Hello All,
I just purchased a 2004 545i with sport package only -- no other options. Basically picked it up as a distress sale from a friend who didn't want to fix it. It was burning a quart of oil every 250 miles for the last several months and the stealership wanted $8500 to do the valve seals.

The car only has 61,000 miles and is in great shape cosmetically. Tires and brakes are new about 5,000 miles ago. I'm having the valve seals replaced and secondary air passages cleaned for about $5,000 at a local shop which uses the new technique not requiring head removal.

The hydraulic sway bar is also leaking and they suggested a new one for $1,900 plus installation, but I'm considering a used one for $375. My understanding also is that the ZF transmission should be fully serviced soon, and there is a local shop which is ZF certified and can do it for $750.

I paid a little over $7,000 for the car and I'd like to think that once the immediate problems are addressed, it will be reliable -- but I just got the records today from the prior owner and it looks like the car has had its share of issues!!

34 separate unscheduled repairs since it was put into service.... as I've listed below. Any thoughts about whether I should keep the car given all its issues?

I think one can look at it two ways:
1. It's a lemon, dump it.
2. Everything that can/usually goes wrong in these cars has more or less been fixed so the car should be pretty reliable from now on.

Any opinions on this would be welcomed!

Unscheduled Maintenance: (R/R = removed and replaced)

1. 1/17/05 1,143 mi DME Reprogramming -- Recall
2. 6/9/06 2,207 mi All Door Seals Replaced
3. 7/28/06 2,434 mi Crankcase Vent Valves Replaced – Recall
4. 3/28/07 4,567 mi Driver’s Seat Back R/R
5. 3/28/07 4,567 mi Rear Door Seal and Driver’s Door Seal R/R
6. 3/28/07 4,567 mi Both Front Cupholders R/R
7. 6/29/07 6,065 mi Teflon Tape Applied to Door Seals
8. 12/5/07 9,507 mi Passenger Seat Mat Reprogrammed -- Recall
9. 12/5/07 9,507 mi Blower Resistor R/R
10. 12/5/07 9,507 mi Center Cluster Squeak. Removed/Insulated with Fabric Tape
11. 4/9/08 11,171 mi Transmission Mechanotronic Sleeve R/R
12. 4/9/08 11,171 mi Driver’s Sun Visor R/R
13. 2/10/09 16,407 mi Intake Silencer R/R
14. 2/10/09 16,407 mi Passenger Front Seat Foam replaced – Mat Fault
15. 3/13/09 17,362 mi Windshield replaced
16. 7/8/09 20,313 mi EGS Software Recalibrated.
17. 7/8/09 20,313 mi HVAC Water Valve R/R
18. 8/7/09 20,720 mi Transmission Mechanotronic Sleeve R/R (2nd time)
19. 10/25/11 35,967 mi Front Thrust Bushings R/R
20. 10/25/11 35,967 mi Brake Booster Hose R/R – Recall
21. 10/25/11 35,967 mi Both Sides Crankcase Vent Valves R/R
22. 10/25/11 35,967 mi Windshield Washer Pump R/R
23. 10/25/11 35,967 mi Engine Vacuum Pump & Hose R/R
24. 12/19/13 54,960 mi Upper Timing Cover Seals R/R
25. 12/19/13 54,960 mi Cylinder Head Cover Seals R/R
26. 12/19/13 54,960 mi Alternator Bracket Seal R/R
27. 12/19/13 54,960 mi Head lamps Refinished
28. 3/17/14 57,100 mi Passenger Seat Occupancy Mat R/R – Recall
29. 4/1/14 57,239 mi Internal Coolant Tube R/R
30. 4/1/14 57,239 mi Valley Pan Gasket R/R
31. 4/1/14 57,239 mi Water Pump Gasket R/R
32. 6/13/14 58,610 mi Secondary Air Non-Return Valves R/R
33. 6/13/14 58,610 mi Expansion Tank Water Hose R/R
34. 10/13/14 60,784 mi Trunk Lid Lock R/R

 

Honeslty, it looks like a lot of stuff that is common to go wrong has already happened.

