Ready for more boost in your E60 535i N54? Not without a bigger intercooler!
It's easy to make more boost and more power in a turbocharged engine like the N54 - until other components show their weaknesses. The stock BMW intercooler on the E60 535i N54 is decent enough for maintaining intake air temps on a stock engine (though there's still room for improvement). But adding more boost will raise intake air temps and lead to fuel and timing adjustments that could actually reduce power levels! If your N54 turbo upgrades are not living up to expectations it could be the rest of your system letting your down.
The Wagner Intercooler for the E60 535i N54 is larger to take advantage of the surface area on the front of the E60. It uses a stepped design to maximize surface area. With more surface area comes more cooling capability and the Wagner has 87% larger area for 95% more air volume compared to the stock intercooler. CAD and FEA design has optimized the air flow into and out of the heat exchanger thanks to turbulator fins and cast aluminum endtanks. There is less pressure drop than stock which means air velocity stays high. The Wagner Performance line of intercoolers uses tried and true bar and plate layout which has excellent heat soak properties and cooling capability (but are a little heavier than the Competition intercoolers). The weight of the Performance intercooler is 21.6lbs.
One of the best attributes of Wagner intercoolers is their direct fit installation on the E60 models. The bumper does not have to be removed or modified and the Evo I fits with the stock intercooler connectors and hoses. Wagner uses a durable anti-corrosive coating that also helps dissipate heat. Installation instructions are included.
Notice of Emissions Non-Compliance. The intake system is part of a vehicle's emissions equipment. Removing, disabling, or altering emissions equipment on a pollution-controlled road vehicle is illegal. Installing devices or software that trick, disable, or modify emissions controls and monitors on a pollution-controlled road vehicle is also illegal. Unless noted above, this product is not legal for sale or use in California on any pollution controlled motor vehicle.
E60 / E61 (04-10) > 535i