BMW 540I SEDAN 2003 Owners Manual

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OverviewControlsMaintenanceRepairsDataIndex
Overview
Controls and features
Operation, maintenance
Owner service procedures
Index Technical data
Mainte-

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Break-in proceduresTo ensure that your vehicle provides
maximum economy throughout a long
service life, we request that you
observe the following suggestions.Engine and differentialUp 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).
Comply with all official 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.
TiresOwing 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, you should drive with
extra care during the initial 200 miles
(300 km).
Comply with all official 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 systemApprox. 300 miles (500 km) must
elapse before the brake pads and
rotors 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
traffic conditions allow you to do so.
To avoid corrosion, repeat this proce-
dure 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
vehicle with the engine switched off Ð
when towing, for instance Ð substan-
tially higher levels of pedal force will be
required to brake the vehicle.< ClutchThe clutch will also begin to function
optimally after about 300 miles
(500 km). Engage the gears carefully
during the break-in period.

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Driving notes Antilock Brake System
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.
Hydroplaning:
When driving on wet or slushy roads,
reduce vehicle speed. If you do not, a
wedge of water may form between the
tires and the road surface. This phe-
nomenon is referred to as aquaplaning
or hydroplaning. It is characterized by a
partial or complete loss of contact
between the tires and the road surface.
The ultimate results are loss of steering
and braking control.
Driving through water:
When there is water on the roads, do
not drive in it if it is deeper than
1 ft (30 cm), and even then, only at
walking speed, otherwise the vehicle
can sustain damage to the engine, the
electrical systems and the transmission.
Rear parcel tray:
Do not place heavy or hard objects on
the rear parcel tray. These objects
could endanger vehicle occupants
during heavy brake applications or eva-
sive maneuvers.
Clothes hooks:
Hang items of clothing from the hooks
so that they will not obstruct the driver's
vision. Do not hang heavy objects on
the hooks. If you do so, they could
cause personal injury during braking or
evasive maneuvers.<
The conceptThe Antilock Brake System (ABS) keeps
the wheels from locking during braking,
thereby enhancing active driving safety.
With ABS, the shortest possible braking
distances are achieved under most
conditions (on straight-aways and in
curves, on asphalt, ice, wet road sur-
faces, etc.).Braking with ABSIf you are in a situation that requires full
braking, you will exploit the full benefits
of the ABS system if you apply max-
imum pedal pressure ("panic stop").
Pulsation at the brake pedal combined
with sounds from the hydraulic circuits
indicates to the driver that ABS is in its
active mode.

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Brake systemBrake fluid level If the brake fluid level is too low and
brake pedal travel has become notice-
ably longer, there may be a defect in
one of the two brake system's hydraulic
circuits.
Proceed to the nearest BMW
center. Higher brake application
pressure may be necessary under these
conditions, and the vehicle may exhibit
a slight tendency to pull to one side
when the brakes are applied. Braking
distances may also be longer. Please
remember to adapt your driving style
accordingly.<
Disc brakesLimited vehicle use, extended periods
with the vehicle parked or in storage,
and operating conditions in which
braking is restricted to gentle, low-
pressure applications will all increase
the tendency for corrosion to form on
the rotors; this is often accompanied by
a simultaneous accumulation of con-
tamination on the brake pads. The pads
must exert a certain minimal level of
pressure against the rotors for the disc
brakes' inherent self-cleaning effect to
remain effective; the pressure available
under the above conditions may not
provide adequate cleansing.
If the brake rotors are corroded, they
will tend to respond to braking with a
pulsating effect that even extended
brake applications will fail to cure.
When driving in heavy rain and on wet
roads it is a good idea to apply light
pressure to the brake pedal every few
miles. Monitor traffic conditions to
ensure that this maneuver does not
pose a hazard to you or to other road
users. The heat generated in this pro-
cess helps dry the pads and rotors to
ensure that your brake system will
respond with undiminished efficiency
when you need it.When descending steep hills and
extended grades, downshift to a gear
that will allow you to continue safely
with only a minimal amount of braking.
By minimizing the loads placed on the
brake system, this strategy helps
ensure that optimal brake system
response will remain available at all
times.
Do not coast with the clutch
depressed or with the transmission
or selector lever in Neutral. Do not coast
with the engine switched off. The engine
provides no braking effect when the
clutch is depressed 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 movement.<
Brake pads
For your own safety: use only
brake pads that BMW has
approved for your particular vehicle
model. BMW cannot evaluate non-
approved brake pads to determine if
they are suited for use, and therefore
cannot ensure the operating safety of
the vehicle if they are installed.<

