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2004 BMW 645CI CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT BMW REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Tire Pressure Monitoring System
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
Electrical Symbol & Wire Color Code Identification -> Wire Color Code Identification -> Imported Vehicles
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
BMW -> Fuel Filter Replacement -> Except X3 & Z4 -> Fuel System Pressure Relief -> Models w/Fitting Or Union Bolt Connection -> Models w/Fuel Hose Connection -> Removal & Installation
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while it relearns its adaptive strategy.
Fuel System Pressure Relief
- Obtain the vehicle owner's radio theft protection code.
- Remove the fuel pump relay(s).
- Start the engine and allow it to stall.
- Crank engine for 10 seconds to ensure the fuel pressure has been...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
CV AXLE SHAFT, Replace -> Rear
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
Rear
The CV drive shafts differ in length. If required, mark CV drive shafts. The left CV drive shaft is shorter than the right CV drive shaft.
- Raise vehicle on lift.
- Remove rear wheel lug nuts.
- Apply hand brake.
- Remove hub cover.
- Remove collar nut.
- Assemble suitable tool and remove drive ...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
Component Replacement -> Installation -> Removal -> Tire Pressure Sensor
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
Tire Pressure Sensor
Removal
- Dismount tire using suitable tire machine ensuring not to damage tire pressure sensor.
- Remove the Torx screw, then the tire pressure sensor.
- Release valve stem union nut using removal tool No. 00 2 190, or equivalent Fig. .
- Remove washer from wheel.
Installation
- Install new Torx screw on tire pressure sensor, then twist new valve stem by hand approximately three turns. Do not tighten Torx screw, sensor and v...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
Starter, Replace
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
- Disconnect battery ground cable.
- Raise vehicle on suitable lift.
- Remove bolts securing engine under body cover then remove cover.
- Remove bolts from reinforcement plate then remove plate.
- Disconnect oxygen sensor connector.
- Remove control sensor using suitable tool.
- Disconnect monitor connector.
- Remove control sensor using suitable tool.
- Support exhaust system using suitable tool.
- Remove nuts and gasket from front exhaust pipe to engine manifold.
- Remove vacuum hose from vacuum unit and remove nut from exhaust bracket.
- Remove bolts from exhaust system reinforcement plate and lower exhaust s...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
Cabin Air Filter Service -> BMW -> 2004-05 645 & 2006-07 525, 530 & 2006-09 550, 650, M5, M6 & 2008-09 528 & 535
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
The service interval is determined by the service indicator.
- Open the hood.
- Rotate the quick release fastener 90° counterclockwise, Fig. .
- Release the retainer located at the side of the cabin air filter cover, the r...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
BMW -> Air Bag Warning Lamp ->
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
If the Air Bag warning lamp lights and stays on, diagnosis and ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
Inlet
- Drain coolant into a suitable container.
- Reposition hose clamp at heater core and remove hose.
- Reposition hose clamp at coolant connection and remove hose.
- Remove hose from vehicle.
- Reverse procedure t...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 BMW 645CI AUTOMOBILES
Serpentine Drive Belt, Replace -> A/C Compressor Drive Belt -> Alternator Drive Belt
Vehicle: 2004 BMW 645CI 4.4 V8 GAS
Alternator Drive Belt
- Remove fan clutch and fan impeller.
- Unfasten cap nut from water pump, using suitable tools.
- Remove fan wheel with fan coupling from water pump, using suitable spanner wrench. Fan has left handed threads.
- Mark direction of travel and reinstall drive belt in same direction of travel, if belt is to be reused.
- Rotate or lift the belt tensioner arm, using a suitable Torx socket to relieve tension from drive belt.
- Remove the drive belt.
- Clean pulleys and inspect for ...
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COMPONENT LOCATION DIAGRAMS FOR 2004 BMW 645CI AUTOMOBILES
Component location diagrams for most 2004 BMW 645CI cars and light trucks sold in the U.S. from 1990+.
Body Components Diagram for 2004 BMW 645CI 4.4 V8 GAS Components on diagram: |
Instrument Panel Components Diagram for 2004 BMW 645CI 4.4 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 BMW 645CI AUTOMOBILES
OEM drawn wiring diagrams for most 2004 BMW 645CI cars and light trucks sold in the U.S.
2004 BMW 645CI 4.4 V8 GAS Wiring Diagram Components on diagram: |
2004 BMW 645CI 4.4 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 BMW 645CI AUTOMOBILES
OEM TSB listings for most 2004 BMW 645CI cars and light trucks sold in the U.S. from 1985+.
Document: Tools and Equipment Vehicle: 2004 BMW 645CI 4.4 V8 GAS Auto Systems: |
Document: Turbocharger Installation Tool Vehicle: 2004 BMW 645CI 4.4 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 BMW 645CI AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 BMW 645CI cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 BMW 645CI cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 BMW 645CI cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 BMW 645CI cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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