2004 BMW 525i Sedan Owners Manual

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Replacing components

Onboard tool kit

The onboard tool kit is located in the lug- gage compartment lid. Loosen the wingnut to open.

Windshield wiper blades

To replace, fold the wiper arm up and hold. Press the catches together while pushing the wiper blade out of the front.

Lamps and bulbs The lamps and bulbs are essential factors contributing to the safety of your vehicle. Therefore, comply fully with the following instructions during bulb replacement. If you are not familiar with the specified proce- dures, have the replacements carried out at your BMW center.

Never touch the glass of new bulbs with your bare fingers, as even minute amounts of contamination will burn into the

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bulb's surface and reduce its service life. Use a clean cloth, napkin, etc., or hold the bulb by its metal socket. In the case of bulbs where the replacement is not described, please consult your BMW center.< You can obtain a selection of replacement bulbs at your BMW center.

To prevent short circuits, before working on any electrical system,

equipment or accessory you should always switch it off and disconnect the cable from the battery's negative terminal before start- ing. To avoid possible injury or equipment dam- age when changing bulbs, observe any instructions provided by the bulb manufac- turer.<

When maintaining the headlamps, please comply with the instructions in

the separate Caring for your vehicle bro- chure.<

Headlamps The illustration shows the left-hand side of the engine compartment.

1 Cover cap for low beams 2 Cover cap for high beams Turn the cover cap to the left and remove. Always wear gloves and eye protec- tion – the atmosphere within the H7

bulb is pressurized. Failure to observe this precaution can lead to personal injury should the bulb be damaged.<

For checking and adjusting headlamp aim, please contact your BMW cen-

1. Turn the cover cap for low beams or

high beams to the left and remove

ter.<

Halogen low beams

H7 bulb, 55 Watts 1. Turn the bulb holder to the left and

remove

2. Remove and replace the bulb.

Halogen high beams

H7 bulb, 55 Watts 1. Turn the bulb holder to the left and

remove

2. Remove and replace the bulb.

Parking and standing lamps

2. Pull the bulb holder out 3. Remove and replace the bulb.

Xenon lamps* The service life of these bulbs 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 respond by switching on your fog lamps and proceed- ing 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 always be entrusted to qualified personnel.<

Parking and standing lamps Please contact a BMW center in case of a malfunction.

Turn signal indicators, front

Bulb 21 Watts, PY 21 W 1. Turn the bulb holder to the left and

remove

2. Apply gentle pressure to the bulb while

turning it to the left for removal and replacement.

Bulb 5 Watts, W 5 W

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Side-mounted turn signal indicators

Center brake lamp This lamp uses LED technology for opera- tion. Please contact a BMW center in case of a malfunction.

Lamps in the fender

Bulb 5 Watts, W 5 W 1. Press against the front edge of the lamp with the tip of your finger, then push it to the rear and release the detent at the front

2. Turn the lamp 903 and remove 3. Turn the bulb holder to the left and

remove

4. Extract the bulb for replacement.

Side marker lamps, front and rear Please contact your BMW center for replacement.

Tail lamps

1 Turn signal indicators 2 Tail and brake lamp 3 Tail lamp 4 Backup lamps 5 Reflector 6 Reflector 7 Standing, tail and brake lamp

> Backup lamps:

Bulb 16 Watts, W 16 W

> Other lamps:

Bulb 21 Watts, P 21 W

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The illustration shows the recess on the left side of the luggage compartment. All the bulbs are integrated in a central bulb holder. 1. Remove the side panel 2. Unclip the bulb holder and remove 3. Backup lamps:

Remove and replace the bulb. Other bulbs: Apply gentle pressure to the bulb while turning it to the left for removal and replacement.

Lamps in the luggage compartment lid

License plate lamp Bulb 5 Watts, C 5 W 1.

Insert a screwdriver in the slot and press to the left, refer to arrows; this unlocks the lamp

2. Remove the lamp and replace the bulb.

Changing a wheel

Safety measures in the event of a breakdown or wheel change:

Park the vehicle as far away as possible from moving traffic and on firm ground. Switch on the hazard warning flashers. Lock the steering wheel in straight-ahead setting of the wheels. Apply the handbrake and engage first gear, reverse gear or selector lever to position P. Have all vehicle occupants get out of the vehicle and ensure that they remain outside the immediate area in a safe place, such as behind a guardrail. If a warning triangle or portable hazard warning lamp is required, set it up on the roadside at an appropriate distance from the rear of the vehicle. Comply with all safety guidelines and regu- lations. Change the wheel only on a level, firm sur- face which is not slippery. The vehicle or the jack could slip to the side if you attempt to raise the vehicle on a soft or slippery surface such as snow, ice, tiles, etc. Position the jack on a firm support surface. Do not use a wooden block or similar object as a support base for the jack, as this would prevent it from extending to its full support height and reduce its load-car- rying capacity. To avoid serious or fatal injury: never lie under the vehicle, and never start the engine while it is supported by the jack.<

What you will need To avoid rattling noises later on, note the positions of the tools before removing them, then return them to their initial posi- tions after completing work.

