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BMW 545i 2003 2004 2005 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 545i Generation: E60 Model Years Covered: 2003, 2004, 2005 Codes Chassis Code: E60 👋 Introduction Market Position Segment: Executive/Luxury Sedan Target Audience: Performance-oriented...
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Type: Car
Vendor:
Bmw
Sku: 427488
Tags: 2003 2004 2005 545i BMW Car Cars Misc
BMW 545i 2003 2004 2005 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
545i
Generation:
E60
Model Years Covered:
2003, 2004, 2005
Codes
Chassis Code:
E60
👋 Introduction
Market Position
Segment:
Executive/Luxury Sedan
Target Audience:
Performance-oriented luxury car buyers, often with a focus on driving dynamics
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type
Key Features
Design:
Chris Bangle's flame surfacing design language, distinct modern aesthetic for its era
Performance Focus:
Rear-wheel drive platform, powerful V8 engine, advanced chassis dynamics
Technology:
Introduction of iDrive infotainment system, optional advanced driver assistance systems
📋 Manual Details
Coverage Areas
Primary Coverage:
Mechanical and electrical systems, troubleshooting, diagnostics, repair procedures
Additional Coverage:
Maintenance schedules, specifications, wiring diagrams, technical service bulletins (TSBs) if included in original source
Page Count
Estimated Page Count:
Likely several thousand pages (typical for comprehensive BMW workshop manuals)
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English (primary for international market)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (N62 V8), transmission (SMG, automatic), drivetrain, exhaust system
Chassis:
Suspension (front and rear), steering, brakes (including ABS/DSC), wheels and tires
Electrical:
Body electrical systems, lighting, instrumentation, infotainment, comfort systems (HVAC, seats), ECUs, sensors, wiring diagrams
Body And Interior:
Body panels, doors, windows, sunroof, interior trim, airbags
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, inspections
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, symptom-based diagnostics
Repair:
Step-by-step repair instructions for all major components, including disassembly, assembly, and adjustments
Special Tools And Procedures:
Identification and use of BMW-specific tools, calibration procedures
Technical Depth
Depth:
Comprehensive, covering everything from basic checks to complete engine and transmission rebuilds, advanced electrical diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF
Print Quality
Quality:
High-resolution images and diagrams, suitable for printing
Binding Type
Binding:
N/A (digital format)
Paper Type
Paper Type:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
N62B44
Engine Type:
Naturally Aspirated V8
Displacement:
4.4 liters (4398 cc)
Bore X Stroke:
92 mm x 82.7 mm
Compression Ratio:
10.5:1
Valvetrain:
DOHC, 4 valves per cylinder, VANOS (variable valve timing)
Performance
Horsepower:
325 hp @ 6100 rpm
Torque:
330 lb-ft @ 3600 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-Point Injection (MPI)
Recommended Fuel:
Premium Unleaded Gasoline (91 octane or higher)
🔧 Transmission
Standard
Transmission Type:
6-speed manual (less common, often optional)
Optional
Transmission Type:
6-speed SMG (Sequential Manual Gearbox) or ZF 6HP Automatic Transmission
Features
Smg:
Clutchless shifting via paddles or gear lever, often with sport modes
Automatic:
Adaptive shift logic, manual shift mode (Steptronic)
📐 Dimensions
Exterior
Length:
191.1 inches (4854 mm)
Width:
73.5 inches (1868 mm)
Height:
57.7 inches (1466 mm)
Wheelbase:
116.4 inches (2956 mm)
Weights
Curb Weight:
Approximately 3700-3900 lbs (1680-1770 kg), depending on transmission and options
🛡️ Safety Features
Ratings
NHTSA:
Frontal crash: 5-star driver, 5-star passenger; Side impact: 5-star front, 5-star rear (typical for the era, refer to specific test results for exact ratings)
Active Features
Stability Control:
Dynamic Stability Control (DSC), Dynamic Traction Control (DTC)
Braking:
Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Brake Assist
Lighting:
Optional Xenon Adaptive Headlights
Passive Features
Airbags:
Frontal airbags, front side-impact airbags, curtain head protection airbags (front and rear)
Seatbelts:
Three-point seatbelts with pretensioners and force limiters
💡 Technology Features
Infotainment
System Name:
iDrive (first generation)
Features:
Centralized control for navigation, audio, climate control, and vehicle settings via a rotary knob and buttons.
Driver Assistance
Adaptive Cruise Control:
Optional Adaptive Cruise Control (ACC) available
Parking Sensors:
Park Distance Control (PDC) front and rear standard or optional
Connectivity
Bluetooth:
Optional Bluetooth hands-free interface
Comfort Features
Seats:
Multi-way power adjustable front seats, optional heated and ventilated seats, active comfort seats
🔧 Maintenance
Service Intervals
Oil Change:
Condition-based servicing (CBS) system, typically around 10,000-15,000 miles or annually, depending on driving conditions. Check oil level frequently between changes.
Brake Fluid:
Every 2 years (BMW recommendation)
Spark Plugs:
Typically around 60,000 miles for platinum or iridium plugs (N62 engine specific)
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) or BMW Longlife-01 FE (FE version for fuel economy) synthetic oil, viscosity typically 0W-30 or 5W-30
Coolant:
BMW Blue Antifreeze/Coolant (G48 formulation), typically a 50/50 mix with distilled water
Transmission Fluid Auto:
ZF LifeguardFluid 6 (for ZF 6HP automatic transmission), often considered 'lifetime' by BMW but recommended for change at higher mileage intervals (e.g., 100,000 miles)
Transmission Fluid Smg:
Specific Pentosin fluid (e.g., Pentosin CHF 11S) for hydraulic system, transmission oil will be standard GL-4 or GL-5 gear oil
Brake Fluid:
DOT 4 (BMW High Performance Brake Fluid)
Known Issues
Valve Stem Seals:
Common on N62 engines, leading to blue smoke on startup or during deceleration.
Cooling System:
Water pump failures, coolant leaks from plastic components (expansion tank, hoses), thermostat issues.
Oil Pan Gaskets:
Leaking oil pan gaskets and valve cover gaskets can be common due to age and material degradation.
ABS/Dsc Module:
Failure of the ABS/DSC hydraulic control unit can lead to warning lights and loss of function.
Idrive System:
Early versions of the iDrive system could be prone to software glitches or hardware failures.
📚 Vehicle History
Brand Heritage
Heritage:
BMW is renowned for its focus on 'The Ultimate Driving Machine', emphasizing performance, luxury, and engineering precision.
Model Evolution
E60 Introduction:
The E60 generation replaced the E39 5 Series, marking a significant shift in design and technology. The 545i was a high-performance variant introduced early in this generation.
Production
Manufacturing Location:
Primarily Dingolfing, Germany
Production Period:
The E60 generation was produced from 2003 to 2010. The 545i specifically covered the 2003-2005 model years before being succeeded by the 550i.
🏆 Awards & Recognition
Recognitions
Car And Driver 5 Best List:
The E60 5 Series generally received positive reviews and frequently appeared on '10Best' lists from automotive publications like Car and Driver.
Ward Best Engines:
BMW's V8 engines have historically been recognized for their performance and refinement.
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