engine BMW 540I SEDAN 2001 Service Manual

Index
Data
Technology
Repairs
Car care
Controls
Overview
Overview
Controls and features Operation, care
and maintenance
Owner service procedures
Technical dataIndex
Advanced technology
139
n
Special operating instructions:
Break-in procedure 140
Driving notes 141
Catalytic converter 142
Antilock Brake System (ABS) 143
Disc brakes 144
Brake system 146
Winter operation 146
Power steering 148
Level control system 148
Cellular phone 149
Radio reception 149
Wheels and tires:
Tire inflation pressure 150
Tire condition 150
Tire replacement 151
Tire rotation 152
Wheel and tire combinations 153
Winter tires 154
Snow chains 155
Approved wheel and tire specifications 156 Under the hood:
Hood
159
Engine compartment 160
Washer fluids 164
Washer nozzles 164
Engine oil 165
Coolant 167
Brake fluid 168
Vehicle Identification Number 169
Care and maintenance:
The BMW Maintenance System 170
Caring for your car 171
Airbags 176
Vehicle storage 176
Laws and regulations:
Technical modifications 177
California Proposition 65 Warning 177
OBD interface socket 178

140nBreak-in procedure
To ensure that your vehicle provides
maximum economy throughout a long
service life, we request that you ob-
serve the following.
Engine and differential
Up to 1,200 miles (2,000 km):
Drive at varying engine speeds and
road speeds, but do not exceed
4,500 rpm and the following road
speeds during this initial period:
BMW 525i, 530i: 100 mph (160 km/h)
BMW 540i: 106 mph (170 km/h)
Obey your local and state maximum
speed limits.
Refrain from using full throttle and avoid
pressing the accelerator beyond the
kickdown point.
Once you have driven 1,200 miles
(2,000 km), engine and vehicle speeds
can gradually be increased.
You should also comply with these
break-in procedures if the engine or dif-
ferential is replaced later in the course
of the vehicle service life.
Tires
Due to technical factors associated
with their manufacture, tires do not
achieve their full traction potential until
an initial break-in period has elapsed
for this reason, drive with extra care
during the initial 200 miles (300 km).
Obey your local and state maximum
speed limits.
When the vehicle is operated on
wet or slushy roads, a wedge of
water may form between the tire and
the road surface. This phenomenon is
referred to as aquaplaning, or hydro-
planing, and can lead to partial or com-
plete loss of traction, vehicle control
and braking effectiveness. Reduce your
speed on wet roads. <
Brake system
Approximately 300 miles (500 km) must
elapse before the brake pads and ro-
tors achieve the optimal pad-surface
and wear patterns required for trouble-
free operation and long service life later
on.
To break in the separate parking brake
drums, apply the parking brake lightly
when coasting to a standstill (at a traffic
signal, for instance), provided that traf-
fic conditions allow you to do so. To
avoid corrosion, repeat this procedure
from time to time.
The brake lamps do not come on
when the parking brake is applied.
Vacuum for the brake system servo unit
on your BMW is available only when the
engine is running. When you move the
car with the engine shut off – when
towing, for instance – substantially
higher levels of pedal force will be
required to brake the vehicle. <
Clutch
The clutch will also begin to function
optimally after about 300 miles
(500 km). Engage the gears carefully
during the break-in period.

Index
Data
Technology
Repairs
Car care
Controls
Overview
141nDriving notes
Brakes:
Do not drive with your foot resting
on the brake pedal. Even light but con-
sistent pedal pressure can lead to high
temperatures, brake wear and possibly
even brake failure.
Aquaplaning:
When driving on wet or slushy roads,
reduce road speed. If you do not, a
wedge of water can form between tires
and road surface. This phenomenon is
referred to as aquaplaning or hydro-
planing. It is characterized by a partial
or complete loss of contact between
the tires and the road surface. The ulti-
mate results are loss of steering and
braking control.
Driving through water:
Do not drive through water more than
1 ft (30 cm) deep. Drive only at walking
speed. Driving at a faster speed could
cause damage to the engine, the elec-
trical system and the transmission.Rear parcel tray:
Do not use the rear parcel tray to store
heavy or bulky objects. They could
pose a danger to the occupants during
braking, evasive maneuvers, or in an
accident.
Clothes hooks:
Hang items of clothing from the hooks
so that they will not obstruct the driver's
vision. Do not hang any heavy objects
on the hooks, as otherwise passengers
could be injured, e.g. during any hard
braking or evasive maneuvers, or dur-
ing an accident. <

