2003 BMW 540I SEDAN maintenance

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OverviewControlsMaintenanceRepairsDataIndex
Overview
Controls and features
Operation, maintenance
Owner service procedures
Index Technical data
Repairs

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OverviewControlsMaintenanceRepairsDataIndex
Lamps and bulbsThe lamps and bulbs are essential fac-
tors contributing to the safety of your
vehicle. For this reason, you should
follow the instructions 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 elec-
trical system, switch off the elec-
trical 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,
comply with any instructions provided
by the bulb manufacturer.<
The right side of the engine compart-
ment.
1 Low beams
2 High beams
For checking and adjusting head-
lamp aim, please contact your
BMW center.< Low and high beamsH7 bulb, 55 watt
The bulb is pressurized. There-
fore, you should always wear
safety glasses and protective gloves.
Failure to observe these precautions
can result in physical injury if the bulb
breaks.< 390de767
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 Ð never
use a scraper.<

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OverviewControlsMaintenanceRepairsDataIndex
Lamps and bulbsSide turn signal indicators5 watt bulb
1. Use finger pressure against the rear
end of the lens (arrow) to press it for-
ward for removal
2. Press gently on the bulb and turn it to
the left to remove it.390de768
Front fog lampsH8 bulb, 35 watt
The bulb is pressurized. There-
fore, wear safety glasses and pro-
tective gloves. Failure to observe these
precautions can result in physical injury
if the bulb breaks.<
1. Using a screwdriver, remove the
mounting clips for the air grill (arrow)
and remove the grill by bringing it
toward the front390de671
2. Loosen both screws (arrows)
3. Take off the cover panel next to the
headlamp
4. Turn the headlamp 903 to the left and
remove it by bringing it toward the
front
5. Disconnect the plug
6. Turn the lamp to the left and remove
it.390de672

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OverviewControlsMaintenanceRepairsDataIndex
Lamps and bulbsLamps in the rear apron panel:
1. Open the cover in the side panel
2. Turn the quick-release fastener and
remove the trim panel in front of the
bulb holder
3. Open the quick-release fastener
(arrow) and remove the bulb holder
4. Apply gentle pressure to the bulb
while turning it to the left to remove.
If a subwoofer
* is installed behind the
right-hand panel, unscrew the T-screw
and swing the subwoofer to the side.
392de770
Lamps in the luggage compartment lid/
tailgate:
1. Open the trim panel in the luggage
compartment lid/tailgate
2. Open the quick-release fastener
(arrow) and remove the bulb holder
3. Apply gentle pressure to the bulb
while turning it to the left to remove.392de771
Center (high-mount) brake lamp21 watt bulb
1. Open the luggage compartment lid
2. Unclip the cover panel (on the
underside of the rear tray) with
a screwdriver (arrow)
3. Turn the bulb to the left and remove
4. Apply gentle pressure to the bulb
while turning it to the left to remove.
sport wagon: LED strip in the tailgate.
Please contact a BMW center in case of
a malfunction.394de123

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OverviewControlsMaintenanceRepairsDataIndex
Changing a wheelWhat you will needIn order to avoid rattling noises later,
note the position of the tools when you
remove them and return them to their
original positions when you are through
using them.
>Car jack
sedan: fold back the luggage com-
partment floor mat for access, then
unscrew the wingnut to release the
jack (arrow).
sport wagon: raise the floor panel
and spare tire cover (refer to
page 127).
When you have completed work,
screw the jack all the way back
down. Fold the handle back and
insert it in its holder394de090
>Wedge (wheel chock)
Located next to the jack. Loosen the
wingnut to remove it
>Spare tire and adapter
* for removing
the lug bolt cover
* (refer to the next
page)
Both are next to the jack. Remove the
adapter or the plastic cover. Unscrew
the wingnut (arrow) by hand and
remove the wheel
>Lug wrench and screwdriver
In the onboard tool kit under the lug-
gage compartment lid (refer to
page 152).
sport wagon: the lug wrench is next
to the spare tire.
394de091
Procedure1. Carefully read and comply with the
safety precautions on the previous
page
2. Secure the vehicle to prevent it
from rolling:
Place the wedge against the rear
surface of the front tire on the side
opposite the side being raised. If
the vehicle is parked on a down-
ward slope, place the wedge
securely in front of the tire. If the
wheel must be changed on a sur-
face with a more severe slope, take
additional precautions to secure the
vehicle from rolling
3. Wheels with full wheel covers
*:
Reach into the ventilation openings
and pull the cover off

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OverviewControlsMaintenanceRepairsDataIndex
Changing a wheel16. Wheels with hub covers:
Position the hub cover and press it
on tightly
17. If equipped with lug bolt covers:
Align the arrow on the cover with
the line in the wheel and press the
cover into place
18. Check and correct the tire inflation
pressure at the earliest opportunity.
For vehicles with Tire Pressure
Monitor (RDC)
*:
After mounting the spare tire or cor-
recting the inflation pressure, reac-
tivate the system. Refer to
page 101.
The vehicle jack is designed for
changing wheels only. Do not
attempt to raise another vehicle model
with it or to raise any load of any kind.
To do so could cause accidents and
personal injury.
To ensure continued safety, have the
lug bolts checked with a calibrated
torque wrench [torque specification
72 lb-ft (100 Nm)] at the earliest
opportunity.<
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.
Protect valve inserts against dirt using
screw-on valve stem caps. Dirty valve
stems frequently lead to slow pressure
loss.
Size 255/40 R17 94 W
* tires on
the rear axle:
In the event of a flat tire, it may be nec-
essary to mount the spare tire of dif-
ferent size at the rear. This tire is suit-
able for use in all load and speed
ranges. Nevertheless, you should
remount a tire of the correct size as
soon as possible.<

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Battery Fuses
Battery posts, terminals and other
components contain lead and lead
compounds. Wash hands after han-
dling.<
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 ter-
minal locations, refer to "Jump-starting"
on page 164).
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

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OverviewControlsMaintenanceRepairsDataIndex
FusesIn the luggage compartmentUse the handle to pull down the trim on
the right wall.394de678
In the cargo area Ð sport wagonOpen the right access door by pressing
the button and pull the trim panel to the
side.
If a subwoofer
* is installed, loosen the
T-screw and swing the subwoofer to
the side.
Do not attempt to repair a burned
fuse or replace it with a fuse
having a different color or ampere
rating. To do this could cause a fire in
the vehicle resulting from a circuit over-
load.<
392de172