VRSF E60 535i / 535xi N54 Intercooler Upgrade | 2008-2010

This VRSF kit replaces the overworked factory intercooler on the N54-powered E60 535i and 535xi with a far larger bar-and-plate front mount. It is offered in three sizes, from a 5-inch core for tuned stock-turbo cars to a 7.5-inch race core for big-turbo builds, and every version comes with E60-specific couplers and clamps.

What It Does

The N54 responds strongly to a tune, but the small factory intercooler cannot keep up with the extra boost. It heat soaks after a gear or two, intake temperatures rise, and the DME pulls timing. A VRSF core holds intake temperatures down pull after pull, so the car makes consistent power and has more margin against knock on hot days and long highway runs.

Choosing a Core

The 5-inch Performance HD core is rated to about 550 whp and is the best value for a tuned car on stock turbos. The 7.5-inch Competition HD is rated to about 850 whp, and the 7.5-inch Race HD is rated to about 1,100 whp for upgraded turbos and E85.

Materials and Construction

All three cores use staggered, offset high-density fins and cast aluminum end tanks. Tabs keep the factory fan shroud in place, and extra mounting hardware adds support. Each intercooler is hand finished and pressure tested before shipping.

Features

• Three bar-and-plate core sizes
• Cast aluminum end tanks
• E60-specific molded couplers
• Stainless steel T-bolt clamps
• Keeps the factory fan shroud
• Install in about 2.5 hours
• VRSF lifetime warranty and No Hassle fitment guarantee

What Is Included

• VRSF front mount intercooler in the size you choose
• Custom molded couplers for the E60
• Stainless steel T-bolt clamps
• Mounting hardware

Required Parts

• None. The kit includes everything needed to replace the factory intercooler.

Specs

• Part numbers: 10903070 (5in Performance HD), 10903040 (7.5in Competition HD), 10903050 (7.5in Race HD)
• Brand: VRSF
• Core: aluminum bar and plate
• End tanks: cast aluminum
• Rated power: about 550 / 850 / 1,100 whp
• Shipping dimensions: 33 x 16 x 15 in (84 x 41 x 38 cm) for the 5in core; 32 x 15 x 16 in (81 x 38 x 41 cm) for the 7.5in Competition core; 34 x 16 x 16 in (86 x 41 x 41 cm) for the 7.5in Race core
• Shipping weight: 30 lb (13.6 kg) for the 5in core; 30 lb (13.6 kg) for the 7.5in Competition core; 45 lb (20.4 kg) for the 7.5in Race core

Fitment Notes

• The 5in core may need minor trimming of the black plastic shroud and relocation of the auxiliary coolers.
• Both 7.5in cores need the black plastic shroud trimmed. The bumper never needs trimming.
• Fits left- and right-hand-drive cars.
• See more in our VRSF intercoolers collection.