🏷️ Basic Information

Make:

BMW

Model:

540i

Year:

2000

Chassis Code:

E39

Engine Code 540I:

M62B44

👋 Introduction

Segment:

Executive Sedan

Target Audience:

Affluent consumers seeking performance, luxury, and advanced engineering

Key Competitors 2000:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS

Performance Focus:

V8 engine, balanced chassis, rear-wheel drive dynamics

Luxury Appointments:

High-quality interior materials, advanced features for its era

Value Proposition:

Enables owners and independent mechanics to perform expert-level maintenance and repairs, saving on dealership costs.

Accuracy Source:

Official BMW factory documentation, ensuring precision and adherence to manufacturer standards.

📋 Manual Details

Primary Coverage:

Complete Factory Service and Repair

Secondary Coverage:

Diagnostic Procedures, Troubleshooting, Maintenance

Estimated Pages:

Hundreds (Specific count not provided, but reflects a comprehensive manual)

Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul, component testing, timing, lubrication, cooling system

Engine Management:

Fuel injection system (Siemens MS43/MS43.1), ignition system, emissions control (OBD-II)

Transmission Automatic:

ZF 5HP30: overhaul, fluid service, electronic control unit (TCU), torque converter

Drivetrain:

Driveshafts, differential, rear axle components

Suspension And Steering:

Front and rear suspension components, shock absorbers, springs, control arms, power steering system

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake disc and pad replacement, hydraulic component testing

Electrical System:

Wiring diagrams, component locations, battery, alternator, starter, lighting system

Body And Chassis:

Body panels, doors, windows, sunroof, interior trim, frame specifications

HVAC:

Heating, ventilation, and air conditioning system, refrigerant handling, component diagnosis

Comfort Features:

Power seats, central locking, mirrors, cruise control

Maintenance Tasks:

Oil changes, filter replacements, spark plug service, fluid checks and changes, belt inspection and replacement

Diagnostic Procedures:

Troubleshooting flowcharts, fault code interpretation (OBD-II), component testing methods

Repair Procedures:

Step-by-step instructions for major component removal and installation (engine, transmission, suspension, brakes)

Electrical Diagnostics:

Using multimeters, oscilloscopes, and diagnostic scan tools; interpreting wiring diagrams

Overhaul Procedures:

Detailed instructions for engine and transmission rebuilds

Depth:

Comprehensive: Covers routine maintenance to major component overhauls and complex diagnostics

Diagnostic Scope:

Advanced: Includes diagnosis of electronic control units (ECUs) and sensor data interpretation

Rebuild Scope:

Complete: Detailed procedures for rebuilding major mechanical assemblies

📊 Manual Specifications

Format:

PDF

Searchability:

Typically searchable text within PDF for easy information retrieval

Quality:

High-resolution scans of original factory documentation

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

M62B44TU (Technical Update)

Engine Type:

4.4L V8, Naturally Aspirated

Displacement:

4398 cc

Horsepower:

290 hp @ 5400 rpm

Torque:

324 lb-ft @ 3600 rpm

Bore X Stroke:

92 mm x 82.7 mm

Compression Ratio:

10.0:1

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI)

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

ECU Type:

Siemens MS43/MS43.1

🔧 Transmission

Type:

ZF 5HP30 5-Speed Automatic

Type:

None (All 540i models for this year featured the automatic)

Electronic Control:

Steptronic (Manual shifting capability)

Fluid Type:

BMW ATF LT-2 or equivalent (e.g., Pentosin ATF1)

📐 Dimensions

Length:

188.5 inches (4788 mm)

Width:

71.0 inches (1803 mm)

Height:

56.2 inches (1427 mm)

Wheelbase:

111.4 inches (2830 mm)

Front Track:

60.4 inches (1534 mm)

Rear Track:

60.7 inches (1542 mm)

Curb Weight:

3792 lbs (1720 kg)

Gross Vehicle Weight Rating Gvwr:

4784 lbs (2170 kg)

Trunk Volume:

15.0 cu ft (425 L)

🛡️ Safety Features

NHTSA Frontal Impact:

4/5 Stars (Driver/Passenger)

NHTSA Side Impact:

4/5 Stars (Front/Rear Passenger) - Note: Side impact testing protocols varied significantly in 2000.

