CSF Charge-Air Cooler Manifold for BMW S58 Engine [8233]

CSF Charge-Air Cooler Manifold for BMW S58 Engine [8233]

CSF has developed advanced cooling solutions for the BMW S58 engine, featured in models like the 2021+ G80 M3, G82 M4, F97 X3M, F98 X4M, and upcoming G87 M2. Recognizing the platform’s potential for competitive motorsports and power levels exceeding 1200hp, CSF partnered with PWR, a leader in high-performance motorsports cooling, to create the CSF by PWR billet intake manifold with an integrated water-to-air charge-air cooler. Manufactured entirely in the USA with rigorous testing and documentation, the manifold is designed to support both current and future performance demands. This collaboration combines CSF’s expertise in the high-performance aftermarket, OEM, and industrial cooling with PWR’s dominance in motorsports, aerospace, and military cooling. Together, they leverage advanced heat transfer technology and real-world validation to deliver cutting-edge solutions for high-performance applications.

The CSF by PWR Advantage

• CSF highlights that PWR manufactures each core in-house at its tier-1 OEM facility in Indianapolis, USA, with aerospace-level precision and tolerances. What sets PWR’s core technology apart is its ability to source and utilize extremely lightweight and thin materials, enabling the highest level of thermal transfer between the charge air and the water used to absorb heat from the turbocharged air. By combining this advanced core efficiency with a ~25% increase in core volume, CSF delivers a best-in-class cooling solution for the BMW S58 engine. This performance is backed by scientific data and proven through extensive testing and logged results.

Core Construction

• CSF emphasizes that the intricate manufacturing process of these cores, using delicate and ultra-thin materials, makes production a meticulous and time-intensive task. Experienced factory technicians can only produce around five cores per day, with labor costs being a significant factor in the manifold’s price. Building these cores correctly, efficiently, and consistently requires highly skilled technicians, and the thin materials used demand exceptional precision during assembly. Welding the cores to aluminum end tanks, for example, requires advanced temperature control and steadiness to avoid damaging the 0.3mm cladding sheets, a task that only the most experienced and skilled fabricators in the U.S. can perform reliably. The high cost reflects not just the product itself but the exceptional craftsmanship and expertise required to create such a premium, high-performance cooling solution. CSF hopes this explanation helps customers better understand the value behind the product’s pricing.

Counter-Flow Design:

• CSF explains that achieving optimal thermal transfer efficiency in a charge-air-cooler requires a counter-flow core design. In this configuration, water and air enter at opposite ends, flow in opposite directions, and exit at opposite ends. While CSF keeps certain details proprietary, extensive science and engineering expertise have gone into the design of the water-flow structure within the manifold’s inlet and outlet “quick-connect” fittings and water inlet tube. The precision-machined components are designed to increase the velocity of water entering the core, directing it in two opposing flows against the charge air coming from the throttle body. This design ensures maximum cooling efficiency and performance.

CSF vs. the Competition

• CSF highlights the core as the most critical component of the manifold. While the OEM unit, supplied by a competitor, is already efficient, improving its performance required extensive research and development. BMW’s factory manifold design is impressive, but CSF identified opportunities to enhance cooling efficiency further. By increasing the core volume from the OEM’s 215 in³ to 315 in³—a nearly 50% improvement—CSF achieved superior performance. Key enhancements included increasing the stack height from the OEM’s 0.225″ to 0.270″, maintaining fin density to prevent flow restrictions under higher pressure. This optimized design ensures the manifold delivers outstanding cooling performance, exceeding OEM capabilities.

CNC billet manifold design

• CSF brings unmatched expertise in designing BMW charge-air coolers, having sold thousands of units for the S55, S63, and B58 platforms. Each product undergoes rigorous design, testing, and refinement processes, both before and after release. The success of the CSF “Super” Manifold, a consistent best-seller, has provided invaluable insights that have been applied to the development of the S58 manifold. Machined from high-quality billet aluminum and TIG welded into a solid, one-piece construction, the CSF manifold offers numerous benefits, ensuring durability, performance, and reliability for high-performance applications.

