2003 BMW 540I SEDAN Owners Manual

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Cargo loading Roof-mounted luggage rack
Always position and secure the
load correctly. If you do not, it can
endanger the passengers during
braking or evasive maneuvers.
Do not exceed the approved gross
vehicle weight or the permissible axle
loads (refer to page 173). If you do, the
operating safety of the vehicle is no
longer ensured and you are in violation
of the law.
Do not carry hard or heavy objects
unsecured in the passenger compart-
ment. If you do so, they may be pro-
jected through the air during braking
and evasive maneuvers, thus endan-
gering vehicle occupants.<
A special roof-rack system is available
as an optional extra for your BMW.
Please observe the precautions
included with the installation instruc-
tions.AnchoragesAccess to the anchorages:
To fold up the cover (arrow), please use
the tool provided with the roof-rack
system.Loading and driving notesRoof-mounted luggage racks raise the
center of gravity of the vehicle when
they are loaded. For this reason, they
exercise a major effect on the vehicle's
handling and steering response.394de757
You should therefore always remember
not to exceed the approved roof
weight, the approved gross vehicle
weight or the axle loads when loading
the rack. You will find the specifications
under "Technical data" on page 173.
Make sure that the load is not too bulky,
and attempt to distribute it evenly.
Always load the heaviest pieces first (on
the bottom). Ensure that adequate room
remains for the tilt sunroof to extend
upward and that no objects protrude
into the tailgate's travel range on the
sport wagon.
Always ensure that roof-mounted
loads are tightly secured, as loose
loads can shift or even fly off the roof,
posing a serious hazard for following
traffic.<
Drive smoothly and avoid sudden
acceleration and braking. Do not corner
at high speeds.

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Overview
Controls and features
Operation, maintenance
Owner service procedures
Index Technical data
Mainte-

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Break-in proceduresTo ensure that your vehicle provides
maximum economy throughout a long
service life, we request that you
observe the following suggestions.Engine and differentialUp to 1,200 miles (2,000 km):
Drive at varying engine speeds and
road speeds, but do not exceed
4,500 rpm and the following road
speeds during this initial period:
BMW 525i, 530i: 100 mph (160 km/h)
BMW 540i: 106 mph (170 km/h).
Comply with all official speed limits.
Refrain from using full throttle and avoid
pressing the accelerator beyond the
kickdown point.
Once you have driven 1,200 miles
(2,000 km), engine and vehicle speeds
can gradually be increased.
You should also comply with these
break-in procedures if the engine or dif-
ferential is replaced later in the course
of the vehicle service life.
TiresOwing to technical factors associated
with their manufacture, tires do not
achieve their full traction potential until
an initial break-in period has elapsed.
For this reason, you should drive with
extra care during the initial 200 miles
(300 km).
Comply with all official speed limits.
When the vehicle is operated on
wet or slushy roads, a wedge of
water may form between the tire and
the road surface. This phenomenon is
referred to as aquaplaning or hydro-
planing, and can lead to partial or com-
plete loss of traction, vehicle control
and braking effectiveness. Reduce your
speed on wet roads.<
Brake systemApprox. 300 miles (500 km) must
elapse before the brake pads and
rotors achieve the optimal pad-surface
and wear patterns required for trouble-
free operation and long service life later
on.
To break-in the separate parking brake
drums, apply the parking brake lightly
when coasting to a standstill (at a traffic
signal, for instance), provided that
traffic conditions allow you to do so.
To avoid corrosion, repeat this proce-
dure from time to time.
The brake lamps do not come on
when the parking brake is applied.
Vacuum for the brake system servo unit
on your BMW is available only when the
engine is running. When you move the
vehicle with the engine switched off Ð
when towing, for instance Ð substan-
tially higher levels of pedal force will be
required to brake the vehicle.< ClutchThe clutch will also begin to function
optimally after about 300 miles
(500 km). Engage the gears carefully
during the break-in period.

