Forge Motorsport S55 Top Mount Chargecooler & Expansion Tank for BMW M2 Competition (F87), M3 (F80) & M4 (F82/F83) - Bar & Plate Quadruple Pass Intercooler Upgrade FMCC1

Serious power needs serious cooling. This UK-engineered water-to-air charge cooler and auxiliary reservoir transforms intake temperature control on the twin-turbo six in the F80, F82, F83 and F87 M cars. Built by Forge in England and created as a direct, drop-in upgrade for the factory top-mounted cooler brick, it stabilises IATs, fights heat soak and keeps performance consistent on fast road, dyno and track. Part number FMCC1.

Why this uprated charge air cooler is a must-have

The standard unit’s plastic end tanks and seals are a known weak link once boost and temperature rise. This all-alloy assembly replaces the fragile components with a robust, precision-welded construction that resists splitting and leakage. A dedicated header tank relocates the fill point to the system’s highest position, making bleeding straightforward and ensuring the circuit is completely full for maximum efficiency. More coolant volume, smarter internal routing and a high-density core deliver superior charge temperature control so your M car can repeat pulls without power fade.

Standout technical advantages

• Fully aluminium cooler with alloy end tanks for long-term reliability under elevated boost
• Four-pass coolant circuit for exceptional heat transfer and fast recovery between runs
• High efficiency bar-and-plate core chosen using CAD and flow simulation for optimum performance
• Remote reservoir with sight glass and highest-point filler simplifies bleeding and eliminates trapped air
• 1/8 NPT take-off on the outlet tank for easy integration of water methanol injection hardware
• Every unit pressure-tested to 4 bar as part of strict quality control
• Engineered and manufactured in England to exacting standards
• Bolt-on, OEM-style fitment for the S55 platform with no cutting required

Real-world gains you can feel

• Approx. 71 percent increase in core volume and around 42 percent more frontal area compared with stock
• Hot climate dyno sessions showed repeatable reductions in intake temps and power increases up to 20 bhp versus the factory cooler

We have installed and run this kit ourselves and our customers love it. Expect faster recovery between pulls, rock-solid IAT control on track days and consistent performance during spirited driving.

What you get in the box

• Charge cooler assembly
• Remote header tank with sight glass
• Header tank cap
• Small radiator cap
• Billet radiator cap cover
• Billet blanking cap
• 1/8 NPT grub screw
• 7 x M6 x 12 mm Allen cap bolts
• 7 x 6 mm washers
• 1 x M8 x 20 mm Allen cap bolt
• 1 x 8 mm washer
• 1 x M8 Nyloc nut
• 3 x 8–16 mm hose clamps
• 8 mm ID vacuum hose x 170 mm
• 8 mm ID vacuum hose x 750 mm

Compatibility

• BMW F87 M2 Competition from Sept 2019 onwards
• BMW F80 M3 2014 onwards
• BMW F82 M4 2014 onwards
• BMW F83 M4 Convertible 2014 onwards

Installation

Professional fitting and correct bleeding are essential for best results. Book expert installation with MJ Modifications in Warwickshire. Request a quote: info@mjmodifications.co.uk. The integrated 1/8 NPT boss is ready for a meth kit should you wish to add water-methanol injection.

Part number and warranty

Part number: FMCC1

Manufacturer: Forge Motorsport

Warranty: Forge Lifetime Warranty, non-transferable

Built for hard use and future power

Whether your M2C, M3 or M4 is stock, stage 1, hybrid turbo or track-prepped, this UK-made cooler is the go-to solution for controlling charge temps and unlocking repeatable performance. It is a proven upgrade for S55 owners seeking a reliable heat soak fix, improved IAT stability, stronger mid-range and sustained power on long pulls.

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