BMW G9X M5 High-Performance Charge-Air-Coolers

Description:

The M5 has long been the king of full size sport sedans and the new G9X M5 is no exception. People can complain about how big and heavy it has gotten. At the end of the day, it goes like hell, handles incredibly well, and is dripping in luxury. One of the limiting factors in making power on the S68 engine are the fragile factory charge air coolers. CSF quickly resolved that issue by revising the S63/S68 Charge-Air-Coolers for the F9X M5/M8/X5M/X6M for the new G90/G99 M5.

Sharing an engine with the F9X X5M/X6M meant there were readily available tunes and power upgrades for the engine when the new M5 hit the market. We have already seen the BMW S68 engine produce over 900whp on stock internals. However, that extra power creates a lot more heat and pressure. F9X M5/M6 & X5M/X6M owners have relied on CSF Charge-Air-Coolers (CSF #8178 & #8315) for years to deal with that extra power. Now, CSF is pleased to announce the High-Performance Charge-Air-Coolers for the G9X M5.

The Charge-Air-Coolers come in an OEM+ Crinkle Black Finish. In addition, custom finishes are available at an additional cost for those looking for a more unique engine bay look.

Details:

Design & Engineering

CSF originally designed the BMW S63 Charge-Air-Coolers for the F9X M5/M6. Over five hundred of these Intercooler kits have been sold with many of them on 1000+ hp builds. Due to the popularity and success of these previous kits, it wasn't long before our dealers and tuning partners got their hands on these new M5s. With a little R&D/Test fitting help from the likes of IND Distribution, Evolve/Eventuri, and R44 Performance, CSF quickly developed a new drop-in fit kit for the G90 and G99 M5.

OEM vs CSF

The CSF Charge-Air-Cooler Cores are ~100% larger in volume than the factory coolers. CFD analysis and testing was used to design the cores ensuring optimal performance as well as perfect fitment. Both coolers come with OEM-Style "Quick Connect" water connections as well as sensor ports for fast and easy installation. You can read the full press release of the full press release of the CSF #8178 Coolers for more details & performance data.

The weak OEM crimped-on plastic end tanks have been replaced with CSF's larger, CFD analyzed, 100% TIG-welded cast end tanks. CSF also integrated the charge pipe into the design of the top end tank eliminating the glued-on factory plastic charge pipes. This single piece cast design creates a much stronger system that can handle much higher boost pressures.

Integrated dual 1/8 NPT ports are located on both outlet side air tanks for quick and easy installation of aftermarket methanol/nitrous injection systems. The positioning of these ports have been carefully designed to place the injection system directly into the post-intercooled charge-air stream for maximum performance.

Real World Testing

Real world testing on these coolers was originally performed on a Stage 3 F90 M5 with ~900whp. While the vehicles differ slightly, the overall performance gains/results will be similar. These coolers are currently installed on the top 5 world's fastest S63 powered M cars. This includes Mr. Vanos 1200+ HP F90 M5

This new kit has been independently tested on several G9X M5s by several companies and customers.

IND Distribution

IND was the first company to test fit the Charge-Air-Coolers on their new M5. They were crucial in helping develop the fitment kit and did the initial dyno testing as well. A baseline run at Performance Eurowerks in Elk Grove, IL produced an impressive 696.13 whp @ 5,230 RPM and 729.59 wtq @ 2,420 RPM in completely stock form.

After establishing a baseline, IND installed:

• CSF High-Performance Charge-Air-Coolers
• Eventuri fully prepreg Carbon Intake System + Turbo Inlet Set
• Eisenmann Performance Exhaust System
• RaceChip GTS Black module, set to Map 7 (conservative tune)

The baseline session was done in November in cooler conditions. The follow up test took place during a heat wave with ambient temps near 100°F and extremely high humidity. The M5 was on 93 octane pump gas for both sessions to keep comparisons as consistent as possible. Despite the challenging temps, the results speak for themselves: 757.01 whp @ 5,110 RPM & 828.07 wtq @ 3,740 RPM. A gain of +60.88 horsepower and nearly +100 lb-ft of torque over stock shows just how capable this platform is with the right upgrades.

Read the IND Blog - World's First G90 M5 On A Dyno

Kies Motorsport

The team at Kies Motorsport did some final test fitting for the new kit. They loaded up Miguel's M5 with the CSF Charge-Air-Coolers paired with a dÄHLer Tuner on 93 octane pump gas. The results from 3 consecutive pulls were quite impressive and consistent: 765.7 whp & 778.0 wtq, 776.8 whp & 786.8 wtq, and 776.2 whp & 778.5 wtq.

MTech Performance

In Fort Lauderdale (Florida), MTech Performance has been helping @1fastg90 push his M5 to the limits. They used a Femto Flash to unlock the ECU allowing for a full custom tune by Gtp.Tuned. With the CSF Charge-Air-Coolers, the S68 put out a whopping 956 whp & 865 wtq. They've also done some Dragy testing and the G90 is doing 60-130mph in 6 second flat.

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 best selling B58 Charge-Air Cooler systems. Most of the same custom finishes can be ordered on CSF #8351.

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

Thermal Dispersion Black

CSF's most popular custom finish, Thermal Black Heat Dispersion Cerakote is available as a custom 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.

Thermal Dispersion: The Best Coating for Intercoolers

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.

See All Custom Finishes

Make it a package

CSF collaborated with the team at Carbahn to ensure maximum compatibility and performance, creating a drop-in Engine Oil Cooler (CSF #8317) solution for both platforms. Designed specifically to handle the extra heat of their new S63 Stroker Kit, this oil cooler is built for ultimate performance and power.

However, performance isn't the only reason to upgrade. Many M5 owners have been forced to replace their oil coolers due to leaks and damage, largely because of their vulnerable mounting position; a problem that worsens with lowered suspension setups. A stronger, more robust design was needed to solve these issues.

CSF #8317 Installed on IND Distribution's G99 M5 Touring

CSF #8351 Installed Media

R44 Performance - G90 M5

IND Distribution - G99 M5

@ali416_m - G99 M5

Evolve Automotive - G90 M5

⚠ Fitment Notes

This product requires some minor modifications to install. The mounting pins that the coolers rest on will need to be shaved down to help the CSF coolers sit in a better position. CSF also recommends trimming the the air balancing tube to improve the fitment. The installation requires fine adjustments and aesthetic results will depend on the skill of the installer.

Features:

• Custom Designed CSF Liquid-To-Air Intercooler Core (CFD Analysis and Testing Completed to Ensure Optimal Performance)
• 100% Increase in Core Volume Per Each Charge Cooler Compared to the OEM Charge Air Coolers
• 1-Piece Seamless Air Inlet End Tanks with Integrated Charge Pipes
• Integrated E85/Methanol Injection Ports Built into Air Outlet End Tank (Dual 1/8 NPT Ports Per Cooler)
• Complete with OEM-Style "Quick Connect" Water Connections and Sensor Ports
• Designed with 3D Scanning and Rapid Prototype Technology to Ensure Precise Fitment and Maximum Surface Area Utilization
• "Drop-In Fit" Design - Requires Minor Modification for optimal fitment - see fitment notes*
• Significantly Reduces Intake Air Temperatures (IATs)
• Finished with a Professional "Crinkle Black" Powder-Coated Finish (CSF #8315) - Custom Powder-Coating Available (Inquire for More Details on Lead Time and Pricing)
• Sold as a Complete Set with Left and Right Charge-Air Coolers + Installation Hardware