Wagner Tuning BMW 5 Series E60/E61 525d 530d 535d & 6 Series E63/E64 635d Front Mount Intercooler Upgrade FMIC Charge Air Cooler | M57 Diesel Direct-Fit Stepped Bar-and-Plate Performance Kit 2003–2010

Uprated FMIC Upgrade for BMW 5 Series Diesel and 6 Series Diesel

Unlock cooler intake temps, stronger sustained performance and rock-solid reliability on your BMW diesel with this premium front mount charge air cooler upgrade from Wagner Tuning. Purpose-built for the M57 platform, this stepped bar-and-plate unit delivers a massive increase in cooling area and air volume for serious road and track use while remaining a direct replacement for the factory cooler.

Why upgrade

• Huge stepped core for rapid heat rejection and stable intake temps during hard driving
• Flow-optimised cast alloy end tanks reduce restriction for better turbo efficiency
• Lower pressure drop compared with the stock unit for sharper boost response
• Ideal companion for remaps, hybrid turbos and towing where charge temps climb
• Durable anti-corrosion coating for long-term reliability in UK weather
• Direct-fit design uses the factory pipework and clamps - bumper stays on

Technical highlights

• Core size: 530 mm x 244 [134] mm x 150 [50] mm stepped volume = 13,500 cm³
• Frontal area increase: 87 percent vs stock
• Internal volume increase: 95 percent vs stock
• Construction: high-quality bar-and-plate core with turbulators
• End tanks: CAD-developed cast aluminium for superior internal flow
• Weight: 9.8 kg
• Protective finish: anti-corrosion coating with excellent thermal dissipation

Real-world results

We have fitted this cooler to multiple customer cars and our own builds at MJ Modifications. Feedback has been consistently positive, with noticeably cooler charge temps, strong midrange pull and dependable performance during repeated full-throttle runs.

Fitment compatibility

• BMW 525d 2004–2010 E60/E61 130–145 kW / 177–197 PS
• BMW 530d 2003–2010 E60/E61 160–173 kW / 218–235 PS
• BMW 535d 2004–2010 E60/E61 200–210 kW / 272–286 PS
• BMW 635d 2006–2010 E63/E64 200–210 kW / 272–286 PS

Installation

Direct replacement using the standard boost pipes. No front bumper removal required on compatible models. For professional fitting and peace of mind, book with MJ Modifications in Warwickshire. Request a quote at info@mjmodifications.co.uk.

What is included

• 1 x charge air cooler
• Fitting instructions

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