142nCatalytic converter
The catalytic converter reduces harmful
exhaust emissions, and is designed for
use with unleaded fuel only.
Even minute quantities of lead would be
enough to permanently damage both
the catalytic converter and the system
oxygen sensor.
To ensure efficient, trouble-free engine
operation and avoid potential damage:
>Be sure to comply with the scheduled
maintenance requirements.
> Fill the fuel tank well before it is
empty.
> Tow-start the vehicle only when the
engine is cold, since unburned fuel
may otherwise reach the catalytic
converter. It is better to start the vehi-
cle with an outside starting aid. >
Avoid other situations in which the
fuel is not burned, or burns incom-
pletely, such as engaging the starter
frequently or for extended periods, or
repeated start attempts in which the
engine does not start (stopping and
restarting an engine which is running
properly does not present a problem).
Never let the engine run with any of
the spark plug cables disconnected. Be sure to comply with the in-
structions above to prevent un-
burned fuel from reaching the catalytic
converter. Otherwise there is danger of
overheating and damage to the cata-
lytic converter.
Extreme temperatures occur at the cat-
alytic converter on this and every cata-
lyst-equipped vehicle. Heat shields are
installed adjacent to some sections of
the exhaust system. Never remove
these shields; do not apply undercoat-
ing to their surfaces. When driving,
standing at idle, and parking the vehi-
cle, take care to avoid contact between
the exhaust system and flammable ma-
terials (grass, hay, leaves, etc.). Such
contact could lead to a fire, resulting in
personal injury and property damage. <

Index
Data
Technology
Repairs
Car care
Controls
Overview
145nDisc brakes
Driving notes
When driving in wet conditions and in
heavy rain, it is effective to apply light
pressure to the brake pedal every few
miles (kilometers). Watch traffic condi-
tions to ensure that this maneuver does
not endanger other road users. The
heat which is generated by the brake
applications helps to dry the brake
pads and rotors.
Maximum braking force is obtained
while the wheels continue to rotate,
peaking when the wheels remain on the
verge of locking without actually doing
so. ABS maintains this state automati-
cally. If the ABS fails, you should revert
to the staggered braking technique
described below (refer to page 147).
Extended or steep mountain descents
should be driven in the gear in which
only minimal periodic brake applica-
tions is required. This avoids excessive
strain on the brakes and possible im-
pairment of the braking effect.
The braking effect of the engine can be
further increased by downshifting, into
first gear, if necessary. In the manual
mode of the automatic transmission,
you can also downshift into first gear.
Refer to page 76. Should engine braking prove inade-
quate, you should still avoid extended,
continuous braking. Instead of main-
taining low to moderate pressure over
an extended period of time, you should
decelerate by applying more substantial
pressure to the brake pedal (watch for
following traffic!), then releasing the
pedal, then repeating the application.
This staggered braking technique
allows the brakes to cool in the intervals
between active braking phases,
preventing overheating and ensuring
that full braking capacity remains avail-
able at all times.
Do not coast with the clutch de-
pressed or with the transmission
or selector lever in Neutral. Do not
coast with the engine shut off. The
engine provides no braking effect when
the clutch is depressed or the transmis-
sion is in neutral, and there is no
power-assist for braking or steering
when the engine is not running.
Never allow floor mats, carpets or any
other objects to protrude into the area
around the accelerator, clutch and
brake pedals and obstruct their move-
ment. <
Dynamic Brake Control (DBC)*
If you apply the brakes rapidly, this
system automatically produces the
maximum braking force boost and thus
helps to achieve the shortest possible
braking distance during "panic stops."
All of the benefits of the ABS system
are exploited under these circum-
stances.
Do not reduce the pressure on the
brake pedal for the duration of the
brake application. When the brake
pedal is released, the DBC is deacti-
vated.
In the event of a malfunction, the yellow
warning lamp comes on. Conventional
braking efficiency is available without
limitations.
Have the system checked and repaired
at your BMW center as soon as possi-
ble.
For "Information for your safety"
covering the ABS system, refer to
page 144. This information also gener-
ally applies for DBC. <

