2001 BMW 540I SEDAN service

170n
The BMW Maintenance System has
been designed as a reliable means of
providing maximum driving and operat-
ing safety – and as cost-effectively as
possible for you.
Please keep in mind that regular main-
tenance is not only necessary for the
safety of your vehicle, but also plays a
significant role in maintaining the resale
value of the vehicle.
Service Interval Display
Advanced technology is employed to
calculate the optimal maintenance in-
tervals, which are then indicated in the
Service Interval Display. While conven-
tional systems rely on distance traveled
alone to determine when service is due,
the BMW Maintenance System has for
years considered the actual conditions
under which the vehicle operates, be-
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cause mileage can be accumulated in
very different ways.
From a maintenance standpoint,
62,000 miles (100,000 km) accumulated
in short-distance urban driving are not
the equivalent of the same distance
covered at moderate speeds in long-
distance highway travel.
The BMW Maintenance System
includes the Engine Oil Service and
Inspections I and II.
Determining the maintenance intervals
according to the actual loads on the
vehicle covers every kind of operating
situation. However, even those who
drive only short distances – significantly
less than 6,000 miles (10,000 km) annu-
ally – should have the engine oil
changed at least every 2 years since oil
deteriorates over time, regardless of
use.Service and Warranty Information
Booklet (US models) or Warranty
and Service Guide Booklet (Cana-
dian models)
Please refer to the Service and War-
ranty Information Booklet (US models)
or to the Warranty and Service Guide
Booklet (Canadian models) for addi-
tional information on maintenance inter-
vals and procedures.
As a precaution against rust, it might be
a good idea to have the body checked
for damage from rocks or gravel at the
same time, depending upon operating
conditions. Have your BMW center do the
maintenance and repair.
Your BMW center is always informed on
the latest maintenance work and repair
techniques and equipped with the re-
quired special tools. In addition, check-
ing parts known from experience to be
subject to wear is a permanent part of
the maintenance specifications.
Be sure that all maintenance work is
confirmed in the Service and Warranty
Information Booklet (US models) or in
the Warranty and Service Guide Book-
let (Canadian models).
These entries will constitute your proof
that the vehicle has received regular
maintenance. They are also required in
the event of a warranty claim. <
The BMW Maintenance System

Index
Data
Technology
Repairs
Car care
Controls
Overview
173nCaring for your car
Caring for the vehicle finish
Regular washing is a preventive mea-
sure against long-term effects from
substances that are harmful to the vehi-
cle's finish, especially if you drive your
vehicle in areas with high levels of air
pollution or aggressive natural sub-
stances (tree resins, pollen).
Nevertheless, you should immediately
remove especially aggressive sub-
stances. Failure to do so can lead to
changes in the paint's chemical struc-
ture or to discoloration. Gasoline spilled
during refueling, oil, grease and brake
fluid should always be cleaned away
immediately, as should bird droppings
(finish damage).
Any contamination remaining on the
surface of the vehicle will be especially
conspicuous after washing. Use clean-
ing fluid or alcohol with a clean cloth or
cotton pad to remove. Remove tar
spots with tar remover. After cleaning,
the affected areas should be waxed to
ensure continued protection.
Use cleaning and car-care
products that you can obtain
at your BMW center. <
Waxing your car
Protect the finish using carnauba or
synthetic-based waxes only.
The best way to determine when the
finish needs to be waxed is by noting
when water stops beading on the sur-
face.
You can use a glass cleaner to remove
any wax or silicone that may have been
left on the windows during waxing.
Use cleaning and car-care
products that you can obtain
at your BMW center. <
Paint damage
You can touch up small areas of dam-
age with BMW spray paint or a BMW
touch-up stick.
The paint color code for your vehicle is
provided on a sticker located on the
right hand side under the hood and on
the first page of your Service and War-
ranty Information Booklet.
Damage caused by flying stones,
scratches, etc., must be touched up
without delay to prevent rust from form-
ing.
If corrosion has started to form in an
area with paint damage, remove all rust
and clean the area. Then prime the area
with a BMW Primer Stick. Finally, apply
the finish coat. After a few days, polish
and protect the touched-in areas.
More extensive paint damage should
be repaired professionally in accor-
dance with the manufacturer's instruc-
tions. Your BMW center uses original
BMW finish materials in accordance
with approved repair procedures.

