France's Fabrice Santoro, a finalist in 2001, beat Mikhail Youzhny of Russia 7-6 (7-4) 6-2.
Others seeds to progress were Mikhail Youzhny (20) and Nicolas Almagro (26) and Albert Montanes (31).
Second seed Mikhail Youzhny was also beaten, losing 6-2 6-0 to defending champion Jonas Bjorkman .
Youzhny's quarter-final opponent, Philipp Kohlschreiber, retired after losing the first set when he felt unwell.
Eighth seed Fabrice Santoro was unable to follow suit as he went dowm 6-0 7-6 to Russia's Mikhail Youzhny.
In Thursday's quarterfinals, fifth seed Robin Soderling of Sweden takes on No. 13 Mikhail Youzhny of Russia.
The second seed now plays another Russian, 2004 champion Mikhail Youzhny, for a place in Sunday's final.
Callieri now faces French seventh seed Sebastien Grosjean , a 7-6 (7-2) 6-1 victor over Russia's Mikhail Youzhny .
However, Mikhail Youzhny was too strong for Leonardo Mayer, easing to a 6-3, 6-1, 6-4 triumph to level matters.
The two-time quarterfinalist will face Russian 27th seed Mikhail Youzhny in round three.
Youzhny admitted his win owed much to coming up against an off-key Nadal.
Youzhny made an edgy start, losing his first service game, and that proved decisive as Ivanisevic served out the set.
The BMW Open title in Munich went to Czech Tomas Berdych who edged out Mikhail Youzhny of Russia 6-4 4-6 7-6.
World number 19 Youzhny closed out the match after just 58 minutes on court for the fourth title of his career.
Russia have named Marat Safin in their squad, despite his wrist injury, along with Yevgeny Kafelnikov, Mikhail Youzhny and Nikolay Davydenko.
Two rain breaks in the second set disrupted Ivanisevic's rhythm but some careful baseline rallying in the tie-break forced errors from Youzhny.
"This victory is a present from Rafael, " said Youzhny, who has beaten Nadal in four of their seven encounters on hard courts.
Henman will face Mikhail Youzhny or Jiri Novak in the third round.
Russian second seed Mikhail Youzhny defeated German Andreas Beck 6-3 6-3 to reach the third round, where he faces Jan Hajek of the Czech Republic.
Second seed Mikhail Youzhny, the runner-up for the past two years, also moved into the semis with a 6-1 6-3 win over Czech Jan Hajek.
Earlier, third seed Nicolas Almagro made a shock exit when he was beaten in straight sets by Russia's Mikhail Youzhny in their second round match.
The Spaniard thrashed Russian 27th seed Mikhail Youzhny 6-0 6-2 6-2 to set up a clash with compatriot Marcel Granollers, who beat a tired Paul-Henri Mathieu.
Gonzalez beat Juan Carlos Ferrero of Spain 6-2 6-1, Moya defeated Germany's Denis Gremelmayr 6-1 6-4 and 13th-seeded Berdych downed Russian Mikhail Youzhny 7-6 (3) 6-4.
Russia are already without 2002 hero Mikhail Youzhny, who is missing after failing to regain top form since missing the US Open with a neck injury.
World number one Federer thrashed Vik 6-3 6-2, while Russia's Youzhny reached his first semi-final of the year when he overwhelmed Belgium's Olivier Rochus 6-3 6-1.
Youzhny is one of Murray's rivals for the remaining two places and next week's Masters Series tournament in Paris is the last chance to earn qualifying points.
Youzhny shocked the number five seed by breaking his serve in the first game of the match but Soderling clicked into gear and was not overly troubled again.
However, 16th seed Juan Monaco was beaten 7-6 6-4 by Romanian Victor Hanescu, while ninth seed Mikhail Youzhny lost 6-4 4-6 6-3 to former world number one Lleyton Hewitt.
Russia called up Andreev to give regular doubles player Mikhail Youzhny more time to recover from a back injury sustained late in his five-set defeat to Ljubicic on Friday.
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