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Driving notes Antilock Brake System
Brakes:
Do not drive with your foot resting
on the brake pedal. Even light but con-
sistent pedal pressure can lead to high
temperatures, brake wear and possibly
even brake failure.
Hydroplaning:
When driving on wet or slushy roads,
reduce vehicle speed. If you do not, a
wedge of water may form between the
tires and the road surface. This phe-
nomenon is referred to as aquaplaning
or hydroplaning. It is characterized by a
partial or complete loss of contact
between the tires and the road surface.
The ultimate results are loss of steering
and braking control.
Driving through water:
When there is water on the roads, do
not drive in it if it is deeper than
1 ft (30 cm), and even then, only at
walking speed, otherwise the vehicle
can sustain damage to the engine, the
electrical systems and the transmission.
Rear parcel tray:
Do not place heavy or hard objects on
the rear parcel tray. These objects
could endanger vehicle occupants
during heavy brake applications or eva-
sive maneuvers.
Clothes hooks:
Hang items of clothing from the hooks
so that they will not obstruct the driver's
vision. Do not hang heavy objects on
the hooks. If you do so, they could
cause personal injury during braking or
evasive maneuvers.<
The conceptThe Antilock Brake System (ABS) keeps
the wheels from locking during braking,
thereby enhancing active driving safety.
With ABS, the shortest possible braking
distances are achieved under most
conditions (on straight-aways and in
curves, on asphalt, ice, wet road sur-
faces, etc.).Braking with ABSIf you are in a situation that requires full
braking, you will exploit the full benefits
of the ABS system if you apply max-
imum pedal pressure ("panic stop").
Pulsation at the brake pedal combined
with sounds from the hydraulic circuits
indicates to the driver that ABS is in its
active mode.

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Brake systemBrake fluid level If the brake fluid level is too low and
brake pedal travel has become notice-
ably longer, there may be a defect in
one of the two brake system's hydraulic
circuits.
Proceed to the nearest BMW
center. Higher brake application
pressure may be necessary under these
conditions, and the vehicle may exhibit
a slight tendency to pull to one side
when the brakes are applied. Braking
distances may also be longer. Please
remember to adapt your driving style
accordingly.<
Disc brakesLimited vehicle use, extended periods
with the vehicle parked or in storage,
and operating conditions in which
braking is restricted to gentle, low-
pressure applications will all increase
the tendency for corrosion to form on
the rotors; this is often accompanied by
a simultaneous accumulation of con-
tamination on the brake pads. The pads
must exert a certain minimal level of
pressure against the rotors for the disc
brakes' inherent self-cleaning effect to
remain effective; the pressure available
under the above conditions may not
provide adequate cleansing.
If the brake rotors are corroded, they
will tend to respond to braking with a
pulsating effect that even extended
brake applications will fail to cure.
When driving in heavy rain and on wet
roads it is a good idea to apply light
pressure to the brake pedal every few
miles. Monitor traffic conditions to
ensure that this maneuver does not
pose a hazard to you or to other road
users. The heat generated in this pro-
cess helps dry the pads and rotors to
ensure that your brake system will
respond with undiminished efficiency
when you need it.When descending steep hills and
extended grades, downshift to a gear
that will allow you to continue safely
with only a minimal amount of braking.
By minimizing the loads placed on the
brake system, this strategy helps
ensure that optimal brake system
response will remain available at all
times.
Do not coast with the clutch
depressed or with the transmission
or selector lever in Neutral. Do not coast
with the engine switched off. The engine
provides no braking effect when the
clutch is depressed and there is no
power-assist for braking or steering
when the engine is not running.
Never allow floor mats, carpets or any
other objects to protrude into the area
around the accelerator, clutch and brake
pedals and obstruct their movement.<
Brake pads
For your own safety: use only
brake pads that BMW has
approved for your particular vehicle
model. BMW cannot evaluate non-
approved brake pads to determine if
they are suited for use, and therefore
cannot ensure the operating safety of
the vehicle if they are installed.<

