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BMW E60 Stage-2 intake details
aFe 54-11042 is the Magnum FORCE Stage-2 Pro 5R intake identified by aFe for BMW 525i, 528i and 530i E60 2006-2009 naturally aspirated 3.0L applications. It combines one oiled filter, a molded intake tube, metal heat shield, six-inch filter adaptor and a throttle-body coupler. The current replacement-filter listing differs from the linked installation-sheet bill, so confirm the supplied revision before ordering replacement media.
Key Features
- One washable, reusable five-layer oiled Pro 5R filter; the dry shared-kit option is not the selected media.
- Current primary specifies an 18-gauge powder-coated metal heat shield and a heat-insulating molded plastic tube.
- Current replacement reference is 24-91054; the linked sheet lists 24-60505. These are documented as a revision conflict.
- One coupler, two #056 clamps and one six-inch filter adaptor appear in the exact bill.
- The tube-flange gasket belongs between the tube and housing; the separate MAF gasket belongs between the original sensor and new tube.
- Original vacuum line reconnects through the supplied grommet and nylon barbed fitting.
- One saved original T25 airbox bolt secures the new housing.
- Periodic clamp and hose checks are specified without a numeric torque or mileage interval.
Fitment
Manufacturer coverage is E60 525i/528i/530i 2006-2009 with naturally aspirated 3.0L engines. The manual separately lists 525i/530i 2006-2009 and 528i 2007-2009. Existing catalog rows below also include later 2010, xDrive/xi, 535i and 535i GT applications supported by exact-part retailer tables, including WheelFlip and SOHi. Those broader rows remain source conflicts requiring confirmation of the actual engine, chassis and intake connections; they are not manufacturer-certified extensions. In particular, BMW identifies the 2010 535i Gran Turismo as F07 with an N55 turbo engine, distinct from the primary E60 naturally aspirated application. No physical incompatibility is concluded solely from this source disagreement. Confirm the exact configuration before purchase; do not infer fitment from a model name alone.
| Years | Make | Model | Named trim; actual engine and hood requirements apply |
|---|---|---|---|
| 2006-2007 | BMW | 525i | Base |
| 2008-2010 | BMW | 528i | Base |
| 2009-2010 | BMW | 528i xDrive | Base |
| 2008 | BMW | 528xi | Base |
| 2006-2007 | BMW | 530i | Base |
| 2008-2010 | BMW | 535i | Base |
| 2010 | BMW | 535i GT | Base |
| 2009-2010 | BMW | 535i xDrive | Base |
| 2008 | BMW | 535xi | Base |
Verify 54-11042 against the actual engine, sensor and vent connections, mounting locations and applicable emissions requirements before ordering.
Specifications
| Brand | aFe POWER |
| Manufacturer Part Number | 54-11042 |
| Product type | Magnum FORCE Stage-2 cold air intake |
| Primary application | BMW E60 525i / 528i / 530i, 2006-2009 naturally aspirated 3.0L |
| Selected media | One five-layer oiled Pro 5R filter |
| Filter revision | Current reference 24-91054, six-inch flange / five-inch height; linked bill 24-60505 |
| Housing | 18-gauge powder-coated metal heat shield |
| Tube | Heat-insulating molded plastic |
| Adaptor | One six-inch filter adaptor |
| Coupler and clamps | One coupler; two #056 clamps |
| Tube seal | One tube-flange gasket between tube and housing |
| MAF hardware | Original sensor; one gasket and two M4 x .7 x 10 screws |
| Adaptor hardware | Four M6 x 1 x 25 screws and four M6 washers |
| Vacuum connection | One grommet and one 1/4 x 3/16-inch nylon barbed fitting |
| Trim | 33 inches of 7/16-inch trim seal |
| Performance evidence | Advertised 48% flow / 8 hp / 10 lb-ft; no flow report, chart lacks legend and run conditions |
| Emissions | Primary cites D-550-38 for some or all applications; exact full conditions held |
| Recheck | Periodic clamp/hose checks; no numeric torque or mileage stated |
| UPC | 802959501955 |
| WARNING | This product can expose you to chemicals including lead and phthalates, which are known to the State of California to cause cancer and reproductive harm. For more information go to www.P65Warnings.ca.gov. |
What's Included
| Quantity | Manufacturer service part | Component |
|---|---|---|
| 1 | Pro 5R filter | Oiled selection; linked bill 24-60505 versus current 24-91054 reference |
| 1 | Intake tube | Molded plastic |
| 1 | Housing | Metal heat shield |
| 1 | Coupler | Throttle-body connection |
| 1 | Tube-flange gasket | Between tube and housing |
| 2 | #056 | Clamps |
| 1 | Grommet | Vacuum fitting mount |
| 1 | 1/4 x 3/16-inch nylon fitting | Barbed vacuum connection |
| 33 inches | 7/16-inch trim seal | Housing edge |
| 4 | M6 x 1 x 25 | Adaptor screws |
| 4 | M6 | Washers |
| 2 | M4 x .7 x 10 | MAF screws |
| 1 | MAF sensor gasket | Between sensor and tube |
| 1 | Six-inch adaptor | Filter attachment |
The selected package contains one oiled filter. Current primary replacement 24-91054 and linked-sheet 24-60505 references are not treated as proof of the actual boxed revision. The shared dry-kit identifier and blue filter in old photos do not convert the selected kit to dry media. Original MAF sensor and vacuum line are reused. Tools listed as required, including T20 and T25 bits, are not listed as supplied contents. No new MAF sensor or top cover is included in the bill.
