2002 BMW 525I SPORT WAGON jump start

Contents

Operation, maintenance
Owner service procedures
Technical data

Under the hood:

Hood137
Engine compartment
essentials138
Washer fluids139
Engine oil140
Coolant142
Brake fluid143

Maintenance:

The BMW Maintenance
System144

Laws and regulations:

Technical modifications145
California Proposition
65 Warning145
OBD interface socket146

Replacement procedures:

Onboard tool kit150
Windshield wiper blades150
Lamps and bulbs151
Changing a wheel156
Battery160
Fuses160

Assistance, giving and
receiving:

Jump-starting162
Towing the vehicle163Engine specifications168
Dimensions169
Weights171
Capacities173

67n
OverviewControlsMaintenanceRepairsDataIndex
Starting the engineStarting the engineDo not press the accelerator pedal
while starting the engine.
While it is important not to release
the key prematurely, you should
also avoid allowing the starter to
operate continuously for more than
20 seconds at a time. Release the igni-
tion key immediately as soon as the
engine starts.
BMW 540i with automatic transmission:
Your BMW is equipped with the conve-
nience starting feature. Simply turn the
key to position 3 (starter) and then
release it immediately.
The starter continues to operate auto-
matically and will be deactivated as
soon as the engine starts.
The automatic starting mode will not
operate if the battery voltage is low.
The engine can be jump-started using
an external power source (refer to
page 162).<
Do not allow the engine to warm up
by leaving it running while the vehicle
remains stationary. Instead, begin to
drive immediately at a moderate engine
speed.
Should the engine fail to start on the
first attempt (if it is very hot or cold, for
instance):
>Press the accelerator pedal halfway
down while engaging the starter.
Cold starts at extremely low tempera-
tures of roughly +5 7 (Ð15 6) or below
and at altitudes of over 3,300 ft
(1,000 m):
>Allow the starter to turn somewhat
longer (approximately 10 seconds)
during your initial starting attempt.
Engine idle speed is controlled by the
engine-management system. Higher
idle speeds at startup are normal and
should decrease as the engine warms
up. If engine speed does not decrease,
service is required.
To prevent the battery from discharging,
always deactivate electrical devices
that are not in use. Switch the ignition
off when the vehicle is not being driven.Extended starting attempts, char-
acterized by excessively frequent
or long periods with the starter
engaged, can lead to catalyst
damage.<
When driving, standing at idle,
and parking the vehicle, take care
to avoid contact between the exhaust
system and flammable materials (grass,
hay, leaves, etc.). Such contact could
lead to a fire, resulting in serious
personal injury and property damage.<

72n
Automatic transmission
*
Electronic transmission control
module
If the indicator lamp comes on
and/or if the message "TRANS.
FAILSAFE PROG" appears in
the Check Control
* display panel, this
indicates a malfunction in the transmis-
sion control system.
Bring the vehicle to a stop, select the
"Park" position, apply the parking brake
and shut the engine off (ignition key
position 0). Restart the engine after a
few seconds. If the indicator lamp goes
out again after a few seconds, the
normal transmission functions have
been restored. You may continue to
drive as usual.
If the indicator lamp does not go out,
you can move the selector lever to all
positions. However, the vehicle will now
only drive forward with limited gear
selection.
You should respond by avoiding
extreme engine loads and referring the
problem to the nearest BMW center.
Never perform work in the engine
compartment without first
ensuring that the transmission is in
"Park" or "Neutral" as the vehicle could
otherwise start to move off on its own.<
For jump-starting, towing and tow-
starting, refer to pages 162 and 163.

75n
OverviewControlsMaintenanceRepairsDataIndex
Automatic transmission with Steptronic
*
ATC executes upshifts and downshifts
only when the new gear will provide a
suitable combination of vehicle and
engine speed, i.e., ATC will not execute
downshifts that would cause the engine
to overrev. The gear selected will
appear briefly in the instrument cluster
followed by the current gear.
If you are driving in the manual
mode and wish to accelerate
rapidly from low road speeds (when
passing, for instance), you must shift
down manually or with the "kickdown"
function.<
You can only change from "S/M" to
selector lever positions "P," "R," and
"N" via the "D" position.
Electronic transmission control
module
If the indicator lamp comes on
or the message "TRANS. FAIL-
SAFE PROG" appears in the
Check Control
*, there is a fault in the
transmission system.
Bring the vehicle to a stop. Move the
transmission selector lever to "P."
Engage the parking brake and turn the
engine off (ignition key to position 0).
Wait a few seconds, then start the
engine.
If the indicator lamp goes out after a
few seconds, normal transmission
performance has been restored. You
may continue to drive as usual. If the
indicator lamp does not go out, you can
place the selector lever in all positions.
However, the vehicle will now only drive
forward with limited gear selection.
If this happens, avoid extreme engine
loads and refer the problem to the
nearest BMW center.
Never perform work in the engine
compartment without first
ensuring that the transmission is in
"Park" or "Neutral" as the vehicle could
otherwise start to move off on its own.<
For jump-starting, towing and tow-
starting, refer to pages 162 and 163.

138n
1 Reservoir for brake fluid (under the
housing of the microfilter)143
2 Auxiliary terminal for
jump-starting1623 Engine oil dipstick140
4 Engine oil filler neck140
5 Coolant expansion tank1426 Reservoir for intensive-cleaning
system
*
139
7 Reservoir for windshield and
headlamp washer system
*
139
Engine compartment essentials
390de791

160n
Battery Fuses
Battery posts, terminals and other
components contain lead and lead
compounds. Wash hands after
handling.<
Battery careThe battery is maintenance-free, that is,
the original electrolyte will normally last
for the service life of the battery under
moderate climatic conditions.
For all questions that regard the
battery, please consult your BMW
center. The battery is completely main-
tenance-free; the following section is
provided for your information only.<
Do not disconnect the battery
when the engine is running, as the
ensuing voltage surge would damage
the vehicle's onboard electronics.<
Charging the batteryWhen charging the battery in the
vehicle, leave the engine off at all times.
Connect the charge cables to the termi-
nals in the engine compartment (for
terminal locations, refer to "Jump-
starting" on page 162.
Return used batteries to a recy-
cling point or your BMW center.
Maintain the battery in an upright posi-
tion for transport and storage. Secure
the battery against tilting during trans-
port.<
In the glove compartmentOpen the glove compartment and turn
the two white quick-release fasteners
to the left.390de085

162n
Do not use spray starter fluids to start
the engine.
When your battery is discharged you
can used two jumper cables to start
your car with power from the battery 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
support vehicle is also rated at
12 volts. This information is
provided 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
circuit hazard
4. Start the engine on the support
vehicle and allow it to run
5. Use one jumper cable (+) to
connect the positive terminal of the
battery in the support vehicle with
the auxiliary positive terminal
provided in the engine compart-
ment 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
support vehicle's negative battery
terminal 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

163n
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
bottoms 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
possible 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