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2003 BMW 540I CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT BMW REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Tire Pressure Monitoring System
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2003 BMW 540I car and truck
repair procedures including BMW engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your BMW 540I automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
BMW -> Manual A/C & Heater System Diagnosis & Testing -> Description -> A/C Compressor Switch -> Air Center Control Lever -> Air Down Control Lever -> Air Up Control Lever -> Air Volume Control Switch -> Fresh Air/Bypass Air Switch -> Refrigeration System -> System Control -> Temperature Control
Vehicle: 2003 BMW 540I 4.4 V8 GAS
Refrigeration System
Switching on the A/C system will activate the refrigerant circuit, Fig. . The solenoid coil receives power, producing a magnetic field causing the armature clutch plate to be pulled, and which is fixed onto the compressor shaft next to an inner plate operating freely on the same shaft. The compressor increases refrigerant vapor pressure, which is drawn into the suction end of the compressor assembly. The refrigerant is then compressed, raising refrigerant vapor temperature. The high pressure vapors pass through a high pressure line to a condenser loc...
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BRAKE SERVICE PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
Anti-lock Brakes -> Troubleshooting
Vehicle: 2003 BMW 540I 4.4 V8 GAS
Refer t...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
BMW -> Fuel Filter Scheduled Maintenance -> 1999-06
Vehicle: 2003 BMW 540I 4.4 V8 GAS
Inspection interval is determ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
CV AXLE SHAFT, Replace -> REAR
Vehicle: 2003 BMW 540I Sport Wagon 4.4 V8 GAS
REAR
- On models equipped with air suspension, proceed as follows:
- Remove air supply system fuse.
- Disconnect distributor block lines.
- On all models, raise and support vehicle, then remove rear tire and wheel assembly.
- Remove rear axle carrier.
- Remove output shaft to transmission m...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
Component Replacement -> 1997-2003 -> Installation -> Removal -> Tire Pressure Sensor -> TPMS Antenna -> TPMS Control Module
Vehicle: 2003 BMW 540I 4.4 V8 GAS
Tire Pressure Sensor
Removal
- Dismount tire using suitable tire machine ensuring not to damage tire pressure sensor.
- Remove the Torx screw, then the tire pressure sensor.
- Release valve stem union nut using removal tool No. 00 2 190, or equivalent Fig. .
- Remove washer from wheel.
Installation
- Install new Torx screw on tire pressure sensor, then twist new valve stem by hand approximately three turns. Do not tighten Torx screw, sensor and valve stem must be loosely joined together.
- Install the tire pressure sensor on wheel. Ensure the radial bore for gripping on the circumference of t...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
Alternator, Replace -> Air Cooled -> Liquid Cooled
Vehicle: 2003 BMW 540I 4.4 V8 GAS
Air Cooled
- Remove drive belt.
- Remove mounting bolts and place oil filter housing aside.
- Disconnect alternator electrical connectors.
- Remove mounting nut and disconnect battery positive lead.
- Disconnect cable clip and cooling air guide.
- Remove mounting bolts and alternator.
- Reverse procedure to install.
Liquid Cooled
- Lock belt pulley in position using suitabl...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
Cabin Air Filter Service -> BMW -> 1996-2005 5 Series
Vehicle: 2003 BMW 540I Sport Wagon 4.4 V8 GAS
Service interval is determined by the service indicator.
- Open the hood.
- Turn quick-release fastener approximately, 90° counterclockwise. Unlatch the cabin air filter cover retainers.
- Remove the cabin air fi...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
BMW -> Air Bag Warning Lamp ->
Vehicle: 2003 BMW 540I 4.4 V8 GAS
If the Air Bag warning lamp lights and stays on, diagnosis and ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
Radiator, Replace
Vehicle: 2003 BMW 540I Sport Wagon 4.4 V8 GAS
- Raise and support vehicle, then remove mounting bolts and front splash shield.
- Remove radiator plug and drain coolant into suitable container.
- Remove engine block left and righthand plugs, then
- Remove air cleaner cover drain coolant into suitable container.
- Lock belt pulley in position using holding tool No. 11 5 050, or equivalent, then remove water...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 BMW 540I AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 BMW 540I Sport Wagon 4.4 V8 GAS
- If reusing belt, mark rotational direction for installation.
- Lock belt pulley in position using suitable holding tool, then remove mounting nut using suitable wrench. Nut has lefthand threads.
- Remove fan clutch.
- Remove engine splash shield.
- Tighten a...
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COMPONENT LOCATION DIAGRAMS FOR 2003 BMW 540I AUTOMOBILES
Component location diagrams for most 2003 BMW 540I cars and light trucks sold in the U.S. from 1990+.
 In Head Lining Diagram for 2003 BMW 540I Sport Wagon 4.4 V8 GASComponents on diagram: |
 Rear RH Side of Engine Compartment in E-Box Diagram for 2003 BMW 540I Sport Wagon 4.4 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 BMW 540I AUTOMOBILES
OEM drawn wiring diagrams for most 2003 BMW 540I cars and light trucks sold in the U.S.
 2003 BMW 540I Sport Wagon 4.4 V8 GAS Wiring DiagramComponents on diagram: |
 2003 BMW 540I 4.4 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 BMW 540I AUTOMOBILES
OEM TSB listings for most 2003 BMW 540I cars and light trucks sold in the U.S. from 1985+.
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Document: Tools and Equipment Vehicle: 2003 BMW 540I 4.4 V8 GAS Auto Systems: |
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Document: Tools and Equipment Vehicle: 2003 BMW 540I 4.4 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 BMW 540I AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 BMW 540I cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2003 BMW 540I cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2003 BMW 540I cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2003 BMW 540I cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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