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Information for your safetyThe factory-approved radial tires are
matched to the vehicle and have been
selected to provide optimum safety and
driving comfort.
It is not merely the tire's service life, but
also driving comfort and Ð above all else
Ð driving safety which depend on the
condition of the tires and the mainte-
nance of the specified tire inflation
pressure.
Incorrect inflation pressures are a
frequent cause of tire problems
and flat tires. Tire pressure also has a
major effect on your BMW's handling
response. We recommend that you
check the tire pressure Ð remember to
check the spare tire as well Ð before
every extended trip, as well as at least
every two weeks in normal use (refer to
page 26). Failure to observe these pre-
cautions can result in incorrect tire
pressures, which cause instable han-
dling response as well as tire damage,
and can ultimately lead to an acci-
dent.<
Tire tread Ð Tire damageInspect your tires frequently for tread
wear, signs of damage and for foreign
objects lodged in the tread. Check the
tread depth.
The tread depth should not drop
below 0.12 in (3 mm), even though, for
example the legally specified minimum
tread depth in Europe is only 0.063 in
(1.6 mm). Below a tread depth of
0.12 in (3 mm) there is an increased risk
of hydroplaning, even at relatively mod-
erate speeds and with only small
amounts of water on the road.
Tread wear indicators, refer to arrow,
are embedded around the tire circum-
ference in the base of the tire tread.
Their locations are indicated on the tire
sidewall with TWI Ð Tread Wear Indi-
cator. At a tread depth of 0.063 in 390de331
(1.6 mm) these indicators, signal that
the tires have reached the legally per-
missible wear limit.
Do not drive on a deflated (flat)
tire. A flat tire greatly impairs
steering and braking response, and can
lead to complete loss of control over
the vehicle.
Avoid overloading the vehicle so that
the permitted load on the tires is not
exceeded. Overloading leads to over-
heating and causes damage inside the
tires. The ultimate result can assume
the form of a sudden air loss.
Unusual vibrations encountered during
normal vehicle operation can indicate a
flat tire or some other vehicle malfunc-
tion. The type of problem can be
caused by contact with curbs, etc. This
is also true for irregularities in the
vehicle's handling characteristics, such
as a pronounced tendency to pull to the
left or right. Should this occur, respond
by immediately reducing your speed.
Proceed carefully to the nearest BMW
center or professional tire center, or
have the vehicle towed in to have it, its
wheels and tires inspected.
Tire damage (up to and including blow-
outs) can endanger the lives of both the
vehicle occupants and other road
users.<
Tire inflation pressure Tire condition

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Tire replacementTo maintain good handling and vehicle
response, use only tires of a single
tread configuration from a single manu-
facturer. BMW tests wheel and tire
combinations and approves them.DOT Quality GradesTreadwear
Traction AA A B C
Temperature A B C
All passenger car tires must con-
form to Federal Safety Require-
ments in addition to these grades. rating based on the wear rate of the tire
when tested under controlled condi-
tions on a specified government test
course.
For example, a tire graded 150 would
wear one and one-half (1 1/2) times as
well on the government course as a tire
graded 100. The relative performance
of tires depends upon the actual condi-
tions of their use, however, and may
depart significantly from the norm due
to variations in driving habits, service
practices and differences in road char-
acteristics and climate.
TractionThe traction grades, from highest to
lowest, are AA, A, B and C.
Those grades represent the tire's ability
to stop on wet pavement as measured
under controlled conditions on speci-
fied government test surfaces of
asphalt and concrete. A tire marked C
may have poor traction performance.
The traction grade assigned to
this tire is based on straight-
ahead braking traction tests, and does
not include acceleration, cornering,
hydroplaning, or peak traction charac-
teristics.<
TemperatureThe temperature grades are A (the
highest), B and C, representing the
tire's resistance to the generation of
heat and its ability to dissipate heat
when tested under controlled condi-
tions on a specified indoor laboratory
test wheel.
Sustained high temperature can cause
the material of the tire to degenerate
and reduce tire life, and excessive tem-
perature can lead to sudden tire failure.
The grade C corresponds to a level of
performance which all passenger car
tires must meet under the Federal
Motor Car Safety Standard No. 109.
Grades B and A represent higher levels
of performance on the laboratory test
wheel than the minimum required by
law.
The temperature grade for this tire
is established for a tire that is
properly inflated and not overloaded.
Excessive speed, underinflation, or
excessive loading, either separately or
in combination, can cause heat buildup
and possible tire failure.<

