CSF’s industry-leading reputation and deep knowledge of high-performance BMW cooling systems is second to none. CSF is proud to announce its new halo product, the “Level-Up” Charge-Air-Cooler Manifold for the 2021+ G8X M3/M4 platform. CSF set out to create a charge-air manifold that would not only match the S58 engine performance, but take it to a whole other level with its ultra high performance features and durability.

DESIGN, ENGINEERING, AND DEVELOPMENT

CSF worked closely with its strategic manufacturing partner PWR and Local R&D Partner Studio RSR on the development of the “Level-Up” Charge-Air-Cooler Manifold. The relationship with PWR offers CSF access to exclusive cutting edge Formula 1 grade technology, while Studio RSR offers expertise in real world race experience and hands on mechanical knowledge of the G8X platform.

There are many engineering details CSF isn’t ready to divulge prior to the official release. However, there is still a lot of information to share and details to be seen.

KEY FEATURES

BILLET CONSTRUCTION & PWR CORE

The manifold is fully made from the highest grade billet aluminum. Each part is CNC machined with the highest precision and TIG welded to form a single air-to-water charge-air-cooler that is integrated into the intake manifold. The CSF manifold is not only capable of achieving the highest levels of performance of the s58 engine, but it’s all metal design is capable of withstanding extreme boost levels.

The ultra high performance liquid-to-air core is made by PWR. This Bar & Plate core is pressure tested to 120 psi to ensure it will withstand the high boost levels motorsports race teams can throw at it. Feedback from the community has shown the OEM core which is crimped onto plastic end tanks is prone to failure starting at just 27 pounds (psi) of boost pressure.

 

FUEL AND NITROUS

Adding power always requires more fuel. Similar to the industries best selling B58 “Super Manifold” (CSF #8200), the G8X M3/M4 S58 “Level-Up” Manifold features a top feed port injection system. The injector bungs are machined directly into the intake runners. The kit includes both the Fuel Rail and CNC Machined Block-Off Caps for non-use.

 

In addition, the manifold also has integrated ports on each runner for Nitrous or Methanol Injection. Individual ports for each runner allows for maximum control and tuning.

G8X M3/M4 “LEVEL-UP” CHARGE-AIR-COOLER MANIFOLD FEATURES (CSF #8233/8233B/8233C)

• Faster recovery of Intake Air Temperatures (IATs)
• ~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 target power levels
• 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 120psi
  • OEM cooler is a tube/fin core which is prone to failing at pressures over ~27psi
• Top feed port injection w/ included fuel rail (w/ CNC machined block-off caps included for non-use)
• Integrated Nitrous/Methanol Injection Ports
  • Individual ports for each runner for maximum control
• 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
  • 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)
• All necessary brackets, hardware, and instructions to install
• Raw Billet Aluminum Finish (#8233)
• Thermal Black Heat Dispersion Powder-Coating Finish (#8233B)
• Available in custom colors from the leader in BMW cooling customization (#8233C)
• True Plug-and-Play “Drop-in Fit” Installation – Requires Absolutely No Modifications.
• OEM level of fit and finish
• Limited Lifetime Warranty

FINISHES

1. 8233 is the ‘standard finish’ in raw aluminium
2. 8233B is a special thermal dispersion coating which helps with dissipating heat (current images are of a different product, used to illustrate the finish)

CSF’s strategic partnership with PWR brings F1 cooling design and technology to the high-performance aftermarket. These intercoolers help to keep charge temperatures consistently lower than the factory intercooler. This is because your factory intercooler was designed for standard power levels and expected type of use, as soon as you go outside of the factory power levels and expected type of use, your factory intercooler will begin to struggle. As well as this, as your intercooler goes through its life the core will deteriorate externally as well as fill with contaminates internally which results in a reduction in its performance.  

Over time the factory plastic end-tanks which are crimped onto the factory core can leak, losing precious boost pressure resulting in a significant lack of performance and risk to the engine. 

However, not all intercoolers are made equal. 

CSF CORE DESIGN – ROLLED TUBE & BILLET END TANKS

The CSF intercooler for the FERRARI 488, PISTA & F8 is a larger, more efficient intercooler for significantly improved cooling power. 

PWRs rolled tube cores are optimised in PWRs in-house wind tunnel, through this process PWR select the optimum stack height and multi-louvred fin design for both the ambient and pressure sides for optimum balance between cooling power and pressure drop.

