B58 Development

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BMW B58 Engine Development by do88 

Development cars:
BMW 340i (F31)
BMW M340i (G21)
Toyota Supra (A90)



 
Background:
 
It was a long time coming but we finally had the opportunity to develop products for the BMW B58 engine which is quickly becoming a living legend. Many consider it the best tuning platform there is and it's even available in the Toyota Supra.
(insert "not a real Supra" comment here)

Much like the S55 M-cars the intercooler is integrated into the intake manifold and cooled using liquid rather than air. The benefit of this is the much shorter travel distance from turbo to engine, and more efficient cooling. But it also adds complexity in terms of an additional water pump, two additional radiators and a second expansion tank since the intercooler is a separate cooling circuit from the engine coolant.

To add another layer of complexity, the decorative (but also sound insulating) engine cover sits on top of the intake manifold. A lot of aftermarket charge coolers disregard fitment for this in the name of volume or to add a fuel rail. In the spirit of do88 we wanted to offer the best possible performance, while retaining all OEM-functionality and fitment. As far as we could find, no one had managed to fit both a fuel rail to the intake manifold, and maintain compatability with the engine cover.


 
Early Development:
 

Our goal with this was to offer an array of products for both the Gen 1 and Gen 2 engines. With a lineup strategically selected to target essential areas for improved performance:

 

  • A high-efficiency intercooler/intake manifold solution that maintains OEM engine cover fitment
  • Air intake systems for multiple chassis and generations
  • Charge pipes with more tolerance for heat expansion and increased boost
  • Heat exchangers/radiators at the front of the car
  • Fuel rail option for the intercooler while maintaing OEM engine cover fitment
  • Additional radiators for specific models

 

We quickly realized that maintaining OEM engine cover fitment with an intercooler that both performs to our standard AND has a fuel rail option would be an immense task. But it would also make us unique and set a kind of benchmark as we couldn't find any other aftermarket solution that had achieved this.
It was also important to cover multiple versions as the B58 engine sits in different cars and chassis. After a lot of planning and research it was time to start "taming the beast" and start the process of development.

We also came to understand that the factory intake manifold and charge pipe have reliability concerns, especially the Gen.2 charge pipe which decided to "rapidly disassemble" itself after only 3 laps on track in a Toyota Supra (A90) when driven by one of our local dealerships. After all, this isn't the first time we've encountered issues with BMW's charge pipes and other plastic parts. 



 
Development Results:
 
This ended up becoming one of, if not our biggest, project to date and includes 3 radiators, 3 air intake systems, 4 charge coolers and 2 sets of charge pipes. Let's break it down:
Charge Cooler Manifold

Our manifold was carefully developed to maintain bolt-on fitment, especially in regards to the engine cover which is often disregarded by other products on the market. This is also our first BMW product offered in a MERA edition, meaning that there are 2 levels of performance available at different price points, but both offering the same functionality and fitment. It incorporates advanced thermal management with a thermal barrier spacer to reduce heat transfer between the engine and intake manifold. We've also added plenty of optional functionality, such as integrated measurement and vacuum ports that provide additional flexibility for performance monitoring. 
The MERA edition is meant to be the absolute peak of what's possible in this form factor. While using the same design and overall dimensions as the standard version, it switches out the core for a high-performance, motorsport-grade Garrett Bar & Plate core that is 102mm (4 inches) thick. This allows for even better cooling efficiency without sacrificing airflow, and is better suited for highly tuned, modified and track driven cars. As the fitment is somewhat different there's also a Gen.1 and Gen.2 version of each manifold.


Air Intake System

The air intake system ended up becoming 3 distinct variants:
An aluminum version for the Gen.1
A carbon fiber option for the Gen.2
Carbon fiber/aluminum mix for the B48 engine.
While they all obviously focus on increased airflow, the Gen.1 variant has small openings in the lid to provide additional intake sound under acceleration. The Gen.2 variant also has the option of an upgraded turbo inlet to further increase efficiency and compatability with aftermarket Pure 800 turbo builds. All in all, each air intake system is molded to its particular platform and designed accordingly.


Charge Pipes

Numerous aftermarket charge pipe kits for the B58 engine exist but, we believe, lack optimal design. These often have a simplistic approach of connecting two pipes with a straight, reducing silicone hose. This design oversight fails to accommodate thermal expansion, often resulting in the hose detaching due to temperature-induced movements. The typical remedy of tightening the clamps even more usually leads to pipe damage.
So we've embraced a different strategy. Recognizing the need for a flexible connection that accommodates thermal expansion and contraction, we developed a solution using an aramid-reinforced silicone hose with three humps. This design facilitates movement in all directions without causing the hose to fold or stressing the connections. Additionally, our pipes feature CNC-machined 6063 connections with a 3mm wall thickness that resists deformation, even when clamps are overtightened. We also engineered our pipes with a greater diameter and smooth mandrel bends to optimize airflow.

Radiators
The B58 engine features an intercooler cooling system with three frontal radiators, consisting of one large central radiator and two smaller auxiliary radiators located in front of each wheel. Since tuned engines produce significantly more heat, the factory parts can struggle to maintain optimal engine temperatures during intense driving. The OE auxiliary radiators have slim cores and plastic tanks, upgrading these auxiliary radiators will help to ensure proper engine temperature.
Fortunately, the design space available for the auxiliary radiators allows for both increased frontal surface area and core thickness on both sides of the car. The OE radiator is identical for both sides, and our do88 Performance Radiators are designed to be drop-in replacements for both left and right sides. We've also upgrade the larger front intercooler radiator to make sure the system doesn't just move heat away from the intake, but also gets it out of the system entirely.
Transmission Oil Cooler

Designed specifically for BMW M340i/Z4 and Toyota GR Supra, our Automatic Transmission Cooler aims to ensure smooth and efficient shifting. Thankfully the Supra / M340i feature the renowned ZF 8HP transmission which already performs great. But like all sports cars, heat remains a significant challenge especially in tuned cars that generate even more heat during rigorous street, track, or drag strip driving.
Our solution is a redesigned core, increasing the core volume by 184% and the cooling surface area by 176%, while maintaining similar fluid pressures. We upgraded the tubes with harmonica tubes with internal channels, ensuring optimal cooling efficiency. Whether you're spending a day on the track or enjoying a drive through the backroads, you shouldn't have to stop because of an overheating transmission.

Thoughts on this car / platform:

We’re always on the lookout for new ways to boost performance for car enthusiasts! With a solid range of BMW products already under our belt, stepping into the B58 territory felt like a natural move. This engine is well-known for its solid performance and versatility, earning it a favorite spot in the tuning community and substantial aftermarket support. By developing high-quality cooling and airflow solutions, we wanted to show B58 owners not just what they can get out of their vehicles in terms of power and efficiency, but also showcase our commitment to design, performance and functionality to a new audience.

This was a big one, but in the end the response has been worth it, our B58 range has quickly become one of our most popular. Getting to see how these products are used in so many different builds and pushing the boundaries of perfomance is awesome to see. At the end of the day, we make products to be used, so seeing them get used in so many ways and receive such good feedback is the ultimate reward.