top of page

Common Problems of BMW 6 Series E64 645i: A Comprehensive Guide

The BMW 6 Series E64 645i is the convertible variant of the E63 coupe, featuring a powerful 4.4-liter V8 engine that provides a blend of luxury, performance, and open-air driving pleasure. While the 645i is a well-regarded model within the BMW lineup, it is not without its potential issues. Being aware of these common problems can help owners maintain their vehicles and avoid costly repairs.


BMW 6 Series E64 645i

BMW 6 Series E64 645i Engine Performance Issues


The BMW E64 645i is powered by the N62 engine, a 4.4-liter V8 that delivers strong performance but is known for several issues that can affect its reliability and longevity. One of the most common problems with the N62 engine is the failure of the valve stem seals. Over time, the valve stem seals can wear out, leading to oil leakage into the combustion chamber. This can result in excessive oil consumption, blue smoke from the exhaust, and potential fouling of the spark plugs. If left unaddressed, this issue can reduce engine performance and increase emissions. Replacing the valve stem seals is a complex and labor-intensive process, but it is crucial to prevent further engine damage.


Another common issue with the N62 engine is the failure of the timing chain guides. The timing chain is responsible for synchronizing the engine's camshaft and crankshaft, and the guides help keep the chain in place. However, the plastic guides can become brittle and break over time, leading to a loose timing chain. A loose or broken timing chain can cause the engine's timing to become off, leading to rough idling, poor performance, and in severe cases, catastrophic engine damage. Symptoms of failing timing chain guides include a rattling noise from the front of the engine, particularly during cold starts. If these symptoms are present, it is essential to have the timing chain and guides inspected and replaced if necessary.


The N62 engine is also prone to oil leaks from various locations, including the valve cover gaskets, oil pan gasket, and oil filter housing gasket. These gaskets can become brittle over time and develop leaks, leading to oil seeping onto the engine components. Oil leaks not only create a mess under the hood but can also lead to a low oil level, which can cause inadequate lubrication and increased wear on engine components. Regular inspections and timely replacement of worn gaskets can help prevent these issues from becoming more serious.


Cooling System Failures


The cooling system in the BMW E64 645i is another area where problems can arise, particularly as the vehicle ages and accumulates mileage. The N62 engine generates a significant amount of heat, and the cooling system is designed to manage this heat effectively. However, the cooling system's components, including the electric water pump, thermostat, and radiator, can develop issues over time.


One of the most common problems is with the electric water pump, which is responsible for circulating coolant throughout the engine to prevent overheating. Unlike traditional mechanical water pumps, the electric pump in the E64 645i is prone to failure, often without much warning. When the water pump fails, the engine can quickly overheat, leading to potential damage to the cylinder head, head gasket, or even the engine block. Symptoms of a failing water pump include the engine temperature rising rapidly, coolant leaks, and warning lights related to the cooling system appearing on the dashboard. Regular replacement of the water pump as part of preventative maintenance can help avoid these issues.


In addition to the water pump, the thermostat is another component of the cooling system that can fail. The thermostat regulates the engine's temperature by controlling the flow of coolant, and if it becomes stuck in the open or closed position, it can cause the engine to run too hot or too cold. This can affect performance and fuel efficiency and lead to increased wear on the engine components. Replacing the thermostat as part of regular cooling system maintenance can help prevent this issue from occurring.


The cooling system in the E64 645i also includes several plastic components, such as the radiator, coolant hoses, and expansion tank, which can become brittle and crack over time. These components are particularly prone to failure in older vehicles or those that have been exposed to extreme temperatures. If any of these components fail, it can lead to coolant leaks and the risk of overheating. Regular maintenance of the cooling system, including timely replacement of the water pump, thermostat, and coolant, can help prevent these issues and keep the engine running at the proper temperature.


Transmission Issues


The BMW E64 645i is equipped with either a 6-speed manual transmission or a 6-speed automatic transmission, both of which are generally reliable. However, transmission issues can still arise, particularly as the vehicle ages or accumulates high mileage. One common problem reported by owners is harsh or delayed shifting, especially when the transmission is cold or under heavy load. This issue can be caused by worn transmission fluid, a faulty mechatronic unit (in automatic models), or software glitches. In some cases, a transmission fluid change or software update can resolve the issue, but more severe cases may require more extensive repairs.


Transmission slipping is another issue that some 645i owners have reported. This occurs when the engine revs increase without a corresponding increase in vehicle speed, which can be particularly dangerous when trying to accelerate or merge into traffic. Transmission slipping can be caused by low or contaminated transmission fluid, worn clutch packs, or internal transmission damage. If the transmission fluid is low or dirty, a fluid change may resolve the issue. However, persistent slipping may indicate a more serious internal problem that requires professional diagnosis and potentially a transmission rebuild or replacement.


Transmission fluid leaks are another potential issue with the E64 645i. Leaks can occur from the transmission seals, gaskets, or cooler lines, leading to a loss of fluid and potential transmission damage. If a transmission fluid leak is detected, it should be addressed promptly to avoid further complications. Regular inspections of the transmission and cooling system, as well as timely fluid changes, can help prevent these issues and ensure the transmission continues to operate smoothly.