Index
Data
Technology
Repairs
Car care
Controls
Overview
147nWinter operation
Rubber seals and components
In order to prevent the weather-strip-
ping from freezing, apply BMW rubber
treatment or silicone spray to the seals
on the doors, hood and luggage com-
partment lid/tailgate.
A full range of car-care products is
available from your BMW center. <
Snow chains
BMW snow chains* can be mounted on
both summer and winter tires. Mount
them in pairs on the rear wheels only
and comply with the manufacturer's
safety precautions. Do not exceed a
maximum speed of 30 mph (50 km/h).
For maximum traction, we recommend
that you manually deactivate the
ASC+T/DSC
* when driving with snow
chains mounted. Refer to page 102.
Starting off
We recommend that you use the
manual control switch to deactivate
ASC+T/ DSC
* when starting off in deep
snow or when rocking the car to free it
(refer to page 102).
Driving on low-traction road
surfaces
Use smooth, gentle pressure to control
the accelerator pedal. Avoid excessive
engine speeds and shift to the next
higher gear at an early point. Adapt
your speed and driving style when ap-
proaching grades or slopes. Maintain
an adequate distance between yourself
and the vehicle ahead.
Brakes
Winter road conditions substantially
reduce the amount of traction available
between the tires and the road surface.
The resulting increases in braking dis-
tance are considerable and should be
kept in mind at all times.
ABS is intended to prevent the wheels
from locking during brake applications,
thus helping to maintain vehicle stability
and steering response. If the ABS does not respond in a critical
braking situation and the wheels lock:
reduce the pressure on the brake pedal
until the wheels just start to roll again
while still maintaining enough force to
continue braking.
Following that, increase pedal pressure
again. Reduce the pressure as the
wheels lock, then reapply pressure.
Repeat this procedure.
This type of staggered braking will
reduce the braking distance, and the
vehicle still remains responsive to
steering.
You can then attempt to steer around
hazards after you have reduced pres-
sure on the brake pedal.
Do not shift down on slick road
surfaces. Doing so could cause
the rear wheels to lose traction and
skid, which could result in the loss of
vehicle control. <
Depress the clutch during hard
braking on road surfaces which
provide only poor or uneven traction. <

Index
Data
Technology
Repairs
Car care
Controls
Overview
159nHood
To unlock
Pull the lever located under the left-
hand side of the instrument panel.
Do not work on your vehicle with-
out appropriate skills. Switch off
the engine and allow it to cool down
before working in the engine compart-
ment. Always disconnect the battery
before working on any electrical
systems or equipment, especially when
these are located within the engine
compartment. Comply with all applica-
ble instructions and warnings. Failure to
work in an informed, professional
manner when servicing components
and materials constitutes a safety
hazard for vehicle occupants and other
road users. If you are not familiar with
the guidelines, please have the opera-
tions performed by your authorized
BMW center. <
390de071
To open
Pull the release handle and open the
hood.
390de072
To close
Allow the hood to fall from a height
of about 12 in (30 cm) so that it audibly
engages.
To avoid injuries, be sure that the
travel path of the hood is clear
when it is closed, as with all closing
procedures.
If it is determined that the hood is not
completely closed while driving, stop
immediately and close it securely. <
390de677

160n
390de649
Engine compartment – BMW 525i, 530i

Index
Data
Technology
Repairs
Car care
Controls
Overview
161n
1 Auxiliary terminal for jump starting 200
2 Reservoir for brake fluid (under the housing of the microfilter) 168
3 Engine oil dipstick 165
4 Coolant expansion tank 167
5 Engine oil filler neck 165
6 Reservoir for intensive-cleaning system
*164
7 Reservoir for windshield and headlamp washer system
*164
Engine compartment – BMW 525i, 530i

162nEngine compartment – BMW 540i
390us621