CSF Charge-Air Cooler Intake Manifold (raw billet aluminum) for Gxx BMW 2 Series, 3 Series, 4 Series, 5 Series, 6 Series, 7 Series, 8 Series, X Series and Z4 M40i / A9x Toyota GR Supra [8200]
$4,299.00
IN STOCK, READY TO SHIP
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CSF has introduced its most advanced cooling system, the Charge-Air Cooler Manifold, for the A90/A91 Toyota Supra and BMW G-Series (B58) models. Developed over 1,500 hours with VF Engineering and Custom Plenum Creations, this CNC-machined manifold features a larger, more efficient water-to-air intercooler, reduced pressure drop, an included fuel rail, and a top-feed port injection kit. Designed to eliminate common engine limitations, this Super Manifold enables B58 owners to maximize their vehicle’s performance potential.
This item and any similar items are not CARB approved and therefore not for sale in the state of California or other states that require CARB certification. No assessment is being made regarding this product's compliance with the EPA's anti tampering policy, only that the necessary testing and validation has not been completed. Please check with your local enforcement officials regarding legality of use in your place of residence.
CSF Charge-Air Cooler Intake Manifold (raw billet aluminum) for Gxx BMW 2 Series, 3 Series, 4 Series, 5 Series, 6 Series, 7 Series, 8 Series, X Series and Z4 M40i / A9x Toyota GR Supra [8200]
CSF is thrilled to unveil its most advanced cooling system to date, the revolutionary Charge-Air Cooler Manifold designed specifically for A90/A91 Toyota Supra and BMW G-Series (B58) models. After an extensive development process involving over 1,500 hours of design, prototyping, machining, and rigorous testing, CSF, in collaboration with VF Engineering (USA) and Custom Plenum Creations (Australia), has successfully introduced a cutting-edge CNC machined Charge-Air Cooler Manifold. This remarkable product addresses a common weakness in the impressive new engine platform. Featuring a larger and more efficient water-to-air intercooler, reduced pressure drop throughout the system, an included fuel rail, and a top feed port injection kit, among other pioneering features, the CSF Super Manifold empowers B58 owners to unleash the full potential of their vehicles. With this groundbreaking innovation, performance boundaries can be pushed further than ever before on this remarkable platform.
The Missing Link to Maximum B58 Performance
The second-generation B58 engine, which can be found in the Mk5 Supra, has rapidly established itself as an extraordinary platform for performance enthusiasts. Since its release, it has taken the performance and motorsports industry by storm. In a remarkably short period of time, enthusiasts have managed to surpass the stock engine output by more than twofold, with power figures now exceeding 700whp and even reaching the 800whp range. Some daring individuals are even exploring the boundaries of achieving the coveted four-digit milestone of 1,000whp.
The original equipment manufacturer (OEM) water-cooled charge air cooler intake manifold designed for the B58 engine is sufficient for vehicles with minimal or no modifications. However, its limitations become more evident in vehicles with aftermarket bolt-on upgrades, turbo enhancements, increased fueling (such as port injection), and performance tuning. Additionally, the OEM intercooler system is prone to heat soak in demanding racing conditions, including time attack, endurance racing, drag racing, drifting, and even spirited driving on the street. As a result, elevated intake air temperatures (IATs) can lead to timing retardation in the engine, and if temperatures surpass a certain threshold, the vehicle’s electronic control unit (ECU) may activate “limp mode” to safeguard the engine by reducing power output.
Design & Engineering
CSF and R&D partner VF Engineering conducted comprehensive testing on the dyno to ensure significant performance improvements before proceeding with the production of the new manifold. Over the course of a single day, we conducted more than 50 dyno runs on the same vehicle, under relatively high ambient temperatures of around 90°F (~32°C). The objective was to compare the performance of the CSF Charge-Air Cooler Manifold against the OEM manifold. Both manifolds underwent approximately 25 consecutive dyno pulls every 30 seconds to assess the performance of the vehicle over time, resistance to heat soak, recovery time, and the impact on the turbo system duty cycle.
To ensure the credibility and accuracy of the testing, reputable automotive website and performance part testing specialist, MotoIQ, was present on-site to witness and assist in organizing the testing process. Their independent validation of the improvements and benefits of the upgraded manifold was published on their website, providing more specific details on the enhanced performance achieved with the CSF B58 upgraded intake manifold.