Larger Plenum

• CSF’s manifold offers the largest plenum volume by utilizing a highly efficient construction method. TIG welding the billet aluminum sections together provides not only the strongest join but also the most space-efficient design. Inside the plenum and runners, the smooth transitions between components ensure optimal airflow and maximize volume. In contrast, the factory plastic manifold loses significant internal space to gasketed joins and strengthening lattice work. CSF’s billet design repurposes this wasted space to increase plenum volume and enhance airflow. Unlike Competitor R’s CNC billet manifold, which features a much smaller plenum volume, CSF’s design optimizes both strength and performance.

Welded not Gasketed

• CSF acknowledges that gaskets play a crucial role in automotive engineering, but in manifold construction, they come with certain drawbacks. The provisions needed to secure two pieces of a manifold with a gasket require additional space and materials, reducing plenum volume. Moreover, gaskets introduce a potential weak point, which may be sufficient for modest boost increases but becomes a limitation for BMW owners aiming for maximum performance. To address this, CSF chose the strongest and most durable construction method, ensuring optimal performance for its customers. Additionally, not all CNC machining is created equal. The Competitor R manifold shows rougher cuts within the plenum, which can disrupt airflow, whereas CSF’s manifold features finer, smoother cuts to enhance airflow efficiency. While this precision adds to production costs, it reflects CSF’s commitment to delivering the highest quality product. Every detail was carefully considered in the engineering of the S58 manifold, ensuring a product that meets the demands of performance-focused enthusiasts.

Water Flow + Bleeder

• CSF emphasizes that water flow is just as critical as airflow in an air-to-water system. While many companies prioritize the flow capabilities of their intercooler cores, they often overlook the importance of water flow into and out of the manifold. CSF dedicated significant effort to engineering the water inlet and outlet channels for its intercooler core, ensuring even water distribution for optimal heat dissipation. The water line quick connections were designed with enlarged inner diameters to minimize restrictions and maximize flow efficiency. This improved flow enhances not only the performance of the core but also supporting systems, such as an upgraded heat exchanger. To simplify installation, CSF incorporated a bleeder valve at the top of the charge-air cooler. This feature makes the often frustrating task of purging air from the system significantly easier, providing peace of mind that the system is properly bled before startup. With these innovations, CSF delivers a comprehensive solution for maximizing the efficiency and performance of air-to-water systems.

Air Guides

• CSF emphasizes that proper airflow is critical for engine performance and reliability, especially when tuning for higher power levels. Uneven air distribution between the plenum and runners can result in some cylinders receiving insufficient air, potentially leading to catastrophic engine failure. To address this, CSF and PWR utilized advanced CFD (Computational Fluid Dynamics) software to precisely engineer the airflow through the plenum. Special air guides were incorporated to ensure equal airflow to all cylinders. While the plenum could function without these air guides, CSF implemented them as an added precaution, understanding that customers will push the S58 platform well beyond BMW’s original specifications. This attention to detail is just one of the many features that set the CSF “Level Up” Manifold apart from the competition, ensuring both performance and reliability for high-powered builds.

O-Rings / Gaskets

• CSF intake runners are machined specifically to accommodate OEM O-Rings, featuring factory-style “teeth” for secure retention—an exclusive design that prevents O-Rings from dislodging during preparation and installation. Billet dowel pins, strategically positioned between runners 1 and 2 as well as 5 and 6, enhance stability by securing the Thermal Rejection Competition Spacer and ensuring proper alignment of the manifold during installation. These innovations, refined through test-fit installations prior to final production, significantly simplify the installation process. Furthermore, the Thermal Rejection Competition Spacer serves as both a gasket and an insulating layer between the cylinder head and manifold. Its precision machining guarantees a flawless seal while maintaining superior insulation properties. Unlike Competitor R’s phenolic spacer, which falls short of these standards and necessitates the use of aftermarket O-Rings alongside factory ones for adequate sealing, the CSF spacer sets a new benchmark in performance and reliability.