Benefits

• Eliminates heat soak
• Lowers charge air temperatures
• Eliminates end-tank failure at elevated boost levels

Features

• Sold as a pair (Left & Right Intercoolers)
• Eliminates Heat Soak and Lower Intake Air Temperatures (IATs) for Maximum Performance in High-Performance and Race Conditions
• Formula-1 Performance Grade Cores by PWR (2-Row Cores features Rolled Tubes w/ Inner Fins)
• 100% TIG Welded CNC Machined Billet End Tanks for Maximum Strength & Durability
• Made in the USA at PWR North America
• OEM Style Inlet/Outlet Connections for Precise Fitment With All OEM Components
• Available in Black Thermal Dispersion Ceramic Coating upon request
• Precision machined integrated BPV/BOV connection
• High-density foam installed for OEM Fit & Finish
• Integrated OEM Style Fan Shroud
• True Plug-and-Play “Drop-in Fit” Installation – Requires Absolutely No Modifications
  • Additional installation steps for 488 Pista/F8 – Instruction Guide Download (Click Here)
• R&D and Performance Testing by Industry-Leading Tuning Companies M-Engineering, World Motorsports, and Voodoo Design

CSF MANUFACTURING, TESTING & FINISH

These intercoolers are manufactured PWRs North American factory, this means PWR has total control over our production, unlike other white-label brands. PWR’s intercoolers start life in their factory as an aluminium sheet or bar and from there they create their own rolled tubes, multi-louvred fins, CNC machine all of the fittings. The core is then CAB brazed in their state of the art clean room and the end-tanks and fittings TIG welded together by their master welders. 

All of PWR’s intercoolers are individually leak tested and go through a fitment inspection to ensure critical dimensions are per our design. 

To finish our intercoolers are only available in a raw finish.

• OEM Part Numbers:
  • Ferrari 488 GTB/Spider: 328422 (right) | 328423 (left)
  • Ferrari 488 Pista/Pista Spider: 748559 (right) | 748562 (left)
  • Ferrari F8 Tributo/Spider: 748559 (right) | 748562 (left)

• Applications:
  • 2016-2019 Ferrari 488 GTB
  • 2016-2019 Ferrari 488 Spider
  • 2019-2021 Ferrari 488 Pista
  • 2019-2021 Ferrari 488 Pista Spider
  • 2020+ Ferrari F8 Tributo
  • 2020+ Ferrari F8 Spider

CSF Race Radiator for 98-05 Mazda MX-5 / Miata

CSF manufactures the most advanced and efficient radiator cores in the industry by using innovative tube and fin technologies with industry leading testing methods to maximize airflow and heat dissipation. These techniques allow CSF to stay ahead of the pack when it comes to radiator technology!

• “B-Tube” technology – Unlike a regular oval shape “O” type radiator tube, CSF uses a specially engineered tube in a shape of a “B”. These “B-tubes” are carefully formed and then brazed over the seam to seal. CSF is able to use thinner and lighter aluminium material (better cooling efficiency) because this design is actually stronger than normal “O” shape tubes that are welded.
• The design (inlet in the middle of tube that is seam brazed) increases the heat transfer surface area of the tubes by approximately 15% over regular tubes. You get the efficiency of 2 smaller tubes vs. 1 large tube within the same space criteria. With “B-tubes” you are able to get “dual liquid laminar flow.”
• High Efficiency Multi Louvered Fin – CSF uses ultra efficient multi louvered fins that are carefully and precisely aligned to maximize airflow through each radiator core. Fin specifications are carefully measured and calculated for each application, and tested for maximum heat rejection efficiency in our wind-tunnel lab.

CSF’s industry-leading reputation and deep knowledge of high-performance BMW cooling systems is second to none. CSF is proud to announce its new halo product, the “Level-Up” Charge-Air-Cooler Manifold for the 2021+ G8X M3/M4 platform. CSF set out to create a charge-air manifold that would not only match the S58 engine performance, but take it to a whole other level with its ultra high performance features and durability.

DESIGN, ENGINEERING, AND DEVELOPMENT

CSF worked closely with its strategic manufacturing partner PWR and Local R&D Partner Studio RSR on the development of the “Level-Up” Charge-Air-Cooler Manifold. The relationship with PWR offers CSF access to exclusive cutting edge Formula 1 grade technology, while Studio RSR offers expertise in real world race experience and hands on mechanical knowledge of the G8X platform.

There are many engineering details CSF isn’t ready to divulge prior to the official release. However, there is still a lot of information to share and details to be seen.

