Pipercross Intake Kit for F87 BMW M2 - PK461

Pipercross BMW M135i/M235i/335i/435i/M2 Non-Comp. N55 3.0T Intake System

The Pipercross Intake System has been designed and engineered to directly replace the OEM airbox and integrated intake plumbing on BMW FXX M135i, M235i, 335i, 435i and F87 M2 (Non-Competition) vehicles with the N55 3.0T engine

KEY FEATURES

• Large filter heatshield 
• Bespoke Pipercross conical air filter 
• Powder coated, single piece CNC mandrel-bent aluminium intake pipe
• Thick-walled silicone coupler for long-term durability
• Designed, prototyped and iteratively refined using latest 3D scanning and CAD technology
• Up tp +25 BHP/+28.0 ft.-lbs. TQ maximum power gain 

OEM INTAKE ASSESSMENT

The OEM intake system on the BMW N55 3.0T engine (found in various FXX chassis vehicles and F87 M2 non-competition vehicles) features several performance-focused aspects that are indicative of M-tier OE BMW performance engineering. This engineering allows the OE intake parts to adequately support the N55 engine in most scenarios, when the engine is operating with OE ECU programming. However, aftermarket engine tuning (even conservative tuning) increases boost (and subsequent turbocharger air demand) enough that the OE intake components begin to limit performance of the engine, even in typical driving scenarios.

The Pipercross engineering team identified the OE intake filtration media type/total surface area, OE airbox and the airbox-integrated plumbing as areas of potential system performance improvement. Alternatively, the OE lower fresh-air ducting and turbocharger inlet hose were deemed adequate to support significantly increased boost/airflow demands, based on the M-tier engineering aspects, specific part size/functionality and the Pipercross engineers’ experience with overall performance intake design across a multitude of chassis/engines.

CONICAL AIR FILTER

The heart of the Pipercross intake kit is the Pipercross conical air filter. This filter features Pipercross’ time-tested and proven air filter construction methods, to achieve the targeted airflow performance of the kit while maintaining the headroom required to support significant future tuning packages/hardware upgrades. The bespoke Pipercross foam filtration media blend strikes the perfect balance between increased flow and air filtration, while the coated steel backing and formed -then-coated aluminium base draws from decades of successful in-house Pipercross filter manufacturing. The utilisation of a conical filter increases filtration surface area 10.14% over a typical foam panel filter insert and features a 180mm OD filter with a 90mm diameter spun aluminium outlet. This filter serves as the foundation for the performance increase offered by the Pipercross intake kit.

HEATSHIELD

The Pipercross heatshield was meticulously designed to maximise the shielded volume within FXX/F87engine bays, while optimising the use of the OE fresh-air ducting - thus maximising the performance of the air filter. The part fully shields the filter from ambient engine heat with a solid three wall design towards the engine, fully insulating the cavity from heated air ingress. The lower portion of this three-wall design is tailored to the OE fresh-air ducting, with off-plane bends designed to shape the fresh air flow from the OE ducting throughout the enclosed space. The Pipercross heatshield is CNC laser cut from corrosion-resistant 2mm aluminium sheet and powder coated for additional corrosion resistance/aesthetic appeal. The heatshield also makes use of the OE vibration-damping chassis mounts, in addition to several fixed mounting points for stability and long-term kit durability. To further assure the long-term durability of the Pipercross parts, hybrid EPDM edging trim is used to isolate the heatshield from direct contact with any other components - preventing any vibration-related part failures.

HARD PIPE

The Pipercross N55 3.0T hard pipe assembly supplements the benefits offered by the air filter and heatshield, rounding out the overall performance capabilities of the Pipercross kit. The assembly is constructed of a single-piece, 90mm outer diameter aluminium CNC mandrel-bent pipe, for a consistent internal cross-sectional flow area throughout the tubing (vs. welded sections that can create flow-destabilizing and cross-sectional reducing internal swarf areas). The end of the Pipercross hard pipe assembly features an 80mm outer diameter reducing swage, to properly connect with the OE turbocharger inlet hose while maintaining the single-piece tube construction. MAF sensor placement was also carefully considered, with a CNC-machined sensor boss placed in an almost identical location to the OE plumbing. The pipe assembly also features integrated mounting brackets designed to accept vibration-isolating mounts, to eliminate the potential of part failure due to long-term weld/tubing vibration-based loading. Finally, each assembly is powder coated to stringent specifications for additional corrosion resistance and aesthetic appeal, without any internal bore/boss overcoating.

DETAILS

The subtle details of the Pipercross Intake Kit are what elevate it beyond the competition. The silicone coupling hose features a smooth internal bore and 5-ply wall construction; ensuring long term durability without any of the airflow destabilization associated with typical corrugated couplers. All Pipercross brackets are CNC laser cut from steel plate and powder coated to match; for better long-term fatigue/failure and corrosion resistance. All stainless-steel hardware is provided to ensure corrosion, oil and other adverse engine bay environmental factors have no effect on the Pipercross kit’s function or aesthetic – no matter how hard the vehicle is driven.

RESEARCH AND DEVELOPMENT

All Pipercross products are designed in-house, utilising the latest 3D-printing, 3D-scanning, CAD, CFD, airflow testing and performance testing product development technologies. The Pipercross N55 3.0T Intake Kit saw several design stages/iterations, to integrate the largest air filter, shielded engine bay volume and intake pipe diameter possible, while maintaining required part clearances. Bench airflow testing was conducted on the full OEM intake system and the final Pipercross intake design, using Pipercross’ in-house, custom designed and built airflow test apparatus inside a controlled environment. Performance testing of the OEM and final Pipercross intake design was completed at a third party, independent, environmentally regulated Dyno Dynamics four-wheel drive dynamometer cell; to ensure unbiased performance gain data was captured.

AIRFLOW TESTING DATA

Both the OE and final Pipercross intake configurations were tested on Pipercross’ in-house, custom built stationary airflow test apparatus. To develop an initial airflow baseline, the OE intake system was tested to its maximum airflow value. The complete final Pipercross intake system was then tested to its maximum flow value. The table and graph below summarize the results of this testing, illustrating the Pipercross kit’s 60.33% maximum and 50.31% average decrease in airflow restriction (and thus confirming the performance benefit of Pipercross intake components). The maximum airflow values for both the full Pipercross and OE intake systems are of note as well; the Pipercross system supported up to 974 CFM, while the OE system supported up to 891 CFM (a 9.32% increase, respectively).

PERFORMANCE TESTING DATA

Building upon the data gathered from the airflow testing, the final version of the Pipercross Intake Kit was tested on a 2017 BMW non-Competition M2 (N55 3.0T engine) with an aftermarket intercooler, downpipe and a tuning box installed. This performance testing was conducted utilising a third-party, independent Dyno Dynamics four-wheel drive dynamometer within a temperature and airflow-controlled test cell. Three runs of each intake configuration (six runs in total) were tested on the same day, within the same cell and the vehicle was allowed to cool between testing sets.

The data displayed shows the average of three runs for each intake configuration. As clearly visible within the data sets, the Pipercross intake kit provides significant performance benefit to the N55 3.0T throughout the engine’s speed range. Of particular note is the large power delta at the top of the engine’s speed range, as well as the large torque delta (and location of the maximum torque gained) within the most usable part of the engine’s speed range (3250-4000 RPM) – both indicating that the drivability of the vehicle with the Pipercross intake installed is significantly improved. With a maximum recorded gain of +25 BHP/+28.0 ft.-lbs. TQ. 

*Data collected correct on day of testing, different dynos and set ups may differ.