engine BMW 540I SEDAN 2003 Workshop Manual

164n
Do not use spray starter fluids to start
the engine.
When your battery is discharged you
can used two jumper cables to start
your vehicle with power from the bat-
tery in a second vehicle. You can also
use the same method to help start
another vehicle. Always use jumper
cables with fully insulated handles on
the terminal clamps.
Do not touch high-voltage wiring
and cables on a running engine.
Contact with components carrying high
voltage can be harmful or fatal. Care-
fully observe the following instructions
to avoid personal injury and/or damage
to one or both vehicles.<
1. Ensure that the battery in the sup-
port vehicle is also rated at
12 volts. This information is pro-
vided on the top of the battery
casing
2. Do not disconnect your battery from
your vehicle's electrical system.
Switch off all electrical accessories
in both vehicles
3. Make absolutely certain that there
is no contact between the body-
work of the two vehicles Ð short cir-
cuit hazard
4. Start the engine on the support
vehicle and allow it to run
5. Use one jumper cable (+) to con-
nect the positive terminal of the
battery in the support vehicle with
the auxiliary positive terminal pro-
vided in the engine compartment of
your BMW specifically for jump-
starting. The cover on this auxiliary
terminal is identified by a "+"
symbol, refer to the illustration. Pull
up to open the cover390de690
6. Next, connect one end of the other
jumper cable (Ð) to either the sup-
port vehicle's negative battery ter-
minal or a suitable ground on its
engine or bodywork. Connect the
other end to the negative battery
terminal or a suitable ground on the
vehicle being started. There is a
special nut on the strut dome of
your BMW; refer to the arrow in the
illustration
Always adhere to this sequence
when connecting jumper cables;
failure to observe this procedure can
lead to sparks at the battery terminals
and pose an injury hazard.< 390de146
Jump-starting

165n
OverviewControlsMaintenanceRepairsDataIndex
Jump-starting Towing the vehicle7. Start the support vehicle's engine
and let it run at an increased idling
speed for a few minutes. Start the
engine on the vehicle needing the
jump-start, and allow it to run as
usual. If the first start attempt is not
successful, wait a few minutes
before another attempt in order to
allow the discharged battery to
recharge
8. Before disconnecting the jumper
cables let the engines run for a few
minutes
9. Then disconnect the jumper cables
in reverse sequence.
Depending on the cause of the fault,
have the battery recharged by your
BMW center.
Tow fittingThe screw-in tow fitting is stored in the
onboard tool kit; be sure that it remains
in the vehicle at all times. This fitting is
designed for installation in the tow
sockets located at the front and rear of
the vehicle, and is intended for towing
on paved road surfaces only.
It should not be used to pull a vehicle
out of deep snow, mud, sand, etc.
Always observe all applicable towing
laws and regulations.Access to tow socketsFront:
Apply pressure to the arrow symbol on
the cover panel to remove.390de087
Rear:
Apply pressure to the arrow symbol on
the cover panel to remove.
Screw the tow fitting in until it bot-
toms firmly. Failure to screw the
fitting all the way in can cause thread
damage.
Never attach tie-down hooks, chains,
straps, or tow hooks to tie rods, control
arms, or any other part of the vehicle
suspension, as severe damage to these
components will occur, leading to pos-
sible accidents.<
Use only a nylon towing strap to tow
the vehicle, since the inherent resil-
ience of this material helps protect both
vehicles from sudden jerking move-
ments.394de088

166n
Towing the vehicle
The towed vehicle should always
be the lighter of the two vehicles.
If this is not the case, it is no longer
possible to control vehicle response.<
Tow-startingIt is not possible to start the engine of
vehicles equipped with an automatic
transmission by towing or pushing.
For instructions on jump-starting: refer
to page 164.
Never attempt to use your vehicle to
push another vehicle, since damage to
the energy-absorbing bumpers could
result.
Towing a vehicle with automatic
transmission1. Place the selector lever in position N
2. Towing speed:
Max. 45 mph (70 km/h)
3. Towing distance:
Max. 95 miles (150 km)
4. Leave the ignition key in position 1 to
ensure that the brake lamps, turn
signal indicators, horn and wind-
shield wipers remain operative, and
to prevent the steering lock from
engaging
5. Switch on the hazard warning
flashers (observe official regulations).
Find some means of identifying the
vehicle in tow, for instance, place a sign
or warning triangle in the rear window.
Make sure that the ignition key
remains in position 1 even when
the electrical system has failed to pre-
vent the steering lock from engaging.
The steering and brakes are without
power-assist when the engine is off.
This means that increased effort is
required for steering and braking.<
Towing with a commercial
tow truck>Do not tow with sling-type equipment
>Use a wheel-lift or flatbed carrier
>Please comply with applicable towing
laws.
Never allow passengers to ride in
a towed vehicle for any reason.< 380us124

