light BMW 540I SEDAN 2003 Owner's Guide

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Cargo area Cargo loadingRaise the cargo floorFor access to the compartment under
the floor or to the spare tire, etc.:
>Raise the cargo floor and secure it
with the support rod (arrow)
>Open the quick-release fasteners on
the spare tire cover.392de756
Stowing cargoWhen transporting loads in your BMW:
>Position heavy loads as far forward
as possible Ð directly behind the
backrests or the luggage compart-
ment partition panel Ð and at the
bottom (the illustration shows the
sport wagon)
>Cover sharp edges and corners
>Do not pile objects higher than the
top edge of the backrest
>Pull out the partition net
* (refer to
page 125) and ensure that carried
items cannot pass through the parti-
tion net
>For very heavy loads when the rear
seat is not occupied, secure each
safety belt in the opposite buckle.
392de177
Securing the load>Secure smaller, light pieces with the
retaining straps or a luggage net
*, or
use elastic straps (refer to page 42)
>For large, heavy pieces, visit your
BMW center for load-securing
devices
*. Lashing eyes are provided
at the corners of the luggage com-
partment/cargo area for attaching
these load-securing devices (the
illustration shows the sport wagon)
>Read and comply with the informa-
tion enclosed with the load-securing
devices.
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132n
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.

133n
OverviewControlsMaintenanceRepairsDataIndex
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.

134n
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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OverviewControlsMaintenanceRepairsDataIndex
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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OverviewControlsMaintenanceRepairsDataIndex
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
behind 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 and
reproductive harm. In addition, certain
fluids contained in vehicles and certain
products of component wear contain or
emit chemicals known to the State of
California to cause cancer and birth
defects or other reproductive harm.
Battery posts, terminals and related
accessories contain lead and lead
compounds. Wash your hands after
handling.
Used engine oil contains chemicals that
have caused cancer in laboratory ani-
mals. Always protect your skin by
washing thoroughly with soap and
water.<
Technical modifications California Proposition 65 Warning

148n
OBD interface socketThe Onboard Diagnostic (OBD) inter-
face socket is located on the left of the
driver's side at the bottom of the instru-
ment panel and under a cover. The
cover has the letters "OBD" on it.
The purpose of the OBD system is to
ensure proper operation of the emis-
sion control system for the vehicle's
lifetime. The system monitors emis-
sions-related components and sys-
tems to detect deterioration and mal-
function.390us739
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
seriously damage emission control
components, especially the catalytic
converter.
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
go out within a few days.<

152n
Attached to the underside of the lug-
gage compartment lid/tailgate.
Unscrew the wingnut for access.
394de080
Front1. Pull the wiper arm up slightly and
hold it firmly
2. Press back the release (arrow) and
pull the wiper blade back toward the
base of the wiper arm
3. Install the new blade and slide the
release back into position.390de766
Rear
*
1. Hold the wiper blade on the window
and remove/unclip the wiper arm at
the articulated joint (arrow)
2. Insert a new wiper blade and press it
on/clip it into the wiper arm.
Use only wiper blades approved
by BMW.< 530de301
Onboard tool kit Windshield wiper blades

154n
Lamps and bulbsXenon lamps
*
The operating life of these lamp units is
extremely long and the likelihood of
failure very low, provided that they are
not switched on and off an excessive
number of times. If one of these bulbs
should nevertheless fail, it is possible to
continue driving with great caution
using the fog lamps, provided traffic
laws in your area do not prohibit this.
Because of the extremely high
voltages involved, any work on the
xenon lighting system should be carried
out by technically-qualified personnel
only. Otherwise, there is a risk of fatal
injury.<
Standing lamps10 watt bulb
The bulb holder and reflector are a
single unit and are both changed
at the same time.<
1. Turn the bulb holder with reflector to
the left and remove
2. Disconnect the plug
3. Plug the new bulb holder into the
plug connector. Be sure that it is
securely engaged
4. Insert the reflector with bulb holder
and turn to the right as far as
possible.390de669
Turn signal indicator/Parking
lamps (side marker lamps)Dual-filament bulb, 21 watt
1. Turn the bulb to the left and remove
2. Remove and replace the bulb.390de670

160n
Changing a wheel4. Wheels with adapter
*: position the
lug bolt adapter on the lug bolt
cover. Then apply the lug wrench
and turn it to the left (refer to the
illustration)
5. Wheels with hub cover*: pry the
hub cover off with the screwdriver
in the slot
6. Loosen the lug bolts 1/2-turn
390de773
7. Position the jack at the jacking
point closest to the flat tire so that
the jack base is vertically below the
jacking point and the entire surface
of the head of the jack will move
into the square recess of the
jacking point (refer to the illustration
detail) when the jack is cranked
8. Jack the vehicle up until the wheel
you are changing is raised from the
ground
9. Unscrew the lug bolts and remove
the wheel
10. Remove accumulations of mud or
dirt from the mounting surfaces of
the wheel and hub. Clean the lug
bolts390de707
11. Position the spare tire. Secure the
wheel by turning at least two lug
bolts into opposite bolt holes
12. Screw in the remaining lug bolts.
Tighten all the bolts securely in a
diagonal pattern
13. Lower the jack and remove it from
beneath the vehicle
14. Tighten the lug bolts in a diagonal
pattern
15. Wheels with full wheel covers:
Place the wheel cover with the
valve opening over the valve
(arrow). Use both hands to press
the cover securely onto the rim
For this light-weight wheel, use
only the full wheel cover installed
by the factory. Other wheel covers may
not fit securely.< 390de360