Improve the performance of your B58 engine with the MERA do88 charge cooler!
Background
The B58 engine, introduced with the F-Series a few years ago, has proven to be a true gem, 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 B58 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. The intercooler is integrated into the B58’s intake manifold, making it a complex and dense construction, requiring precision in design and execution from us as an aftermarket manufacturer.
Challenges with Factory Components
Owners of tuned B58 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. Even regular, brisk road driving can cause similar problems.
Furthermore, the factory-installed direct injection system, with its obvious advantages, is not suitable for high-horsepower applications or for the use of flex fuel with ethanol. To inject more fuel, many turn to installing fuel injector spacers between the intake manifold and the cylinder head. The disadvantage of this solution is that it positions the injectors at an odd angle. As a result, the fuel hits the intake runner walls, potentially causing fuel puddles.
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
This high-performance charge cooler is part of our MERA range! MERA as in plus 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, manufactured by the esteemed Garrett Motorsport, which sets the industry standard for quality and performance. Its construction incorporates thin, densely stacked cooling fins, which offer exceptionally efficient heat transfer. The core is precisely 102 mm (4 inches) thick, maximizing its effectiveness for this specific application. Both the air and water fin characteristics were meticulously 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!
Engine Cover Compatibility
A key objective during the development of our do88 intercooler was ensuring its compatibility with the standard engine cover. It goes without saying that enthusiasts prefer to maintain the original look of their engine bays whenever possible. With this in mind, we invested significant effort in designing an intercooler that not only provides a massive performance boost but also fits under the engine cover. We even accomplished the challenging task of accommodating our auxiliary fuel line under the engine cover. 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 crafted by enthusiasts who value looks as much as uncompromising performance.
Key Features
Versatile Manifold Design: From Fuel Injection to Power Modifications
Our manifold outlet reservoir is pre-configured to accommodate fuel injection from the auxiliary port. A custom-made fuel rail with AN-8 female thread is included, which easily installs onto the outlet reservoir. We designed it to be compatible with Injector Dynamics ID1050x-34-14 or Bosch EV14 Compact (K) 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 B58 engine (sealing plugs are included).
Extra Gauging and Vacuum Ports
Integrated into the side of the manifold inlet tank, do88 has incorporated a 3-port buffer 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.
Two 1/8″ BSPT ports are strategically placed on top of the rear water tank. These ports serve a dual purpose. They can be used to monitor inlet and outlet water temperatures, but they also act as bleed ports to assist in the air purging process, ensuring all air is effectively eliminated from the intake manifold. For convenience, 1/8″ BSPT plugs are included 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 constructed 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, 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 competing methods, which often rely on less reliable sealing agents.
Plugs and caps included for manifold customization
If you wish to seal the crankcase vacuum connection on the manifold outlet tank, a plug is included specifically for this purpose. Additionally, a plug is provided to close the fuel tank vent line connection on the manifold inlet tank. These ports are commonly blocked for higher outputs, so we include them.
Product Details:
Utilizes a high-performance, motorsport-quality, 102mm (4″) thick Garrett Bar & Plate air-to-water intercooler core. 11 rows of water cooling, OE 6 rows.
Lower inlet air temperature under identical conditions: 23°C (73°F) compared to OEM 41°C (106°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 0.1 bar / 1.45 psi pressure drop: 874 CFM (595 CFM), 47% more! See the diagram below the product images.
Maximum power gain of 5 HP! Measured on cars with bootmod3 Stage 2+ (BMW 340i 2017).
Highest average power gain of 18 HP!
Maximum torque gain of 28 Nm!
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).
Fuel rail included (included in the MERA version) for auxiliary injection of the top fuel port.
Injection plugs are included for each cylinder rail.
Individual 1/8″ NPT ports on the top of each cylinder rail for nitrogen or methamphetamine injection (plugs included).
Individual 1/8″ BSPT vent ports for both inlet and outlet water connections on the back of the manifold for easy system air purging (plugs included).
Plug-and-play design, requiring no modifications for installation.
All essential brackets required for various components, such as wiring harnesses and the engine cover, are included.
Can be installed with OE or aftermarket engine covers (with OE connections). It also fits with minor modifications when using the auxiliary port injection fuel rail.
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).