Forge Motorsport FMCC1 Charge Cooler for BMW M3 M4

In addition to the Forge Motorsport PolarCooler range, we are introducing the top-mounted intercooler and expansion tank for the BMW MSport S55 engine.

The intercooler features an all-aluminum construction that solves the problems of plastic tank splitting, high-pressure failures, and leaks between the core and the tanks, as well as seal failures in the latter. The tanks are made from precision laser-cut sheet metal panels and TIG-welded by hand for maximum strength and durability.

Designed and manufactured at the Forge Motorsport headquarters in Gloucestershire, England, we use our Solidworks CAD design system for the creation, modification, CFD (Computational Fluid Dynamics) analysis, and optimization of this innovative intercooler. During the development process, three different core configurations were evaluated. The final design, featuring a bar-and-plate core, far outperformed the other two alternatives. To achieve this, Forge Motorsport development engineers created a four-pass design, which allows water to circulate through four stages of the cooler, thereby improving cooling efficiency beyond any other product available on the market.

The Forge intercooler system for the BMW M3/M4 S55 (also compatible with the 2018- F22 M2 Competition) is unique on the market and uses an expansion tank instead of a header tank like the original system. It features a filler cap on top that ensures the system is completely full of coolant, without air bubbles. This maximizes the heat dissipation efficiency of the coolant within the intercooler's water jacket.

It offers a volume increase of over 71% and a frontal area increase of over 42%.

In hot-climate testing, consistent dyno measurements showed significantly lower intake temperatures compared to the stock system and a power increase of up to 20 hp.
As part of Forge Motorsport's strict quality control, every intercooler unit is thoroughly inspected and pressure-tested to 4 bar before shipment.

Also located in the intercooler's outlet tank is a 1/8" NPT port ready for water/methanol injection, should it be required.

The original intercooler rubber mounts are used for this expansion tank and intercooler, thereby isolating the system from heavy engine vibrations. No vehicle modification is required and all parts can be returned to their original configuration if necessary.