1 Chock 2 Vehicle jack 3 Lug wrench are located in the tool space in the rim of the compact wheel. Raise the floor mat and the cover beneath it. Take out the required tool(s). After using the tools, return them to the storage space.

Compact wheel*

1. Unscrew the wing nut 1 2. Remove the disk 2 to the side 3. Take out the tool brackets 3 4. Remove the compact wheel.

Procedure 1. Read carefully and comply with the

safety precautions on left-hand column

2. To secure the vehicle against move-

ment: Place the wheel chock behind the front wheel on the side opposite the side being raised. If the vehicle is parked on a downward slope, place the chock in front of the wheel. If the wheel must be changed on a surface with a more severe slope, take additional precau- tions to secure the vehicle from rolling

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3. Loosen the lug bolts 1/2 a turn

4. Set up the jack beneath the jacking

point closest to the flat tire. Ensure that the entire surface of the jack's base is in firm contact with the ground and that the jack itself is standing completely vertical, not tilted, and that the fitting on the top of the jack will align with the rectangular recess on the vehicle when you raise it, refer to illustration

5. Jack the vehicle up until the wheel you are changing is raised from the ground 6. Unscrew the lug bolts and remove the

wheel

7. Remove accumulations of mud or dirt

from the mounting surfaces of the wheel and hub. Clean the lug bolts 8. Position the new wheel or compact

wheel. Secure the wheel by turning at least two lug bolts into opposite bolt holes

9. Screw in the remaining lug bolts.

Tighten all the bolts securely in a diag- onal pattern

10. Lower the jack and remove it from

beneath the vehicle

11. Tighten the lug bolts in a diagonal pat-

tern

12. Check and correct the tire inflation pressure at the earliest opportunity.

Protect valve stems and valve stem seal caps against dirt and contamina- tion. Dirt in valve stems is a frequent source of gradual air loss.< After mounting the wheel or correcting the inflation pressure, reinitialize the Flat Tire Monitor, refer to page 81.

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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 safety, always have the lug bolts checked with a calibrated torque wrench as soon as possible to ensure that they are tightened to the specified torque. The tightening torque is 120 Nm.< Reverse the removal sequence to store the wheel and tools in the vehicle. When you mount wheels other than Genu- ine BMW light-alloy wheels, different lug bolts may also be required. Always have damaged tires replaced and the wheel and tire assembly rebalanced at the earliest possible opportunity.

Driving with the compact wheel Drive reservedly and do not exceed a speed of 50 mph/80 km/h. The driving characteristics change, for example reduced track stability on braking, extended braking distance, and altered self-steering characteristics in the limit range. In conjunction with winter tires, these characteristics are more pro- nounced.

Only one compact wheel may be mounted. You should fit wheels and tires of the original size as quickly as possi- ble.<

Battery

Battery care The battery is 100% maintenance-free, i.e., the electrolyte will last for the life of the bat- tery when the vehicle is operated in a tem- perate climate.

For all questions that regard the bat- tery, please consult your BMW cen-

ter.<

In the luggage compartment

Raise the floor mat and the cover beneath it. Undo the screw connection of the right side panel and pull out the panel.

Charging the battery Only charge the battery in the vehicle via the terminals in the engine compartment with the engine off. Connections, refer to Jump-starting on page 192.

Disposal

Return used batteries to a recycling point or your BMW center. Maintain the battery in an upright position for trans- port and storage. Always restrain the bat- tery to prevent it from tipping over during transport.<

Fuses

Never attempt to repair a blown fuse, and do not replace a defective fuse

with a substitute of another color or amper- age rating, as this could lead to a circuit overload, ultimately resulting in a fire in the vehicle.< Spare fuses, plastic tweezers and details of the fuse assignment are located in the compartment for the onboard tool kit, refer to page 184.

In the glove compartment

Turn the two snap fasteners outwards. Fold the cover forwards or remove.