Nitrous / Methanol Ports

• The CSF Manifold is equipped with individual 1/8″ NPT ports located on the underside of each intake runner. These ports are designed to support Nitrous or Methanol injection, providing an optimal placement for direct and efficient delivery. Strategically positioned, the ports remain hidden from plain view, enabling a stealthy installation that minimizes visibility and deters unwanted attention.

Plug and Play Port Injection

• Each CSF manifold comes equipped with a high-performance extruded fuel rail, precision-machined to ensure maximum flow for any injector size. Compatible with standard pump gas, race gas, or E85, the AN-8 fuel rail is versatile and adaptable to various fuel systems. It includes a -8 internal hex plug fitting for use with an OE-style feed-only fuel system, which can be removed to accommodate upgraded systems with a fuel return. The fuel rail features a 7mm aperture for each cylinder, optimized for compatibility with most commonly used high-performance injectors. For optimal results, CSF recommends Injector Dynamics (ID) injectors.

KIYLEX® Thermal Rejection Competition Spacer

• The CSF Intake Manifold Spacer is crafted from KIYLEX®, a patented high-performance final-stage polymer renowned for its exceptional strength and thermal resistance. As durable as aluminum and capable of withstanding temperatures up to 1100°F, KIYLEX® serves as an effective thermal insulator, preventing conductive heat transfer from the cylinder head to the intake manifold. This advanced thermal barrier reduces manifold temperatures, lowers Intake Air Temperatures (IATs), enhances charge air cooler efficiency, and mitigates heat soak. CSF proudly serves as the exclusive distributor of the KIYLEX® Intake Manifold Spacer for the S58 and B58 engines.
• How it Works:
  • The CSF Thermal Rejection Spacer is particularly beneficial for drag and roll-racing events, where vehicles often idle in staging lanes between runs. During these periods, insufficient airflow passes over the front-mounted heat exchanger responsible for cooling the charge air fluid in the liquid-to-air manifold, leading to significant heat soak. This results in elevated starting Intake Air Temperatures (IATs) for subsequent runs compared to the initial run. CSF’s billet aluminum, 100% TIG-welded manifold construction provides exceptional strength, allowing it to handle higher boost pressures than the OEM plastic manifold. However, aluminum’s higher thermal conductivity increases heat transfer between the cylinder head and manifold. The Thermal Rejection Spacer effectively addresses this issue by acting as a thermal barrier. It absorbs heat from the cylinder head and dissipates it, preventing excessive heat transfer to the manifold and maintaining optimal performance.

CFD Analysis

• The development of the CSF S58 “Level Up” Manifold involved over a year of rigorous testing and extensive Computational Fluid Dynamics (CFD) analysis. CSF, in collaboration with PWR, conducted numerous design iterations during this process to achieve optimal performance. The results of this meticulous testing and refinement are now proudly showcased. For those unfamiliar, CFD simulations use advanced software to model and analyze airflow through a design. This method enables precise refinements and testing before physical prototypes are built or modifications are made, ensuring superior design efficiency and performance.
• Results:
  • As air slows down upon entering the plenum, CSF’s precisely engineered air guides ensure even distribution of airflow into the runners. This design promotes a smooth and consistent balance of airflow in both volume and velocity. Uneven distribution can result in engine damage, so CSF, in collaboration with PWR, has meticulously optimized the manifold to safeguard engine reliability and performance.

