amp BMW 645CI COUPE 2004 E63 Workshop Manual

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Warning lamp* lights up.
Fuel filler cap is not properly closed
or is missing. Check whether the
fuel filler cap is properly closed.
Fuel specifications
The engine uses lead-free gasoline only.
Required fuel
Premium Unleaded Gasoline,
Minimum Octane Rating: 91.
Minimum Octane Rating corresponds to
the Anti Knock Index AKI and is deter-
mined according to the so-called (R+M)/
2 method.
Do not use leaded gasoline, as other-
wise the lambda probe and catalytic
converter will be permanently damaged.<
Use high-quality brands
Field experience has indicated significant
differences in fuel quality: volatility, compo-
sition, additives, etc., among gasolines
offered for sale in the United States and
Canada. Fuels containing up to and includ-
ing 10 % ethanol or other oxygenates with
up to 2.8 % oxygen by weight, that is,
15 % MTBE or 3 % methanol plus an equiv-
alent amount of co-solvent, will not void
the applicable warranties with respect to
defects in materials or workmanship.
The use of poor-quality fuels may
result in drivability, starting and stall-
ing problems, especially under certain
environmental conditions such as high
ambient temperature and high altitude.
Should you encounter drivability problems
which you suspect could be related to the
fuel you are using, we recommend that you
respond by switching to a recognized high-
quality brand.
Failure to comply with these recommenda-
tions may also result in unscheduled main-
tenance.<

Wheels and tires
166
Tire identification marks
Knowledge of the labeling on the side of
the tire makes it easier to identify and
choose the right tires.
Tire size
Speed letter
T = up to 118 mph/190 km/h
H = up to 131 mph/210 km/h
V = up to 150 mph/240 km/h
W = up to 167 mph/270 km/h
Y = up to 186 mph/300 km/h
Tire Identification Number
Tires with DOT codes meet the guidelines
of the U.S. Department of Transport.
DOT code:
Tire age
The tire's date of manufacture is indicated
on the sidewall:
DOT ... 1204 indicates that a tire was man-
ufactured in week 12 of the year 2004.
BMW recommends for various reasons,
including beginning brittleness, replacing
all tires after 6 years at the latest, even if a
tire age of 10 years is possible.
Uniform Tire Quality Grading
Quality grades can be found where appli-
cable on the tire sidewall between tread
shoulder and maximum section width.
For example:
Treadwear 200 Traction AA
Temperature A
DOT Quality Grades
Treadwear
Traction AA A B C
Temperature A B C
All passenger car tires must conform
to Federal Safety Requirements in
addition to these grades.<
Treadwear
The treadwear grade is a comparative rat-
ing based on the wear rate of the tire when
tested under controlled conditions on a
specified government test course.
For example, a tire graded 150 would wear
one and one-half, 1g, times as well on the
government course as a tire graded 100.
The relative performance of tires depends
upon the actual conditions of their use,
however, and may depart significantly from
the norm due to variations in driving habits,
service practices and differences in road
characteristics and climate.
Traction
The 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 specified govern-
ment 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 brak-
ing traction tests, and does not include
acceleration, cornering, hydroplaning, or
peak traction characteristics.< e.g.
Nominal width
in mm
Aspect ratio in X
Radial type
Rim diameter in inches
Load rating
not on ZR tires
Speed rating
before R on ZR tires
205/60 R1591W
e.g.
Manufacturer code
for tire make
Tire size and tire design
Tire ageDOT xxxx xxx 1204

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Temperature
The 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 con-
trolled conditions on a specified indoor lab-
oratory test wheel.
Sustained high temperature can cause the
material of the tire to degenerate and
reduce tire life, and excessive temperature
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 Vehicle Safety
Standard No. 109. Grades B and A repre-
sent 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 load-
ing, either separately or in combination,
can cause heat buildup and possible tire
failure.<
RSC – run-flat tires
You will recognize run-flat tires by a circular
symbol containing the letters RSC on the
side of the tire, refer to page 168.
M+S
Winter and all-season tires.
These have better winter properties than
summer tires.
Tire condition
Before driving off, inspect your tires for
tread wear, signs of damage and foreign
objects lodged in the tread, and check the
tread depth.
Minimum tread depth
The tread depth should not drop below
0.12 in/3 mm, although, for example, Euro-
pean legislation only specifies a minimum
tread depth of 0.063 in/1.6 mm. At tread
depths below 0.12 in/3 mm there is an increased risk of high-speed hydroplaning,
even when only small amounts of water are
present on the road surface.
As winter tires display a noticeable loss in
their ability to cope with cold-weather driv-
ing conditions once the tread wears to
below 0.157 in/4 mm, to ensure continued
safety you should always have such tires
replaced.
Wear indicators at the tread-groove base,
refer to arrow, are distributed over the tire's
circumference and are marked on the side
of the tire with TWI – Tread Wear Indicator.
These indicators signal at a tread depth of
0.063 in/1.6 mm that the legal wear limit
has been reached. The tread is then no
longer visible at these points.
Tire damage
Due to low-profile tires, please note
that wheels, tires and suspension
parts are more susceptible to road hazard
and consequential damages.
Unusual vibrations encountered during
normal vehicle operation can indicate tire
failure or some other vehicle defect. This
can, for example, be caused by driving over
curbs. These kinds of problems may also
be signaled by other changes in vehicle
response, such as a strong tendency to pull
to the left or right.
In these cases, immediately reduce speed.
Drive cautiously to the nearest BMW center
or tire dealer or, if necessary, have the
vehicle towed there.
Tire damage, extending to sudden and
complete loss of pressure in extreme
cases, can pose a potentially lethal safety
hazard for the vehicle's occupants and
other road users alike.<