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Giving and receiving assistance

Activating BMW Assist, refer to page 161. If the navigation system fails, the cur- rent position of the vehicle is not

transmitted.< If the indicator lamp flashes, but you are unable to hear the emergency call center through the hands-free system, this could indicate, for instance, that the hands-free system is no longer operational. However, the emergency call center can still hear you.

For technical reasons, the emergency call cannot be guaranteed under

unfavorable conditions.< Under certain conditions, an emergency call is started automatically immediately after a severe accident. The automatic emergency call is not affected by the but- ton being pressed.

Starting an emergency call* Conditions for an emergency call: > The car phone is logged on to a porta-

ble phone network

> The emergency call system is operable. To start an emergency call:

1. To open the cover flap:

Briefly press the cover flap

2. Press the button for at least 2 seconds. The indicator lamp in the button lights up. As soon as the voice connection to the general emergency number has been set up, the indicator lamp flashes.

If conditions allow, remain in the vehicle until the connection has been established. You will then be able to provide a detailed description of the situation. In vehicles where BMW Assist is enabled, the phone system will automatically estab- lish contact with the BMW Assist emer- gency call center. If the current position of your vehicle can be determined, this is transferred to the BMW Assist emergency call center.

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Roadside Assistance The Roadside Assistance of the BMW Group offers you assistance in the event of a breakdown around the clock, also at weekends and on public holidays. The phone numbers of the Roadside Assis- tance control center in your home country can be found in the BMW Dealer Directory. In the case of vehicles with BMW Assist or TeleService, you can call the Roadside Assistance of the BMW Group directly via the Control Center, refer to page 162.

Warning triangle*

The warning triangle is conveniently stored in the onboard tool kit mounted on the inside of the luggage compartment lid.

Comply with legal requirements requiring you to carry a warning trian-

gle in the vehicle.<

First-aid kit*

You will also find the first-aid kit in the onboard tool kit's container.

Some of the articles contained in the first-aid kit have a limited service life. For this reason, check the expiration dates of each of the items regularly, and replace any whose expiration dates have passed. You can find replacements in any phar- macy. Comply with legal requirements requiring you to carry a first-aid kit in the vehicle.<

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Jump-starting When your battery is discharged you can use two jumper cables to start your vehicle with power from the battery in a second vehicle. You can also use the same method to help start another vehicle.Use only jumper cables with fully-insulated clamp handles.

To avoid the risk of potentially fatal injury, always avoid all contact with electrical components while the engine is running. Carefully adhere to the following sequence, both to prevent damage to one or both vehicles, and to guard against pos- sible personal injuries.<

Preparing 1. Check whether the battery of the other

vehicle has a voltage of 12 Volts and approximately the same capacitance in Ah. This information can be found on the battery

2. Switch off the engine of the support

vehicle

3. Switch off any consumer units in both

vehicles.

There must not be any contact between the bodies of the two vehi-

cles, as otherwise there is a danger of short circuits.<

Connecting the jumper cables

To avoid personal injury from sparks, always observe this sequence when

connecting jumper cables.<

On your BMW, the so-called starting-aid terminal in the engine compartment serves as the battery positive terminal, refer also to Engine compartment overview on page 178. The symbol + is embossed on the cover. 1. Open the cover of the BMW starting-aid

terminal. To do so, pull the tab

2. Attach one end of the jumper cable plus/+ to the positive terminal of the battery or a starting-aid terminal of the vehicle providing assistance

3. Attach the second end of the cable to the positive terminal of the battery or to a starting-aid terminal of the vehicle to be started

Your BMW has a special nut as body ground or negative pole. 4. Attach one end of the jumper cable

minus/– to the negative terminal of the battery or to an engine or body ground of the vehicle providing assistance

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5. Attach the second end of the cable to the negative terminal of the battery or to the engine or body ground of the vehi- cle to be started.

Starting the engine 1. Start the engine on the support vehicle and allow it to run for several minutes at a fast idle

2. Start the engine on the other vehicle in

the usual way. If the first start attempt is not success- ful, wait a few minutes before another attempt in order to allow the discharged battery to recharge

3. Let the engines run for a few minutes 4. Disconnect the jumper cables by

reversing the connection sequence.

If required, have the battery inspected and recharged at your BMW center.

Never use spray fluids to start the engine.<

Towing

Always observe all applicable towing laws and regulations.<

Towing with a commercial tow truck

> Use a wheel lift or flatbed carrier > Do not tow with sling-type equipment. Never allow passengers to ride on a towed vehicle for any reason.<

Towing with raised front axle

Vehicles with automatic transmission: 1. Towing speed:

Maximum 45 mph/70 km/h

2. Towing distance:

Maximum of 90 miles/150 km.