KEY FEATURES

BILLET CONSTRUCTION & PWR CORE

The manifold is fully made from the highest grade billet aluminum. Each part is CNC machined with the highest precision and TIG welded to form a single air-to-water charge-air-cooler that is integrated into the intake manifold. The CSF manifold is not only capable of achieving the highest levels of performance of the s58 engine, but it’s all metal design is capable of withstanding extreme boost levels.

The ultra high performance liquid-to-air core is made by PWR. This Bar & Plate core is pressure tested to 120 psi to ensure it will withstand the high boost levels motorsports race teams can throw at it. Feedback from the community has shown the OEM core which is crimped onto plastic end tanks is prone to failure starting at just 27 pounds (psi) of boost pressure.

 

FUEL AND NITROUS

Adding power always requires more fuel. Similar to the industries best selling B58 “Super Manifold” (CSF #8200), the G8X M3/M4 S58 “Level-Up” Manifold features a top feed port injection system. The injector bungs are machined directly into the intake runners. The kit includes both the Fuel Rail and CNC Machined Block-Off Caps for non-use.

 

In addition, the manifold also has integrated ports on each runner for Nitrous or Methanol Injection. Individual ports for each runner allows for maximum control and tuning.

G8X M3/M4 “LEVEL-UP” CHARGE-AIR-COOLER MANIFOLD FEATURES (CSF #8233/8233B/8233C)

• Faster recovery of Intake Air Temperatures (IATs)
• ~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 target power levels
• 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 120psi
  • OEM cooler is a tube/fin core which is prone to failing at pressures over ~27psi
• Top feed port injection w/ included fuel rail (w/ CNC machined block-off caps included for non-use)
• Integrated Nitrous/Methanol Injection Ports
  • Individual ports for each runner for maximum control
• 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
  • 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)
• All necessary brackets, hardware, and instructions to install
• Raw Billet Aluminum Finish (#8233)
• Thermal Black Heat Dispersion Powder-Coating Finish (#8233B)
• Available in custom colors from the leader in BMW cooling customization (#8233C)
• True Plug-and-Play “Drop-in Fit” Installation – Requires Absolutely No Modifications.
• OEM level of fit and finish
• Limited Lifetime Warranty

FINISHES

1. 8233 is the ‘standard finish’ in raw aluminium
2. 8233B is a special thermal dispersion coating which helps with dissipating heat (current images are of a different product, used to illustrate the finish)

First up in our G8X M3 & M4 product range, CSF is pleased to announce the release of our front mount heat exchanger (charge cooler water radiator).

Like the previous S55 powered M2C, M3 & M4 the G8X platform has an air-to-water intercooler system to keep charge temperatures in check, and also like the previous generation, the standard coolers really start to struggle once ambient temperatures are hot, drivers are pushing the cars and especially once boost levels are increased with ECU software tuning.

CSF’s front mount heat exchanger replaces the factory heat exchanger with a High-Performance All-Aluminium part which helps to keep the coolant that removes heat from the charge air more consistently cool, when the ECU sees these lower and consistently lower temperatures it will operate the engine in its higher power modes for longer – maintaining performance.

• Significantly Reduces Intake Air Temperatures (IATs) for Maximum Performance (with Faster Heat Soak Recovery)
• Improves Air Flow to the Rest of the Cooling System for Lower Engine Coolant and Engine Oil Temperatures
• 2-Row, 42mm Ultra-High-Performance Core
• 6.5mm Tall Multi-Louvered Fin with CSF’s Exclusive B-Tube Technology
• CNC Machined Mounting Brackets and OEM Style “Quick Connect” Inlet/Outlet
• 100% All Aluminum TIG-Welded Construction
• Includes Black Rock Guards (upper and lower) & Transmission Cooler Mounting Kit
  • Upper and Lower Rock Guards for Manual Transmission
  • Upper Rock Guard and Transmission Cooler Mounting Kit for ZF8 Auto
• True Plug-and-Play “Drop-in Fit” Installation Requires Absolutely No Modifications
• 2-Year Limited Warranty
• 1-Hour “Mirror Finish” Hand Polish
• Tested and Proven by CSF’s Global Network of R&D Partners, Including Leading Time Attack Teams, Tuners, and Turbo Kit Manufacturers

• Applications:
  • 2021+ BMW G80/G81 M3 (incl. Competition) – 6MT & ZF8 Auto
  • 2021+ BMW G82/G83 M4 (incl. Competition) – 6MT & ZF8 Auto
• OEM Part Number:
  • BMW: 17-11-8-095-283

• Applications:
  • All Vehicles with the CSF B58 Super Manifold (CSF #8200) Installed

CSF is continually updating and adding new products In an effort to help customers achieve the highest level of competition in motorsports. CSF is pleased to release the latest B58 performance product. The CSF B58 Thermal Rejection Competition Spacer (CSF #8200S).

