🏷️ Basic Information

Make:

BMW

Model:

540i

Model Variant:

540

Year:

1999

Chassis Code:

E39

👋 Introduction

Vehicle Segment:

Executive Sedan, Luxury Mid-size Sedan

Primary Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS300, Jaguar S-Type.

Distinctive Attributes:

Renowned BMW driving dynamics, potent V8 engine, sophisticated interior, advanced engineering for its era.

📋 Manual Details

Engine Options Covered:

All Engine Types for 1999 BMW 540i

Transmission Options Covered:

All Transmission Types for 1999 BMW 540i

Trim Levels Covered:

All Trim Levels for 1999 BMW 540i

Body Styles Covered:

Sedan (4-door)

Estimated Page Count:

High (Comprehensive Workshop Manual)

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Management:

Detailed diagnostics, repair procedures, specifications for engine control unit (ECU), sensors, actuators, ignition system, fuel injection system.

Engine Mechanical:

Comprehensive coverage of engine teardown, assembly, internal component specifications (pistons, rings, bearings, crankshaft, camshaft), cylinder head, valve train, timing systems.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan clutch, expansion tank, bleeding procedures, pressure testing.

Lubrication System:

Oil pump, oil pan, oil filter, oil cooler, lubrication passages, oil pressure testing.

Exhaust System:

Exhaust manifolds, catalytic converter, muffler, oxygen sensors, exhaust hangers, leak detection.

Fuel System:

Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, fuel tank, evaporative emission control (EVAP) system.

Transmission Automatic:

Detailed overhaul procedures, valve body operation, torque converter, transmission control module (TCM), fluid specifications, fill procedures, shift solenoid testing.

Transmission Manual:

Clutch assembly, transmission gear ratios, input/output shafts, bearings, seals, shift linkage, lubrication.

Drivetrain:

Driveshafts, universal joints, CV joints, differential, axle shafts, wheel bearings.

Brakes:

Brake system diagnosis, ABS/DSC system, hydraulic components (master cylinder, brake lines, calipers, wheel cylinders), brake pads, rotors, drum brakes, parking brake system, bleeding procedures.

Suspension Front:

Control arms, ball joints, tie rod ends, sway bar, strut assembly, wheel bearings, steering knuckle, alignment specifications.

Suspension Rear:

Multilink suspension components, shock absorbers, springs, trailing arms, control arms, alignment specifications.

Steering System:

Power steering pump, steering gear/rack, power steering hoses, steering column, steering wheel, alignment.

Electrical System Chassis:

Lighting system (headlights, taillights, interior lights), horn, wipers, washers, power windows, power locks, mirrors, seats, sunroof.

Electrical System Engine:

Alternator, starter motor, battery, wiring harnesses, relays, fuses, ignition coils.

Comfort Systems:

Climate control (HVAC) system diagnosis and repair, blower motor, A/C compressor, refrigerant, heater core, evaporator, control panels.

Body And Frame:

Body panel removal and installation, door mechanisms, hood, trunk lid, bumpers, interior trim panels, glass replacement, rust prevention.

Diagnostic Trouble Codes:

Extensive listing of DTCs, their meanings, and troubleshooting flowcharts.

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), fluid level checks and top-offs, spark plug replacement, belt inspections and replacement.

Troubleshooting Diagnostics:

Systematic approach to identifying and resolving common and uncommon faults, using diagnostic tools and symptom-based repair.

Component Replacement:

Step-by-step guides for replacing virtually every component on the vehicle.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Torque Specifications:

Precise torque values for all critical fasteners.

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems.

Depth Of Coverage:

Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and body repair.

📊 Manual Specifications

File Format:

PDF

Image Resolution:

High-resolution scans for clear diagrams and text.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code:

M62B44

Engine Type:

4.4L V8 (32-valve)

Displacement:

4398 cc (268.3 cu in)

Horsepower:

282 hp @ 5400 rpm (approx.)