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Information for your safetyThe factory-approved radial tires are
matched to the vehicle and have been
selected to provide optimum safety and
driving comfort.
It is not merely the tire's service life, but
also driving comfort and Ð above all else
Ð driving safety which depend on the
condition of the tires and the mainte-
nance of the specified tire inflation
pressure.
Incorrect inflation pressures are a
frequent cause of tire problems
and flat tires. Tire pressure also has a
major effect on your BMW's handling
response. We recommend that you
check the tire pressure Ð remember to
check the spare tire as well Ð before
every extended trip, as well as at least
every two weeks in normal use (refer to
page 26). Failure to observe these pre-
cautions can result in incorrect tire
pressures, which cause instable han-
dling response as well as tire damage,
and can ultimately lead to an acci-
dent.<
Tire tread Ð Tire damageInspect your tires frequently for tread
wear, signs of damage and for foreign
objects lodged in the tread. Check the
tread depth.
The tread depth should not drop
below 0.12 in (3 mm), even though, for
example the legally specified minimum
tread depth in Europe is only 0.063 in
(1.6 mm). Below a tread depth of
0.12 in (3 mm) there is an increased risk
of hydroplaning, even at relatively mod-
erate speeds and with only small
amounts of water on the road.
Tread wear indicators, refer to arrow,
are embedded around the tire circum-
ference in the base of the tire tread.
Their locations are indicated on the tire
sidewall with TWI Ð Tread Wear Indi-
cator. At a tread depth of 0.063 in 390de331
(1.6 mm) these indicators, signal that
the tires have reached the legally per-
missible wear limit.
Do not drive on a deflated (flat)
tire. A flat tire greatly impairs
steering and braking response, and can
lead to complete loss of control over
the vehicle.
Avoid overloading the vehicle so that
the permitted load on the tires is not
exceeded. Overloading leads to over-
heating and causes damage inside the
tires. The ultimate result can assume
the form of a sudden air loss.
Unusual vibrations encountered during
normal vehicle operation can indicate a
flat tire or some other vehicle malfunc-
tion. The type of problem can be
caused by contact with curbs, etc. This
is also true for irregularities in the
vehicle's handling characteristics, such
as a pronounced tendency to pull to the
left or right. Should this occur, respond
by immediately reducing your speed.
Proceed carefully to the nearest BMW
center or professional tire center, or
have the vehicle towed in to have it, its
wheels and tires inspected.
Tire damage (up to and including blow-
outs) can endanger the lives of both the
vehicle occupants and other road
users.<
Tire inflation pressure Tire condition

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Tire replacementTo maintain good handling and vehicle
response, use only tires of a single
tread configuration from a single manu-
facturer. BMW tests wheel and tire
combinations and approves them.DOT Quality GradesTreadwear
Traction AA A B C
Temperature A B C
All passenger car tires must con-
form to Federal Safety Require-
ments in addition to these grades. rating based on the wear rate of the tire
when tested under controlled condi-
tions on a specified government test
course.
For example, a tire graded 150 would
wear one and one-half (1 1/2) times as
well on the government course as a tire
graded 100. The relative performance
of tires depends upon the actual condi-
tions of their use, however, and may
depart significantly from the norm due
to variations in driving habits, service
practices and differences in road char-
acteristics and climate.
TractionThe 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 speci-
fied government 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 braking traction tests, and does
not include acceleration, cornering,
hydroplaning, or peak traction charac-
teristics.<
TemperatureThe 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 controlled condi-
tions on a specified indoor laboratory
test wheel.
Sustained high temperature can cause
the material of the tire to degenerate
and reduce tire life, and excessive tem-
perature 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 Car Safety Standard No. 109.
Grades B and A represent 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 loading, either separately or
in combination, can cause heat buildup
and possible tire failure.<