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Engine compartment
1Filler neck for engine oil, refer to
Topping up engine oil
2Brake fluid reservoir, located beneath
the microfilter cover, refer to page 173
3Dipstick for engine oil, refer to
Checking oil level
4Starting-aid terminal, refer to page 184
5Washer fluid reservoir of the headlamp
and windshield cleaning systems, refer
to page 62
6Expansion tank for coolant, refer to
page 172
Engine oil
Checking oil level
1.Park the vehicle on a level surface with
the engine at operating temperature
2.After approx. 5 minutes, pull the
dipstick 3 out and wipe it off with a
clean lint-free cloth, paper towel, or
similar material3.Carefully push the dipstick all the way
into the guide tube and pull it out again
4.The oil should extend to between the
two marks on the dipstick.
The engine oil consumption is dependent
on driving style and driving conditions.
The oil quantity between the centers of the
two marks on the dipstick, refer to arrows,
is approx. 1.6 US quarts/1.5 liters. Do not
fill beyond the upper mark on the dipstick.
Excess oil can damage the engine.

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3.The coolant level is correct when the
measuring range of the fill level indica-
tor is at the level of the upper edge of
the filler neck, also refer to the drawing
next to the filler neck
4.If the coolant is low, slowly add coolant
up to the specified level – do not overfill
5.Turn the cap until you hear a click
6.Have the reason for the coolant loss
eliminated as soon as possible.
Brake system
Malfunction
Brake fluid
The warning lamp lights up in red
in spite of the handbrake being
released; a message appears on
the Control Display.
Stop the vehicle immediately.
The brake fluid in the reservoir has fallen to
below the minimum level. At the same time,
a significantly longer brake pedal path is
noticeable. Have the system checked
immediately by a BMW center.
Warning lamp for Canadian models.
When you continue driving, an
increased brake pedal path can be
necessary, and significantly longer braking
distances might be required. Please adapt
your driving style accordingly.<
Brake pads
The warning lamp lights up in red
in spite of the handbrake being
released; a message appears on
the Control Display. The brake pads have
reached their minimum pad thickness.
Have the brake pads replaced as soon as
possible.
Warning lamp for Canadian models.For your own safety: use only brake
pads that BMW has approved for your
particular vehicle model. As BMW cannot
assess the suitability of other brake pads
for use on your vehicle, BMW is unable to
assume continued responsibility for the
vehicle's operating safety if non-approved
pads are installed.<

Rules and regulations
176
Rules and regulations
California laws
Proposition 65 Warning
California laws require us to issue the fol-
lowing warning:
Engine exhaust and a wide variety of
automobile components and parts,
including components found in the interior
furnishings in a vehicle, contain or emit
chemicals known to the State of California
to cause cancer and birth defects and
reproductive harm. In addition, certain flu-
ids contained in vehicles and certain prod-
ucts 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 acces-
sories contain lead and lead compounds.
Wash your hands after handling.
Used engine oil contains chemicals that
have caused cancer in laboratory animals.
Always protect your skin by washing thor-
oughly with soap and water.<
Event Data Recorders
Your vehicle may be equipped with one or
more sensing and diagnostic modules or a
recording device capable of recording or
transmitting certain vehicle data or infor-
mation. In addition, if you have a Subscrip-
tion Service Agreement for the BMW Assist
system, certain vehicle information may be
transmitted or recorded in order to provide
such services.
OBD connector
The Onboard Diagnostic OBD interface
socket is located on the left of the driver's
side under the instrument 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 emission
control system for the vehicle's lifetime.
The system monitors emission-related
components and systems for deterioration
and malfunction.
An illuminated indicator 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.
Display of the previously described
malfunction on Canadian models.
Under certain conditions, the indicator
lamp 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
emissions control components, especially
the catalytic converter.

