Wagner Tuning BMW E60-Series 535d 635d Performance Package

Ultimate cooling and flow upgrade for BMW E60 E61 535d and E63 E64 635d

Enhance reliability, response and real-world performance with this matched bundle from Wagner Tuning. This package pairs a high-capacity front mount charge cooler with a precision stainless exhaust front section to cut intake temperatures, reduce backpressure and free up torque on your 3.0 twin-turbo diesel. Perfect for tuned cars and a brilliant foundation for future software calibration.

Vehicle compatibility

• BMW 5 Series E60 E61 535d 210 kW 286 PS 2006 to 2009
• BMW 6 Series E63 E64 635d 210 kW 286 PS 2006 to 2010

Why this bundle

• Colder charge air for consistent power on road and track
• Lower pressure drop for quicker response and stronger mid‑range
• Less thermal stress on the turbocharger for durability
• Direct-fit components that work with factory pipework

Charge-air cooler details 200001060

Stepped core size 530 x 244/134 x 150/50 mm with a massive 87% increase in frontal area and 95% more internal volume than the factory unit. Weight 9.8 kg. Designed to maximise flow and cooling without cutting or removing the bumper, this front mount cooler keeps intake temps low and pressure drop minimal.

• Bar-and-plate performance core with turbulators for efficient heat exchange
• Cast aluminium end tanks, CAD-optimised for smooth internal airflow
• Anti-corrosion coating for long-term thermal performance
• Plug-and-play installation using OEM hoses and mounts
• Comprehensive quality control for fit and function

In the box:

• 1 x Charge air cooler
• 1 x Installation instructions

Exhaust front section details 500001009

• Material: SS304 stainless steel
• Direct replacement fitment 1:1 with the original part
• Lowers exhaust backpressure for improved power potential
• Reduces heat load on the turbocharger assembly

BMW OE reference: 18308508523

Note: ECU coding will be required to prevent an engine management light after installation.

Real-world results

We have fitted this setup for customers and the feedback is consistently positive. Smoother pull, stronger acceleration and stable temperatures even under sustained motorway and spirited driving.

Professional fitting

Want it installed properly the first time? Book fitting with MJ Modifications in Warwickshire. Email info@mjmodifications.co.uk for a quote and scheduling.

Also searched as

BMW 5 Series diesel FMIC, E60 535d charge cooler, E61 535d front mount intercooler, 6 Series 635d intake air cooler, M57 twin turbo cooling upgrade, performance intercooler kit for 535d, stainless front pipe for 635d, 3.0d twin turbo exhaust upgrade, bolt-on FMIC for BMW E60 E61, E63 E64 diesel tuning hardware, bar and plate cooler for M57, Wagner 535d FMIC kit, high flow downpipe replacement 535d, BMW 286 PS diesel power upgrades.