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, 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 displayed significantly lower inlet temperatures, measuring around 230 degrees or 30 degrees cooler than the stock manifold. The outlet temperatures also showed a decrease of approximately 6 degrees, staying under 125 degrees. This data reveals that there is more to it than meets the eye. The lower inlet temperatures indicate a reduced restriction to airflow across the core, which is expected due to the larger frontal area of the core. With less intake restriction, the compressor of the engine’s turbo operates in a more efficient area of the compressor map, further away from the surge line. This enhanced efficiency results in less heat being transferred to the intake air by the turbo. Moreover, the improved compressor efficiency means that the turbine doesn’t have to extract as much power from the exhaust stream to generate the same boost, leading to reduced backpressure. As a consequence, the engine benefits from increased total volumetric efficiency. This synergistic cascade has a profound impact, increasing power output and alleviating strain on the engine and its components. It’s important to note that these effects extend beyond lower intercooler outlet temperatures.
Individual Nitrous / Methanol Injector Ports
The outlet tank of the CSF manifold features a 1/8th NPT port on each cylinder runner, which offers the option for nitrous or methanol injection. This modification is popular among B58 engine enthusiasts seeking increased power. The CSF manifold ensures optimal spray control and uniform distribution throughout the engine. Leading industry player Nitrous Express will soon release a nitrous system specifically designed for the CSF manifold.
During the TX2K event, a few cars experienced engine failures due to the improper setup of their nitrous systems. The OEM plastic manifold typically accommodates a single spray system, which can be challenging to install correctly due to the difficulty of threading into plastic. Unfortunately, this setup often results in uneven spray distribution among the cylinders, leading to some receiving too much or too little spray. Such imbalances significantly increase the risk of severe engine damage.
Top Feed Port Injection with Included Fuel Rail
The CSF manifold comes with an extruded fuel rail that can be conveniently attached to the outlet side of the manifold. The AN-8 fuel rail is equipped with feed and return -8 internal hex plug fittings from Radium Engineering, ensuring a hassle-free plug and play installation experience.
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.
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
Integrated into the tank’s machining on the manifold inlet, CSF has incorporated a 3 port pad. This feature provides the flexibility to measure additional parameters or serve as an extra vacuum source. The three 1/8th NPT ports can be easily plugged with the included hardware kit if they are not utilized.
Easy Access to Spin-Off Oil Filter With Counter Balanced Design
Consider the inconvenience of having to remove the manifold every time you need to change the oil, especially if your vehicle is frequently used in motorsports where oil changes are more frequent. CSF took its customer base into account during the design phase and incorporated a recessed design at the back of the manifold, allowing for convenient access to the spin-off oil filter. To ensure optimal cooling efficiency, a counterbalanced design protrusion above the recess was simulated in SolidWorks CFD software to ensure smooth airflow delivery into the rear of the core, maximizing the cooling effect.
Air Inlet Divider
The CSF manifold offers another exclusive feature: an air divider that is welded into the inlet side tank of the manifold. With the length of the design taken into consideration, the engineers at VF Engineering wanted to ensure that the volume and velocity of air reaching the back of the manifold, specifically cylinders four, five, and six, would be equal to the airflow passing through the front half of the manifold, catering to cylinders one, two, and three. Extensive simulations in SolidWorks CFD software were conducted, and as a result, an air divider was incorporated into the design to ensure the best possible and equal cooling performance for each cylinder of the engine.
Breather Ports for Inlet / Outlet of Water Tanks
Located on the top of the back water plate are two 1/8th NPT ports. These ports serve multiple purposes, including measuring inlet/outlet water temperatures and functioning as breather ports during the bleeding procedure to ensure proper clearing of air from the water system. The supplied hardware kit includes 1/8th NPT plugs for these ports. It is important to follow the OEM BMW or Toyota bleeding procedure, which typically takes around 15 minutes to complete.
Hardware Kit
The supplied hardware kit includes various brackets, bolts, washers, and mounting posts designed specifically for installing the OEM and OEM-style engine covers. This exclusive feature, developed in collaboration between CSF and VF Engineering, was a challenging endeavor in terms of both engineering and manufacturing. Each item in the kit is individually vacuum packaged and labeled with corresponding letters that match the user-friendly Bill-of-Materials List (BOM). The kit also includes exploded diagrams and a straightforward installation procedure, allowing racers and DIY enthusiasts to easily follow the step-by-step instructions for installation.