Vehicles with Sequential manual transmission SMG With the ignition switched on, engage the selector lever position N, then switch off the ignition again.

Tow fitting The threaded tow fitting is stored in the tool kit mounted on the inside of the luggage compartment lid, refer to page 184, and should always remain in the vehicle. It can be screwed to the front or rear of the vehi- cle.

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Access to tow sockets

Front

Rear

Press the arrow symbol to push out the cover.

Only use the tow fitting carried in the vehicle and screw it in firmly as far as it will go. Only use the tow fitting for towing on roads. Follow these instructions; other- wise the tow fitting can come loose and lead to damage to the vehicle. Never attempt to tow or tie down the vehi- cle using suspension components, as this could lead to damage that might ultimately result in an accident.<

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Reference

This is where to look to find information on any desired topic as quickly as possible. This chapter includes the section with technical information as well as the manual's index.

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Technical data

Engine specifications

Displacement Number of cylinders Maximum output at engine speed Maximum torque at engine speed Compression ratio Stroke Bore Fuel-injection system

Displacement Number of cylinders Maximum output at engine speed Maximum torque at engine speed Compression ratio Stroke Bore Fuel-injection system

cu in/cmm

hp rpm lb ft/Nm rpm in/mm in/mm

cu in/cmm

hp rpm lb ft/Nm rpm in/mm in/mm

525i 152.2/2,494
184
6,000
175/237
3,500
10.5
2.95/75.0
3.31/84.0

530i 181.8/2,979
225
5,900
214/290
3,500
10.2
3.53/89.6
3.31/84.0

Digital electronic engine-management system

545i 268.4/4,398
325
5,900
330/448
3,600
10.0
3.26/82.7
3.60/92.0
Digital electronic engine-management system

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Dimensions

All dimensions in inch/mm. Minimum turning circle dia.: 37.5 ft/11.44 m

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Weights

Curb weight with manual transmission with automatic transmission Approved gross weight with manual transmission with automatic transmission Load Approved front axle load Approved rear axle load Approved roof load capacity Luggage compartment volume

Curb weight with manual transmission with automatic transmission Approved gross weight with manual transmission with automatic transmission Load Approved front axle load Approved rear axle load Approved roof load capacity Luggage compartment volume

lbs./kg

lbs./kg

lbs./kg lbs./kg lbs./kg lbs./kg cu ft/l

lbs./kg

lbs./kg

lbs./kg lbs./kg lbs./kg lbs./kg cu ft/l

Never exceed either the approved axle loads or the gross vehicle weight.

525i

530i

3,428/1,555
3,450/1,565

3,472/1,575
3,494/1,585

4,530/2,055
4,552/2,065
1,102/500
2,161/980
2,601/1,180
220/100
18.4/520

4,575/2,075
4,597/2,085
1,102/500
2,227/1,010
2,601/1,180
220/100
18.4/520

545i

3,803/1,725
3,814/1,730

4,905/2,225
4,916/2,230
1,103/500
2,403/1,090
2,679/1,215
220/100
18.4/520

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Capacities

Fuel tank Reserve Window and headlamp washer system Engine with oil filter renewal 525i/530i 545i Manual, automatic transmission and differential

gal/liters gal/liters quarts/liters

approx. 18.5/70
approx. 2.1/8
approx. 3.2/3

quarts/liters quarts/liters

6.9/6.5
8.5/8.0
–

Notes Fuel quality: page 169

For details: page 57

BMW High Performance Synthetic Oil. Oil grades: page 179

Lifetime fluid, no fluid change required

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Everything from A to Z

Index ABS Antilock Brake

System 77

– indicator lamp 77
Acceleration assistant 54
Accessories, refer to Your

individual vehicle 5
"Activation time" for

independent ventilation 95

Active cruise control 59
– malfunctions 64
Active head restraints,

front 40

Active roll stabilization 80
Active seat 42
Active seat ventilation 42
Active steering 82
Adaptive Head Light 88
"Address book" for

navigation 120

Address for navigation – deleting 120
– entering 116
– selecting 120
"Add to address book" for

navigation 120

"Add to destination

list" 118

Adjusting temperature for

upper body 93

Adjusting the thigh

support 37

"After door is opened" 39
"After unlocking" 39
Airbags 83
– indicator lamp 84
– sitting safely 36
Air circulation, refer to

