🏷️ Basic Information

Make:

BMW

Model:

540i

Year:

1999

Chassis Code:

E39

Engine Code Primary:

M62B44

👋 Introduction

Market Segment:

Mid-size Luxury Sedan

Competitors:

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

Distinctive Attributes:

Refined driving dynamics, powerful V8 engine, high-quality interior, advanced technology for its era, strong brand prestige.

Target Owner:

Owners seeking to perform their own maintenance and repairs, enthusiast mechanics, restoration projects.

📋 Manual Details

Coverage:

Complete Service and Repair

Page Count:

High (estimated 1000+ pages)

Manual Type:

Full Service Repair Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Complete engine disassembly, assembly, timing, cooling system, lubrication system, fuel injection, exhaust system.

Engine Electrical:

Ignition system, starter system, alternator, battery, ECU diagnostics and repair, sensor testing.

Transmission Automatic:

Automatic transmission overhaul, fluid changes, torque converter, valve body, electronic control module (GM 5L40-E).

Drivetrain:

Driveshafts, universal joints, differential overhaul, axle bearings, wheel bearings.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.

Brakes:

Brake system inspection, repair, ABS system diagnostics, hydraulic components, brake pad and rotor replacement.

Steering:

Power steering system, steering rack, tie rod ends, steering column.

Electrical System:

Wiring diagrams, fuse box locations, relay functions, lighting systems, power windows, central locking, climate control electronics.

Bodywork:

Body panel removal and installation, door mechanisms, hood, trunk, exterior trim, interior trim.

Climate Control:

HVAC system service, refrigerant, compressor, evaporator, heater core, blower motor.

Maintenance:

Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid change, belt replacement.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, common faults and solutions.

Repair:

Component replacement, system overhaul, rebuild procedures.

Diagnostics:

OBD-II diagnosis, sensor testing, actuator testing, electrical circuit testing.

Depth:

Comprehensive (from basic maintenance to full engine rebuild and electrical system diagnostics).

📊 Manual Specifications

File Format:

Likely PDF with searchable text and high-resolution diagrams.

Diagram Quality:

High resolution, clear and detailed schematics.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated V8

Displacement:

4.4 Liters (4398 cc)

Bore X Stroke:

91.0 mm x 84.5 mm

Compression Ratio:

10.0:1

Valvetrain:

DOHC, 4 valves per cylinder (32 total)

Engine Management:

Bosch Motronic M5.2 (or M5.2.1 for later models)

Horsepower:

290 hp @ 5500 rpm

Torque:

324 lb-ft @ 3600 rpm

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MFI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher)

🔧 Transmission

Transmission Type Std:

5-speed Steptronic Automatic (GM 5L40-E)

Transmission Type Opt:

6-speed Manual (Getrag Type D)

Steptronic Operation:

Allows manual gear selection via shifter or steering wheel buttons (on some models).

Automatic Transmission Fluid:

BMW ATF LT-3 (or equivalent Dexron III/Mercon)

Automatic Transmission Fluid Capacity:

Approx. 8.5 Liters (17.8 US Pints) (total capacity, fill level checked via level plug)

📐 Dimensions

Length:

190.6 inches (4841 mm)

Width:

71.1 inches (1806 mm)

Height:

56.7 inches (1440 mm)

Wheelbase:

111.4 inches (2830 mm)

Curb Weight Auto:

Approx. 3759 lbs (1705 kg)

Curb Weight Manual:

Approx. 3640 lbs (1651 kg)

Gross Vehicle Weight Rating:

Approx. 4718 lbs (2140 kg)

Wheel Bolt Pattern:

5x120 mm

Wheel Offset:

ET 20-25 (typical)

🛡️ Safety Features

NHTSA Front Impact:

4-Star (Driver), 4-Star (Passenger)

IIHS Side Impact:

Good

ABS:

Standard (Bosch ABS 5.3)

Traction Control:

Standard (ASC+T - Automatic Stability Control + Traction)

Stability Control:

Optional (DSC - Dynamic Stability Control) on later models or as part of performance packages.

Airbags:

Dual front airbags, optional front side-impact airbags.

Seatbelts:

Three-point seatbelts with pretensioners for all occupants.

💡 Technology Features

Head Unit:

BMW Professional RDS or Business CD. Optional navigation system (MK II/III).

Audio System:

Standard 6-speaker system, optional premium Hi-Fi system with subwoofer.

Parking Sensors:

Optional Park Distance Control (PDC).

Cruise Control:

Standard electronic cruise control.

Phone Integration:

Optional Bluetooth or cellular phone preparation kit with external antenna.

Rain Sensing Wipers:

Optional automatic rain sensor for wipers.

Xenon Headlights:

Optional Xenon headlights with automatic leveling.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 - 10,000 miles or 12 months, depending on driving conditions and oil used (check OBC - On-Board Computer service indicators).

Spark Plug Replacement:

Every 60,000 - 100,000 miles (depending on spark plug type, e.g., iridium plugs).

Coolant Flush:

Every 2 years or 30,000 miles.

Brake Fluid Change:

Every 2 years.

Engine Oil Type:

SAE 5W-30 or 5W-40, API SJ or higher, BMW Longlife-98 specification (e.g., Castrol Syntec).

Engine Oil Capacity:

Approx. 7.0 Liters (7.4 US Quarts)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)

Power Steering Fluid:

BMW Power Steering Fluid (or Pentosin CHF 11S).

Cooling System:

Plastic coolant expansion tanks can become brittle and crack; water pumps are known to leak.

Vanos System:

Variable Valve Timing (VANOS) seals can degrade, leading to rough idle, loss of low-end torque, and increased fuel consumption. Repair kits are available.

Oil Leaks:

Common leaks from valve cover gaskets, oil pan gaskets, and vacuum hoses due to age and material degradation.

Ignition Coils:

Coil-on-plug ignition systems can experience coil failure, leading to misfires.

Window Regulators:

Plastic components in power window regulators can break.

📚 Vehicle History

Bmw Philosophy:

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

E39 Introduction:

Introduced in late 1995 as a 1996 model year, replacing the E34 5 Series. The 540i variant with the M62 V8 was launched shortly after.

E39 Facelift:

The E39 received a significant facelift (LCI - Life Cycle Impulse) in September 2000, which included updated headlights, taillights, bumpers, and interior trim. The 1999 model year predates this facelift.

Production Location:

Dingolfing, Germany

Production Years:

1996-2003 (E39 generation)

🏆 Awards & Recognition

Car And Driver 10Best:

Car and Driver magazine's 10Best list multiple times during its production run, highlighting its balance of performance, luxury, and handling.

Edmunds Review:

Consistently highly rated for its driving dynamics, build quality, and V8 power.

Historical Significance:

Considered by many enthusiasts to be one of the best sedans of its era, representing a peak in BMW's driver-focused engineering before the widespread adoption of more complex electronic systems.