170n
BMW 525i/sport wagon BMW 530i BMW 540i/sport wagon
Displacement
Number of cylinderscu in (cm
m) 152.2 (2,494)
6181.8 (2,979)
6268.4 (4,398)
8
Maximum output
at engine speedhp
rpm184
6,000225
5,900290
5,400
Maximum torque
at engine speedIb ft (Nm)
rpm175 (236)
3,500214 (289)
3,500324 (440)
3,600
Compression ratioe10.5 10.2 10.0
Stroke
Borein (mm)
in (mm)2.95 (75.0)
3.31 (84.0)3.53 (89.6)
3.31 (84.0)3.26 (82.7)
3.62 (92.0)
Fuel-injection system
Digital electronic engine-management system
Engine specifications

175n
OverviewControlsMaintenanceRepairsDataIndex
Capacities

Notes
Fuel tank
Reservegal. (liters)
gal. (liters)approx. 18.5 (approx. 70)
approx. 2.0 (approx. 8) Ð BMW 525i, 530i
approx. 2.5 (approx. 10) Ð BMW 540iFuel specification: page 25
Windshield washer system
with headlamp washer system
Intensive cleaning systemquarts (liters)
quarts (liters)
quarts (liters)approx. 3.7 (approx. 3.5)
approx. 6.3 (approx 6.0)
approx. 1.1 (approx 1.0)For details: page 141
Cooling system including
heater circuitquarts (liters) 11.1 (10.5) Ð BMW 525i, 530i
12.7 (12.0) Ð BMW 540iFor details: page 144
Engine oil and filter change quarts (liters) 6.9 (6.5) Ð BMW 525i, 530i
7.9 (7.5) Ð BMW 540i"BMW High Performance
Synthetic Oil."
For details: page 143
Manual transmission, automatic
transmission and differentialÐ Ð Lifetime fluid, no fluid
change required

Everything from A to ZA
ABS (Antilock Brake
System)20, 133
Accessories9
Activated-charcoal
filter114
Active seat52
Adaptive Transmission
Control (ATC)72, 75
Add
antifreeze144t
brake fluid145t
engine coolant144t
engine oil142t
washer fluid141t
Adjusting
backrest50
head restraints52
mirrors57
seats48
steering wheel56
temperature107, 111
thigh support50
Air conditioning106
Air distribution107, 111
Air outlets106, 109
Air pressure,
tires26t, 135
Air supply107, 111
Air vent106, 109
Airbags20, 59 Alarm system42
Anchorage points
child-restraint system with
tether strap62
Antifreeze, disposal144t
Antifreeze, radiator144
Antilock Brake System
(ABS)20, 133
Anti-theft alarm system42
Anti-theft protection34
Approved axle load173
Approved gross vehicle
weight173
Aquaplaning133, 135
ASC+T (Automatic Stability
Control plus Traction)21
ASC+T/DSC (Automatic
Stability Control plus
Traction/Dynamic Stability
Control)99
Ashtray, front119
Ashtray, rear120
ATC (Adaptive Transmission
Control)72, 75
Attach vacuum cleaner120
AUC (Automatic
recirculated-air
control)112 Automatic climate
control109
removing condensation
from windows111
Automatic cruise control80
Automatic curb monitor55
Automatic rear window
cleaning79
Automatic recirculated-air
control (AUC)112
Automatic Stability Control
plus Traction (ASC+T)21
Automatic Stability Control
plus Traction/Dynamic
Stability Control (ASC+T/
DSC)99
Automatic
transmission20, 72
Automatic transmission with
Steptronic20, 75
Average fuel
consumption88
Average speed88, 96
Avoiding unintentional
alarms43t, 44
B
Backrest, adjusting50
Backup lamps
bulb replacement156t Battery162
care162t
charging162t
discharged164t
disposal162t
Belts53
Beverage holder119
Blower107, 111
BMW active seat52
BMW comfort seat51
BMW Maintenance
System146t
BMW Universal
Transmitter115
Bottle holder, refer to
beverage holder119
Brake fluid145
adding145
Brake hydraulic system19
Brake lamps, bulb
replacement156t
Brake malfunctions134
Brake system134
brake fluid level134
brake pads20, 134
disc brakes134
malfunctions134
Break-in procedures132
Bulbs and lamps153t