Recirculated air 91

Air distribution – automatic 91
– individual 93

202

Air flow, refer to Air

volume 91

Airing, refer to Ventilation 94

"Air recirculation on /

off" 44

Air vent outlets of

automatic climate control 90

Air volume 91
AKI, refer to Fuel

specifications 169

Alarm system 32
– avoiding unintentional

alarms 33

All around the steering

wheel 10

"All channels" 138
"All doors" 28
All-season tires, refer to

Winter tires 175

"AM", wave-

band 130, 134

Antenna for portable

phone 150

Antifreeze – coolant 179
– washer fluid 57
Anti-theft system 27
Anti-trapping mechanism – glass roof 35
– windows 34
Approved axle loads, refer

to Weights 200

Assisting systems, refer to

DSC Dynamic Stability Control 78

AUC Automatic

recirculated-air control 91
"Audio" 131
Audio 130
– adjusting the tone 131
– controls 130
– switching on/off 130
– volume 131
Audio systems, refer to

Tone control 131

Automatic – air distribution 91
– air volume 91
– cruise control 58, 59
– storing stations 135
Automatic car wash, refer to Caring for your vehicle brochure

Automatic climate

control 90

– automatic air distribution 91

– settings using the Control

Center 92

– switching off 92
Automatic curb monitor 39
Automatic headlamp

control 87

"Automatic programs" 93
Automatic recirculated-air

Approved gross vehicle

control AUC 91

Automatic steering wheel – adjustment 43

weight, refer to Weights 200

Arrival time, refer to

Computer 71

Ashtray – front 99
– rear 100
Assistance window 18

Belts, refer to Safety

belts 36, 40

Beverage holders 99
Black ice, refer to Ice

warning 65

Blocking sections of a route

for navigation 125
Blower, refer to Air

volume 91

BMW Assist 161
– enabling 161
– services offered 162
"BMW Info" 163
BMW Maintenance

System 181

"BMW Service settings" 161

Bore, refer to Engine

data 198

Bottle holder, refer to Beverage holders 99

Brake Assistant, refer to DBC Dynamic Braking Control 79

Brake fluid 180
– indicator lamp 180
– level 180
– replacing 180
Brake force display 82
Brake hydraulic

systems 180

Brake lamps, replacing the

bulbs 186

Brake pads 107
– breaking-in

procedure 106

Brake pedal, refer to

Brakes 107

Brake rotors 107
Brakes 107
– ABS 77
– brake fluid 180
– breaking-in

procedure 106
– handbrake 50

Automatic transmission

with Steptronic 54
– indicator lamp 56
– interlock 49
– selector lever interlock 55
– shiftlock 55
– sport program 55
– starting the engine 50
– towing 193
AUTO program, refer to

Automatic air distribution and volume 91

"Autostore" on the

radio 136

"AUTO" with automatic

climate control 93

Average fuel

consumption 70

– setting the units 74
Average speed 70
"Avoid ferries" for

navigation 121

"Avoid freeways / tolls" for

navigation 121

Avoiding unintentional

alarms 33

"Avoid tollroads" for

navigation 121

Axle loads, refer to

Weights 200

"A - Z" 154

Backrests, refer to

Seats 36

Backrest width adjustment 37

Backup lamps, refer to

Reverse gear 51

– replacing the bulbs 186
"Balance", audio

system 132

Balance, refer to Tone

control 131

"Bass", audio system 132
Bass, refer to Tone

control 131

Battery 188
– in the remote control 26
– jump-starting 192

Brake system 106
– brake-fluid level 180
– brake pads 107
– breaking-in

procedure 106
– disc brakes 107
– indicator lamp 13, 107
Breakdown services, refer

to Roadside Assistance 191

Break-in procedures 106
– brakes 106
– clutch 106
– differential 106
– engine 106
Brightness on the Control

Display 73

Bulbs and lamps – replacing the bulbs 184
Buttons on steering

wheel 11

California Proposition

65 Warning 183

"Call" 154
Call – accepting 153
– display accepted 154
– ending 154
– in absence 154
– starting 153
Calling – from phone book 154
– from the Top 8 list 154
– redialing 154
Calling up traffic information 126
"Call sender" 156
"Call Sirius" 138
Can holder, refer to

Beverage holders 99

Capacities 201
Car battery, refer to

Battery 188

Car care, refer to Caring for

your vehicle brochure

Car-care products, refer to

Caring for your vehicle brochure

203