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.