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Tire replacement Wheel and tire combinationsUniform Tire Quality GradingQuality grades can be found where
applicable on the tire sidewall between
tread shoulder and maximum section
width. For example:
Treadwear 200 Traction AA
Temperature A
Do not use retreaded tires, since
driving safety may be impaired.
This is due to the possible variations in
casing structures and, in some cases,
to their extreme age, which can lead to
a decrease in their durability.< Tire ageThe date on which the tire was manu-
factured is indicated by the code on the
sidewall:
DOT ... 2601 indicates that the tire was
manufactured in Week 26 of the year
2001.
Although tires may have a theoretical
service life of up to 10 years, BMW
strongly recommends that you replace
all tires after an absolute maximum of
6 years.
The right choice
Never mount wheels and tires that
have not been specifically
approved by BMW for use on your par-
ticular model. Although other wheels
and tires may theoretically have the
same dimensions, variations in factors
such as manufacturing tolerances can
result in contact between tire and body-
work, ultimately leading to serious acci-
dents. If non-approved wheels and tires
are used, BMW cannot evaluate their
suitability, and therefore cannot be held
liable for driving safety.<
BMW has tested certain tires for each
tire size, rated them according to road
safety and approved them. Your BMW
center can inform you which tires have
been tested in this way. Observe pos-
sible national guidelines, e.g. regarding
entry into vehicle documents.
The correct wheel and tire combi-
nation affects different systems
such as ABS, ATC, ASC+T/DSC.
The function of these systems is
impaired if improper wheel and tire
combinations are used.
Always ensure that all of the tires
mounted on the vehicle are the same
series, from the same manufacturer and
with the same tread pattern. If you have
to mount the spare tire in response to a
flat tire, etc., you should remount a tire
of the correct specifications as soon as
possible.<
The use of rims and wheel bolts
that do not meet the specifica-
tions of the original factory-installed
equipment will affect the safe operation
of your vehicle and may cause an acci-
dent and personal injury.
Never mix tires of different design, such
as steel-belted radials with radial bias-
belted or bias-ply tires, etc. Mixing tire
types will adversely affect roadholding
and can lead to loss of vehicle con-
trol.< Storage Store tires in a cool, dry place, pro-
tecting them against light whenever
possible. Protect the tires against con-
tact with oil, grease and fuel.

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Special characteristics of winter tires Snow chains
*
Choosing the right tireBMW recommends winter tires (M+S
radial tires) for operation under
inclement winter driving conditions.
While all-season tires (M+S designa-
tion) provide better winter traction than
summer tires with the load ratings H, V,
W, Y and ZR, they generally do not
achieve the performance of winter tires.
In the interests of safe tracking and
steering response, install radial tires
made by the same manufacturer and
with the same tread configuration on all
four wheels if you elect to mount winter
tires.Do not exceed specified
maximum speeds
Never exceed the maximum
speed for which the winter tires
are rated.
Unprofessional attempts by laymen to
service tires can lead to damage and
accidents.
Have this work performed by skilled
professionals only. Any BMW center
has the required technical knowledge
and the proper equipment and will be
happy to assist you.<
Tire condition, tire inflation
pressureWinter tires display a perceptible loss in
their ability to cope with winter driving
conditions once the tread wears to
below 0.16 in (4 mm), and should thus
be replaced.
Comply with the specified tire inflation
pressures and be sure to have the
wheel and tire assemblies balanced
every time you change the wheels/tires.BMW narrow-link snow chains
are
approved exclusively for use in combi-
nation with winter tires on the rear
wheels only. Comply with all manufac-
turer's safety precautions when
mounting the chains. Do not exceed a
speed of 30 mph (50 km/h) while
driving with mounted snow chains.
It is not possible to mount snow
chains on tires with 17-inch
wheels.<

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HoodTo unlockPull the lever located under the left-
hand side of the instrument panel.
Do not work on your vehicle
without appropriate skills. 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 BMW center.<390de759
To openPull the release handle and open the
hood.390de760
To closeAllow 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 you notice that the hood is not com-
pletely closed while driving, stop imme-
diately and close it securely.< 390de761

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1 Reservoir for brake fluid (under the
housing of the microfilter)145
2 Auxiliary terminal for
jump-starting1643 Engine oil dipstick142
4 Engine oil filler neck142
5 Coolant expansion tank1446 Reservoir for intensive-cleaning
system
*
141
7 Reservoir for windshield and
headlamp washer system
*
141
Engine compartment essentials
390de791