CSF Gen 1 B58 Charge Air Cooler Manifold

CSF has had tremendous success with its Gen 2 B58 “Super Manifold” for G-Chassis BMW and Supra with over 450 units sold and counting (CSF #8200/8200B/8200C). Due to its industry leading design and proven performance, CSF has received countless requests to engineer its “Super Manifold” for the Gen 1 B58 F-Chassis BMW platform. Finally, the wait is over for Gen 1 B58 customers! The “Super Manifold” is now available for your BMW. You no longer have to settle for a lower quality product.

The Gen 1 B58 Charge-Air-Cooler Manifold has all the same features and specs as the lasted version of the CSF Gen 2 manifold. This also includes some additional improvements for a better fit and finish over the competition. You can read about the development of the CSF Gen 2 B58 “Super Manifold” in our original press release.

*Please note that additional time may be needed for Color options, for inquiries on lead time please reach out to us via sales@mashimarho.com

Why Upgrade?

With the Gen 1 B58 powered BMWs getting a little bit older, more tuners and enthusiasts are picking them for competition. This has greatly increased the demand for more motorsports grade products for more power and reliability. Many vehicles are pushing well over 600 horsepower and needing additional fuel and cooling to reach their power goals. The CSF “Super Manifold” is the all in one solution for proven performance and the largest feature set in the industry.

The OEM charge-air-cooler manifold for the B58 engine is adequate in cars with little or no modifications. However, it starts to really its weaknesses in cars that have bolt-on modifications, turbo upgrades, increased fueling (such as port injection), and performance tuning. In addition, the OEM intercooler system has been known to suffer from heat soak in demanding racing conditions such as time attack, endurance racing, drag racing, and drifting, as well as spirited driving on the street. This can cause the car to pull timing out of the engine due to high intake air temperatures (IATs). This can send the car into “limp mode” once temperatures reach a certain threshold. In high boost applications the OEM manifold is also prone to failing at the crimp on gasket joining of the core and tanks.

Design & Engineering

In development of the Charge-Air-Cooler Manifold for the Gen 2 B58, CSF conducted extensive testing on the dyno with R&D partner VF Engineering. This consisted of over 50 dyno runs on the same car, on the same day, in relatively hot ambient conditions (~90°F) comparing the performance of the CSF Charge-Air Cooler Manifold to the OEM. Both the CSF and OEM cooler went through roughly 25 back-to-back dyno pulls every 30 seconds to measure the performance of the car overtime, resistance to heat soak, recovery time, and the effect on the turbo system duty cycle. You can read all about the testing procedures and results on MotoIQ‘s website – read the article here. This in-depth and through testing sets CSF apart from the competition.

Summary of Testing

• Faster recovery of intake air temperatures
• ~30°F reduction of intake air temperatures (IAT’s) compared to OEM
• Less pressure drop compared to OEM core
  • Puts less stress on the turbo system, allowing more boost to be made at higher targets
• Avoided going into limp mode after prolonged demanding conditions, simulating motorsports use
• On a stage 2 car with bolt-on upgrades, making ~400whp (with no port injection), comparing dyno run 19 between CSF and OEM, an increase of ~26whp and 11wtq were achieved
  • The performance increase and delta between CSF and OEM will be larger as power is increased in the vehicle

Proven Design & Results

Because the CSF #8300 is the same overall design as the CSF #8200 with some small design adjustments to fit the Gen 1 B58, there is no question that it will perform. The Gen 2 B58 “Super Manifold” (CSF #8200) has been real world tested and proven in some of the most extreme motorsport competitions around the world. It has stood up to the rigors of the Pikes Peak International Hill Climb, Global Time Attack competitions, and Texas 2K drag racing, just to name a few. In addition, it has also been dyno proven on many vehicles pushing over 1000 whp. While there are countless features and details to show just how superior the CSF Manifold is, real world examples speak louder than words.