About aFe Power
aFe Power develops application-specific intake, filtration, exhaust, cooling, tuning, suspension, drivetrain, and truck-performance components supported by product testing and documented installation requirements.
Related Parts
- Manufacturer product specifications for 54-11042
- Exact illustrated installation manual
- Manufacturer-linked dyno comparison and run configuration
- Shop the complete aFe Power collection
Frequently Asked Questions
What is the 54-11042?One oiled Pro 5R filter, molded tube, metal housing, coupler, two #056 clamps, adaptor, tube and MAF gaskets, vacuum fitting/grommet, trim seal and the specified mounting hardware.
Why are two replacement-filter numbers mentioned?The current primary lists 24-91054 while its linked sheet lists 24-60505. Confirm the actual supplied revision before ordering replacement media; only one selected oiled filter is included.
Does this kit include a top cover or new MAF sensor?Neither appears in the exact bill. Reuse the original sensor with the supplied MAF gasket and M4 screws.
Where do the two gaskets go?The tube-flange gasket goes between tube and housing. The separate MAF gasket goes between the original sensor and new tube.
How is the vacuum line connected?Install the supplied grommet and nylon barbed fitting in the new tube, then reinsert the original vacuum line.
Are all listed 535i and GT rows manufacturer confirmed?No. Exact retailers list broader applications than the naturally aspirated E60 manufacturer coverage. BMW identifies the 2010 535i GT as F07/N55 turbo; confirm engine, chassis and connections before purchase.
Are the advertised gains and exemption fully verified?No flow report is linked, and the dyno image lacks legend and run conditions. D-550-38 is cited for some or all applications, while full exact conditions and exclusions remain held.
What torque, battery and recheck instructions apply?The exact sheet gives no numeric torque, battery-disconnection step or mileage interval. It calls for periodic checks of clamps and hoses.
Installation Instructions
Verify aFe 54-11042. Follow all fifteen illustrated steps of the exact sheet. Release the three upper factory airbox clips, loosen the factory clamp and remove the original MAF sensor with T20. Lift the upper airbox and filter, remove the lower airbox with its two T25 bolts and save those bolts. Loosen the original throttle-body clamp and remove the original intake tube. Position the supplied coupler and clamps on the throttle body. Put the new housing in place and slide the new tube into the coupler with the tube-flange gasket between the tube and housing. Position the six-inch adaptor inside the housing and join it to the tube using the four M6 screws and washers, then apply the trim seal. Fit the grommet and barbed fitting to the new tube and reinsert the original vacuum line. Secure the housing using one saved original T25 bolt. Install the original MAF sensor into the new tube with its separate gasket between sensor and tube, attach the supplied M4 screws and reconnect the sensor harness. Align and tighten the coupler clamps, then install the selected filter. Confirm applicable EO labeling and exact application conditions before relying on the sheet sticker instruction. Check all clamps and hoses periodically. The sheet supplies no battery-disconnection step, numeric torque or mileage interval.
Important Disclosures
The current exact product page, complete one-page manual, full bill and all fifteen installation images were reviewed along with the linked dyno chart. The linked chart has curves without a legend, exact vehicle/run table, dates or test conditions, so it does not independently certify the advertised 8 hp or 10 lb-ft. No linked flow report verifies 48%. Current 24-91054 versus manual 24-60505 filter references remain a revision question for the actual supplied kit. Exact retailer application tables conflict with narrower manufacturer coverage; broader existing rows are retained with confirmation required, including the distinct F07/N55 535i GT. Indexed D-550-38 naturally aspirated application rows do not establish turbo/GT coverage or replace full order conditions and exclusions. Full order access remains unavailable after the earlier challenge. No battery step, torque, mileage interval, top cover or extra filter is borrowed from a different intake.
California Proposition 65 warning: this product can expose you to chemicals known to the State of California to cause cancer and reproductive harm.
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