engine BMW 525I SPORT WAGON 2001 Workshop Manual

Index
Data
Technology
Repairs
Car care
Controls
Overview
163nEngine compartment – BMW 540i
1 Reservoir for brake fluid (under the
housing of the microfilter) 168
2 Auxiliary terminal for jump starting 200
3 Engine oil dipstick 165
4 Engine oil filler neck 165
5 Coolant expansion tank 167
6 Reservoir for intensive-cleaning system
*164
7 Reservoir for headlamp washer
* and
windshield washer system 164

Index
Data
Technology
Repairs
Car care
Controls
Overview
165nEngine oil
Checking oil level
1 Park the vehicle on a level surface.
2 Shut the engine off after it has
reached normal operating
temperature.
3 After approx. 5 minutes, pull the dipstick out and wipe it off with a
clean lint-free cloth, paper towel, or
similar material.
4 Carefully push the dipstick all the way into the guide tube and pull it out
again.
5 The oil level should be in between the
two marks on the dipstick.
As with fuel economy, oil consumption
is directly influenced by your driving
style and vehicle operating conditions.
390de647
The oil volume between the two marks
on the dipstick corresponds to approx.
1.1 US quarts (1 liter). Do not fill beyond
the upper mark on the dipstick. Excess
oil will damage the engine.
460de189
To add oil
Wait until the level has dropped to just
above the lower mark before adding oil.
However, do not wait until the oil level
drops below the lower mark.
BMW engines are designed to op-
erate without oil additives; the use
of additives could lead to damage in
some cases. This is also true for the
manual transmission, the automatic
transmission, the differential, and the
power steering system. <
390de646

166nEngine oil
Specified engine oils
The quality of the engine oil selected
has critical significance for the opera-
tion and service life of an engine. Based
on extensive testing, BMW has
approved only certain engine oils.
Use only approved "BMW High
Performance Synthetic Oil."
If you are unable to obtain "BMW High
Performance Synthetic Oil," you can
add small amounts of synthetic oil in
between oil changes. Only use oils with
the API SH specification or higher.
Ask your BMW center for details
concerning the specific "BMW
High Performance Synthetic Oil" or
"synthetic oils" which have been
approved. <
You can also call BMW of North
America at 1-800-831-1117 or visit
this website: www.bmwusa.com to
obtain this information.
Viscosity ratings
Viscosity is the oil flow rating as estab-
lished in SAE classes.
The selection of the correct SAE class
depends on the climatic conditions in
the area where you typically drive your
BMW. Approved oils are in SAE classes
5W-40 and 5W-30. <
These oils may be used for driving in all
ambient temperatures.
530us20 0

Index
Data
Technology
Repairs
Car care
Controls
Overview
167nEngine oil Coolant
Comply with the applicable envi-
ronmental laws regulating the dis-
posal of used oil. <
Recommendation: have the oil changed
by your BMW center. Continuous exposure to used oil
has caused cancer in laboratory
testing. For this reason, any skin areas
that come into contact with oil should
be thoroughly washed with soap and
water.
Always store oil, grease, etc., out of
reach of children. Comply with all warn-
ing labels and information on lubricant
containers. < Do not add coolant to the cooling
system when the engine is hot. If
you attempt to do so, escaping coolant
can cause burns.
To avoid the possibility of damage later
on, never use anything other than fac-
tory-approved, nitrite and amino-free
extended-duty antifreeze with corrosion
inhibitor. Your authorized BMW center
is familiar with the official specifica-
tions.
Antifreeze and anticorrosion agents are
hazardous to health. You should always
store them in their original container
and in a location which is inaccessible
to children.
Extended-duty antifreeze with corro-
sion inhibitor contains the flammable
substance ethylene glycol. For this rea-
son, do not spill antifreeze with corro-
sion inhibitor on hot engine parts. It
could catch fire and cause serious
burns. <
Comply with the applicable envi-
ronmental laws regulating the dis-
posal of extended-duty antifreeze with
corrosion inhibitor. <
Checking coolant level
Correct coolant level when the engine
is cold (approx. 68 7/20 6):
Unscrew the cap from the expansion
tank.
The coolant level is correct when the
upper end of the red float is at least
even with the upper edge of the filler
neck (refer to the arrow in the illustra-
tion), but no more than 0.8 in (2 cm)
above it – that is, up to the second mark
on the float (refer also to the schematic
diagram next to the filler neck).
380de081