ABS:

Standard Anti-lock Braking System

Dsc:

Standard Dynamic Stability Control

Traction Control:

Standard Automatic Stability Control (ASC+T)

Airbags:

Frontal airbags (driver and passenger), optional side-impact airbags

Seatbelts:

3-point front and rear seatbelts with pretensioners

Chassis Design:

Reinforced safety cage, crumple zones

💡 Technology Features

Head Unit:

BMW Business CD or Professional CD with optional navigation system (MK III or MK IV).

Display:

Central monochrome or color display for navigation, climate, and vehicle settings.

Audio System:

Standard 6-speaker system, optional Harman Kardon premium audio.

Cruise Control:

Standard electronic cruise control.

Parking Assistance:

Optional rear parking sensors (Park Distance Control - PDC).

Phone Integration:

Optional Bluetooth phone preparation with cradle.

Diagnostics:

OBD-II port for engine and emissions diagnostics, BMW proprietary diagnostic connectors (e.g., 20-pin under the hood) for deeper system access.

🔧 Maintenance

Oil Change Interval:

BMW Condition Based Service (CBS) system; typically 10,000-15,000 miles or annually, depending on driving conditions. Refer to manual for specific CBS reset procedures.

Spark Plug Replacement:

Approximately 60,000 miles (refer to manual for exact interval and part number, typically Bosch FGR7DQP+).

Transmission Fluid Service:

BMW originally stated 'lifetime' fluid, but recommended fluid and filter changes every 50,000-80,000 miles for longevity, especially for the ZF 5HP30. Manual provides detailed procedure.

Engine Oil:

BMW Longlife-01 (LL-01) certified synthetic oil, SAE 5W-30 or 5W-40. Capacity: ~6.5 liters (6.9 US quarts).

Coolant:

BMW Blue Antifreeze/Coolant (G48 specification), typically a 50/50 mix with distilled water. Capacity: ~10.5 liters (11.1 US quarts).

Brake Fluid:

DOT 4 Low Viscosity (LV) or DOT 4 Plus. Replace every 2 years. Capacity: ~1 liter.

Cooling System:

Plastic expansion tank cracking, water pump failure (often with plastic impeller), coolant hoses degradation.

Engine Oil Leaks:

Valve cover gasket leaks, oil pan gasket leaks, oil separator (PCV) system issues.

Transmission Issues:

Mechatronic sealing sleeve leaks (on later variants of ZF transmissions), torque converter lock-up clutch issues. Proper fluid maintenance is crucial.

Suspension Wear:

Control arm bushings, tie rod ends, ball joints, and rear subframe bushings are common wear items due to the vehicle's weight and performance.

Electrical Gremlins:

Water ingress into LCM (Light Control Module), ABS/DSC sensor failures, pixelation on instrument cluster displays, faulty door lock actuators.

📚 Vehicle History

Bmw Philosophy:

Sheer Driving Pleasure, focus on performance, engineering, and driver engagement.

E39 Generation:

Introduced in 1995 (Europe) / 1997 (North America), the E39 was the fourth generation of the BMW 5 Series. It was renowned for its improved handling, refined interior, and advanced technology over its predecessor (E34).

540I Positioning:

The 540i served as the flagship model in the E39 lineup, offering a powerful V8 engine in a more compact and agile package compared to the larger 7 Series.

Production Years E39:

1995-2003 (Sedan), 1997-2003 (Touring)

Manufacturing Locations:

Dingolfing, Germany; also assembled in various other international locations.

🏆 Awards & Recognition

Car And Driver 10Best:

The E39 5 Series (including the 540i) was a frequent recipient of Car and Driver's 10Best awards during its production run, highlighting its exceptional balance of performance, luxury, and handling.

Automotive Journalism Reviews:

Consistently praised by automotive journalists for its driving dynamics, build quality, and sophisticated engineering, solidifying its status as a benchmark in the executive sedan class.