Formula Z 2000WHP BMW S63TU4 Turbo System

The World’s First 2000WHP-Capable S63TU4 Turbo System

Developed for serious BMW S63TU4 builds, the Formula Z turbo system combines true equal-length manifold engineering, mirror-image Xona Rotor turbochargers and advanced 3D metal printing.

The production version now features improved collector merges, fewer welded joints and fully 3D-printed upper and lower heat shields.

First-batch production is now underway, with limited pre-order allocations remaining.

Key Features

• Supports approximately 1,000–2,000WHP

• True 100% equal-length 180-degree crossover design

• Full-size, long-runner exhaust manifold

• Choice of:

  • 0.100-inch 316L stainless steel

  • 0.063-inch Inconel 718

• DMLS 3D metal-printed construction

• CNC-machined cylinder-head flange surfaces

• Large 1.66-inch OD exhaust runners

• Improved flow compared with the restrictive factory manifolds

• Mirror-image Xona Rotor X3C turbo configuration

• 3.5-inch turbine outlet V-bands

• External TurboSmart 45mm wastegate mounting

• Individual EGT ports for every cylinder

• Exhaust backpressure sensor provision

• Triple-wall Inconel 625 flex bellows

• 3D-printed aluminium compressor outlets

• 3D-printed 316L stainless upper and lower heat shields

• Designed to accommodate direct 4-inch turbo intake routing

Turbo Options

Xona XRC5757S

• Approximately 1,000WHP

• Fast response

• Ideal for street and circuit-focused builds

Xona XRC6464S

• Approximately 1,400WHP

• Strong balance of response and top-end power

Xona XRC7269S

• Up to approximately 2,000WHP

• Developed for extreme drag, roll-racing and maximum-output builds

The modular Xona design allows different turbo sizes to interchange without replacing the complete manifold system.

Equal-Length 180-Degree Design

Unlike the short, uneven and restrictive factory manifolds, the Formula Z system uses full-size runners with four crossover pipes to create a true equal-length exhaust layout.

Benefits include:

• Improved exhaust flow

• Greater turbine efficiency

• More consistent exhaust pulse timing

• Improved exhaust scavenging

• Exceptional high-RPM sound

• Distinctive exotic V8 exhaust note

Pairing the system with the optional Formula Z Z-pipe further improves pulse balance, scavenging and exhaust sound.

Advanced Turbo Positioning

The turbochargers are positioned further rearward and angled slightly outward to improve packaging and airflow.

This layout provides:

• Straighter compressor inlet routing

• Space for full-size 4-inch turbo intakes

• Cleaner compressor outlet routing

• Easier blow-off valve installation

• Improved wastegate access

• Better engine-bay symmetry and presentation

Optional Extras

• 3.5-inch Formula Z Z-pipe

  • Straight or 45-degree inlets

  • Straight outlets

• 3D-printed aluminium compressor outlets

  • 60mm outlet compatibility

  • $650 MSRP

• Heat-isolated air-filter mounting brackets

  • Designed for K&N RE-1040 oval filters

  • $120 per pair MSRP

• Pre-modified turbocharger options available on request

Installation Requirements

Installation requires modification or extension of the factory lower turbocharger oil and coolant hardlines.

Formula Z recommends stainless hardline extensions for a clean and reliable installation.

Important Information

• Designed for the BMW 4.4-litre S63TU4 twin-turbo V8

• Final power depends on turbo selection, engine specification, fuel system, transmission, tuning and supporting modifications

• Professional installation and calibration are required

• Free shipping included

• Limited pre-order pricing is currently available

Enquire or Pre-Order

Contact M Lab by Boost & Tune to discuss turbo selection, supporting modifications, installation and complete vehicle packages.