do88 Chargecooler Manifold BMW B58 F-Series Gen.1

do88 Chargecooler Manifold BMW B58 F-Series Gen.1

The B58 engine, introduced with the F-series, is a remarkable engine known for its high output and great character. However, there are a few weaknesses that need addressing for both performance and reliability. The B58 is equipped with a water-to-air charge cooler coupled with a front-positioned heat exchanger (water radiator). The heat exchanger cools the water circulating through the charge air cooler, which in turn helps dissipate heat from the charge air before it enters the engine. The charge air cooler is integrated into the intake manifold, making it an intricate and dense construction demanding accuracy in design and execution by us as an aftermarket producer.

Challenges with the Factory Components

Owners of tuned B58 engines often face rapid heat soak in the charge air cooling system, particularly during track days. Elevated intake air temperatures may prompt the ECU to reduce power output or even switch the car into limp-home mode. Regular spirited street driving can also cause similar issues.

Additionally, the factory-installed direct injection system, despite its benefits, is not well-suited for high horsepower applications or ethanol flex fuel usage. To inject more fuel, many install port fuel injector spacers between the intake manifold and the cylinder head. However, this positions the injectors at an awkward angle, causing fuel to hit the walls of the intake runners and potentially leading to fuel puddling.

Factory components can limit high power levels, particularly in terms of airflow. The factory (OE) intake manifold restricts airflow and poses a significant risk of cracking under high boost levels due to its plastic construction.

The do88 Solution

Bar & Plate Core

Our manifold features a Bar & Plate design air-water core with densely stacked cooling fins, offering excellent heat transfer. The core is precisely 102 mm (4 inches) thick, maximising effectiveness for this specific application. Both air and water fins’ characteristics have been carefully evaluated to achieve the ideal balance between optimal cooling and airflow.

Innovatively Designed Cast End Tanks

The charge air and cooling water are evenly distributed across the core through carefully designed cast end tanks. The development of these end tanks involved a comprehensive process, including 3D scanning, multiple design iterations, Computational Fluid Dynamics (CFD) analysis, and 3D printing before arriving at the final prototype. Casting allows complex shapes that better serve the desired function, prioritising performance over appearance.

Engine Cover Compatibility

A goal during the development of our do88 manifold was to maintain compatibility with the standard engine cover. Many enthusiasts prefer to keep the original appearance of their engine bay. We designed a charge air cooler that not only provides a massive performance upgrade but also allows the use of the engine cover. Modifications may be necessary to integrate our auxiliary fuel rail. The sound-dampening material beneath both the engine cover and the hood must be removed, and the standard engine cover mounting pins replaced with longer ones included in our kit. This compatibility has been verified exclusively on the BMW 340i F30/F31 models.

This unique feature sets the do88 kit apart from the competition, as high-performance builds tend to be made by enthusiasts who value appearance equally as much as performance.

Key Features

Versatile Manifold Design: From Fuel Injection to Power Modifications

Our manifold outlet tank is pre-configured for auxiliary port fuel injection. A custom-made fuel rail with female AN-8 threads is available separately and easily installs to the outlet tank. It is compatible with Injector Dynamics ID1050x-34-14 or Bosch EV14 Compact (K) fuel injectors. Injector blanking plugs are provided for convenience if port fuel injection is not used. Each cylinder runner on the outlet tank is equipped with a 1/8” NPT port suitable for nitrous or methanol injection, with sealing plugs included.

Extra Measurement & Vacuum Ports

Integrated into the side of the manifold inlet tank is a 3-port pad directly into the casting, offering flexibility to measure additional parameters or serve as an extra vacuum source. Sealing plugs are provided if these 1/8” NPT ports are not utilised.

Advanced Thermal Management

Included with the intake manifold is a special thermal barrier spacer designed to insulate the aluminium intake manifold from conductive heat transfer from the cylinder head. This barrier lowers intake air temperatures (IATs), enhances the efficiency of the charge air cooler, and minimises heat soak. Unlike the OE plastic intake manifold, the do88 manifold is made from aluminium, capable of withstanding higher boost pressures. The thermal barrier spacer reduces conductive heat transfer, typical to aluminium components, with robust custom-made FKM-silicone O-rings installed in precision-machined grooves for a secure fit.

Product Details

• Utilises a high-performance, Bar & Plate, air-to-water intercooler core, 102 mm (4”) thick.
• 11 water cooling rows, compared to OE 6 rows.
• Lower inlet air temperature under identical conditions: 26°C compared to OEM 40°C.
• More air to your engine, less backpressure and better airflow! Airflow at 0.1 bar / 1.45 psi pressure drop: 873 CFM (615 CFM), 42% higher!
• Peak power gain of 5 hp! Measured on a car with bootmod3 Stage 2+ (BMW 340i 2017).
• Highest midrange power gain of 18 hp!
• Highest torque gain of 28 Nm!
• Designed in SolidWorks using Computational Fluid Dynamics (CFD).
• Easy access to spin-off oil filter for quick oil changes – no need to remove the manifold.
• Integrated sensor pad with three 1/8″ NPT ports to measure additional parameters (sealing plugs included).
• Optional fuel rail (not included) for auxiliary top feed port injection.
• Injection plugs for each cylinder runner included.
• Individual 1/8″ NPT ports on the top of each cylinder runner for nitrous or meth injection (sealing plugs included).
• Plug-and-play design, requiring no modifications to install.
• All essential brackets for various components, such as wire harnesses and the engine cover, included.
• Can be installed with OE engine cover. Fits with modification when running with the auxiliary port injection fuel rail (confirmed only on BMW 340i F30/F31).
• Thermal barrier spacer included, engineered to insulate the aluminium intake manifold from conductive heat transfer from the cylinder head.
• Custom-made high-spec FKM-silicone O-rings included for both the thermal barrier spacer and intake manifold (12 pcs in total).

Fits Models

• 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′ 540i 540iX (G30 G31)
  Engine: B58 Gen 1
  Model years: 10/2015 –
• BMW 6′ 640i 640iX (G32)
  Engine: B58 Gen 1
  Model years: 09/2016 –
• BMW 7′ 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 –