The CSF B58 Thermal Rejection Competition Spacer is the next level upgrade for the B58 Super Manifold (CSF #8200). 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.

COMPETITION TESTED

Tested at the Race Motive Event at Pocono Raceway (⅓ Mile Roll-Racing) in the B58/S58 Motor Class (July 9th 2022). One of the most respected B58 Tuners in the world, who has also been a development partner with CSF for the Gen-2 B58 Super Manifold, Visconti Tuning performed the testing with @peppa_aka_skull’s A90 Supra with @mrnohesi’s G20 M340i for direct comparison. Both cars are running the same setup and tune pushing ~900whp and 40 PSI of boost pressure.

 

The data logs from the subsequent runs after the first run of each racer showed IATs were an average of 77°F (25°C) lower at the start of the run for the A90 Supra with the CSF B58 Thermal Rejection Competition Spacer installed compared to the G20 M340i without the spacer. These results demonstrated the Thermal Rejection Spacer’s ability to combat heat soak and keep the B58 Super Manifold performing at peak efficiency during competitive driving.

HOW IT WORKS AND WHY YOU NEED IT

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 B58 Super 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. With that being said, there are significant advantages to adding this spacer upgrade to any vehicle with the CSF B58 Super Manifold installed.

CSF B58 THERMAL REJECTION COMPETITION SPACER FEATURES (CSF #8200S)

• Made from KIYLEX® – A patented revolutionary high-performance final stage polymer
• Spacer Height = 6.5mm
• 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)
• Can withstand temps up to 1100°F and is as strong as Aluminum
• Self-Sealing and do NOT require gaskets, silicon products, or sealing agents of any kind.
• Tested on @peppa_aka_skull’s (1000HP) A90 Supra by Visconti Tuning
• Includes installation hardware and instructions
• Highly recommended for Drag/Roll-Racing Applications where vehicles typically sit in staging lanes in-between racing
• Limited Lifetime Warranty
• Will not work with the OEM Manifold

• Applications:
  • All Vehicles with the CSF B58 Super Manifold (CSF #8200) Installed

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.

CSF’s Creates the Missing Link to Maximum B58 Performance

The newer 2^nd gen B58 engine, found in the Mk5 Supra, has already been 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 have already started to more than double the stock engine output – now pushing through 700whp, 800whp, and looking into the elusive 4 digit 1,000whp mark.

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.

From left to right: the OEM Charge-Air Cooler Manifold, the CSF x VF 3D printed prototype model, and the first official CSF x VF model

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 overtime, 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.

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 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 of MotoIQ.com

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

Several months ago, during the final design stage of CSF’s new manifold, owner of CSF, Ravi Dolwani, hopped on a plane to Texas to attend the TX2K drag race invitational. Included at this year’s event was an 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 1/8^th 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 will be coming soon from industry leaders Nitrous Express.

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 1/8^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

• 

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 for allows 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

• 

Another exclusive feature of the CSF manifold is the inclusion of an air divider welded into the inlet side tank of the manifold. With the length of the design, the engineers at VF Engineering wanted to make sure that the volume and velocity of air received to the back of the manifold to cylinder areas four, five, and six would be equal to the airflow passed through the front half of the manifold for cylinders one, two, and three. 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.

CFD analysis in SolidWorks during the R&D phase of the design

Breather Ports for Inlet/Outlet of Water Tanks

• 

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

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

• 

Included in the supplied hardware kit is 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.

New for 2021, CSF is pleased to announce the pre-release of their Audi C8 RS6 High-Performance Intercoolers. Pre order basis, first batch arriving in August.

Building upon our existing partnership with Formula-1 Cooling manufacturer, PWR – CSF is excited to officially release to the public the world’s first and only high-performance intercooler upgrade for the new Audi C8 RS6 Intercooler Set If you want to build the worlds fastest C8 Audi RS6, you’ll need these. Test results On an average of seven 4th gear dyno pulls, done every ~50 seconds, the results were: • Stage 2 tune comparing CSF intercoolers to OEM = +20 wtq / +10whp • Stock tune comparing CSF intercoolers to OEM = +18 wtq / +20whp Looks like the OEM turbo was running out of juice for more horsepower gains on the stage 2 tune, but the intercoolers worked as expected, and will be great for big power builds – it was hot (33°C-37°C) inside the dyno room, and IAT’s were consistent at 17°C less than the OEM intercoolers without spiking on the dyno runs.