Dyno Testing

• Dyno testing is a critical component of CSF’s development process. While software accelerates design refinement, real-world testing is indispensable. During the initial release of the CSF S58 “Level Up” Charge Air Cooler Manifold, testing was conducted on three different G8X vehicles, all of which performed flawlessly and delivered impressive results. To push the limits of the manifold, testing was conducted on GTP’s Dynomite AWD2500 Dyno, with data collected using an AEM CD-7. Baseline pulls were performed at a tuned target boost of 44 PSI, with actual turbo output at 41.6 PSI. After installing the CSF manifold, pulls were conducted at a 45 PSI target boost, achieving an actual 41.5 PSI. Heat soak resistance was tested with eight consecutive pulls simulating speeds from ~30 mph to ~130 mph, each at full throttle with boost pressure set to 45 PSI. Over the 80-second test, post-cooler IATs began at 87.8°F (31°C) and increased by just 21.2°F (11.8°C). The test ended prematurely when the dyno began to overheat, underscoring the effectiveness of the manifold in extreme conditions that track drivers might encounter.
• Pressure drop testing, a vital metric for any intercooler, showed minimal loss, well within the ideal range of 1–1.5 PSI. While PWR’s cores are flow-bench tested as part of their validation process, real-world conditions can differ. PWR, which supplies cooling systems for F1, WRC, MotoGP, NASCAR, and more, recognizes the importance of combining engineering metrics with practical data. Achieving above 90% efficiency in air-to-water intercoolers is exceptionally challenging, but CSF and PWR’s design delivers top-tier performance. The manifold’s construction was designed not only for efficiency but also to address the OEM manifold’s structural limitations, which commonly fail at 30–35 PSI. During testing, the OEM manifold held up to a target of 44 PSI (with turbos producing 41.6 PSI), but consistent operation at higher pressures requires a more robust solution. The CSF by PWR core, rated up to 120 PSI, combined with 100% TIG-welded billet construction, provides unmatched strength and durability, enabling safe and reliable performance at significantly higher boost levels.
  

Quality Control

• CSF collaborates with PWR and PWR North America to ensure every manifold undergoes rigorous quality control and leak testing. As Tier-1 OEM suppliers with ISO certifications, PWR’s processes guarantee exceptional standards. Each manifold is brazed in-house, visually inspected, and pressure-tested at 80 PSI for leaks, both after core assembly and following air-side tank welding. Threaded ports are checked, holes deburred, and fine metal shavings removed to maintain CSF’s flawless raw aluminum billet finish. The port injection kit and hardware are QC-checked by CSF and packaged with the manifold by PWR. Factory-level sealed packaging ensures the CSF by PWR S58 manifold is delivered globally without damage or defects.
• TÜV Certification:
  • CSF underwent TÜV certification for installation and use in Germany, Belgium, and Switzerland. CSF was the only manufacturer, including its German-based competitor, to invest the time and cost into this rigorous testing validation and approval process. This effort further distinguished CSF from its competitors.

OEM+ Fit and Installation

• CSF takes pride in delivering drop-in-fit cooling solutions that require no modifications for installation, and the CSF S58 “Level Up” Charge Air Cooler Manifold is no exception. Meticulous attention to detail ensures a straightforward installation process while maintaining the highest standards of design and performance.
• Brackets and Stays:
  • Every wire and wire have been accounted for with OEM+ style mounting provisions. Many of these details are exclusive to the CSF Manifold.
  • Stand-offs on top of the plenum secure the emissions lines (exclusive).
  • The included removable engine cover mounting pin matches the billet finish perfectly (exclusive)
  • CSF’s front wire harness mounting bracket is adjustable for better fit and easier installation (exclusive). The design matches the OEM bracket for a perfect OEM fit and includes holes for the OEM harness clips to secure to.
  • The hose clip harness stay on the side of the manifold keeps the emissions line secure and in place (exclusive).
  • The overflow tank is securely mounted in the factory location and reuses the factor grommet for the lower mounting point