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When the fuel filler cap is not properly
tightened, the OBD system can
detect the vapor leak and the indicator
lamp will light up. If the filler cap is subse-
quently tightened, the indicator lamp
should go out within a few days.<

Replacing components
178
Replacing components
Onboard tool kit
The onboard tool kit 1, the screw-in tow
fitting 2 and spare fuses and a pair of plas-
tic tweezers 3 are stored in the luggage
compartment. Fold up the cover located
under the floor mat.
Windshield wiper blades
To replace, fold the wiper arm up and hold.
Press the locking lugs together while push-
ing the wiper blade out of the detent toward
the front.
Lamps and bulbs
Lamps and bulbs make an essential contri-
bution to vehicle safety. Therefore, comply
fully with the following instructions during
bulb replacement. If you are not familiar
with the specified procedures, have the
replacements carried out at your BMW
center.Never touch the glass on new bulbs
with your bare fingers, as even minute
amounts of contamination will burn into the
bulb's surface and reduce its service life.
Use a clean cloth, napkin etc., or hold the
bulb by its metal socket.<
You can obtain a selection of replacement
bulbs at your BMW center.
When working on the lighting system
you should always switch off the
lights affected to prevent short circuits.
To avoid possible injury or equipment dam-
age when changing bulbs, observe any
instructions provided by the bulb manufac-
turer.<
When performing maintenance on the
headlamps, comply with the instructions in
the separate Caring for your vehicle bro-
chure.
In the case of bulbs where the
replacement is not described, please
consult your BMW center.<
Xenon lamps
The service life of these lamps is very long
and the probability of a failure is very low,
provided that they are not switched on and
off an unusual number of times. In the
unlikely event that one of these lamps
should fail, you can continue driving under
poor visibility conditions by switching on
your fog lamps and proceeding carefully,
where allowed by law.
To avoid the risk of potentially fatal
injuries: owing to the extremely high
voltages at which these units operate, ser-
vice work on the xenon lighting system
should only be carried out by a BMW cen-
ter.<

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High beams, parking lamps
The illustration shows the front left side of
the engine compartment.
High beams
Bulb 55 watts, H 7
1.Remove the cover cap 1 by pressing
the tab and removing the cover cap
upward
2.Press the bulb holder from above to
release it
3.Remove the bulb holder
4.Remove and replace the bulb.
Parking lamps
Bulb 10 watts
Bulb holder and reflector are one unit
and are replaced together.<
1.Turn the bulb holder 2 to the right and
remove
2.Press the detent on the plug connector,
pull off the bulb holder and replace.
Front turn signal, sidemarker
Your BMW is equipped with two turn signal
lamps per side in the front. Turn signal
lamp 1 can be replaced via the engine
compartment, and turn signal lamp 2 via
the wheel well.
Turn signal lamp 1
Bulb 21 watts, WY 21 SV
The illustration shows the front right side of
the engine compartment.
1.The lever shown:
>Right turn signal: press downwards
>Left turn signal: press upwards
2.Remove the bulb holder towards the
rear
3.Remove and replace the bulb.
Turn signal lamp 2
Bulb 21 watts, WY 21 SV
The bulb of the turn signal lamp 2 can be
replaced via a cover at the front of the
wheel well.
The illustration shows the left side of the
vehicle.
1.Turn the steering all the way to lock to
obtain access to the cover, refer to
illustration
2.Remove the cover by unscrewing the
two bolts with an open-end wrench
from the onboard tool kit
3.Location of the bulb holder of turn sig-
nal lamp 2, refer to arrow

Replacing components
180 4.Turn the bulb holder to the left and pull
out
5.Remove and replace the bulb.
Sidemarker
Bulb 5 watts, WY5W ST
The bulb can be replaced via a cover at the
front of the wheel well, refer to the descrip-
tion for turn signal lamp 2.
1.The bulb holder of the sidemarker lamp
is located toward the outside of the
vehicle next to the bulb holder of turn
signal lamp 2
2.Turn the bulb holder to the left and pull
out
3.Remove and replace the bulb.
Side turn signals
Bulb 5 watts, WY 5 W
1.Press against the front edge of the lamp
with the tip of your finger, then push it to
the rear, release the detent at the front
and take it off the trim strip
2.Turn the bulb holder 905 to the left and
remove
3.Remove and replace the bulb.
Tail lamps
The roadside parking, rear and brake
lamps are LEDs. The backup lamps
are fitted with longlife bulbs. Please con-
tact a BMW center in case of a malfunc-
tion.<1Turn signal
2Roadside parking, rear and brake lamp
3Backup lamp
4Reflector
Rear turn signals
Bulb 21 watts, PY 21 W
The illustration shows the recess on the left
side of the luggage compartment.
1.Remove the cover
2.Unclip the bulb holder and remove
3.Apply gentle pressure to the bulb while
turning it to the left for removal and
replacement.
License plate lamps
Bulb 5 watts, WY 5 W