BMW 540i 2000 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 540i Year: 2000 Codes Chassis Code: E39 👋 Introduction Market Position Segment: Luxury Mid-size Sedan Competitive Analysis Competitors: Mercedes-Benz E-Class, Audi A6, Lexus...

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Type: Car

Vendor:

Sku: 427986

Tags: 2000 540i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Luxury Mid-size Sedan

Competitive Analysis

Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type

Key Features

Driver Focus:

Driver-oriented cockpit, engaging handling, refined ride quality

Powertrain:

Powerful V8 engine, rear-wheel drive bias

Value Proposition

Manual Benefit:

Empowers owners and independent mechanics to maintain and repair the vehicle to factory standards, reducing reliance on dealership service.

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Full Service Repair

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Factory Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

V8 Engine (M62TU), Cylinder Head, Pistons, Crankshaft, Timing System, Oil System

Engine Management:

Fuel Injection System (Sequential Multi-Point), Ignition System, Engine Control Unit (ECU), Sensor Diagnostics (MAF, O2, Crank, Cam), Emissions Control (Secondary Air Injection, EGR)

Transmission:

5-Speed Automatic Transmission (Steptronic - GM 5L40-E), Gearbox Mechanics, Valve Body, Torque Converter, Transmission Control Module (TCM)

Drivetrain:

Rear Wheel Drive (RWD), Driveshaft, Differential, Axles, CV Joints

Suspension:

Front Suspension (Double Wishbone), Rear Suspension (Multi-link), Shock Absorbers, Springs, Bushings, Control Arms, Sway Bars

Steering:

Hydraulic Power Steering System, Steering Rack, Power Steering Pump, Tie Rods

Brakes:

Front Disc Brakes, Rear Disc Brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), Brake Booster, Master Cylinder, Brake Lines, Parking Brake

Electrical System:

Battery, Alternator, Starter Motor, Fuses, Relays, Wiring Diagrams, Lighting System (Headlights, Taillights, Interior), Power Windows, Power Locks, Power Seats

Climate Control:

Automatic Climate Control, HVAC System, Blower Motor, Evaporator, Condenser, Refrigerant System

Bodywork:

Body Panel Removal/Installation, Doors, Hood, Trunk, Bumpers, Glass, Seals

Procedures Included

Routine Maintenance:

Oil Change, Filter Replacements (Oil, Air, Cabin), Spark Plug Replacement, Fluid Checks and Replenishment

Engine Repair:

Head Gasket Replacement, Piston Ring Replacement, Crankshaft Bearing Service, Timing Chain/Belt Service (if applicable to specific M62 variant), Valve Stem Seal Replacement

Transmission Repair:

Transmission Fluid and Filter Change, Valve Body Rebuild, Solenoid Replacement, Torque Converter Replacement

Brake System Repair:

Brake Pad and Rotor Replacement, Caliper Service, Brake Fluid Flush, ABS/DSC Component Diagnosis and Replacement

Electrical Troubleshooting:

Diagnostic Trouble Code (DTC) Retrieval, Wiring Harness Repair, Sensor Testing, Module Diagnosis

Suspension And Steering Repair:

Component Replacement (Shocks, Struts, Bushings, Control Arms), Alignment Procedures, Power Steering System Bleeding

Diagnostics:

Comprehensive Diagnostic Procedures, Troubleshooting Flowcharts, Explanations of Diagnostic Trouble Codes (DTCs)

Technical Depth

Depth:

Advanced Diagnostics and Full Rebuild Procedures

Manual Type

Coverage Scope:

From basic fluid changes to complete engine and transmission overhauls

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, Searchable Text

Print Quality

Printability:

Printable pages for workshop use

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M62TU (Technical Update)

Engine Type:

4.4L Naturally Aspirated V8

Bore X Stroke:

93 mm x 82 mm

Compression Ratio:

10.0:1

Valvetrain:

DOHC, 32 Valves (4 valves per cylinder), VANOS (Variable Valve Timing)

Performance

Horsepower:

290 hp @ 5400 rpm

Torque:

324 lb-ft @ 3600 rpm

Fuel System

Fuel Type:

Unleaded Gasoline (Premium Recommended)

Fuel Delivery:

Sequential Multi-Point Fuel Injection (Bosch Motronic ME 7.2)

Engine Oil

Oil Capacity:

7.0 Liters (7.4 US Quarts)

Recommended Oil Viscosity:

SAE 5W-30 or 5W-40 (BMW LL-01 Approved)

🔧 Transmission

Standard

Transmission Type:

5-Speed Automatic (Steptronic)

Transmission Model:

GM 5L40-E

Optional

Manual Transmission:

Not available for 540i in 2000

Features

Shift Modes:

Drive (D), Sport (S), Manual (M) via Steptronic shifter

Fluid Specifications

Transmission Fluid Type:

ATF Dexron III or equivalent (BMW LT-3 recommended for later models, verify specific OE recommendation for 2000)

Fluid Capacity

Transmission Fluid Capacity:

Approx. 8.5 Liters (17.7 US Pints) for full refill

📐 Dimensions

Exterior

Length:

4,819 mm (189.7 in)

Width:

1,769 mm (69.6 in)

Height:

1,435 mm (56.5 in)

Wheelbase:

2,830 mm (111.4 in)

Weights

Curb Weight:

Approx. 1,710 kg (3,770 lbs)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4/5 stars (Driver/Passenger)

NHTSA Side Impact:

4/5 stars (Driver/Passenger)

Active Features

Stability Control:

Dynamic Stability Control (DSC)

Traction Control:

Automatic Stability Control and Traction (ASC+T)

Passive Features

Airbags:

Frontal Airbags (Driver and Passenger), Side Impact Airbags (Front Doors)

Seatbelts:

3-point Inertia-reel Seatbelts with Pretensioners

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD or Professional CD with optional Navigation System (MK III/MK IV).

Audio System:

Standard 6-speaker system, optional upgraded Harman Kardon system.

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Connectivity

Cellular Integration:

Optional Bluetooth hands-free system (via telematics module).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 - 10,000 miles or annually, depending on driving conditions and oil used (refer to owner's manual or condition-based service system).

Transmission Fluid Interval:

Recommended at 60,000 - 80,000 miles for a fluid and filter change, though some sources suggest earlier or lifelong (refer to manual for specific recommendation).

Coolant Flush Interval:

Every 2 years or 30,000 miles.

Spark Plug Replacement:

Approximately 100,000 miles (using Long Life Spark Plugs, check manual for specific type).

Fluid Specifications

Coolant Type:

BMW Blue Coolant (G48 Ethylene Glycol based)

Brake Fluid Type:

DOT 4 (BMW Supreme 2000 or equivalent)

Known Issues

Cooling System:

Plastic coolant expansion tank can become brittle and crack; Water pump and thermostat failures are also common.

Oil Leaks:

Valve cover gaskets, oil pan gaskets, and the O-ring on the oil filter housing are common leak points.

Ignition System:

Coil-on-plug ignition system can lead to individual coil failures, causing misfires.

Vanos:

Seals within the VANOS system can degrade, leading to rough idle, loss of power, and increased fuel consumption.

ABS/Dsc Sensors:

Wheel speed sensors for ABS and DSC can fail, triggering warning lights.

Headlight Alignment:

Electric headlight leveling motors can fail.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Ultimate Driving Machine, focus on performance, engineering, and luxury.

Model Evolution

E39 Generation:

Fourth generation of the BMW 5 Series, produced from 1995 to 2003 (model years 1997-2003 in North America). Known for its balanced chassis, advanced technology for its time, and excellent build quality.

540I Positioning:

Positioned as the performance-oriented variant of the E39, offering a powerful V8 engine and a more engaging driving experience compared to the 528i or 530i.

Production

Manufacturing Locations:

Dingolfing, Germany

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

E39 5 Series chassis was a multiple recipient of Car and Driver's 10Best award.

Ratings

Consumer Reports:

Generally rated well for performance and reliability for its era, though specific issues are noted by owners.