Since the inception of the first water-cooled Porsche 911 Turbo with the 996 variant in 2001, the Turbo has been regarded as “the everyday supercar.” With each subsequent model, from 997, then 991, and now with the new 992, the boundaries of usable performance have been pushed on the street, racetrack, and drag strip. The Porsche Turbo is one of the most advanced tuning platforms around the world, with modifications ranging from simple bolt-ons and tunes, to built engines, upgraded turbos, and standalone ECU management systems on vehicles pushing well over 1,000WHP.

How The New Porsche 992 Intercooler System Works

Unconventional to the typical individual side-mounted intercoolers behind the ducts of the front doors found in previous water-cooled Turbo models, the new 992 generation has moved the intercooler system to the top of the engine compartment with fresh ambient air now being transferred into the intercooler system through redesigned intercooler ducts sitting beneath the rear decklid.

Cold, fresh air is scooped in by the intercooler ducts, positioned on each side of the car’s rear quarter panels. The air then travels into the inlet tanks on each side of the intercooler system module. The heat transfer process takes place as the charge-air moves through the intercooler core and the ambient air passes through the core from the top intercooler ducts, and exits below the vehicle. The intercooled charge-air from both cores is then merged in the single center section outlet tank before entering the y-pipe connected to the engine’s throttle body.

Formula-1 Grade Core Technology

The most important feature of the CSF by PWR 992 Turbo/S Intercooler System is the Formula-1 grade intercooler core. CSF’s strategic relationship with PWR has allowed the inclusion of this core, which is unlike any other available in the performance aftermarket.

• 2-Row Core Featuring Rolled Tubes w/ Inner Fins
• 33 Tubes vs. OEM 17
• 3mm Rolled Tube vs. OEM 7mm
• 4.85mm Fin Height vs. OEM 8mm

CNC Machined Billet Construction

The most apparent difference of the high-performance intercooler system from CSF is the beautiful 100% TIG-welded all aluminum construction, compared to the OEM crimped-on plastic tank design. This feature is especially important in high-boost applications, where the plastic tanks can crack under the stress of higher pressure, or on the racetrack due to higher vibrations.

CSF is the world leader in BMW air-to-water charge-air cooling technology. From its experience starting with its industry-leading one-piece S55 Charge Cooler, to then developing the world’s first Charge-Air Cooling System for the F1X M5/M6, CSF applied several different features exclusive to its manufacturing technologies to create its newest and most innovative Charge-Air Cooling System for the F9X M5 and M8.

This new design truly tested the engineering and manufacturing capabilities of CSF, with over one year of development and several prototype revisions to achieve absolutely perfect fitment into an engine bay with only a few millimeters to spare – a true plug-and-play system requiring no modifications to install.

The weak OEM crimped-on plastic end tanks have been replaced with CSF’s larger, CFD analyzed, 100% TIG-welded cast end tanks. The top side of CSF’s Charge-Air Cooling System now features air inlet tanks with seamless integrated charge pipes versus the OEM plastic charge pipes that are glued to the intercoolers. Like the previous F1X model, CSF has again integrated dual 1/8 NPT ports into the outlet side air tanks for quick and easy installation of aftermarket methanol injection systems. The side-specific positioning of these ports have been designed and strategically placed directly into the post-intercooled charge-air stream for maximum performance.

Before finally releasing these new charge coolers to the market, CSF worked with RK Autowerks to install, verify perfect fitment, and conduct performance testing on two of the world’s fastest and most powerful F90 M5 Sedans.

• World’s 1st and Industry Exclusive Cast End Tank Designed High-Performance Charge-Air-Cooler Set for the BMW F90 M5 & F92 M8
• 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/Rapid Prototype Technology to Ensure Precise Fitment and Maximum Surface Area Utilization
• “Drop-In Fit” Design with No Modifications Necessary
• Finished with a Professional “Crinkle Black” Powder-Coated Finish (CSF #8178), Also Available in Raw Aluminum Finish with Option for Custom Powder-Coating Available (Inquire for More Details on Lead Time and Pricing)
• Lifetime Warranty
• Sold As A Complete Set With Left/Right Charge-Air Coolers + Installation Hardware
• Significantly Reduces Intake Air Temperatures (IATs), Improves 60-130MPH Time By ~0.30 Seconds
• Fits:
  • 2018-2021 BMW F90 M5 (Sedan)
  • 2018-2021 BMW F91 M8 (Convertible)
  • 2018-2021 BMW F92 M8 (Coupe)
  • 2018-2021 BMW F93 M8 (Gran Coupe)