Features
Utilizes a high-performance, motorsports-grade bar / plate air-to-water intercooler core (doubles the capacity than OEM core – 12 rows vs 6 rows OEM)
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
Can be used with OEM or aftermarket engine covers (with OEM connections)
Comes finished in raw billet aluminum, made by world-leading automotive machinist Custom Plenum Creations in Australia
Toyota GR Supra: A90, A91 (2020+) – 3.0L Turbo I6 B58
Notes
This product is intended for off-highway and motorsports use only
Due to the technical and intricate nature of manufacturing this product, it is anticipated that there may be refinements and modifications made to the manifold, hardware, and instructions between production runs.
TÜV application in process (approval pending)
During the Quality Control and Inspection process, CSF conducts pressure tests on each #8200 / #8200C manifold at 60-70 PSI for a duration of 2-3 minutes. It is important to note that the CSF manifold is not intended for operation above 60 PSI. Users who decide to operate their vehicle with the CSF manifold exceeding 60 PSI do so at their own risk. Please be aware that operating the manifold at these pressure levels will nullify the CSF Limited Lifetime Warranty.
Also fits the following BMW xDrive models:
M240i
M340i
540i
630i
640i
740Li
745LE
840i
X3 M40i
X4 M40i
X5 45i
X5 45e
X6 40i
About CSF
Back in 1947, a father and his three sons embarked on a business venture by setting up a small retail shop dealing in automotive parts. The family business blossomed over the years, evolving into an automotive garage specializing in radiator repair, and later, a radiator manufacturing facility. By 1975, the family-owned brand CSF was established, marking a milestone as the first to introduce import applications into the American automotive aftermarket, in line with the influx of Honda, Datsun, and Toyota vehicles. By 2009, the fourth generation of the CSF family joined the business, which had by then become a leading name in the import and domestic radiator and condenser markets, selling over 650,000 units that year despite an economic recession, and totaling over 35 million units to date. CSF’s portfolio expanded to include a diverse range of cooling systems, including commercial trucks, industrial and agricultural applications, marine coolers, intercoolers, pressure caps, and a pioneering Racing & High Performance Division. Today, CSF’s Racing & High Performance Division is renowned for designing and manufacturing advanced, efficient, and reliable cooling systems for a wide array of applications, from high performance all-aluminum direct-fit radiators to custom systems for racecars, power sports, off-road, marine, and industrial use. With over 50 years of experience and more than 40 million cooling systems sold worldwide, CSF has rightfully earned the industry title of “THE COOLING EXPERTS.”
Additional Information
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Shipping Policy
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Items that are in stock in the US, either at Bulletproof’s warehouse or at a supplier’s warehouse, are generally delivered within 7-10 days. Special order items from overseas take considerably longer. As a courtesy Bulletproof offers delivery estimates to our customers which take into consideration manufacturer availability and shipping schedule. These estimates represent our best guess based on previous orders from the manufacturer and do not in any way imply a guaranteed delivery window. Many manufacturers work in a “just in time” inventory system and often take 2-20+ weeks to produce an item once an order is submitted. All deliverable items are then sent to our Japanese warehouse. Bulletproof ships a minimum of one full ocean freight container every month from Japan, oftentimes more than one a month. Ocean freight takes an average of 4 weeks. Typically it breaks down to one week in Japan for paperwork and customs, two weeks by boat and one week in US customs/clearance. Due to the wide number of variables between manufacturer and shipping schedules, delivery estimates are simply just that – estimates. We attempt to estimate conservatively and we usually deliver faster than our estimates suggest. It is not Bulletproof’s policy to guarantee delivery time of any special order item, this is impossible for us to do. By ordering you acknowledge that there is no required delivery ETA and an order may not be canceled or altered due to manufacturing or shipping delays, all ETA’s are provided as a best guess only. Please review the full Terms & Conditions here.
BP Pricing Difference
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For many international customers, it’s much more affordable to ship from the USA than from Japan directly, as the air freight and ocean freight costs are typically much less. However, for customers looking to ship directly from Japan outside of North America, or domestically in Japan, we can provide pricing specifically for that scenario. Please do not hesitate to contact us with any pricing questions or concerns. Please email us at sales@bulletproofautomotive.com with any inquiries.
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