🏷️ Basic Information

Make:

BMW

Model:

545i

Year:

2004

Chassis Code:

E60

Engine Code:

N62B44 (4.4L V8)

👋 Introduction

Market Position:

The 2004 BMW 545i (E60) represented BMW's entry into the mid-size luxury sedan segment with a focus on performance, technology, and refined driving dynamics. It competed against established rivals like the Mercedes-Benz E-Class, Audi A6, and Lexus GS.

Competitive Analysis:

The 545i distinguished itself with its powerful V8 engine and innovative features like iDrive. This manual provides the essential technical documentation to maintain and repair this complex German luxury vehicle, offering a significant advantage over generic repair guides.

Key Features:

Officially licensed software ensuring accuracy and completeness. Provides in-depth technical information for a wide range of repairs and maintenance. Digital format allows for quick searching and easy access to specific procedures. Essential for owners and independent repair facilities dealing with the E60 platform.

📋 Manual Details

Coverage Areas:

Engine, Drivetrain, Suspension, Steering, Brakes, Electrical Systems, HVAC, Bodywork, Diagnostics, Maintenance, Repair Procedures, Troubleshooting

Page Count:

Estimated 2000+ pages (Software)

Manual Type:

Official Service & Repair Manual Software

Language:

English

Format:

Digital Software (Likely PDF or proprietary application)

Updateability:

Software-based manuals may have update capabilities depending on the vendor's release schedule.

📖 Manual Coverage

Systems Covered:

Engine mechanical, Engine management (DME), Fuel System, Ignition System, Cooling System, Lubrication System, Intake & Exhaust Systems, Transmission (Automatic - GM 5L40-E), Driveline & Axles, Suspension (Front & Rear), Steering System, Brake System (ABS, DSC), Power Steering, Electrical Systems (Wiring Diagrams, ECUs), Lighting, Instrument Cluster, HVAC System, Body Electronics, Safety Systems (Airbag, Seatbelts), Infotainment Systems, Diagnostic Procedures, Emissions Control

Procedures Included:

Routine Maintenance (Oil changes, filter replacements, spark plugs), Component Removal & Installation, Reassembly & Torquing Specifications, Troubleshooting Fault Codes, Diagnostic Procedures, Component Testing, Electrical System Diagnosis, Wiring Harness Repair, Fuel System Service, Brake System Bleeding & Repair, Suspension & Steering Alignment, HVAC System Service & Recharge, Body Panel Repair & Adjustment, Software Updates & Programming Guidance (if applicable to software format), Emission System Diagnosis & Repair

Technical Depth:

Comprehensive: Covers all aspects from basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic trees, electrical schematics, component specifications, and torque values. Designed for professional technicians and advanced DIY enthusiasts.

Diagnostic Tools Covered:

BMW's proprietary diagnostic systems (DIS, ISTA/D) are referenced, along with general OBD-II scanning procedures for fault code retrieval and analysis.

Wiring Diagrams Coverage:

Extensive, detailed wiring diagrams for all major vehicle systems, including power distribution, grounds, signal paths, and component locations.

Troubleshooting Guides:

Detailed step-by-step troubleshooting guides for common and complex issues, including diagnostic flowcharts and symptom-based diagnosis.

📊 Manual Specifications

File Format:

Digital Software (Format details depend on specific product implementation, likely searchable PDF or interactive application)

Print Quality:

N/A (Digital Software - High resolution graphics and text for on-screen viewing)

Binding Type:

N/A (Digital Software)

Paper Type:

N/A (Digital Software)

Searchability:

High, due to digital software format, allowing keyword searches across the entire manual.

⚙️ Engine Specifications

Primary Engine:

BMW N62B44 4.4L (4398 cc) Naturally Aspirated V8

Horsepower:

329 hp @ 6100 rpm

Torque:

330 lb-ft @ 3600 rpm

Fuel System:

Sequential Multi-Point Fuel Injection (MPI), Electronic Throttle Control (ETC)

Variable Valve Lift:

Valvetronic Variable Valve Lift System

Variable Valve Timing:

Double VANOS (Variable Valve Timing for both intake and exhaust camshafts)

Block Material:

Aluminum Alloy

Head Material:

Aluminum Alloy

Bore X Stroke:

