Forge Motorsport BMW M3/M4 Chargecooler

Product Description

In addition to the Forge Motorsport PolarCooler range, here we have the top mount replacement chargecooler and expansion tank for the BMW MSport S55 Engine.

The Chargecooler features an all aluminium construction which overcomes all the issues relating to plastic end tank splitting, failure at high boost and leaks between the core and end tanks with end tank seal failure. The end tanks are fabricated using high precision laser cut sheet metal panels which are TIG welded by hand for maximum strength and durability.

Designed and manufactured at Forge Motorsport HQ in Gloucestershire, England, we utilised our Solidworks CAD design system to assist in the creation, modification, CFD (Computational Fluid Dynamics) analysis and optimization of this innovative charge cooler. Three different core constructions were evaluated during the development process. The final design of a bar and plate core far outperformed the other two alternatives. In doing this, the Forge Motorsport development engineers have made a quadruple pass design, allowing the water to flow through four passes of the cooler which improves the cooling efficiency beyond any other products currently on the market.

Unique to the market, the Forge BMW M3/M4 S55 Chargecooler system (that also fits the M2 Competition F22 2018-) uses an expansion tank rather than a header tank like the OEM system. There is a filler cap located at the highest point on the Chargecooler allowing you to be sure that the charge is 100% full of coolant with no air pockets. This maximises the efficiency of the heat rejection of the coolant within the Chargecooler water jacket.

• Offering over 71% increase in volume and over 42% increase of frontal area.
• In hot climate testing, constant dyno runs showed significantly lower inlet temperatures compared with the stock system and an increase in power of up to 20BHP.
• As part of Forge Motorsport’s strict quality control process, each chargecooler unit is carefully inspected and pressure tested to 4BAR before despatch.
• Located on the outlet tank of the chargecooler there is also a 1/8 NPT port ready for water/methanol injection if required.

The existing OEM Chargecooler rubber mounts are used for this expansion tank and Chargecooler, isolating the system from the harsh vibrations of the engine. No trimming or cutting of the vehicle is required and all parts can be returned to standard if necessary.

In the box

• 1x Chargecooler unit
• 1x Expansion tank with sight glass
• 1x Expansion tank cap
• 1x Small radiator cap
• 1x Billet radiator cap cover
• 1x Billet blanking cap
• 1x 1/8 NPT Grub screw
• 7x M6x12mm  Allen cap bolts
• 7x 6mm washers
• 1x M8x20mm Allen cap bolt
• 1x 8mm washer
• 1x M8 Nyloc nut
• 3x 8-16mm Hose clamps
• 1 x 8mm ID Vacuum hose x 170mm
• 1x 8mm ID Vacuum hose x 750mm 

Compatible Vehicles

Note that the models listed here have either had the part fitted by us or a customer or they are listed as being compatible on industry parts databases. Where it has not been directly fitted by Forge there will then be a separate May Also Fit tab where the make and model will also appear and which details our no-risk approach to purchasing this product, so it is worth checking there as well.

Warranty Information

The majority of Forge Motorsport products come with a limited lifetime warranty (brakes pads excluded). All warranty claims must be accompanied by the original proof of purchase to enable us to help you. Failure to supply this proof will result in your claim or enquiry being denied.

Do not use aggressive (acidic) car cleaning products, particularly traffic film remover solutions or shampoos to clean your intercooler, radiator, or oil cooler. The use of these products can damage Forge Motorsport cooling systems and invalidate your warranty. These are often found at car washes. A light, warm, soapy solution (free of harsh acidic cleaning compounds) should be used to clean you cooler and thoroughly rinsed away. We recommend that you should inspect your product on a regular basis for bent and/or crushed fins. Any bent fins should be carefully straightened to allow ambient air to pass through the core face. At the time of installing your Forge radiator, an approved coolant must be used and added to the coolant system. Be sure you never mix coolant and always use distilled water.

This warranty does not apply to any defect in the goods arising from fair wear and tear, wilful damage, accident, negligence by you or any third party, use otherwise than as recommended by the supplier, failure to follow the supplier’s instructions, or any alteration or repair carried out without the supplier’s approval.

We keep a large inventory of stock at our warehouse however due to widespread delays in the industry, some items may be on backorder. If you need parts ASAP then please contact us on the live chat or at support@wayside-performance.co.uk and a member of our team will get back to you.

Unsure on fitment? Just drop us a message on the live chat or support@wayside-performance.co.uk and a member of our team will assist. Please make sure to include as much detail as possible including make, model, registration and the parts you are looking at.