Forge Motorsport chargecooler for BMW M2/M3/M4

• 71% larger volume
• 42% larger frontal area
• Power increase of up to 20 BHP
• Pressure-tested to 4 bar before dispatch
• Ready for water/methanol injection if required

The Forge Motorsport chargecooler is a replacement upper charge-air cooler and expansion tank for the BMW M Sport S55 engine. The cooler is made entirely from aluminium, eliminating problems associated with cracking plastic end tanks, failures at high boost pressure and leaks between the core and end tanks caused by seal failure. The end tanks are made from precisely laser-cut sheet metal panels and hand-welded using the TIG process for maximum strength and durability.

Solidworks CAD was used during development, along with CFD (computational fluid dynamics) analysis and optimisation. Three different core designs were assessed during development. The final bar-and-plate design outperformed the other two options. The cooler uses a four-pass design, in which the water flows through four passes, improving cooling efficiency.

The Forge system for the BMW M3/M4 S55, which also fits the M2 Competition F22 from model year 2018 onwards, uses an expansion tank instead of the original collection tank. The filler cap is positioned at the highest point of the cooler, ensuring that the system can be 100% filled with coolant without air pockets. This increases the efficiency of transferring heat from the coolant in the chargecooler’s water jacket.

The existing original rubber mounts are used for the expansion tank and chargecooler, isolating the system from strong engine vibrations. No cutting or vehicle modification is required, and all parts can be returned to standard condition if required.

The kit includes:

• 1 × chargecooler
• 1 × expansion tank with sight glass
• 1 × expansion tank cap
• 1 × small cooler cap
• 1 × aluminium cooler cap cover
• 1 × aluminium blanking cap
• 1 × 1/8 NPT adjustment screw
• 7 × M6 × 12 mm Allen bolts
• 7 × 6 mm washers
• 1 × M8 × 20 mm Allen bolt
• 1 × 8 mm washer
• 1 × self-locking M8 nut
• 3 × hose clamps for 8–16 mm hoses
• 1 × vacuum hose with an internal diameter of 8 mm and a length of 170 mm
• 1 × vacuum hose with an internal diameter of 8 mm and a length of 750 mm

Suitable for: BMW 4 I (F32/F33/F36/F82/F83), BMW M2 I (F22/F23/F45/F46/F87), BMW M3 VI (F30/F31/F34/F80).

Compatible vehicles (manufacturer data)

Before ordering, check that the product matches your vehicle (model, year and engine). If in doubt, write to us — we will check for you.