A90 Supra / BMW B58 Charge-Air Cooler Manifold - Custom Finish

With well over 1,500 hours of design, prototype development, machining, and testing, CSF, along with partners VF Engineering (USA) and Custom Plenum Creations (Australia), has now brought a state-of-the-art CNC machined, high-performance Charge-Air Cooler Manifold to the B58 platform for Mk5 Supra and BMW models. This product solves what has been commonly known as a weak link of an otherwise impressive new engine platform.

With the larger and more efficient water-to-air intercooler performance, lower pressure drop across the system, included fuel rail, kit for top feed port injection, and several other industry-leading features, the CSF Super Manifold will allow B58 owners to maximize the performance of their vehicles and push the limits further than what has been previously possible with this new platform.

Product Details:

CSF's Creates the Missing Link to Maximum B58 Performance

The 2nd gen B58 engine, found in the Mk5 Supra, has proven to be an incredible platform for performance enthusiasts – taking the performance and motorsports industry by storm in just a couple of years since its release. In a short amount of time, performance enthusiasts easily more than double the stock engine output pushing over 1000whp.

World-leading Supra specialist and CSF R&D partner, Titan Motorsports, putting the new manifold to the test, along with the full range of CSF Cooling products for the MK5 Supra (5-Piece Ultimate-Spec Cooling Package).

The OEM water-cooled charge air cooler intake manifold for the B58 engine is adequate in cars with little or no modifications, but starts to really show an apparent weakness in cars that have bolt-on modifications, turbo upgrades, increased fueling (such as port injection), and performance tuning. Also, 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), and then can cause "limp mode" once temperatures reach a certain threshold, as the vehicle 's ECU will cut power to protect the engine.

Design & Engineering

CSF conducted extensive testing on the dyno with R&D partner VF Engineering to ensure performance improvements before going into production with the new manifold. We performed 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 over time, resistance to heat soak, recovery time, and the effect on the turbo system duty cycle.

Local R&D partner and contender for both BimmerChallenge and the TRD Time Attack Series, Studio RSR, has been working with CSF and testing the new manifold off and on the track.

Reputable automotive website and performance part testing specialist, MotoIQ, was on site to witness and assist in organizing the testing to validate the accuracy of the claims made by CSF on the improvements and benefits of the upgraded manifold. The results were published independently by MotoIQ and are now available on their website – read the article here for more specific details on the increased performance of the CSF B58 upgraded intake manifold.

Ravi, owner of CSF Racing & High-Performance, along with Nik, owner of VF Engineering, go over all the details with owner of MotoIQ and industry legend, Mike Kojima

Summary of Testing

• Faster recovery of intake air temperatures
• ~30°F reduction of intake air temperatures (IATs) 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, 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 bigger as power is increased in the vehicle

Interestingly enough, the CSF/VF manifold had much lower inlet temperatures, right about 230 degrees or 30 degrees cooler than the stock manifold while the outlet temperatures were about 6 degrees cooler, under 125 degrees. There is a lot more to the data that first meets the eye. The lower inlet temperatures are an indicator that the restriction to airflow across the core is much lower. This is to be expected of the larger frontal area of the core. With less intake restriction, the compressor of the engine's turbo is running much farther away from the surge line in a more efficient area of the compressor map. With greater efficiency, the turbo is heating the intake air a lot less. Since the compressor is working much more efficiently, the turbine doesn't need to recover as much power from the exhaust stream to produce the same boost and thus there is less backpressure. This in turn increases the engine's total volumetric efficiency. This is a synergistic cascade that will increase power and reduce strain on the engine and its components which has a much more profound impact than just lower intercooler outlet temperatures.

Mike Kojima
Owner
MOTOIQ.COM

For more testing results, visit MotoIQ.com

To see all the testing results including graphs for water temperature, air temperature, and more details, see Page 6 of the MotoIQ article.

You asked, CSF listened – All the Features You Need to Push the Limits

During the final design stage of CSF 's new manifold, owner of CSF, Ravi Dolwani, hopped on a plane to Texas to attend the 2021 TX2K drag race invitational. Included at that year 's event was a new A90 Supra class. Ravi went to speak with Supra owners and find out what they wanted out of an upgraded performance manifold. He came back to CSF following the race weekend, and worked with long time design partner and CSF customer, VF Engineering, to implement a host of features that took the performance benefits and capabilities of the new CSF manifold to an even higher, industry-leading level.

Individual Nitrous / Methanol Injector Ports

On the outlet tank, each cylinder runner has a 1/8th NPT port which can be used for nitrous or methanol injection (a popular power modification on the B58 engine). The CSF manifold allows for maximum spray control and even spray distribution throughout the engine. A nitrous system set-up specifically for the CSF manifold is from industry leaders Nitrous Express through Titan Motorsports.

