In initially looking at the 530 vs. 545, I looked at the price sheet (this is all in US),
and decided that the extra hp wasn't worth $10,000 (54.3K vs. 44.3K). But then looking closer, it seems that's not the right number, since the premium package (ZPP) and several other items seem to come standard on the 545. My math looks like:

530: 44300 + 1275(steptronic) + 2400(ZPP) + 800(Xenon) = 48775
545: 54300 + 400(code: 488:lumbar front seats) = 54700

So the real difference is 54700 - 48775 or $5925 for the bigger motor.

The other things (sport package), Nav/HUD, etc, look like they're the same price for both models.

Does that make sense, or am I missing something?

I don't know about US, but judging from my price list that sounds just about right...

I agonized over the 530 and 545 before deciding on the 530. I own an E39 540 but decided the difference in price was not worth 1 second less 0-60.

The 545 comes standard with Steptronic, Premium Package, and Xenon lights. There are a few other comfot/luxury items as-well-as some beefed up mechanical components such as larger brakes, exhaust, etc.

Ordering the 530 allowed me to get a pretty well loaded car (including nav) at a substantial savings over the 545.

Well, I guess you just spilled somehow half a liter from 545 engine... care with engine liters next time... ;)

That's probably what I'll do, as well. It was just a easier decision when it was $10,000 as opposed to $6,000 ;-)

If you get comfort seats then the difference drops to ~5200.
Also useful and relevant is th cost of ownership...basic changes like tires, brakes and service costs after the first 4 years...

When I purchased my 530i Sport in 2001 the difference between the 530i and 540i was about 10k (no brainer) now the difference comes to about $5500 for like equipment. Sport Package, Permium Package, Steptronic, Zenon. $52,777.00 for a 530iA... now the GS430 comes into the picture at about $54,000 and some change and that is fully loaded where the 545iA Sport is $58,000 and some change with the Sport Package the only option. Hmmmm.

yup, 545 comes with auto, premium, xenon standard.

with euro delivery, the price is only $4500 more

The odd thing is the lumber control for front seats. Why on earth wouldn't the 545 come with that standard like the rest of the 530's "Premium package". Seems like add odd thing to have "extra".

I have actively purchased and sold 545's as an individual in the US market. In addition, I have tracked the figures for resale of 530' vs. 545 over a 6 + year period. You will also typically be able to sell or trade the 545 for more than the 530 at the end of your ownership period in the US. I would assume a similiar relationship between for sales prices of used 530/545 exists in other countires.
If you are able to do this as I have, it will further reduce the cost difference of buying between the 530/545.