Studio RSR’s Supra

Studio RSR has spent a lot of time racing behind the wheel of their A90 Supra. Their initial focus was on time attack events like Global Time Attack. However, in 2023 they decided to take on one of the most difficult races in motorsports, the Pikes Peak International Hill Climb (PPICH). The car performed amazingly and the full 6-Piece CSF Cooling Package kept the car cool in the most demanding conditions.

Titan Motorsports’ Supra

One of the biggest names in Supra drag racing, Titan Motorsports has been a major player in the inline 6 world for years. They regularly compete in some of the biggest drag racing competitions in the US and know a thing or two about making a fast car. Their Supra is pushing over 1000 whp and has a personal best time of 8.18 seconds in the quarter mile.

Key Features

CSF’s experience with the Gen 2 B58 has led to many industry leading standard features that also appear on the new Gen 1 manifold. Many of these have been developed with testing and feedback from industry partners, sponsored race teams, and engineering collaborations. Each kit includes everything you need to take your BMW to the next level.

Top Feed Port Injection with Included Fuel Rail

The CSF Manifold includes an extruded fuel rail which can be attached to the outlet side of the manifold. The AN-8 fuel rail comes with feed and return -8 internal hex plug fittings from Radium Engineering for a plug and play installation.

• Fuel rail aperture for each cylinder is an optimized 7mm opening for compatibility with most commonly used high performance injectors
• CSF recommends using Injector Dynamics (ID) injectors for the best performance – the most commonly used injector for this engine has been ID model # 1050.34.14.14.6 (qty 6)
• Anodized CNC machined injector hats (qty 6) are included in the supplied hardware kit to accommodate short height injectors aka “shorties”

Individual Nitrous / Methanol Injector Ports

A 1/8th NPT port on each cylinder runner can be used for nitrous or methanol injection. The CSF manifold allows for maximum spray control and even spray distribution throughout the engine.

Vacuum and Parameter Pad

CSF has included a 3 port pad into the machining of the tank on the manifold inlet side. The ports can be used to measure additional parameters or as an additional vacuum source. The three 1/8^th NPT ports can be plugged with the included hardware kit if they are not used.

Easy Access to Spin-Off Oil Filter With Counter Balanced Design

CSF incorporated a recessed design towards the back of the manifold that allows easy access to the spin-off oil filter. This means you do not have to remove your manifold every time you want to change your oil. While this design feature isn’t unique to the CSF manifold, CSF is the only company to account for the airflow issues such a recess can create. CSF Engineers designed and tested a counter balanced protrusion using SolidWorks CFD software. This protrusion sits above the recess to offset the airflow tabulations. This feature ensures smooth air delivery into the rear of the core for the best possible cooling.

Air Inlet Divider

The inclusion of an air divider welded into the inlet side tank of the manifold is another exclusive feature of the CSF manifold. With the length of the manifold, the engineers at VF Engineering wanted to make sure that the volume and velocity of air was consistent to all cylinders. After extensive simulations in SolidWorks CFD software, an air divider was added to the design to ensure the best possible and equal cooling performance to each cylinder of the engine. Airflow to the back of the manifold (cylinders four, five, and six) should be equal to the airflow to the front of the manifold (cylinders one, two, and three) for the best possible performance.

Breather Ports for Inlet/Outlet of Water Tanks

Two 1/8th NPT ports are located on the top of the back water plate. These ports can be used to measure inlet/outlet water temps as well as used as breather ports to help in the bleeding procedure. 1/8th NPT plugs come included in the supplied hardware kit. Please follow OEM BMW or Toyota bleeding procedure which takes roughly 15 minutes to complete.

Thermal Rejection Competition Spacer

Made from KIYLEX®, a patented revolutionary high-performance final stage polymer. KIYLEX® is as strong as aluminum and can withstand temperatures up to 1100°F. This spacer is designed to insulate the intake manifold from conductive heat transfer from the cylinder head. This thermal barrier reduces manifold temperatures which helps lower Intake Air Temperatures (IATs), improve charge air cooler efficiency, and combats heat soak. CSF is the exclusive distributor for the KIYLEX® Intake Manifold Spacer for the B58 Motor.

