The BMW 540i, model year 2001, chassis code E39, is a premium sport sedan renowned for its exceptional engineering and performance, embodying BMW's commitment to being "The Ultimate Driving Machine." This generation, produced from 1996 to 2003, is celebrated for its superior handling, refined driving dynamics, and luxury appointments, often recognized with accolades such as Car and Driver's 10 Best. Powered by a robust 4.4L V8 engine producing 290 horsepower and 324 lb-ft of torque, it offers an engaging driving experience, complemented by either a 5-speed Steptronic automatic transmission or a rare 6-speed manual. Its design emphasizes a balance of sportiness and comfort, making it a compelling choice in its segment.
This comprehensive workshop repair service manual, written in English, serves as an indispensable resource for maintaining and repairing the BMW 540i (E39). It covers all models, engines, trims, and transmission types, offering detailed information on general maintenance, troubleshooting, engine and transmission service, brake systems, electrical systems, suspension, steering, cooling, fuel injection, and more. With professional technician-level depth, including diagnostic procedures, disassembly and assembly instructions, and critical notes, this manual empowers owners and technicians to perform a wide range of tasks, from routine service to complex repairs, ensuring the longevity and optimal performance of the vehicle.
Positioning:
Premium sport sedan
Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS
Brand Promise:
The Ultimate Driving Machine
Value Proposition:
Comprehensive DIY repair and maintenance resource to save significant costs
Coverage:
All Models/Engines/Trim/Transmissions Types
Page Count:
Hundreds of Pages (estimated based on description)
Type:
Workshop Repair Service Manual
Systems:
General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle
Procedures:
Diagnostic, Repair, Maintenance, Disassembly, Assembly, Cleaning, Reinstalling, Troubleshooting steps, Detailed substeps, Notes, Cautions, Warnings
Depth:
Professional Technician Level, Complete Informational Book, Detailed diagrams and information
Print Quality:
Full Printable
Binding Type:
Digital Download (No physical binding)
Paper Type:
N/A (Digital)
Delivery:
Instant Download
Requirements:
Adobe PDF Reader & WinZip
Compatibility:
All Versions of Windows & Mac
Engine Code:
M62B44TU (Technical Update)
Horsepower:
290 hp @ 5400 rpm
Torque:
324 lb-ft @ 3600 rpm
Fuel Delivery:
Sequential Multi-Point Fuel Injection (SFI)
Valve Train:
DOHC, 4 valves per cylinder
Cooling System Type:
Pressurized liquid cooling
Transmission Type:
5-speed automatic (Steptronic)
Transmission Type Optional:
6-speed manual (Rare, limited availability for 540i M-Sport)
Transmission Features:
Steptronic manual shifting mode for automatic transmission
Length:
190.2 in (4831 mm)
Height:
57.0 in (1448 mm)
Wheelbase:
113.7 in (2888 mm)
Curb Weight:
approx. 3,850 - 4,000 lbs (1746 - 1814 kg)
NHTSA Front Impact:
4/5 Stars
NHTSA Side Impact:
4/5 Stars
Active Safety:
ABS, DSC (Dynamic Stability Control), Traction Control
Passive Safety:
Front airbags, Side-impact airbags, Pre-tensioned seatbelts, Reinforced chassis
Infotainment System:
BMW Business CD or Professional CD/Cassette system, optional navigation system (CCC precursor).
Driver Assistance Features:
Park Distance Control (PDC), Cruise Control
Connectivity Features:
Optional cellular phone integration (early Bluetooth or wired systems)
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually.
Spark Plug Replacement:
Approximately every 60,000 miles
Engine Oil Type:
SAE 5W-30 Synthetic (BMW Longlife-01 approved)
Coolant Type:
BMW Blue Coolant (G48) or equivalent ethylene glycol-based coolant with corrosion inhibitors
Transmission Fluid Type Auto:
Dexron III/VI or ZF Lifeguardfluid 5
Common Issues:
Vanos system leaks, cooling system hoses and water pump failures, ABS/DSC module failures, VANOS solenoid failure, oil pan gasket leaks, PCV system issues.
Preventative Maintenance:
Regular inspection of cooling system, VANOS seals, and vacuum lines.
Brand Heritage:
BMW, founded in 1916, renowned for performance, luxury, and engineering excellence.
Model Evolution:
The E39 generation (1995-2003) represented a significant advancement in BMW's mid-size luxury sedan segment, known for its superior handling and refined driving dynamics.
Production Period:
1996-2003 (E39 generation)
Manufacturing Plants:
Dingolfing, Germany; Rosslyn, South Africa
Car And Driver Awards:
Car and Driver 10 Best (multiple years during E39 generation)
Type Of Recognition:
Automotive Journalism and Consumer Recognition