Many thing are cosmetic, so you don't really care about them too much. Door seals, seat mat, headlight polishing, etc.

The Mechanotronic Sleeve was replaced (for a 2nd time??) at 20,720 miles. They had to drop the pan and refill the fluid to do that job.

A costly and common problem is the internal coolant pipe. That's been done already.

 

Yes, believe it or not, Mechanotronic Sleeve replaced two times --

The routine maintenance has been stellar with the exception of the engine air filter, which on the PPI was almost black --

Routine Maintenance:
Oil Change:
1. 8/18/05 1,509 mi
2. 6/9/06 2,207 mi
3. 3/28/07 4,567 mi
4. 2/10/09 16,407 mi
5. 7/6/10 27,472 mi
6. 10/25/11 35,967 mi
7. 12/19/13 54,960 mi
Brake Fluid Change:
1. 6/9/06 2,207 mi
2. 4/9/08 11,171 mi
3. 10/25/11 35,967 mi
4. 12/19/13 54,960 mi
Engine Coolant:
1. 12/19/13 54,960 mi
Engine Air Filter: (never done)
Cabin Filter:
1. 6/9/06 2,207 mi
2. 10/25/11 35,967 mi
Power Steering Fluid:
1. 12/19/13 54,960 mi
Brakes/Rotors:
1. 11/29/13 54,700 mi
Battery:
1. 7/6/10 27,472 mi
Tires:
1. 12/5/07 9,507 mi all 4 tires replaced
2. 6/1/14 58,101 mi all 4 tires replaced
Alignment:
1. 10/25/11 35,967 mi
2. 12/19/13 54,960 mi

 

Sorry to say dude but you bought a lemon! thr car is 10 years old bra!! The numbers dont add up!!!

 

I also have an '04 545i (125k miles, almost fully loaded). I paid $12k for the car when it was 5 years old. No way would I pay others to do the work you say it now needs at the costs you list. The value of the car does not support that kind of expenditure. If you can do it yourself, then maybe. I purchase all the AGA tools/parts to fix the coolant pipe, valve stem seals and plugged secondary air ports (total cost for tools and part was about $2800). Took me about 36 hours of hard labor and I was unsuccessful at clearing the secondary air ports on bank 2. Now I have to purchase AGA pick tool and spend another 12+ hours R&R'ing the exhaust manifold.

My sway bar seeps oil and has for many years, so it does not get fixed. Never enough oil to drip on ground...just wets the underbody cover a bit.

Also, my car has had most of repairs you listed performed while in my ownership. I still love the car.

Caveat emptor and good luck.

 

Wow! I guess I got a good deal on my car!! I bought a 2004 545i with 180,000 kms (108,000 mi) just this past June for $7000 and it ran/runs great so far. other than rock chips on the hood and front bumper, the car is in great shape.


I know, no one likes a bragger!!

 

Don't worry, your not bragging. You got a fair deal compared to current book values.

 

Price depends on the options to an extent depending on if it matters to you. I just bought a used 545i w/ the sports suspension. It drives fantastic.

Why are you doing the valve seals? Is it smoking at idle? How bad? Is it necessary to do now?

The E60 545 is a fun car. Not maintenance free like a Toyota but in my opinion it's the best driving car I've ever driven.

I would get it done. Find an Indy shop that specializes in BMW or DIY (big job). Change the trans pan & fluid and meachatronics seal while you are in there. Drive it another 60k miles.

 

Car was burning a quart of oil every 200 miles when I bought it. Would not pass smog (by a mile).

Paid 5 grand to have the valve seals and secondary air system done.

Then 30 miles after I picked the car up from all the engine work the alternator failed. Paid another 900 for new alternator and battery. Now car seems to be running fine except the active headlights have failed (flashing green light).

I've decided to sell the car, don't have the bandwidth right now to deal with all the failures.