do88 Charge Cooler Intake Manifold - BMW F/G-Series (B58 Gen.1)

Increase the performance of your B58 with the do88 intake with intercooler!

Background
The B58 engine introduced in the F series has proven to be a real gem with great tuning potential and nice character. However, there are a number of weak points that should be reviewed, both in terms of 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 cool the refrigerant 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, which makes the whole construction 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 are often faced with the problem of heat saturation, so-called heat soak, in the intercooler system. This is particularly common when driving on a track, but also occurs when driving inspired on public roads. As a consequence of this, the ECU lowers the power to protect the engine and sometimes the car can even end up in limp-home mode.

The engine is equipped with direct injection, which definitely has its advantages in terms of engine running and efficiency, but which has its obvious limitations when tuning harder or flexfuel optimization. To get around this, many people install a low-pressure injector spacer between the intake manifold and the cylinder head. The disadvantage of this solution is that the spreaders end up at an unfavorable angle. The fuel hits the intake channels and the risk of unwanted fuel accumulation increases. It is not a good solution.

As in many other cases, the original components are intended for the original manufacturer's specified power, but soon become a limiting factor at higher power outputs - especially with regard to airflow. The intake is such a part where the flow is simply not enough. In addition, the plastic casting runs a great risk of cracking as the charging pressure increases.

Bar&Plate Cell Pack
Our intake has a Bar&Plate type water/air cell pack, which is constructed with very thin and incredibly fine, tightly packed heat sinks that ensure exceptional heat transfer! The cell pack measures 102mm (4”) in thickness and is as well sized as it gets. In-depth evaluations of the density and specification of the heatsinks on both the air and water side means that we have reached the perfect balance between flow and cooling!

Innovative design – molded end tanks
The charge air and refrigerant are evenly distributed over the cell pack via carefully designed, molded 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 added to the documents before we reached the final execution. The tanks are made of cast aluminium. CNC machining would have been a viable option, but it would have only added a bling factor as well as higher price and no increased performance. For us, it's about achieving performance in the most efficient way - from several aspects. Casting also allows forms that CNC machining in some cases cannot.

Compatibility with the engine cover
An important goal during this development was to be able to provide the opportunity to mount our intake together with the original engine cover. It's a key feature and a must-have 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.

In addition, it is possible with certain modifications to mount our intake together with our extra fuel rail. For that to be possible, the sound dampening mat under both the hood and engine cover must be removed. Also, the engine cover mounting studs need to be replaced with longer ones, which we include in our kit. Note that installing the engine cover in this raised position brings it close to the engine hood; a minor cutting or reshaping of the bonnet reinforcement on the underside can be done for increased clearance. We have only verified this compatibility on the BMW 340i F30/F31 models.

The whole is founded in the details and we are proud to have succeeded in this goal! To date, do88 is the only manufacturer (to our knowledge) of intercooler intakes for the B58 that offer full compatibility - the obvious choice for the enthusiast who values visual appeal as much as sheer performance!

The design of the outlet tank - prepared for low-pressure sprinklers
Our outlet tank is prepared and adapted for extra low-pressure sprinklers. A unique, custom designed fuel bridge with AN8 (female) connections is included and easily mounts to the intercooler outlet tank. The product is designed for Injector Dynamics ID1050x-34-14 or Bosch EV14 Compact (K) fuel injectors. If you do not want to use any extra diffusers, plugs are included to easily close these openings. In addition, each runner is provided with 1/8” NPT ports for methanol or nitrous oxide injection commonly used on these engines.

Measuring outlets and vacuum ports
Integrated into the inlet tank is a block with three outlets. This gives the opportunity to read additional parameters and gives access to extra vacuum outlets. Plugs in matching 1/8” NPT are included and provide a secure seal if these ports are not in use.

Advanced heat management
The intercooler comes with a thick, heat-dissipating spacer, the purpose of which is to isolate the intake from the cylinder head and thus prevent heat transfer from the engine. This gasket effectively lowers inlet temperature and increases intercooler efficiency as it minimizes heat soak. The intercooler is made of aluminum and thus superior in terms of strength. However, aluminum has the disadvantage of higher conductivity. This spacer eliminates said heat transfer.

The spacer guarantees a secure joining as it is supplied with specially made FKM silicone o-rings, which rest in precision milled grooves. As some competitors rely on caulk and other less secure packing methods, this provides a seal you can trust.

• Bar&Plate water/air cell pack, 102mm 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 (615 CFM), 42% higher! See diagram below the product images.
• Lower inlet temperature under identical conditions: 26°C compared to original 40°C. Exact numbers can be found in the charts below the product images.
• Peak power increase of 5 hp! Measured on car with bootmod3 Step 2+ (BMW 340i 2017).
• Highest power increase in the middle 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 does not need to be dismantled when changing the oil.
• Integrated sensor block with three 1/8” NPT sockets to measure additional parameters.
• Fuel rail is available to buy as an accessory (not included) for extra low pressure injectors fed through the intake.
• Plugs to close the extra diffuser ports are included.
• Each inlet pipe is prepared with 1/8” NPT ports for nitrous oxide or methanol injection.
• Comes complete with all accessories, fasteners and components needed for any given part.
• Compatible with the original engine cover. Even the extra fuel rail works with some modifications (We have only verified it on the BMW 340i F30/F31).
• Heat-dissipating spacer prevents heat transfer from the cylinder head to the intake.
• Specially manufactured O-ring seals in FKM silicone are included. 12 pieces in total.
• Plug and Play! No modifications are required during assembly.

Link to installation instructions

O.E References: 11618603913