The addition of the Thermal Rejection Spacer is especially useful for Drag/Roll-Racing Events where vehicles typically sit in staging lanes in-between racing. This causes extreme heat soak to the liquid-to-air manifold as there is not sufficient airflow passing over the front mount heat exchanger when the car is idling (which is responsible for cooling the charge air fluid that runs through the manifold). This causes the starting IATs on subsequent runs to be higher than on the initial run.

The CSF Manifold is made from Billet Aluminum and 100% TIG Welded for strength, which allows it to be able to withstand higher boost pressures compared to the OEM plastic manifold. Aluminum has higher thermal conductivity than plastic resulting in a higher rate of heat transfer between the cylinder head and manifold. Adding the Thermal Rejection Spacer reduces heat transfer between the two metal components (cylinder head & manifold). The spacer absorbs the heat from the cylinder head and dissipates it rather than transferring it to the manifold.

Hardware Kit, Well Thought-Out Instruction Manual

The supplied hardware kit includes several brackets, bolts, washers, and fittings for installation. This is an industry-exclusive feature to the CSF x VF Engineering design, and was extremely difficult to not only engineer, but to manufacture as well. An array of items come vacuum packaged with corresponding letters listed on an easy to use Bill-of-Materials List (BOM) along with exploded diagrams and a simple order of operation procedure list to follow for installation. Made with mechanics, technicians, racers and DIY enthusiasts in mind.

Improvements and Updates

Experience and feedback with the CSF “Super Manifold” have yielded several updates and improvements on the new Gen 1 B58 Manifold. This includes several innovative design changes that make installation easier as well as giving more options for a cleaner looking install.

Rear Water Plate Breather Ports & Overflow Tank Fitting

CSF added new -6 ORB 90 Swivel fitting (See Photo 1 & 2) with the ability to clock. This gives the installer more options for running the overflow return line. The line can still be run directly to the OEM overflow tank like the factory configuration. This new fitting also allows you to hide the return line for a “clean-tucked” return route to the OEM overflow tank located at the front of the engine bay. The kit includes 40 inches of overflow line hose that can be cut to size based on preference of water line routing. CSF also sourced and includes an OEM quick connect fitting (See Photo 3) for the factory overflow tank. This makes the connection to the overflow tank more secure. The fitting comes pre-installed on the overflow line for an easy and quick to installation.

Slotted Mounting Tabs

Positioning the manifold in the engine bay is fairly straightforward. However, it can be a little frustrating to get the bolt holes on the intake side mounting tabs lined up perfectly. After doing a few test fittings CSF realized this could be resolved my slotting the mounting tabs. This allows the bolts to be installed before final positioning adjustments and makes installation a bit easier.

CSF vs the competition and OEM

CSF isn’t the first company to offer a Charge-Air-Cooler Manifold for the Gen 1 B58. However, CSF is bringing the most sophisticated design and largest feature set to the market. Add that to the years of experience and a proven track record with the Gen 2 B58 Manifold, and you get the best possible product for your vehicle.

Core Differences

Not all cores are created equal. CSF uses a motorsports grade Bar/Plate Air-to-Water core that is double the capacity (100% larger) of the OEM core. In addition, it also uses 12 cooling rows compared to the 6 rows of the OEM. Two of our competitors both use the same core that is only 70% larger than OEM with an unpublished number of cooling rows.

O-Rings, Gaskets, and Thermal Spacer

Each intake runner on the CSF manifold is machined for the OEM O-Rings with the factory style “teeth” to secure them (exclusive feature). This keeps the O-Rings from falling out during prep and installation. This feature makes installation far less frustrating.