Electrical System Problems


The BMW 6 Series E64 645i is equipped with a sophisticated electrical system that controls various aspects of the vehicle, from the engine and transmission to the infotainment and climate control systems. While this system offers a high level of functionality and convenience, it also increases the likelihood of electrical issues arising. One of the most common problems reported by owners is related to the vehicle's battery and charging system. The 645i is known to experience battery drain issues, where the battery loses charge even when the car is not in use. This can be due to various reasons, including faulty wiring, malfunctioning control modules, or issues with the comfort access system, which allows for keyless entry and ignition.


The alternator, responsible for charging the battery while the engine is running, is another component prone to failure in the 645i. A failing alternator can lead to a battery that doesn't hold a charge, resulting in a car that struggles to start or maintain electrical functions. Symptoms of a failing alternator include dimming headlights, flickering dashboard lights, and warning messages related to the charging system. If the alternator fails completely, the vehicle may lose power altogether, leaving the driver stranded. Regular checks of the battery and charging system, including testing the alternator's output, can help prevent these issues from occurring.


In addition to battery and charging system problems, the E64 645i is also prone to issues with its numerous sensors and control units. These sensors and control units monitor and control various aspects of the vehicle's operation, and when they malfunction, they can trigger warning lights on the dashboard, even when there is no underlying mechanical issue. For example, the tire pressure monitoring system (TPMS) is known to give false readings, indicating a tire is low on pressure when it is not. Similarly, the engine control module (ECM) can store fault codes related to the fuel system or emissions control system, even when there is no actual problem. These electrical gremlins can be difficult and expensive to diagnose and fix, as they often require specialized equipment and expertise to address properly.


Suspension and Steering Issues


The suspension and steering system in the BMW 6 Series E64 645i is designed to provide a smooth and responsive driving experience, but it is not without its issues. One of the most commonly reported problems is related to the suspension components, particularly the control arm bushings and ball joints. Over time, these parts can wear out, leading to a noticeable clunking noise when driving over bumps or during sharp turns. Worn bushings and ball joints can also cause the vehicle to feel less stable and precise, especially at higher speeds, as the worn components allow for more movement in the suspension than intended. This can lead to uneven tire wear, poor handling, and a less comfortable ride. In some cases, the entire control arm assembly may need to be replaced to restore proper handling and ride quality.


The E64 645i is also equipped with an adaptive suspension system, which allows the driver to adjust the damping characteristics based on driving conditions. However, the adaptive suspension system can develop issues, particularly with the electronic dampers. Over time, the dampers can leak or fail, leading to a harsh or bouncy ride. Symptoms of failing dampers include a noticeable decrease in ride comfort, poor handling, and increased body roll during cornering. If the dampers fail completely, the vehicle may become difficult to control, particularly during aggressive driving. Regular inspections of the suspension system, including the control arms, bushings, and dampers, are essential to maintain the vehicle's handling characteristics.


Steering problems have also been reported by some 645i owners. The E64 is equipped with a hydraulic power steering system, which provides precise and responsive steering but can develop issues over time. One common problem is with the power steering pump, which can develop leaks or fail, leading to a loss of power assist and making the steering wheel difficult to turn, especially at low speeds. If the power steering fluid level becomes too low due to a leak, it can cause the power steering pump to overheat and fail, leading to a complete loss of power steering. Regular inspections of the steering system, including checking for leaks and ensuring the power steering fluid is at the correct level, are essential to maintain the vehicle's steering performance.


Fuel System Problems


The fuel system in the BMW 6 Series E64 645i, while generally reliable, can develop issues that affect the vehicle's performance and drivability. One common problem is related to the fuel injectors, which can become clogged or leak over time. Clogged fuel injectors can lead to uneven fuel delivery, causing the engine to run lean, which can result in increased exhaust emissions, reduced fuel economy, and potential damage to the catalytic converter. On the other hand, leaking injectors can cause the engine to run rich, leading to black smoke from the exhaust, poor fuel economy, and increased wear on the engine components. In some cases, the injectors may need to be cleaned or replaced to restore proper function.


Another fuel system issue that can occur is related to the fuel pump. The fuel pump is responsible for delivering fuel from the tank to the engine, and if it fails, it can lead to a loss of power, engine stalling, or even a no-start condition. Symptoms of a failing fuel pump include difficulty starting the engine, hesitation during acceleration, and a noticeable drop in performance. If the fuel pump is not replaced promptly, it can lead to more serious issues, such as damage to the fuel injectors or engine components.


The fuel filter is another component of the fuel system that can cause problems if it becomes clogged with debris. A clogged fuel filter can restrict fuel flow to the engine, causing a loss of power and efficiency. If the fuel filter is not replaced regularly, it can lead to more serious issues, such as damage to the fuel pump or fuel injectors. Regular maintenance of the fuel system, including timely replacement of the fuel injectors, fuel pump, and fuel filter, is essential to avoid these problems and ensure the vehicle continues to run smoothly.


Conclusion


The BMW 6 Series E64 645i is a luxurious and powerful convertible that offers an exhilarating driving experience with its robust V8 engine and refined handling. However, like any high-performance vehicle, it is not without its common problems. From engine performance issues and cooling system failures to transmission problems and electrical system glitches, these issues can be costly and inconvenient if not addressed promptly. Regular maintenance and attention to the early signs of trouble can help keep these problems at bay and ensure that your 645i continues to deliver the performance and luxury that BMW is known for. If you’re experiencing any of these issues or need expert advice and service, visit our workshop, European Auto Pro, located at 253 Goodwood Road, Kings Park, 5034 South Australia. Our team of skilled technicians is here to help you maintain your BMW in top condition.

bottom of page