CUSTOM POWDER-COATING & THERMAL REJECTION FINISHING OPTIONS

• CSF provides the industry’s widest selection of custom finishes, ranging from color-matched powder coating to advanced Thermal Dispersion Coatings, offering virtually unlimited options. These custom finishes are available for an additional charge, please contact us for further details.
  • Powder Coating: Powder coating is available in nearly any color you can imagine, with finish choices that include everything from high gloss to crinkle texture. You can even select accent colors or apply different colors to specific components, such as fuel rails (when applicable).
  • Thermal Dispersion Coatings: Thermal Dispersant / Dispersion Coatings are submicron coatings with exceptionally high thermal conductivity. Their dense, unique chemical composition allows for efficient heat transfer. When applied to a heat exchanger like an intercooler, the enhanced thermal conductivity draws heat to the surface of the component, improving performance. These coatings are limited to Black or Grey but deliver the best thermal efficiency.
    • Gloss Black
    • Alpine White
    • Brilliant Frozen White Metallic
    • Frozen ceramic clear
    • Superchrome
    • Bismark gold
    • BMW carbon ceramic match (gold)
    • Custom gold metallic
    • Gold BBS color match (gloss)
    • Titan7 color match (techna bronze)
    • Golden hour
    • Stoplight red
    • Astatic red
    • Fire engine red
    • Illusion cherry
    • Candy apple red
    • F8x GTS acid orange ($800)
    • BMW interior match (Kyalami Orange)
    • Fire orange
    • Brooklyn grey
    • Inozetek wrap color match (snow blue)
    • Hand airbrushed painted (zandvoort blue) ($800)
    • Zandvoort blue powder coat
    • Miami blue
    • Mexico blue
    • Royal blue
    • Peppa blue
    • Blue titanium w/ black cherry rail & hardware
    • Pearl violet

Features

• Faster recovery of intake air temperatures (IATs)
• 40–60°F average reduction of intake air temperatures (IATs) compared to OEM at 45 PSI
• No pressure drop compared to OEM core
• Ultra-strong CNC billet construction replaces weak plastic tanks with crimped-on gasket sealing core
• High-performance bar / plate intercooler core by PWR pressure tested to 120 PSI*
• Top-feed port injection with included fuel rail (with CNC machined block-off caps included for non-use)
• Integrated nitrous / methanol injection ports
• Integrated vacuum and parameter pad to measure additional parameters
• Easy access to spin-off oil filter
• Integrated breather port for easy bleeding of air from the water side of the manifold*
• Included KIYLEX thermal rejection manifold spacer
• All necessary brackets, hardware, and instructions to install
• Also available in thermal black heat dispersion powder-coating finish
• Available in custom colors from the leader in BMW cooling customization
• Raw billet aluminum finish
• True plug-and-play “drop-in fit” installation requires absolutely no modifications
• OEM level of fit and finish
• Limited lifetime warranty

Applications

• BMW M2: G87 (2022+) – 3.0L TT I6 S58
• BMW M3: G80, G81 (2021+) – 3.0L TT I6 S58
• BMW M4: G82, G83 (2021+ ) – 3.0L TT I6 S58
• BMW X3M: F97 (2020+) – 3.0L I6 S58
• BMW X4M: F98 (2020+) – 3.0L TT I6 S58

Notes

• Also fits competition models

ABOUT CSF

The Racing & High Performance Division of CSF Inc. is dedicated to designing and producing the world’s most advanced, efficient, and dependable cooling solutions. CSF offers a broad range of state-of-the-art cooling systems, with over 250 distinct applications. These include high-performance all-aluminum direct-fit radiators, intercoolers, and oil coolers, as well as bespoke manufacturing tailored for racecars, power sports, off-road vehicles, marine, and industrial applications. Every cooling solution from CSF is meticulously crafted to ensure optimal engine temperature management, even in the most rigorous driving scenarios. With a legacy spanning over 50 years and more than 40 million cooling units distributed worldwide, CSF is widely regarded as a luminary in the industry.