168nCoolant Brake fluid
Adding coolant
Wait until the engine cools before
removing the cap from the expansion
tank. The needle of the coolant temper-
ature gauge in the instrument cluster
must be located in the blue zone; other-
wise, there is a danger of scalding.
1 Start by turning the cap counter-
clockwise. Pause to allow any
accumulated pressure to escape,
then open.
2 If the coolant is low, slowly add coolant until the correct level is
reached – do not overfill.
The coolant is a mixture of water and
extended-duty antifreeze with corrosion
inhibitor. Always maintain the pre-
scribed all-season 50:50 mixture ratio
for year-round protection against inter-
nal corrosion. No other additives are re-
quired.
Replace the coolant every four years.
If the indicator lamp for the
brake hydraulic system comes
on or if the "CHECK BRAKE
FLUID" warning appears in the
Check Control
*: the brake fluid
level is too low in the reservoir.
The brake fluid reservoir is located
under the microfilter housing on the
driver's side of the car. Should you de-
termine that the brake fluid is low, refer
the problem to your BMW center, who
can trace and rectify any sources of
leakage when refilling the reservoir.
Your BMW center is familiar with the
specifications for approved brake
fluids (DOT 4).
Brake fluid loss results in extended
pedal travel. For this situation, refer to
the notes on page 146.
Brake fluid is hygroscopic, that is,
it absorbs moisture from the air
over time.
In order to ensure the safety and
reliability of the brake system, have
the brake fluid changed every two years
by an BMW center. Refer also to the
Service and Warranty Information
Booklet (US models) or to the Warranty
and Service Guide Booklet (Canadian
models).
Brake fluid is toxic and damages the
vehicle's paint. You should always store
it in its original container and in a loca-
tion which is out of reach of children.
Do not spill the fluid and do not fill the
brake fluid reservoir beyond the "MAX"
mark. The brake fluid could ignite upon
contact with hot engine parts and
cause serious burns. <
Comply with the applicable
environmental laws regulating the
disposal of brake fluid. <

Index
Data
Technology
Repairs
Car care
Controls
Overview
169nVehicle Identification Number
In the engine compartment, stamped
on the right-hand strut dome (arrow)
and on the upper edge of the instru-
ment panel on the left-hand side.
390de074

170n
The BMW Maintenance System has
been designed as a reliable means of
providing maximum driving and operat-
ing safety – and as cost-effectively as
possible for you.
Please keep in mind that regular main-
tenance is not only necessary for the
safety of your vehicle, but also plays a
significant role in maintaining the resale
value of the vehicle.
Service Interval Display
Advanced technology is employed to
calculate the optimal maintenance in-
tervals, which are then indicated in the
Service Interval Display. While conven-
tional systems rely on distance traveled
alone to determine when service is due,
the BMW Maintenance System has for
years considered the actual conditions
under which the vehicle operates, be-
390us702
cause mileage can be accumulated in
very different ways.
From a maintenance standpoint,
62,000 miles (100,000 km) accumulated
in short-distance urban driving are not
the equivalent of the same distance
covered at moderate speeds in long-
distance highway travel.
The BMW Maintenance System
includes the Engine Oil Service and
Inspections I and II.
Determining the maintenance intervals
according to the actual loads on the
vehicle covers every kind of operating
situation. However, even those who
drive only short distances – significantly
less than 6,000 miles (10,000 km) annu-
ally – should have the engine oil
changed at least every 2 years since oil
deteriorates over time, regardless of
use.Service and Warranty Information
Booklet (US models) or Warranty
and Service Guide Booklet (Cana-
dian models)
Please refer to the Service and War-
ranty Information Booklet (US models)
or to the Warranty and Service Guide
Booklet (Canadian models) for addi-
tional information on maintenance inter-
vals and procedures.
As a precaution against rust, it might be
a good idea to have the body checked
for damage from rocks or gravel at the
same time, depending upon operating
conditions. Have your BMW center do the
maintenance and repair.
Your BMW center is always informed on
the latest maintenance work and repair
techniques and equipped with the re-
quired special tools. In addition, check-
ing parts known from experience to be
subject to wear is a permanent part of
the maintenance specifications.
Be sure that all maintenance work is
confirmed in the Service and Warranty
Information Booklet (US models) or in
the Warranty and Service Guide Book-
let (Canadian models).
These entries will constitute your proof
that the vehicle has received regular
maintenance. They are also required in
the event of a warranty claim. <
The BMW Maintenance System

