Segment:
Executive/Luxury Sedan
Target Audience:
Performance-oriented luxury car buyers, often with a focus on driving dynamics
Key Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type
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
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
Estimated Page Count:
Likely several thousand pages (typical for comprehensive BMW workshop manuals)
Type:
Workshop Service Manual / Repair Manual
Language:
English (primary for international market)
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
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
Depth:
Comprehensive, covering everything from basic checks to complete engine and transmission rebuilds, advanced electrical diagnostics
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)
Horsepower:
325 hp @ 6100 rpm
Torque:
330 lb-ft @ 3600 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-Point Injection (MPI)
Recommended Fuel:
Premium Unleaded Gasoline (91 octane or higher)
Transmission Type:
6-speed manual (less common, often optional)
Transmission Type:
6-speed SMG (Sequential Manual Gearbox) or ZF 6HP Automatic Transmission
Smg:
Clutchless shifting via paddles or gear lever, often with sport modes
Automatic:
Adaptive shift logic, manual shift mode (Steptronic)
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)
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
Airbags:
Frontal airbags, front side-impact airbags, curtain head protection airbags (front and rear)
Seatbelts:
Three-point seatbelts with pretensioners and force limiters
System Name:
iDrive (first generation)
Features:
Centralized control for navigation, audio, climate control, and vehicle settings via a rotary knob and buttons.
Adaptive Cruise Control:
Optional Adaptive Cruise Control (ACC) available
Parking Sensors:
Park Distance Control (PDC) front and rear standard or optional
Bluetooth:
Optional Bluetooth hands-free interface
Seats:
Multi-way power adjustable front seats, optional heated and ventilated seats, active comfort seats
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)
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)
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.
Heritage:
BMW is renowned for its focus on 'The Ultimate Driving Machine', emphasizing performance, luxury, and engineering precision.
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.
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.
