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 Upgrades for BMW F06, F12 & F13 (640i, 640d, 650i)

The third-generation BMW 6 Series F1X 2011-2018 combines long-wheelbase grand-touring luxury with three of Munich’s most capable turbocharged powertrains. Whether you are daily driving the silky twin-scroll petrol N55 3.0L (640i), hunting monstrous low-end torque in the sequential twin-turbo N57 diesel (640d), or tapping into the heavy-hitting N63/N63TU 4.4L Twin-Turbo V8 (650i), these executive chassis possess vast tuning reserves. However, raising boost via Stage 2, Stage 3, or bespoke ECU mapping quickly exposes factory hardware choke points: restrictive primary catalysts and DPFs, thermal saturation in the charge-cooling circuits, and turbo compressor flow limits.

Our curated performance catalogue directly eliminates these hardware restrictions:

• Billet Hybrid Turbochargers: Engineered with 5-to-7-axis CNC-machined lightweight extended-tip billet compressor wheels, enlarged high-flow turbine shafts, and heavy-duty 360-degree motorsport thrust bearings. For the N55 640i, our bolt-on hybrid units eliminate top-end boost taper past 5,500 RPM to sustain 480–520+ bhp. For the N57 640d, our matched sequential twin-turbo hybrid packages (high-pressure + low-pressure) flow the air mass required for 420–450+ bhp and over 850 Nm of torque.

• Direct-Fit Stepped Bar-and-Plate Intercoolers: The F-chassis 6 Series engine bay holds substantial thermal mass under its elongated bonnet. Successive wide-open throttle pulls quickly heat-soak factory tube-and-fin cores, forcing the DME/DDE to pull ignition timing or reduce fuel volume. Our stepped front-mount intercoolers (FMIC) offer up to an 85% increase in frontal core volume and dense internal fin packs, drastically lowering Intake Air Temperatures (IATs) to maintain charge air density on N55 and N57 applications.

• Mandrel-Bent T304 Stainless Downpipes (Decat & Sports-Cat): Relieve massive hot-side backpressure right off the turbine exits. Fabricated from 3-inch, 3.5-inch, and 4-inch aircraft-grade T304 stainless steel with precision TIG welds, our downpipes slash turbine backpressure, drop Exhaust Gas Temperatures (EGTs) by up to 150°C, accelerate turbo spool by 300–400 RPM, and give straight-six platforms an authoritative exhaust tone.

Platform & Engine Compatibility Breakdown

• BMW N55 3.0L Single Twin-Scroll Petrol (640i / 640i xDrive): Available with 3.5-inch (early Pneumatic Wastegate / PWG) and 4.0-inch (late Electronic Wastegate / EWG) turbo-to-downpipe connections, direct-fit stepped intercoolers, and rigid aluminium charge pipes to eliminate boost leaks.

• BMW N57 3.0L Sequential Twin-Turbo Diesel (640d / 640d xDrive): Dedicated 3-inch and 3.5-inch DPF-delete decat downpipes and dual-stage hybrid turbos built to clear the front axle, steering shaft, and transmission crossmember.

• Body & Drivetrain Fitment (F06 vs. F12 vs. F13): The F06 Gran Coupé and F13 Coupé share identical floorpan and transmission-tunnel exhaust routing. The F12 Convertible features structural underbody cross-bracing; our downpipes and mid-pipe transitions are engineered with specific radius clearances to prevent any chassis contact or vibration under engine load.

Frequently Asked Questions

What is the difference between PWG and EWG downpipes on an F06/F12/F13 640i (N55)?

Early N55 models (2011 to mid-2013) use a Pneumatic Wastegate (PWG) with a 3.5-inch (approx. 89mm) turbo outlet flange. Late models (mid-2013 to 2018) feature an Electronic Wastegate (EWG) with an enlarged 4.0-inch (approx. 102mm) turbo outlet flange. Verify your build date or physical turbo outlet diameter before ordering.

What hardware is mandatory for a Stage 2 ECU tune on a BMW 640d?

A 3-inch or 3.5-inch decat or high-flow sports-cat downpipe is mandatory to eliminate turbine backpressure and protect the high-pressure 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 an upgraded downpipe trigger an engine management light (EML)?

Yes. Catless downpipes on petrol N55 and N63 models trigger secondary O2 sensor catalyst efficiency codes (P0420/P0430). On the N57 diesel, removing the factory DPF triggers differential pressure sensor codes. An appropriate Stage 2 ECU tune (DME/DDE calibration) is required to disable catalyst and DPF fault tracking.