Additionally, the Thermal Rejection Competition Spacer acts as a gasket between the cylinder head and the manifold. The precision machining and production of the spacer creates a perfect seal on top of the insulation properties. Our competitor’s phenolic spacer does not meet the same standard forcing them to use aftermarket O-Rings in addition to the factory ones to create a positive seal between the manifold, spacer, and cylinder head.

Oil Filter Recess

CSF’s competitors also incorporated a recessed design towards the back of the manifold that allows easy access to the spin-off oil filter. However, CSF is the only company to account for the airflow issues caused by this recess. CSF Engineers designed and tested a counter balanced protrusion using SolidWorks CFD software. This protrusion sits above the recess to offset the airflow tabulations. This feature ensures smooth air delivery into the rear of the core for the best possible cooling.

BMW Gen 1 B58 Charge-Air Cooler Manifold Features (CSF #8300/8300B/8300C)

• Utilizes a High Performance, Motorsports-Grade Bar/Plate Air-to-Water Intercooler Core
  • Double the Capacity of the OEM Core (12 Rows of Water Cooling vs. OEM 6 Rows)
• Significantly Lower Pressure Drop Across the Core Compared to OEM
• Designed in SolidWorks Using Computational Fluid Dynamics (CFD)
  • Integrated Air Divider in Inlet Tank Evenly Distributes Airflow Throughout the Core
• Improved slotted mounting holes on throttle body side for easier installation.
• Easy Access to Spin-Off Oil Filter for Quick Oil Changes – No Need to Uninstall Manifold Every Oil Change
  • Counter Balanced Design for Optimized Airflow 
• Integrated Sensor Pad with Three 1/8″ NPT Ports to Measure Additional Parameters
• Included Optional Fuel Rail for Top Feed Port Injection
  • Individual Port Injection Bungs on Each Cylinder Runner (Comes Pre-Plugged)
• Individual 1/8″ NPT Ports on the Top of Each Cylinder Runner for Nitrous or Meth Injection
  • Allows for Even Spray Distribution and Control for Maximum Performance and Engine Protection
• Individual 1/8″ NPT Breather Ports for Both Inlet/Outlet Water Connections on Back of Manifold for Easy Air-Bleeding of the System
• Included KIYLEX Thermal Rejection Manifold Spacer*
  • Made from KIYLEX® – A patented revolutionary high-performance final stage polymer
  • Acts as a thermal barrier that dissipates heat between the cylinder head and intake manifold
  • Proven to lower intake manifold temperatures by up to 15%
  • Lowers Intake Air Temps (IATs)
• Plug-and-Play design, Requiring No Modifications to Install
  • Includes Hardware and Installation Kit with Picture Diagrams Containing 32 Different Parts for Easy Installation 
• Comes Finished in Raw Billet Aluminum – Made by World-Leading Automotive Machinist Custom Plenum Creations in Australia
  • Optional Powder-Coating and Thermal Rejection Finishes Available – CSF #8300C 

Disclaimer:

CSF pressure tests each #8300 manifold at 60-70 PSI for a period of 2-3 minutes during the Quality Control and Inspection process. The CSF manifold is not designed to operate above 60 PSI. Any users who chose to operate their vehicle with the CSF manifold over 60 PSI does so at their own risk. Operation at these pressure levels will void the CSF Limited 2 Year Warranty.

Applications:

*B85 (Gen 1 – B58B30M0 & B58M30O0) motor only. Some Model Years equipped with this motor vary by region

• 2017-2019 BMW F20/F21 M140i
• 2017-2021 BMW F22/F23 M240i
• 2016-2019 BMW F30/F31/F34 340i
• 2017-2020 BMW F32/F33/F36 440i
• 2017-2019 BMW G30/G31 540i
• 2017-2019 BMW G32 640i GT
• 2016-2019 BMW G11/G12 740i/740Li
• 2017-2019 BMW G01/G02 X3/X4 M40i

OEM Part Number:

• BMW: 11-61-8-603-913