Forge Motorsport BMW M3 M4 S55 Top Mount Intercooler Chargecooler with Expansion Header Tank - 4 Pass Bar and Plate AWIC TMIC - WMI 1/8 NPT - Direct Fit Charge Air Manifold Cooler F80 F82 F83

BMW M3 M4 S55 Top Mount Cooler Upgrade with Header Tank

Drive harder for longer with a UK-engineered top-mount cooler and matching header tank that keeps intake temps under control and power repeatable. This direct replacement intake cooling system for the S55 in F80, F82 and F83 models transforms heat management on fast road and track, delivering consistent performance run after run.

Engineered to outperform the factory unit

• All aluminium construction replaces fragile factory plastic end tanks to resist splitting and leaks at higher boost.
• Precision laser-cut end tank panels, hand TIG welded for strength, durability and long-term reliability.
• Developed in Gloucestershire using SolidWorks and CFD to optimise internal flow and cooling efficiency.
• High-efficiency bar and plate core selected after evaluating three different core types.
• Four-pass water path maximises heat rejection and slashes intake air temperatures for stronger pulls.
• Integrated header tank with cap positioned at the highest point to purge air easily and ensure a 100 percent coolant fill.
• Approx. 71 percent increase in internal volume and around 42 percent more frontal area versus the stock cooler.
• Hot climate dyno testing recorded markedly lower IATs compared with OEM and gains of up to 20 bhp.
• Every unit pressure tested to 4 bar as part of strict quality control.
• 1/8 NPT port on the outlet side for optional water methanol injection, WMI-ready out of the box.

Real-world results

We have fitted and used this upgrade on customer S55 cars. Feedback is consistently positive, with cooler intake temps, stable timing and repeatable performance even after multiple back-to-back pulls. It is a proven solution for tuned and standard vehicles alike, whether for spirited B-road driving, track days or drag runs.

Vehicle compatibility

Designed as a direct replacement top-mounted charge air cooler and matching reservoir for BMW M3 and BMW M4 models equipped with the S55 engine platform, including F80, F82 and F83.

What’s included

• Charge air cooler assembly
• Expansion/header tank with sight glass
• Expansion 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
• 1 x 8 mm ID vacuum hose x 170 mm
• 1 x 8 mm ID vacuum hose x 750 mm

Installation and support

Professional fitting recommended. MJ Modifications offers installation at our Warwickshire workshop. For a fitting quote or advice, email info@mjmodifications.co.uk.

Why enthusiasts choose this upgrade

• Direct-fit TMIC replacement for F80 F82 F83 without cutting or fabrication.
• Superior IAT control to combat heat soak on tuned S55 engines.
• Stronger, more consistent power delivery on the road and circuit.
• Built to last with UK design, robust welds and bar and plate efficiency.
• WMI-ready 1/8 NPT outlet for meth injection setups.

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