92.0 mm x 82.7 mm

Compression Ratio:

10.0:1

Cooling System Type:

Water-cooled, pressurized system with electric coolant pump

🔧 Transmission

Standard Transmission:

GM 5-speed Automatic (5L40-E)

Optional Transmission:

6-speed Manual (ZF GS6-37BZ - less common on 545i)

Automatic Transmission Features:

Steptronic (manual shifting mode), Adaptive Transmission Control (ATC)

Automatic Transmission Fluid:

BMW ATF 6 HP (Dexron VI equivalent) - Consult specific manual for exact BMW P/N

📐 Dimensions

Length:

191.1 in (4854 mm)

Width:

71.7 in (1821 mm)

Height:

57.5 in (1461 mm)

Wheelbase:

113.7 in (2890 mm)

Curb Weight:

Approx. 3800-3900 lbs (1724-1769 kg)

Gross Vehicle Weight Rating:

Approx. 4900 lbs (2223 kg)

Standard Wheel Size:

17-inch alloy

Optional Wheel Size:

18-inch or 19-inch alloy

Wheel Bolt Pattern:

5x120

Standard Tire Size:

225/50R17

🛡️ Safety Features

NHTSA Front Crash Rating:

5-Star (for driver and passenger)

IIHS Side Impact Rating:

Good

Active Safety Features:

Dynamic Stability Control (DSC), Dynamic Traction Control (DTC), Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist

Passive Safety Features:

Front Airbags, Front Side-Impact Airbags, Front and Rear Head Protection System (HPS) Curtain Airbags, Active Head Restraints, Three-point Seatbelts with Pretensioners

💡 Technology Features

Infotainment System:

iDrive (CCC - Car Communication Computer)

Infotainment Features:

Central Control Display, Navigation System, Radio, CD Player, optional Bluetooth connectivity, optional Satellite Radio

Driver Assistance Features:

Adaptive Headlights, Rain-sensing Wipers, Park Distance Control (PDC), Cruise Control, optional Active Steering, optional Head-Up Display (HUD)

Connectivity Features:

BMW Assist (telematics service), optional Bluetooth Hands-Free Interface

Lighting Technology:

Xenon Adaptive Headlights, LED Taillights

🔧 Maintenance

Oil Change Interval:

Typically 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil used. The vehicle's Condition Based Service (CBS) system will indicate specific needs.

Spark Plug Replacement:

100,000 miles (for iridium-tipped plugs)

Transmission Fluid Change:

BMW generally lists transmission fluid as 'lifetime', but independent specialists recommend changes every 60,000-100,000 miles, especially for the automatic transmission.

Engine Oil Type:

SAE 5W-30 Synthetic (BMW LL-01 or LL-04 approved) - Consult manual for exact specification

Engine Oil Capacity:

Approx. 8.5 US quarts (8.0 liters) with filter change

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 formulation)

Brake Fluid Type:

DOT 4 (BMW High Performance Brake Fluid recommended)

Power Steering Fluid:

BMW Power Steering Fluid (Pentosin CHF 11S or similar synthetic hydraulic fluid recommended)

Known Issues:

Oil leaks from valve cover gaskets and oil pan gasket, VANOS solenoid failures, Coolant expansion tank leaks, Ignition coil and spark plug failures, Power steering pump leaks/whine, Water pump failures (plastic impeller), Electrical issues (CAN bus communication errors), CCC/CIC infotainment system issues, DSC sensor failures, HVAC blower motor resistor failure, ABS wheel speed sensor failures.

📚 Vehicle History

Brand Heritage:

BMW (Bayerische Motoren Werke AG) has a long-standing reputation for producing performance-oriented luxury vehicles with exceptional driving dynamics and engineering excellence.

Model Evolution:

The E60 generation replaced the E39 5 Series, introducing a more modern and aggressive design language, advanced electronics, and the new N62 V8 engine. It marked a significant technological leap for the 5 Series line.

Production Years:

2004-2007 (for the 545i variant of the E60 generation)

Manufacturing Locations:

Germany (Dingolfing Plant)

🏆 Awards & Recognition

Recognitions:

While specific awards for the 2004 545i model year itself are varied and often year-specific, the E60 generation generally received accolades for its chassis dynamics, engine performance, and luxury appointments from automotive journalists and publications at its launch.