🏷️ Basic Information

Make:

BMW

Model:

540i

Year:

1991

Chassis Code:

E34

Engine Code Typical:

M60B40

👋 Introduction

Target Audience:

BMW owners with basic mechanical skills, independent auto service professionals, and enthusiasts seeking in-depth knowledge.

Advantage:

Provides dealership-level service and repair information, ensuring vehicle-specific accuracy and detail not found in generic manuals.

Content Highlight:

Step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications.

Cost Savings:

Enables DIY repairs, potentially saving hundreds or thousands on labor costs for routine maintenance and repairs.

📋 Manual Details

Systems Covered:

Estimated Page Count:

N/A (Digital PDF, page count varies by reader/display)

Type:

Service Repair Workshop Manual

Language:

English

File Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, including cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication, and cooling systems.

Engine Electrical:

Ignition system, starting and charging systems, engine control unit (ECU) diagnostics, sensors, wiring diagrams.

Emission Control:

Catalytic converter, oxygen sensors, EGR system, evaporative emission control (EVAP) system diagnosis and repair.

Fuel System:

Fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel tank, lines, and diagnostics.

Transmission Manual:

Manual gearbox overhaul, clutch replacement, gear selection, driveshaft and U-joint servicing.

Transmission Automatic:

Automatic transmission repair, fluid and filter replacement, valve body diagnosis, torque converter servicing.

Suspension Steering:

Front and rear suspension components (struts, shocks, control arms, bushings), steering rack, power steering system, alignment procedures.

Brakes:

Disc brake system, ABS diagnostics, brake fluid service, caliper, rotor, and pad replacement, parking brake.

Body Electrical:

Lighting systems, power windows, locks, mirrors, wipers, horn, instrument cluster, interior and exterior lighting troubleshooting.

HVAC:

Air conditioning system diagnosis, refrigerant service, heater core, blower motor, climate control panel.

Restraint System:

Includes information on seat belt mechanisms and airbag system components, though advanced airbag diagnostics may be limited in manuals of this era.

Maintenance:

Oil change, filter replacements (oil, air, fuel), spark plug replacement, coolant flush, brake fluid change, belt inspection and replacement.

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon faults across all vehicle systems.

Repair:

Detailed instructions for disassembly, repair, and reassembly of all major and minor vehicle components.

Diagnostics:

Fault code interpretation, component testing, and circuit analysis for various electronic and mechanical systems.

Wiring Schematics:

Detailed wiring diagrams for engine, chassis, body, and HVAC systems, crucial for electrical troubleshooting.

Body Repair:

Covers interior and exterior body panel removal, repair, and adjustment, including doors, hoods, trunk lids, and trim.

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including electrical troubleshooting with wiring schematics.

Torque Specifications:

Includes precise torque values for all critical fasteners, essential for engine and chassis component reassembly.

Diagnostic Tools:

While not listing specific tools, the manual implies the use of standard automotive diagnostic equipment and specialized BMW tools for certain procedures.

📊 Manual Specifications

Format:

PDF

Printability:

Yes, all pages are printable.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Operating Systems:

All Versions of Windows and Mac

Software Requirements:

Adobe PDF Reader

⚙️ Engine Specifications

Engine Type:

4.0L V8 (M60B40)

Displacement:

3982 cc (243 cubic inches)

Horsepower Typical:

282 hp @ 5800 rpm

Torque Typical:

295 lb-ft @ 4500 rpm

Fuel Delivery:

Bosch Motronic M3.3 Fuel Injection

Bore X Stroke Typical:

94.0 mm x 71.0 mm

Compression Ratio Typical:

8.8:1

Valvetrain:

DOHC, 4 valves per cylinder

🔧 Transmission

Transmission Type Standard:

5-speed Manual

Transmission Type Optional:

4-speed Automatic (ZF 4HP22)

Clutch Type:

Hydraulically actuated single dry plate clutch (manual)

📐 Dimensions

Length Typical:

4780 mm (188.2 in)

Width Typical:

1751 mm (68.9 in)

Height Typical:

1410 mm (55.5 in)

Wheelbase Typical:

2799 mm (110.2 in)

Curb Weight Typical:

1650 kg (3638 lbs) (Manual)

🛡️ Safety Features

NHTSA Front Impact Driver Typical:

4-star

ABS:

Standard

Traction Control:

Optional (ASC)

Airbags:

Driver-side airbag standard, passenger airbag optional.

Seatbelts:

Front seatbelt pretensioners.

💡 Technology Features

Audio System:

BMW Business or Professional RDS audio systems, optional CD player.

Cruise Control:

Standard

Telephone:

Optional integrated cellular telephone system available in some trims.

🔧 Maintenance

Oil Change Interval Typical:

Every 7,500 - 10,000 miles or annually (dependent on oil type and driving conditions).

Spark Plug Replacement Interval Typical:

Every 60,000 miles (specific plugs recommended).

Timing Belt Chain:

The M60B40 engine utilizes a timing chain, designed to last the life of the engine, but inspection and tensioner checks are recommended.

Engine Oil Type:

API SJ or higher, SAE 0W-30, 5W-30, 5W-40, or 10W-40 (refer to manual for specific viscosity based on climate).

Coolant Type:

BMW Blue Long-Life Antifreeze/Coolant or equivalent (50/50 mix with distilled water).

Brake Fluid Type:

DOT 4

Transmission Fluid Manual:

SAE 75W-90 GL-4 or GL-5 gear oil (check manual for exact spec).

Transmission Fluid Automatic:

BMW ATF LT 71141 (ZF recommends specific fluid for its transmissions).

Common Problems:

Cooling system leaks (thermostat housing, water pump), VANOS (variable valve timing) seal failures (though VANOS was not on early M60B40), fuel injector issues, ABS sensor failures, blower motor resistor failure, oil pan gasket leaks.

📚 Vehicle History

Bmw Philosophy:

Focus on 'The Ultimate Driving Machine', combining performance, luxury, and advanced engineering.

E34 Generation:

Introduced in 1987, the E34 represented a significant advancement in BMW's executive sedan line, known for its refined driving dynamics and technological features.

540I Introduction:

The 540i variant was introduced in 1992 (as a 1993 model year in North America), featuring the powerful M60 V8 engine, so the 1991 listing might refer to earlier E34 models or indicate a regional specificity. However, the manual explicitly states '1991 540 540i', suggesting it covers the chassis and potentially includes information leading up to the V8 introduction or specific regional configurations.

E34 Production Years:

1987-1996

🏆 Awards & Recognition

Car And Driver Best 10:

The E34 generation of the 5 Series was a frequent recipient of Car and Driver's '10Best' awards, highlighting its driving excellence.