. This gives our intercooler a significantly larger active cooling area compared to the OEM.

Naturally, being a do88 performance product, we conducted rigorous, severe, and continuous testing during its development to ensure optimal performance. No compromises were made.

All this hard work results in a product that will, in one way or another, truly improve the performance of your vehicle, whether it's a standard car or a heavily modified monster! On the track, on the road, on the strip, this intercooler will be your true companion!

Significant advantages with the do88 performance intercooler (stock comparison numbers):
– Maximum power gain of 13 horsepower! Measured on a car with BootMod3 Stage 1 optimization.
– Power gain in the middle of the highest range of 25 horsepower!
– Maximum torque gain of 52 Nm!
– Larger intercooler core volume: 5657cm3 (3052cm3), 85% larger!
– Airflow at a pressure drop of 0,025 bar / 0,36 psi: 298 CFM (256 CFM), 16% higher!
– Lower air temperature after the intercooler under the same conditions: 39°C (48°C), 9°C lower!*
– Fits all cars on the list below!
* Measured at 240 km/h during full-throttle acceleration from 0 to 240 km/h on a runway. Both tests were carried out on the same day under the same conditions.

Compatibilities:

BMW M2 Competition
Model years: 2019-2020
Models: F87

BMW M3 / M3 Competition
Model years: 2015-2018
Models: F80

BMW M4 / M4 Competition / M4 GTS / M4 CS
Model years: 2015-2020
Models: F82 F83