A handful of cars at TX2K had blown their engines due to the way their nitrous systems were plugged into their vehicles. With the OEM plastic manifold, a single spray system is most commonly used as threading into plastic to insert an injector node is already very difficult to install properly. The single fogger system, more often than not, will create unequal distribution of spray in the engine, either giving some cylinders too much or too little spray. This will increase the chance of severely damaging the engine.

Top Feed Port Injection with Included Fuel Rail

An extruded fuel rail is included with the CSF manifold. It 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"

Vacuum and Parameter Pad

On the side of the manifold inlet, CSF has included a 3 port pad into the machining of the tank. This can be used to measure additional parameters or as an additional vacuum source. These three 1/8th 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

Imagine having to remove your manifold every time you wanted to change your oil, especially if your vehicle is used in motorsports where oil changes occur more often. CSF thought of its customer base during the design phase and have incorporated a recessed design towards the back of the manifold that allows for easy access to the spin-off oil filter. A counter balanced design protrusion above the recess was simulated in SolidWorks CFD software to ensure smooth air delivery into the rear of the core for the best possible cooling effect.

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 -4AN 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. The hardware kit includes the -14AN hex plugs. Please follow OEM BMW/Toyota bleeding procedure which takes roughly 15 minutes to complete.

Optional Thermal Rejection Competition Spacer - CSF #8200S

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 optional 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.

The CSF Thermal Rejection Competition Spacer was designed for vehicles competing in motorsports who demand the absolute best cooling in order to gain a competitive edge. However, including this spacer offers significant advantages to any vehicle.

Hardware Kit, Well Thought-Out Instruction Manual & The Ability to Install OEM and OEM-Style Engine Covers

Included in the supplied hardware kit are several brackets, bolts, washers, and mounting posts to be able to install the OEM and OEM-style engine covers. 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 racers and DIY enthusiasts in mind.

⚠ Fitment Notes

This product is intended for off-highway and motorsports use only.

Because of how technical and complex this product is to manufacture, improvements and changes to the manifold, hardware, and instructions are to be expected between production runs.

• CARB application in process – approval pending
• TÜV application in process – approval pending

CSF pressure tests each #8200 / #8200B / #8200C 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 Lifetime Warranty.

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Custom Color Options, From the Leader in BMW Cooling Customization

CSF has become the industry leader and innovator of custom finished cooling products. We first started with our most popular BMW S55 Charge-Air Cooler, then expanded to other BMW models such as our F1X M5/M6 and our latest G9X M5/M8 Charge-Air Cooler systems. Most of the same custom finishes can be ordered on CSF 's new B58 "Super Manifold."

• These manifolds cannot be anodized
• CSF is not responsible for warranties for manifolds coated by anyone other than CSF
• Lead time is 3-4 weeks depending on finish selection

CSF #8200B - Thermal Dispersion Black

CSF's most popular custom finish, Thermal Black Heat Dispersion Cerakote is now available as a standard finish option. This offers faster turn around time for orders and some dealers/distributors stocking this finish option.

Thermal Dispersant/Dispersion Coatings are submicron coatings with extremely high thermal conductivity. Due to their density and chemical composition they offer highly efficient heat transfer. In the case of a coated heat exchanger like an intercooler, the higher thermal conductivity of the coating helps draw heat to the surface of the part.

These coatings are limited to Black or Grey colors but offer the best performance. For more details on Thermal Dispersion Coatings, visit our article explaining the how they work and the performance benefits.

See the CSF #8200BThermal Dispersion: The Best Coating for Intercoolers

CSF #8200C - Custom Finishes

CSF offers the widest variety of custom finishes in the industry. From color matched powder coating to high tech Thermal Dispersion Coatings, the options are limitless.

Powder Coating: Powder coating is available in almost any color imaginable with finish options ranging from full gloss to crinkle texture. You can even opt for accent colors, different colors for certain components like fuel rails (when applicable).

DLC (Diamond Like Coating): DLC Coating stands for diamond-like carbon coating, and is a nanocomposite coating that has unique properties of natural diamond low friction, high hardness, and high corrosion resistance. These coatings are the most expensive available, but can offer some very unique finish options that will provide the greatest durability.

Features:

• 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
• 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
• Plug-and-Play design, Requiring No Modifications to Install
• Includes Hardware and Installation Kit with Picture Diagrams Containing 28 Different Parts for Easy Installation
• Can be Used With OEM or Aftermarket Engine Covers (with OEM Connections)
• Comes Finished in Raw Billet Aluminum (available in custom finishes) - Made by World-Leading Automotive Machinist Custom Plenum Creations in Australia
• CSF pressure tests each #8200 / #8200C 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. 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 Warranty.