2007 – 2010 BMW 535i & 535xi Bolt on Intercooler Upgrade Kit

For your E60 535i with the N54 Engine

Replace your overheated factory intercooler with one of the many available VRSF upgraded intercooler kits to get the most out of your N54 E60 535i. We designed this kit to be one of the best performing, direct bolt on intercoolers available for your BMW with special attention to quality and performance while maintaining a reasonable price. Our intercoolers allow for higher HP gains, mainly due to their ability to keep intake temps down while preventing heat soak which is a common problem with the factory intercooler. This results in a more power and increased reliability with reduced chances of pre-detonation & knock.

Intercooler Core

The most important component of any intercooler is the core. The core cools the charged air from the turbo before it enters the engine and the OEM BMW tube and fin intercooler is designed to support low boost levels and air flow. Once boost levels and air flow are increased, the OEM unit is easily overwhelmed and can not keep up with the cooling demands of a tune running more than OEM boost levels. This results in heatsoak which will result in a power loss and a higher potential for pre-detonation in the upper RPM range.

We remedy this problem with our custom bar and plate core designs which utilizes a staggered and offset high density internal and external fin pack. Our cores have been carefully tuned to provide the the best intake temperature reduction while maintaining minimal pressure drop. Our bar & plate core is also much more durable than the OEM tube and fin core, with a better ability to withstand rocks and other debris.

The VRSF Intercoolers are the most proven, affordable options that will lower intake temps on a full bolt on car without compromise. With the 5″ Performance Stepped HD intercooler you can expect to see an 0-3 degree rise during a 3rd gear pull on a stock turbo, where the 7″ Competition HD Intercooler will show a decrease in starting temperature. In comparison, the OEM intercooler rises about 32 degrees during the same 3rd gear pull.

All VRSF Intercoolers are comprised of an incredibly dense fin pack, both internally and externally. It’s not uncommon to see intake temperatures drop at the end of a 3rd gear pull due to the Competition HD’s larger overall surface area. You can expect to see an intake temperature reduction on a stock turbo, full bolt on car during a 3rd gear pull which is why we recommend the Competition HD FMIC over the regular Performance intercooler if your budget allows.

For anyone looking to run larger upgraded turbos above 650whp, we recommend our ultra high density 1000hp custom bar and plate core design which utilizes a staggered and offset internal and external fin pack. The race core has been carefully balanced to provide the the best intake temperature reduction while maintaining minimal pressure drop. This intercooler was specifically designed for upgraded turbo cars running larger twin turbos or single turbos and is 1080 cubic inches in total which is 134% larger than the stock intercooler.

Our 7.5″ FMIC has been involved in many record breaking builds and is currently featured on the current world’s highest horsepower N54 @ 861WHP as well as the first and only intercooler to officially support a 1000whp N54 and the intercooler found on the record holding highest N54 WHP car by Motiv Motorsport.

Finish & Construction

Our VRSF intercooler features 3D CAD designed cast aluminum end tanks for improved flow in comparison to sheet metal end tanks. Our one piece seamless cast end tanks are also more durable than comparable sheet metal or multiple piece end tanks. Every VRSF intercooler is finished in a beautiful, uniform, bright silver coating which helps protect the intercooler from corrosion and ensures your VRSF intercooler holds up to the elements, no matter where you live.

Every VRSF product includes our lifetime warranty & our “No Hassle” satisfaction guarantee which includes fitment & defects.

Installation

All of VRSF intercoolers feature tabs that allow the retention of the factory fan shroud. We also include additional mounting hardware for extra support along with everything required to replace the OEM intercooler, including custom molded couplers made specifically for the E60 535i and stainless steel t-bolt clamps necessary for installation.

The 5″ stepped core unit does not require trimming of the black plastic shroud (may require relocation of aux coolers). The 7″ & 7.5″ race require trimming of the black plastic shroud behind the bumper. The bumper does not require trimming with either models. Each VRSF intercooler is hand finished and pressure tested to ensure a high quality, leak free experience. Our intercoolers fit both Left Hand Drive (LHD) & Right Hand Drive (RHD) models.

Features

• High Density Bar & Plate Core
• Cast Aluminum End Tanks
• Easy install, less than 2.5 hours
• Includes lifetime warranty

Fits the following BMWs

2007 – 2010 E60 BMW 535i/535xi