Coverage Summary:
All Models, Engines, Trim, and Transmission Types for the 2002 BMW 540i.
Estimated Page Count:
Hundreds of pages
Type:
Workshop Repair Service Manual
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader & WinZip
Operating Systems:
Compatible with All Versions of Windows & Mac
Engine Service And Repair:
YES
Transmission Service And Repair:
YES
Fuel Injection And Fuel System:
YES
Heating And Air Conditioning:
YES
Engine Control System:
YES
Differential And Drive Axle:
YES
Periodic Lubrication:
YES
Diagnostic Procedures:
YES
Disassembly And Assembly:
YES
Cleaning And Reinstallation:
YES
Depth:
Comprehensive, covering all aspects from routine maintenance to in-depth repairs and diagnostics, mirroring factory technician standards.
Diagrams And Illustrations:
Detailed diagrams, drawings, and photos are included to guide through repair procedures.
Troubleshooting Complexity:
Combines troubleshooting with electrical service procedures and detailed wiring diagrams for comprehensive issue diagnosis.
Transmission Type:
5-speed Automatic (Steptronic)
Transmission Type Optional:
6-speed Manual (on select markets/models)
Steptronic Functionality:
Allows manual gear selection.
NHTSA Front Impact:
Not explicitly rated for 2002 model year in easily accessible data, but generally performed well for its era.
Traction Control:
Automatic Stability Control (ASC+T)
Braking System:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)
Airbags:
Driver and front passenger airbags, side-impact airbags.
Seatbelts:
Pretensioning seatbelts with force limiters.
Navigation System:
Available BMW Professional Navigation System (MKIII or MKIV)
Audio System:
Available Hi-Fi or Harman Kardon premium sound systems.
Parking Sensors:
Available Park Distance Control (PDC) front and rear.
Telematics:
BMW Assist with Tele Aid emergency calling available on some models.
Climate Control:
Dual-zone automatic climate control.
Oil Change Interval:
Variable, based on BMW's Condition Based Service (CBS) system. Typically around 10,000-15,000 miles or 12-24 months.
Spark Plug Replacement:
Around 100,000 miles for iridium spark plugs, as specified by BMW for the M62TU.
Engine Oil Type:
BMW Longlife-01 (LL-01) or LL-04 compliant synthetic oil, typically SAE 0W-40 or 5W-30.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based).
Transmission Fluid Automatic:
BMW ATF Dexron III or equivalent (check specific service bulletin for precise fill).
Cooling System Component Failure:
Plastic coolant expansion tanks, hoses, and water pumps can degrade over time. Thermostat failures are also common.
Vibration Issues:
Driveshaft center support bearing, guibo (flex disc), and differential bushings can wear, leading to vibrations, especially under acceleration or deceleration.
Oil Leaks:
Valve cover gaskets, oil pan gaskets, and front crank seal leaks are common due to age and heat.
ABS Wheel Speed Sensor Failure:
Often leads to ABS and DSC warning lights. Sensors are prone to failure due to heat and contamination.
Window Regulator Failure:
Plastic components within the window regulator mechanism can break.
Pixel Loss In Display:
Instrument cluster and infotainment displays can suffer from dead pixels.
Brand Focus:
BMW, Bayerische Motoren Werke AG, is renowned for producing luxury and performance automobiles, with a strong emphasis on driving dynamics ('The Ultimate Driving Machine').
E39 Generation:
The 2002 model year falls within the second generation (E39) of the BMW 5 Series, produced from 1995 to 2003. The 540i was positioned as a high-performance, luxury variant within this generation.
Production Period:
The E39 5 Series was produced from 1995 to 2003. The 540i specifically was a prominent model within this range, particularly known for its V8 engine.