Everything from A to Z
179n
OverviewControlsMaintenanceRepairsDataIndex
C
California Proposition
65 Warning147
Capacities175
Cargo area
floor compartment127
lamps105
opening from the
inside40
partition net125
roll-up cover125
Cargo loading128
Cellular phone119
Center (high-mount) brake
lamp157
Central locking
system32, 37
Changing a wheel/
tire158t
Charge indicator lamp19
CHECK button85
Check Control85t
Check engine oil
level142t
Child seats62
Child-restraint
installation64
Child-restraint system with
tether strap62
Child-restraint systems62
Child-safety locks66
Cigarette lighter120 Clean rear window79
Cleaning windshield79
Climate control, refer to
Automatic climate
control109
Clock90
for additional information
refer to the "Owner's
Manual for Onboard
Computer"
Cockpit14
Code, refer to immobilizer
function96
Cold start69
Comfort seat51
Compartments118
Computer88
for additional information
refer to the "Owner's
Manual for Onboard
Computer"
remote control97
Computer in the MID93
Configuring personal
adjustments, Vehicle and
Key Memory67
Consumption display83
Consumption, fuel88, 95
Convenience operation of
windows and sliding/tilt
sunroof33 Convenience starting
feature69
Coolant144
Coolant temperature
gauge84
Copyright4
Cover, sun blinds114
Cruising range88, 95
Cup holder119
Cup holder, refer to
beverage holder119
Curb monitor55
D
Date
calling up90
changing90
Daytime driving lamps103
DBC (Dynamic Brake
Control)20
Deactivating97
interior motion sensor43
tilt alarm sensor43
Deep water133
Defrost windows108, 111
Defroster mode108, 111
Digital clock in the MID90
Dimensions171
Dipstick, engine oil142t
Displacement170
Display lighting104 Displays16, 17
Disposal
antifreeze with corrosion
inhibitor144t
used batteries162t
used oils143t
Distance from
destination94
Distance warning98
Divided rear-seat
backrest121
Doors
manual operation33
opening and closing34
opening/closing from the
inside34
operation via remote
control34
DOT Quality Grades136
Driving notes133
DSC (Dynamic Stability
Control)21, 99
Dynamic Brake Control
(DBC)20
Dynamic Stability Control
(DSC)21, 99
E
Electric power seat50
Electric power windows44

Everything from A to ZElectrical malfunction
doors33
fuel filler door24
luggage compartment
lid38
sliding/tilt sunroof47
tailgate39
Elements of operation,
cockpit14
Emergency release of
luggage compartment lid
from luggage
compartment's interior41
Energy control83
Engine compartment
essentials140
Engine coolant84, 144
Engine oil142
consumption142
disposal143t
level20
pressure19
specifications143t
viscosity ratings143
Engine specifications170
Estimated time of arrival95
Exterior mirrors57, 58
F
Failure messages85t
Filling the washer
reservoir141t
First-aid kit23
Fittings, tow-starting and
towing165t
Flashlight118
Flat tire135, 158t
Fog lamps104
bulb replacement155t
Fold rear-seat backrest121
Follow me home lamps103
Front ashtray119
Front fog lamps104
Front seat adjustment48
Fuel25
gauge83
quality25
specifications25
tank capacity175
Fuel consumption88, 95
average88, 95
indicator83
Fuel filler door24
electrical malfunction24
manual release24
Fuses162
G
Gasoline25
gauge83
quality25
Glass moonroof47
Glove compartment118
Grilles109
Gross vehicle weight173 H
Handbrake70
Hands-free system119
Hazard warning triangle23
Head restraints50
Headlamp covers,
care153t
Headlamp flasher78
Headlamp washer
system141
Heated seats55
Heated steering wheel56
Heating and
ventilation106, 109
Heating while stopped113
Heavy cargo128
Height adjustment
seats50
steering wheel56
Height of vehicle171
High beams21, 104
bulb replacement153t High Performance Synthetic
Oils143
High-mount brake lamp157
Holder for canned
beverages119
Hood139
release139t
Horn14
Hydraulic Braking Assistant,
refer to DBC20
Hydroplaning133, 135
I
Ice warning82
Identification, tires137
Ignition lock68
Immobilizer function96
activating code96
deactivating code96
selecting code96
Imprint4
Indicator and warning
lamps19
Inflation pressure26t
monitoring101
Inflation pressure,
tires26, 135
INSPECTION84
Instrument
cluster15, 16, 17

