Target Audience:
Owners seeking to perform DIY maintenance and repairs, independent repair shops, BMW enthusiasts.
Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS Series, Jaguar S-Type.
Vehicle Focus:
The BMW 545i (E60) represents a pinnacle of automotive engineering, blending performance, luxury, and advanced technology, requiring a comprehensive service manual.
Diagnostic Procedures:
Comprehensive diagnostic fault code (DTC) interpretation and troubleshooting guides for all major vehicle systems.
Mechanical Repair:
Detailed procedures for engine, transmission, drivetrain, suspension, steering, and braking system repairs.
Electrical Systems:
In-depth coverage of the vehicle's electrical architecture, including wiring diagrams, component locations, and diagnostic strategies for the body, chassis, and powertrain.
Body And Interior:
Procedures for body panel repair, interior trim removal and installation, climate control system servicing, and accessory systems.
Type:
Workshop Service and Repair Manual
Powertrain:
Engine (N62B44), Transmission (GM 5L4750, ZF 6HP19), Differential, Driveshafts.
Chassis:
Suspension (front and rear), Steering, Brakes (including ABS/DSC), Wheels and Tires.
Electrical And Electronics:
ECU diagnosis, Body Control Module (BCM), Lighting, Instrumentation, Audio System, Navigation, HVAC controls, Comfort electronics, Advanced Driver Assistance Systems (ADAS).
Scheduled Maintenance:
Oil changes, filter replacements, spark plug service, brake fluid flush, coolant service, inspections.
Troubleshooting Diagnostics:
Step-by-step fault finding guides for common and complex issues, including electrical gremlins and mechanical failures.
Major Repairs:
Engine overhaul, transmission rebuild, suspension component replacement, brake caliper replacement, differential service.
Component Replacement:
Detailed instructions for replacing sensors, actuators, pumps, control modules, interior and exterior components.
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including complex electronic system diagnostics.
NHTSA Front Impact:
5-Star (for corresponding model year regulations)
IIHS Side Impact:
Good (for corresponding model year regulations)
Traction Control:
Dynamic Stability Control (DSC), including Automatic Stability Control (ASC) and Traction (ASC+T).
Braking System:
Anti-lock Braking System (ABS), Dynamic Brake Control (DBC), Electronic Brake-force Distribution (EBD).
Airbags:
Frontal airbags, front side-impact airbags, head protection system (curtain airbags).
System:
iDrive infotainment system with integrated navigation, radio, CD player, and climate control.
Adaptive Cruise Control:
Optional Adaptive Cruise Control (ACC) with Stop & Go functionality.
Parking Assistance:
Optional Park Distance Control (PDC) with front and rear sensors, and rearview camera.
Phone Integration:
Bluetooth hands-free connectivity (often via a snap-in adapter).
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually, depending on driving conditions.
Brake Fluid Flush Interval:
Every 2 years, regardless of mileage.
Spark Plug Replacement Interval:
Typically 60,000-100,000 miles, depending on plug type.
Engine Oil Type:
SAE 5W-30 Synthetic, API SN/CF, BMW LL-01 approved.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based), mixed 50/50 with distilled water.
Transmission Fluid Auto:
ZF Lifeguardfluid 6 (LF-6) or equivalent approved fluid. Check manual for specific application.
Brake Fluid Type:
DOT 4 Low Viscosity (LV) or DOT 4 High Performance.
Cooling System:
Water pump failures (often electric), thermostat housing leaks, coolant expansion tank cracks.
Valve Stem Seals:
N62 engine can suffer from worn valve stem seals leading to oil consumption and blue smoke.
Oil Seals:
Front and rear main crankshaft seals, oil pan gasket leaks.
Ignition System:
Coil-on-plug ignition failures, spark plug issues.
Electrical:
ABS/DSC module failures, alternator issues, window regulator problems, central body electronics (ZKE/KBM) module faults.
Suspension:
Front control arm bushings, sway bar links, rear air suspension components (if equipped with adaptive suspension).
Bmw Philosophy:
BMW's commitment to 'The Ultimate Driving Machine' is evident in the E60 generation, focusing on performance, driver engagement, and technological innovation.
E60 Generation:
The E60 platform, introduced in 2003, marked a significant departure from the E39 generation with a more modern design, advanced electronics, and the introduction of iDrive.
Production Years:
2003-2010 (E60/E61)
Manufacturing Locations:
Germany (Dingolfing plant primarily)
Ward S 10 Best Engines:
The N62 V8 engine received Ward's 10 Best Engines awards in its early iterations for its smoothness and power delivery.
Consumer Reports Reliability:
Reliability ratings for the E60 generation varied, with specific model years and engine variants showing different trends. Manual provides insights into common issues and preventative maintenance.
