Improve the performance of your S58 engine with the do88 charge cooler!
Background
The S58 engine, introduced with the 2021+ G80/82 M3/M4 models, has proven to be a true gem of an engine, capable of high power and great character. However, there are some weaknesses that need to be addressed, both in terms of performance and reliability. The S58 features a water-to-air charge cooler coupled with a front-mounted heat exchanger (water radiator). The heat exchanger serves to cool the water circulating through the intercooler, which in turn helps dissipate heat from the charge air before it enters the engine.
Challenges with Factory Components
The intercooler is integrated into the S58’s intake manifold, making it a complex and dense construction, requiring precision in design and execution from us as an aftermarket manufacturer. This design, which joins the intercooler to the intake manifold, is effective; however, its performance is compromised by the tube-and-fin core crimped to the thermoplastic tanks. These crimped connections have emerged as a significant vulnerability, with numerous failures occurring at boost just above factory levels.
Owners of tuned S58 engines often face the problem of rapid heat absorption 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 output or even put the car into limp mode.
Furthermore, the factory-installed direct injection system, with its obvious advantages, is not suitable for high-power applications or for flex-fuel use with ethanol. To inject more fuel, many turn to modifying the stock intake by drilling holes for the port fuel injectors.
As is often the case, factory components can become limiting factors when seeking high levels of power, especially in terms of airflow. The factory (OE) intake manifold is a component that not only restricts airflow but also carries a significant risk of failure at high boost levels due to its plastic construction.
THE DO88 SOLUTION
Bar & Plate Core
Our manifold features a Bar & Plate air-to-water core, incorporating densely stacked cooling fins for excellent heat transfer. The core is precisely 127 mm (5 inches) thick, maximizing its effectiveness for this specific application. Our core is significantly larger—62% larger than stock! Both the air and water fin characteristics have been carefully evaluated to achieve the ideal balance between optimal cooling and airflow.
Innovative Cast End Tanks
Charge air and cooling water are evenly distributed throughout the core through carefully designed cast end tanks. The development of these end tanks involved a comprehensive process, including 3D scanning, multiple design iterations, followed by CFD (Computational Fluid Dynamics) analysis, and 3D printing, before arriving at the final prototype. We opted for cast end tanks over CNC machining. Casting allows for complex shapes that better serve the desired function. For us, maximum performance trumps the glitz factor!
Key Features
Versatile Manifold Design: From Fuel Injection to Power Modifications
Our manifold outlet tank is pre-configured to accommodate fuel injection from the auxiliary port. A custom fuel rail with AN-8 female thread is included, which easily installs onto the outlet tank. We designed it to be compatible with Injector Dynamics ID1050x-34-14 or Bosch EV14 (short) fuel injectors. If you choose not to use outlet fuel injection, we provide injector blanking plugs for your convenience. Additionally, each cylinder rail on the outlet tank features a 1/8″ NPT port suitable for nitrous or methanol injection, a commonly used power modification for the S58 engine (sealing plugs are included).
Extra Gauging and Vacuum Ports
Integrated into the outlet tank side of the manifold, the do88 has a 3-port buffer built 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, blanking 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 reduces intake air temperatures (IAT), improves intercooler efficiency, and helps minimize heat buildup. Unlike the OE plastic intake manifold, the DO88 manifold is made of aluminum, which can withstand 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, high-spec FKM silicone O-rings. These O-rings are installed in precisely machined grooves for a secure fit. This approach provides a significantly better seal than competitor methods, which often rely on less reliable sealing agents.
Product Details:
Utilizes a high-performance, 5″ (127 mm) thick Bar & Plate air-to-water intercooler core.
Maintains low air intake temperatures and shows improvements over the OE charge cooler manifold. 28.5°C (83°F) versus the OEM 33°C (91°F). Exact data can be found in the diagrams below the product images.
More air to your engine, less backpressure, and better airflow! Airflow at 0.05 bar / 0.73 psi pressure drop: 511 CFM (422 CFM), 21% more! See the diagram below the product images.
Designed in SolidWorks using Computational Fluid Dynamics (CFD).
Easy access to the spin-off oil filter for quick oil changes: no need to remove the manifold for every oil change.
Integrated sensor mat with three 1/8″ NPT ports for measuring additional parameters (plugs included).
A fuel rail is included for auxiliary top-fuel port injection.
Fuel injector plugs are included for each cylinder rail.
Individual 1/8″ NPT ports on the top of each cylinder rail for nitrous or meth injection (plugs included).
Plug-and-play design, see installation instructions.
All essential brackets required for various components, such as wiring harnesses, are included.
A heat barrier spacer is included, designed to isolate the aluminum intake manifold from conductive heat transfer from the cylinder head.
Custom-made, high-spec FKM silicone O-rings are included for both the heat barrier spacer and the intake manifold (12 total).