Torque:

324 lb-ft @ 3600 rpm (approx.)

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

ECU Type:

Bosch Motronic (e.g., ME7.2)

🔧 Transmission

Transmission Type Std:

5-speed Automatic (Steptronic optional on some models, but 540i often came with automatic)

Transmission Type Opt:

5-speed Manual Transmission (less common for 540i in North America)

Automatic Features:

Steptronic manual shifting mode (sequential gear selection).

📐 Dimensions

Wheelbase:

113.4 inches (2880 mm)

Length:

191.1 inches (4855 mm)

Width:

71.0 inches (1803 mm)

Height:

57.0 inches (1448 mm)

Curb Weight Approx:

3700 - 3800 lbs (1680 - 1725 kg)

🛡️ Safety Features

NHTSA Front Impact:

Likely 4-star (based on contemporary tests, specific data may vary).

IIHS Side Impact:

Likely Acceptable/Good (based on contemporary tests).

Traction Control:

Automatic Stability Control (ASC+T) or Dynamic Stability Control (DSC).

Braking System:

Anti-lock Braking System (ABS) standard on all wheels.

Airbags:

Driver and front passenger airbags. Optional side airbags.

Seatbelts:

Three-point inertia-reel seat belts with pretensioners and force limiters.

💡 Technology Features

Audio System:

BMW Business CD or Professional CD audio systems, optional Harman Kardon sound system.

Navigation:

Optional BMW Business or Professional Navigation system with a dashboard-mounted screen and CD-ROM based maps.

Parking Assistance:

Optional Rear Park Distance Control (PDC).

Phone Integration:

Optional cellular phone integration via Bluetooth or specific cradle systems (requiring specific BMW-approved phones).

🔧 Maintenance

Oil Change Interval:

BMW Condition Based Service (CBS) system often indicated intervals of 7,500-10,000 miles or annually, whichever came first. Manual will specify optimal intervals.

Spark Plug Replacement:

Typically around 100,000 miles for platinum or iridium plugs.

Coolant Flush:

Recommended every 2-3 years or specified mileage.

Engine Oil Type:

Synthetic 5W-30 or 5W-40 meeting BMW Longlife-01 (LL-01) or LL-98 specifications. Manual will confirm exact specification.

Transmission Fluid Type Auto:

Specific ATF fluid (e.g., Esso LT 71141 or equivalent). Crucial to use the correct fluid to avoid transmission damage.

Brake Fluid Type:

DOT 4

Coolant Type:

BMW Blue Antifreeze/Coolant (Ethylene Glycol based)

Common Problems Engine:

Valley pan gasket leaks, oil separator (CCV) system clogging leading to vacuum issues, VANOS (Variable Valve Timing) solenoid issues, spark plug well oil leaks.

Common Problems Transmission:

Automatic transmission torque converter shudder or clutch pack wear, potential Mechatronics unit issues (later models, less common on '99).

Common Problems Suspension:

Worn front control arm bushings, tie rod ends, and ball joints leading to steering wander and premature tire wear.

Common Problems Electrical:

ABS/DSC wheel speed sensor failures, pixelation on the instrument cluster LCD (MID/OBC), blower motor resistor failures, door seal water ingress issues.

📚 Vehicle History

Bmw Legacy:

BMW (Bayerische Motoren Werke AG) is a German manufacturer of luxury vehicles and motorcycles, known for its performance-oriented engineering and driving pleasure ('The Ultimate Driving Machine').

E39 Generation:

The E39 generation of the 5 Series (produced 1995-2003) was a significant evolution, praised for its improved chassis, refined ride quality, and advanced technology compared to its E34 predecessor. The 540i represented the high-performance, V8-powered variant.

Manufacturing Location:

Germany (primarily Dingolfing Plant)

🏆 Awards & Recognition

Car And Driver Awards:

The E39 5 Series consistently appeared on Car and Driver's '10Best' lists during its production run, highlighting its overall excellence.