Contact us if you have any questions about unlocking the full potential of your BMW with our high-performance upgrade hybrid turbos and parts from Falcon Turbos.

Engineered Forced Induction & Exhaust Hardware for BMW E63 & E64 (635d)

The second-generation BMW 6 Series manufactured between 2003-2010 —available in both the E63 Coupé and the E64 Convertible—combines long-wheelbase grand touring composure with serious powertrain headroom. The flagship forced-induction application is the legendary M57D30TÜ2 3.0-litre straight-six diesel (635d), factory-rated at 286 PS and 580 Nm of torque using a sequential twin-turbo configuration.

Pushing the 635d into Stage 2, Stage 3, and bespoke 400+ bhp territory quickly overloads the factory particulate filter (DPF), the restrictive intercooler core, and the limits of the factory turbo compressor profiles. Our performance catalogue targets these hardware bottlenecks directly:

• Billet Hybrid Turbochargers (M57 635d): The factory two-stage BorgWarner system utilises a small high-pressure turbo for instant low-end response and a larger low-pressure turbo for top-end airflow. Our hybrid assemblies feature multi-axis CNC-machined lightweight extended-tip billet compressor wheels, custom clipped turbine profiles, and heavy-duty 360-degree motorsport thrust bearings. Built to bolt into the original exhaust manifold housing and mate to OEM oil/water feeds, these matched pairs flow the air volume required for 420–450+ bhp and over 850 Nm of torque without premature boost taper.

• Direct-Fit Stepped Bar-and-Plate Intercoolers (635d): The E63 front-end packaging houses significant heat from the long straight-six block. The factory tube-and-fin intercooler rapidly heat-soaks during sustained high-speed pulls, causing Intake Air Temperatures (IATs) to climb and forcing the DDE to pull injected fuel volume. Our stepped front-mount intercoolers (FMIC) offer up to an 80% increase in frontal volume, dense internal bar-and-plate fin construction, and CFD-optimised cast-aluminium end tanks that drop IATs by up to 25°C with negligible pressure drop.

• Mandrel-Bent T304 Stainless Downpipes & Exhausts: Eliminating the restrictive primary catalytic converters and dense DPF directly off the turbo hot-side significantly lowers turbine backpressure. Fabricated from 3-inch and 3.5-inch brushed aircraft-grade T304 stainless steel with precision TIG welds, our downpipes drop operating Exhaust Gas Temperatures (EGTs) by up to 150°C, accelerate turbo spool-up by 300–400 RPM, and give the straight-six diesel a deep, purposeful tone.

Platform & Body Compatibility Breakdown

• BMW E63 Coupé : Features standard floorpan geometry and unobstructed transmission-tunnel routing. All hybrid turbos, stepped intercoolers, and downpipes install directly with zero sheet-metal cutting.

• BMW E64 Convertible (Underbody Bracing): To compensate for the structural loss of the roof, the E64 chassis is fitted with heavy diagonal underbody cross-bracing. Our downpipes, mid-pipe sections, and cat-back adapter pipes are engineered with specific clearance profiles to prevent contact or unwanted chassis vibration against these factory support braces under hard engine torque loading.

• Transmission Clearance: Downpipes and exhaust sections are shaped to clear the ZF 6HP26 / 6HP28 automatic transmission bellhousing and shift linkage mechanisms.

Frequently Asked Questions

Do E60 535d performance parts fit the E63 635d?

While the M57D30TÜ2 twin-turbo engine layout is identical, the E63 6 Series features a slightly longer front nose and distinct lower bumper ducting compared to the E60 5 Series. Our hybrid turbos and turbo-manifold downpipes are cross-compatible between both models, but check intercooler bracket and boost pipe configurations to ensure direct bolt-on installation behind the E63 lower grille.

What hardware is mandatory for a Stage 2 ECU tune on an E63 635d?

A 3-inch or 3.5-inch decat/DPF-delete downpipe is mandatory to eliminate turbine backpressure and protect the small turbo from excessive EGTs. An upgraded stepped front-mount intercooler (FMIC) is strongly advised to maintain dense charge air and prevent power derating during repeated pulls.

Will a decat downpipe cause an engine management light (EML) on a 635d?

Yes. Removing the factory DPF will trigger differential pressure sensor codes and initiate failed active regeneration cycles. A custom Stage 2 ECU/DDE calibration is required to disable DPF monitoring routines and optimise boost and injection maps.