🏷️ Basic Information

Make:

BMW

Model:

5 Series (E60/E61)

Model Variant:

545i

Year:

2004

Body Style:

Sedan

Chassis Code:

E60

Engine Code Series:

N62

👋 Introduction

Segment:

Executive/Luxury Sedan

Positioning:

The E60 generation BMW 5 Series represented a significant evolution in design and technology, bridging the gap between sporty handling and luxury comfort. The 545i, with its potent V8 engine, targeted buyers seeking performance within the executive sedan class.

Key Competitors:

Mercedes-Benz E-Class (W211), Audi A6 (C6), Lexus GS (GWS190), Cadillac CTS.

Vehicle Highlights:

iDrive infotainment system, advanced driver assistance options, sophisticated chassis dynamics, premium interior materials, powerful V8 engine in the 545i.

Value To Owner:

Essential resource for understanding vehicle operation, maximizing features, performing basic maintenance, and ensuring safe operation of the 2004 BMW 5 Series.

📋 Manual Details

Coverage Summary:

Covers general information, safety, operating controls, vehicle operation, navigation, communications, mobility, maintenance, and owner-specific functions for the 2004 BMW 525i, 530i, and 545i models.

Page Count:

Approx. 300-400 pages (typical for comprehensive owner's manuals of this era)

Manual Type:

Owner's Operation and Maintenance Manual

Language:

English

Format:

Printed Booklet

📖 Manual Coverage

Powertrain:

Engine operation, lubrication, cooling, fuel system, exhaust system.

Transmission:

Operation of the 6-speed manual transmission, clutch engagement, shifting procedures.

Brakes:

Brake system operation, parking brake, ABS (Anti-lock Braking System) indicators, DSC (Dynamic Stability Control) system.

Electrical:

Lighting system, power windows, mirrors, seats, central locking, instrument cluster, warning lights, battery care.

Chassis Suspension Steering:

Basic understanding of suspension components and steering operation.

Comfort Features:

Climate control (HVAC), seat heating/ventilation, sunroof operation, interior lighting.

Infotainment Navigation:

BMW Professional Radio/Business Radio operation, Navigation system (CCC - Car Communication Computer) basic functions, onboard computer.

Safety Systems:

Airbag system operation, seatbelt usage, child seat installation (ISOFIX), tire pressure monitoring system (TPMS).

Basic Operation:

Starting and stopping the engine, shifting gears, parking, operating lights and wipers.

Maintenance Checks:

Checking fluid levels (oil, coolant, brake fluid, windshield washer fluid), checking tire pressure, inspecting lights.

Scheduled Maintenance:

Guidance on when to perform routine maintenance tasks as indicated by the vehicle's service indicator system (CBS - Condition Based Service).

Troubleshooting:

Explanation of common dashboard warning lights and their meaning, basic troubleshooting steps for minor issues.

Emergency Procedures:

Jumping a dead battery, changing a flat tire, using the spare tire/mobility kit, emergency brake usage.

Fueling:

Correct fuel type, refueling procedure, fuel filler flap operation.

Tire Care:

Recommended tire pressures, tire rotation advice.

Depth Level:

Owner-focused, covering operation, basic maintenance, and understanding vehicle systems. Does not include detailed diagnostic procedures or complete rebuild instructions (typically found in BMW Service Manuals).

📊 Manual Specifications

File Format:

N/A (Printed)

Print Quality:

Professional, clear text and diagrams, high-quality paper.

Binding Type:

Staple-bound or Perfect-bound booklet

Paper Type:

Durable, glossy paper suitable for automotive environments

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated V8

Engine Code:

N62B44

Displacement:

4.4 Liters (4398 cc)

Bore X Stroke:

92.0 mm x 82.7 mm

Compression Ratio:

10.5:1

Horsepower:

325 hp @ 6100 rpm

Torque:

330 lb-ft (447 Nm) @ 3750 rpm

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI), VANOS (Variable Valve Timing)

Recommended Fuel:

Premium Unleaded Gasoline (91 octane or higher)

Engine Management:

Siemens MS45/MS45.1 ECU

🔧 Transmission

Transmission Type:

6-Speed Manual

Transmission Type:

6-Speed ZF 6HP19 Automatic (Steptronic)

Clutch:

Hydraulically Actuated Single Dry Plate

Gear Ratios Manual:

1st: 4.056, 2nd: 2.396, 3rd: 1.575, 4th: 1.156, 5th: 1.000, 6th: 0.840, Reverse: 3.550

Differential:

Rear Wheel Drive with Limited Slip Differential (LSD) often optional or standard on performance variants.

Manual Transmission Fluid:

BMW recommends specific gear oil meeting BMW specifications, often similar to: Pentosin MTF LT-2 or Castrol Syntrans B 75W-90. Capacity approx. 1.5-1.7 liters.