Index
Data
Technology
Repairs
Car care
Controls
Overview
177n
Any BMW center will be glad to inform
you of the advisability, legal require-
ments and factory recommendations
with regard to technical modifications
on the car. For this purpose, the center
requires the Vehicle Identification Num-
ber and, in some cases, also the engine
number.
Light-Emitting Diodes (LEDs)
Light-emitting diodes installed behind
translucent lenses serve as the light
source for many of the controls and dis-
plays in your vehicle. The concept be-
hind their operation is related to that
employed for lasers, and they are offi-
cially designated as Class 1 light-emit-
ting diodes. Do not remove the protective lens
and avoid staring directly at the
unfiltered beam for extended periods
(several hours), as inflammation of the
iris could result. <
California laws require us to state the
following warning:
Engine exhaust, some of its con-
stituents, and certain vehicle com-
ponents contain or emit chemicals
known to the State of California to
cause cancer and birth defects or other
reproductive harm. <
Technical modifications California Proposition 65 Warning

178nOBD interface socket
The Onboard Diagnostic (OBD) socket
is located on the left of the driver's side
at the bottom of the instrument panel
and under a cover (arrow).
The cover has the letters "OBD" on it.
The purpose of the OBD system is to
ensure proper emission control system
operation for the vehicle's lifetime by
monitoring emission-related compo-
nents and systems for deterioration and
malfunction.
390us249
An illuminated lamp informs you
of the need for service, not of
the need to stop the vehicle.
However, the systems should be
checked by your BMW center at the
earliest possible opportunity.
Under certain conditions, the indicator
will blink or flash. This indicates a rather
severe level of engine misfire. When
this occurs, you should reduce speed
and consult the nearest BMW center as
soon as possible. Severe engine misfire
over only a short period of time can se-
riously damage emission control com-
ponents, especially the catalytic con-
verter.
Service Engine Soon warning
lamp for Canadian models.When the filler cap is not properly
tightened, the OBD system can
detect the vapor leak and the indicator
will light up. If the filler cap is subse-
quently tightened, the indicator should
extinguish within a few days. <

Index
Data
Technology
Repairs
Car care
Controls
Overview
183nLamps and bulbs
The lamps and bulbs make essential
contributions to the safety of your vehi-
cle. For this reason, follow the instruc-
tions below carefully when replacing a
bulb. If you are not familiar with any of
the procedures, consult your BMW
center.
Do not touch the glass portion of a
new bulb with your bare hands
since even small amounts of impurities
burn into the surface and reduce the
service life of the bulb. Use a clean
cloth, paper napkin, or a similar mate-
rial, or hold the bulb by its metallic
base. <
A replacement bulb set is available from
your BMW center.
Whenever working on the electri-
cal system, switch off the electri-
cal accessory you are working on or
disconnect the cable from the negative
terminal of the battery. Failure to do this
could result in short circuits.
To prevent injuries and damage, com-
ply with any instructions provided by
the bulb manufacturer. <
The illustration shows the right-hand
engine compartment.
For checking and adjusting head-
lamp aim, please contact your
BMW center. <
1 Low beams
2 High beams
H7 bulb, 55 watts
The H7 bulb is pressurized. There-
fore, wear safety glasses and pro-
tective gloves. Failure to comply with
this precaution could lead to injury if the
bulb is accidentally damaged during re-
placement. <
390de668
1 Turn the bulb holder to the left (arrow)
and remove.
2 Remove and replace the bulb.
When cleaning the headlamps,
please observe the following:
> Do not wipe dry (scratches). Never
use abrasives or strong
solvents to clean the covers.
Remove dirt and contamination (such
as insects) by soaking with BMW Car
Shampoo and then rinsing with plenty
of water.
Always use a deicer spray to remove
accumulated ice and snow – never
use a scraper. <