Everything from A to Z
183n
OverviewControlsMaintenanceRepairsDataIndex
Service Interval
Display84, 146
Shiftlock72, 75
Shoulder support51
Side airbags59
Side Impact Head Protection
System59
Side lamps
bulb replacement154t
Side turn signal indicators
bulb replacement155t
Sitting safely48
with airbags48
with safety belt48
Ski bag122
Ski bag in the sport
wagon124
Sliding/tilt sunroof46
manual operation47
with glass moonroof47
Snow chains138
Socket for attaching
electrical appliances120
Spare tire159t
Speaker119
Special characteristics of
winter tires138
Special oil143t
Speed96
Speed limit93
Speed, average88, 96
Speedometer15, 16, 17 sport wagon
cargo area125
compartments in the cargo
area126
cover in the cargo
area126
folding down the rear
backrest125
lashing eyes128
load-securing
devices128
opening the rear
window40
partition net125
rear window wiper, blade
replacement152t
releasing the tailgate after
an electrical
malfunction39
roll-up cover125
securing a load128
ski bag124
tail lamp assembly, bulb
replacement156t
Standing lamps104
Starting assistance164t
Starting problems69t
Starting the engine69
Steering wheel
heating56
lock68
memory setting54 Steering wheel with
multifunction buttons22
Steptronic75
Stopwatch91
for additional information
refer to the "Owner's
Manual for Onboard
Computer"
Storage compartments118
in the cargo area126
Summer tires137
Sun blinds114
Sunroof46
Switching off the engine70
Switch-on times for parked-
car ventilation92
Symbols8
T
Tachometer83
Tail lamps156
bulb replacement156t
Tailgate
manual operation39
manual release39
opening from the
inside40
opening from the
outside39
Technical
modifications9, 147
Telephone preparation119 Temperature display82, 88
Temperature gauge84
Temperature
layering108, 113
Tether strap62
Third brake lamp157
Through-loading
system121
Tilt alarm sensor42, 43
avoiding unintentional
alarms44
deactivate35
Tilt function, passenger-side
mirror55
Time
calling up90
changing90
of arrival, estimated95
Timer90
for additional information
refer to the "Owner's
Manual for Onboard
Computer"
Tire
change158t
damage135t
inflation pressure26, 135
pressure
monitoring101, 135
replacement136
tread135
Tire inflation pressure26

Everything from A to ZTire Pressure Monitor
(RDC)101
Tire Quality Grading137
Tools152t
Torque170
Tow fittings165t
Towing the vehicle165t
Track171
Traction control system,
refer to ASC+T/DSC
Transmission71, 72, 75
Transmitter key32
Transporting children
safely62
Tread depth, tires135
Trip odometer82
Trunk lid
refer to luggage
compartment lid38
Trunk, refer to luggage
compartment42
Turn signal indicator78
bulb replacement154t
Turning circle171 U
Uniform Tire Quality Grading
(UTQR)137
Universal Transmitter115
Use antifreeze,
radiator144t Used batteries,
disposal162t
Used oils, disposal143t
V
Vacuum cleaner, attach120
Valve caps161
Vehicle Memory67
Vent outlets108, 113
Ventilation106, 108, 113
draft-free108, 113
in the rear108
Viscosity ratings, oils143 W

Warm feet Ð cool
head108, 113
Warning and indicator
lamps19
Warning lamps19t
Warning messages85t
Warning triangle23
Warranty and Service Guide
Booklet (Canadian
models)146
Washer system78
Water on the roads133
Weights173
Wheel and tire
combinations137
Wheel change158t Wheelbase171
Width of vehicle171
Windshield wipers78
blade replacement152t
Winter tires138
Wiper blade
replacement152t
Wiper system78
Work in the engine
compartment139t
X
Xenon lamps154