2004 BMW 545i

The 2004 BMW 545i is a popular car known for its blend of luxury, performance, and driving feel. It’s part of the E60 5 Series generation. The 545i is equipped with a 4.4-liter V8 engine (N62B44) producing 325 horsepower and 330 lb-ft of torque. Other engine options available for the E60 5 Series include inline-6 engines such as the 525i and 530i. Transmission choices typically involved a 6-speed manual or a 6-speed automatic. Owners often appreciate the car’s handling, comfortable interior, and powerful engine. Common complaints revolve around the car’s electrical complexity, higher maintenance costs, and potential for various sensor failures.

Engine

N62B44 4.4L V8

• Valve Stem Seal Failure
  • Description/Symptoms: Excessive oil consumption, blue smoke from the exhaust, especially upon startup after the car has been sitting for a while.
  • Solution: Replacing the valve stem seals.
  • Estimated Cost to Fix: $2,000 - $4,000+ (due to labor-intensive engine work)
  • Recalls: None Found
• Coolant Leaks (Valley Pan)
  • Description/Symptoms: Coolant loss, overheating, visible coolant under the car (though sometimes hard to see as it can evaporate quickly from the hot engine), coolant smell.
  • Solution: Replacing the valley pan gasket and potentially the entire valley pan itself.
  • Estimated Cost to Fix: $1,500 - $3,000+ (significant labor involved)
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery warning light, dimming headlights, car stalling, difficulty starting, fluctuating voltage readings.
  • Solution: Replacing the alternator.
  • Estimated Cost to Fix: $500 - $1,000+
  • Recalls: None Found
• Oil Leaks (Various Locations)
  • Description/Symptoms: Visible oil leaks under the car, oil smell, low oil level warning. Common leak points include valve cover gaskets, oil filter housing gasket, and front crankshaft seal.
  • Solution: Replacing the leaking gaskets or seals.
  • Estimated Cost to Fix: $200 - $1,500+ (depending on location and severity)
  • Recalls: None Found

Transmission

6-Speed Automatic (ZF 6HP26)

• Slipping or Harsh Shifting
  • Description/Symptoms: Noticeable slipping between gears, harsh or jerky shifts, transmission fault codes. Often caused by worn solenoids, low fluid level, or degraded fluid.
  • Solution: Transmission fluid flush and filter replacement (may provide temporary relief), replacing valve body solenoids, or complete transmission rebuild/replacement.
  • Estimated Cost to Fix: $300+ (fluid flush) to $3,000 - $6,000+ (rebuild/replacement)
  • Recalls: None Found
• Mechatronic Sleeve Leak
  • Description/Symptoms: Transmission fluid leak, often manifesting as a puddle under the car near the transmission. Can lead to low fluid levels and transmission problems.
  • Solution: Replacing the mechatronic sealing sleeve.
  • Estimated Cost to Fix: $300 - $700+
  • Recalls: None Found

Suspension

• Front Thrust Arm Bushing Failure
  • Description/Symptoms: Shaking or vibration in the steering wheel at highway speeds, especially when braking.
  • Solution: Replacing the front thrust arm bushings (often recommended to replace the entire thrust arms).
  • Estimated Cost to Fix: $400 - $800+
  • Recalls: None Found
• Air Suspension Issues (if equipped)
  • Description/Symptoms: Car sitting unevenly, compressor not running, suspension malfunction warnings.
  • Solution: Replacing the air springs, air compressor, or related components.
  • Estimated Cost to Fix: $500 - $2,000+ (depending on the failed component)
  • Recalls: None Found

Electrical

• iDrive System Problems
  • Description/Symptoms: iDrive screen freezing, unresponsive buttons, navigation issues, system crashing.
  • Solution: Software update, replacing the iDrive control module (CCC unit).
  • Estimated Cost to Fix: $200+ (software update) to $500 - $1,500+ (module replacement)
  • Recalls: None Found
• Battery Drain
  • Description/Symptoms: Battery draining overnight or within a short period, requiring frequent jump starts. Often caused by faulty modules not properly going to sleep.
  • Solution: Diagnosing and repairing the parasitic draw (can be time-consuming and require specialized equipment).
  • Estimated Cost to Fix: $100 - $500+ (diagnostic) plus the cost of repairing the faulty module.
  • Recalls: None Found
• Sensor Failures (Numerous)
  • Description/Symptoms: Various warning lights, including ABS, TPMS, and DSC.
  • Solution: Replacing the faulty sensor(s).
  • Estimated Cost to Fix: $100 - $500+ per sensor (depending on the sensor and location)
  • Recalls: None Found

Exterior

• Headlight Issues (Xenon)
  • Description/Symptoms: Flickering headlights, one headlight not working, headlight leveling issues.
  • Solution: Replacing the xenon bulbs, ballasts, or headlight leveling motors.
  • Estimated Cost to Fix: $100 - $500+ (depending on the component)
  • Recalls: None Found

Interior

• Sunroof Issues
  • Description/Symptoms: Sunroof not opening or closing properly, getting stuck, making noise.
  • Solution: Repairing or replacing the sunroof motor, cables, or tracks.
  • Estimated Cost to Fix: $300 - $1,000+
  • Recalls: None Found
• Door Lock Actuator Failure
  • Description/Symptoms: Door not locking or unlocking with the remote or key, requiring manual operation.
  • Solution: Replacing the faulty door lock actuator.
  • Estimated Cost to Fix: $200 - $500+ per door
  • Recalls: None Found

Summary

The 2004 BMW 545i, while a well-regarded car, has its share of common issues. The most concerning are typically related to the engine (valve stem seals, coolant leaks) and transmission (slipping, harsh shifting), which can lead to significant repair costs. Electrical problems, particularly with the iDrive system and various sensors, are also frequent. While some repairs are relatively inexpensive, many can be costly due to the car’s complexity and the labor involved. Potential buyers should be aware of these potential issues and factor them into their purchasing decision, ideally having a pre-purchase inspection performed by a qualified BMW mechanic.