Automatic Transmission Fluid:

ZF Lifeguardfluid 6. Capacity approx. 7-9 liters (dry fill).

📐 Dimensions

Length:

4841 mm (190.6 in)

Width:

1846 mm (72.7 in)

Height:

1468 mm (57.8 in)

Wheelbase:

2888 mm (113.7 in)

Front Headroom:

Approx. 980 mm (38.6 in)

Rear Headroom:

Approx. 950 mm (37.4 in)

Trunk Capacity:

520 Liters (18.4 cu ft)

Curb Weight:

Approx. 1720 kg (3792 lbs) for manual transmission

Gross Vehicle Weight Rating:

Approx. 2220 kg (4894 lbs)

🛡️ Safety Features

NHTSA Front Impact:

5-Star (for applicable models)

IIHS Side Impact:

Good (for applicable models)

ABS:

Standard Anti-lock Braking System

Dsc:

Standard Dynamic Stability Control

Traction Control:

Standard Traction Control (ASC+T)

Tire Pressure Monitoring:

Standard Tire Pressure Monitor (TPM)

Airbags:

Frontal airbags, front side-impact airbags, head protection system (HPS) airbags.

Seatbelts:

3-point inertia-reel seatbelts with front belt force limiters and pre-tensioners, rear seatbelts.

Child Seat Anchors:

ISOFIX / LATCH system for rear seats.

💡 Technology Features

Infotainment System:

BMW iDrive system with Car Communication Computer (CCC). Features include radio, CD player, optional CD changer, navigation, climate control integration, and vehicle settings.

Display:

Central LCD screen integrated into the dashboard (typically 6.5 or 8.8 inches).

Connectivity:

Bluetooth preparation (optional), voice control (optional).

Adaptive Cruise Control:

Optional (ACC)

Parking Sensors:

Optional front and rear Park Distance Control (PDC).

Keyless Entry Start:

Comfort Access System (optional) for keyless entry and start/stop.

Headlights:

Xenon Adaptive Headlights (optional), automatic headlight activation.

🔧 Maintenance

Oil Change Interval:

Variable, typically indicated by the CBS system, often around 10,000-15,000 miles or 12-24 months, whichever comes first. Consult vehicle's specific condition indicators.

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Coolant Flush:

BMW Long-Life Coolant, typically first change at 4 years/50,000 miles, then every 2 years/30,000 miles thereafter. Verify specific procedure.

Air Filter Replacement:

Check at 30,000 miles, replace as needed or based on CBS indication.

Cabin Air Filter Replacement:

Check annually, replace every 15,000-20,000 miles or as needed.

Engine Oil Type:

Synthetic Oil meeting BMW Long-Life-01 (LL-01) or LL-04 specifications (e.g., Castrol EDGE Professional OE 5W-30, Mobil 1 0W-40). Check owner's manual for exact specification.

Engine Oil Capacity:

Approx. 6.5 liters (6.9 US quarts)

Coolant Type:

BMW Blue (G48) or Green (pre-2000s) Antifreeze/Coolant (Ethylene Glycol based). Mix 50/50 with distilled water.

Brake Fluid Type:

DOT 4 Low Viscosity (LV) meeting BMW High Performance DOT 4 standard.

Common Issues E60 V8:

Oil leaks from valve cover gaskets, vacuum lines, oil separator system (CCV). Cooling system issues including radiator leaks, water pump failure. Ignition coil failures, spark plug wear. Eccentric shaft sensor (ESS) failures. VANOS solenoid issues can cause rough idle or reduced power. Crankshaft bearing wear (less common on N62 than some earlier V8s, but still a potential concern). Electronic throttle body issues.

Common Issues General E60:

Water pump failure (electric on some models), thermostat housing leaks, power steering hose leaks. ABS/DSC sensor failures. Window regulator failures. iDrive system glitches. Door seal degradation.

📚 Vehicle History

Bmw Philosophy:

BMW's long-standing reputation for engineering excellence, 'Ultimate Driving Machine' slogan, and focus on driver engagement.

E60 Generation Introduction:

The E60 generation replaced the E39 5 Series and debuted in 2003 for the 2004 model year. It featured a controversial design by Chris Bangle and introduced significant technological advancements.

545I Introduction:

The 545i was introduced for the 2004 model year, serving as the V8 flagship of the E60 range before the higher-performance M5 model. It represented a significant upgrade in performance and luxury over the 6-cylinder variants.

Production Years:

2004-2010 (E60/E61 generation)

Manufacturing Locations:

Dingolfing, Germany; Magna Steyr, Austria; various CKD assembly plants globally.

🏆 Awards & Recognition

Car And Driver 10Best:

The E60 5 Series, including variants like the 545i, was a frequent recipient of Car and Driver's '10Best' awards during its production run for its driving dynamics and overall excellence.

Motor Trend Car Of The Year:

While not a winner in 2004, the E60 platform was critically acclaimed and frequently a contender in automotive awards.