176nAirbags Vehicle storage
1 Front airbags on the driver and
passenger sides
2 Side impact Head Protection System on the driver and passenger sides
(front and rear
*)
3 Side airbags on the driver and passenger sides (front and rear
*)
Important safety notices
Do not attempt to remove the gas
generators of the airbag restraint
system from the vehicle. Have testing
and service procedures performed by
specially-qualified technicians only.
In the event of a malfunction, deactiva-
tion, or triggered actuation (as a
response to an accident) of the airbag
restraint system, consult your BMW
center for repairs or service operations.
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Modifications may not be made on
either the wiring or the individual
components in the airbag system.
These include the padded steering
wheel hub, the instrument cluster, the
side trim panels of the front or rear
doors and the roof pillars or the sides of
the headliner. Never apply adhesive
materials to these components or cover
or modify them in any way. Do not at-
tempt to remove or dismantle the steer-
ing wheel.
To ensure compliance with official
safety regulations, entrust disposal of
airbag generators to an BMW center.
Unprofessional attempts to service
the system could lead to failure in an
emergency or undesired airbag activa-
tion, either of which could result in
personal injury. < Consult your BMW center regarding
the required special procedures if you
intend to store the vehicle for longer
than three months.

178nOBD interface socket
The Onboard Diagnostic (OBD) socket
is located on the left of the driver's side
at the bottom of the instrument panel
and under a cover (arrow).
The cover has the letters "OBD" on it.
The purpose of the OBD system is to
ensure proper emission control system
operation for the vehicle's lifetime by
monitoring emission-related compo-
nents and systems for deterioration and
malfunction.
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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 se-
riously damage emission control com-
ponents, especially the catalytic con-
verter.
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
extinguish within a few days. <

Index
Data
Technology
Repairs
Car care
Controls
Overview
Overview
Controls and features Operation, care
and maintenance
Owner service procedures
Technical dataIndex
Advanced technology
181
n
Replacement procedures:
Onboard tool kit 182
Wiper blades 182
Lamps and bulbs 183
Changing a wheel 190
Battery 193
Fuses 196
In case of electrical
malfunction:
Fuel filler door 198
Sliding/Tilt sunroof 198
Tailgate 199
Assistance, giving and
receiving:
Jump-starting 200
Towing the vehicle 201

Index
Data
Technology
Repairs
Car care
Controls
Overview
183nLamps and bulbs
The lamps and bulbs make essential
contributions to the safety of your vehi-
cle. For this reason, follow the instruc-
tions below carefully when replacing a
bulb. If you are not familiar with any of
the procedures, consult your BMW
center.
Do not touch the glass portion of a
new bulb with your bare hands
since even small amounts of impurities
burn into the surface and reduce the
service life of the bulb. Use a clean
cloth, paper napkin, or a similar mate-
rial, or hold the bulb by its metallic
base. <
A replacement bulb set is available from
your BMW center.
Whenever working on the electri-
cal system, switch off the electri-
cal accessory you are working on or
disconnect the cable from the negative
terminal of the battery. Failure to do this
could result in short circuits.
To prevent injuries and damage, com-
ply with any instructions provided by
the bulb manufacturer. <
The illustration shows the right-hand
engine compartment.
For checking and adjusting head-
lamp aim, please contact your
BMW center. <
1 Low beams
2 High beams
H7 bulb, 55 watts
The H7 bulb is pressurized. There-
fore, wear safety glasses and pro-
tective gloves. Failure to comply with
this precaution could lead to injury if the
bulb is accidentally damaged during re-
placement. <
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1 Turn the bulb holder to the left (arrow)
and remove.
2 Remove and replace the bulb.
When cleaning the headlamps,
please observe the following:
> Do not wipe dry (scratches). Never
use abrasives or strong
solvents to clean the covers.
Remove dirt and contamination (such
as insects) by soaking with BMW Car
Shampoo and then rinsing with plenty
of water.
Always use a deicer spray to remove
accumulated ice and snow – never
use a scraper. <

Index
Data
Technology
Repairs
Car care
Controls
Overview
193nChanging a wheel Battery
When storing the wheel, take care to
ensure that you do not damage the
retaining pin in the spare tire recess.
If light-alloy wheels other than original
BMW light-alloy wheels have been
mounted, it may be necessary to use
different lug bolts for those wheels.
Replace the defective tire as soon as
possible and have the new wheel/tire
balanced.
Size 255/40 R17 94 W
* tires on
the rear axle:
In the event of a puncture or other tire
failure, it may be necessary to mount
the spare tire of different size at the
rear. This tire is of full capacity in all
load and speed ranges. Nevertheless,
mount a tire of the correct size as soon
as possible. <
Battery posts, terminals, and re-
lated accessories contain lead
and lead compounds. Wash hands after
handling. <
Installation location
The battery is located behind the right-
hand side trim panel in the luggage
compartment.
Fold the trim panel down with the
handle at the top. On the sport wagon,
press the button.
If a subwoofer
* is installed on the sport
wagon, loosen the T-screw and swing
the subwoofer to the side.
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Maintenance
The battery is absolutely maintenance-
free, that is, the original electrolyte will
normally last for the service life of the
battery under moderate climatic condi-
tions.
Symbols
You will find the following symbols on
your vehicle battery. To avoid injury,
please comply with the corresponding
precautions whenever you work with or
near the battery.
Please read the following infor-
mation before working with the
battery.
Wear eye protection. Do not al-
low particles containing battery
acid or lead to come into con-
tact with your eyes, your skin, or your
clothing.
Battery acid is extremely corro-
sive. Wear eye protection and
protective gloves. Do not tip the
battery. Battery acid can leak from the
ventilation openings.
Be sure that children keep well
away from batteries and battery
acid.

194nBattery
Never allow sparks or open
flame near the battery. Do not
smoke in the vicinity of the
battery. Avoid sparks from electrical
cables or electrical equipment. Turn the
key to position 0 in the steering lock
during the disconnection or connection
of the battery. Never short-circuit the
battery terminals. There is a danger of
injury from powerful sparks.
A highly-explosive gas is
generated when the battery is
charged.
If you happen to get acid in your
eyes, rinse thoroughly for
15 minutes with clear water.
Following that, consult a physician
immediately. If you get acid spray on
your skin or clothing, rinse with plenty
of water. If electrolyte is accidentally
swallowed, consult a physician immedi-
ately.
In order to protect the battery
case from ultraviolet radiation,
do not place it in direct sunlight.
A discharged battery can freeze. Store
the battery in areas where the tempera-
ture remains above freezing.
Charge condition
You can read the charge condition
of the battery with the "Magic Eye"
*
(a hydrometer):
> Green: adequate charge.
> Black: not charged adequately.
The battery must be recharged.
Please contact your BMW center.
> Yellow: replace the battery.
The projected service life of the
battery can only be reached if the
battery is fully-charged at all times.
Check the charge condition of the bat-
tery frequently if the vehicle is used pri-
marily for driving short distances. <
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Charging the battery
If the battery is charged in the vehicle:
Do not charge the battery with the
engine running.
Before performing any work on
the electrical system, disconnect
the cable from the negative terminal. If
you do not, short circuits can create the
risk of fire or personal injury. <
If you plan to store the vehicle for more
than four weeks, disconnect the battery
from the vehicle electrical system by
disconnecting the cable at the negative
terminal and then recharge using a suit-
able charging device.
If you intend to store your vehicle for
longer than 12 weeks: remove the bat-
tery, charge it and store it in a cool (but
frost and dust-free) room. Every three
months and before reinstalling the bat-
tery, have it recharged. If it is not
recharged, it will not be serviceable.
Every time the battery is discharged,
especially over extended periods, its
service life is reduced.