The BMW 540i, produced in 1993 as part of the E34 generation, represents a pinnacle of German luxury and performance engineering. This executive sedan, powered by a robust 4.0L V8 M60B40 engine delivering approximately 282 horsepower and 295 lb-ft of torque, was designed to offer a superior driving experience, embodying BMW's philosophy of "The Ultimate Driving Machine." Known for its sophisticated design, comfortable interior, and advanced (for its time) features like an optional automatic climate control and anti-lock braking system, the 540i was a testament to BMW's commitment to quality and driving dynamics, earning accolades such as a place on Car and Driver's 10Best lists.
This comprehensive workshop repair service manual provides detailed information for the BMW 540i (E34), covering all engine and transmission variants. It is an indispensable resource for DIY enthusiasts, independent repair shops, and technicians, offering factory-level technical data for maintenance, diagnostics, and repair procedures. The manual covers all major systems, including engine management, drivetrain, suspension, steering, braking, electrical systems, climate control, and body/chassis. With hundreds of pages featuring detailed illustrations, step-by-step instructions, and critical notes, this English-language manual empowers users to maintain their vehicle effectively, ensuring longevity and optimal performance while potentially saving costs compared to dealership services.
Engine Code Primary:
M60B40
Target Audience:
DIY enthusiasts, independent repair shops, and BMW owners seeking in-depth maintenance and repair knowledge.
Value Proposition:
Provides factory-level technical data, enabling significant cost savings on repairs and maintenance compared to dealership services.
Documentation Source:
Original manufacturer documentation, identical to what professional technicians use.
Navigation:
Numbered table of contents for quick information retrieval.
Vehicle Models:
BMW 540i (E34), all engine and transmission variants
Estimated Page Count:
Hundreds (as stated in product description)
Type:
Workshop Repair Service Manual
Engine Management:
Fuel Injection, Engine Control System (DME)
Drivetrain:
Transmission, Differential, Axle
Suspension Steering:
Suspension, Steering System
Braking:
Brake System (including ABS)
Electrical:
Electrical System, Wiring Diagrams
Climate Control:
Heater/Air Conditioning
Body Chassis:
Chassis/Body, Interior
Safety Restraint:
Restraint System (Airbags)
Maintenance:
General Maintenance, Periodic Lubrication
Diagnostics:
Troubleshooting
Repair:
Engine Service/Repair, Transmission Service/Repair, Brake System Repair, Suspension Repair, Steering Repair, Cooling System Repair, Fuel System Repair, Emission System Repair, HVAC Repair, Electrical System Repair, Chassis/Body Repair, Interior Repair
Disassembly Assembly:
Detailed disassembly and reassembly procedures for all major components
Depth:
Professional-level diagnostics, repair, and maintenance; detailed substeps, notes, cautions, and warnings
Availability:
Detailed illustrations, drawings, photos, and enlarged insets
Printability:
Full Printable
Zoom Capabilities:
Zoom IN/OUT
Software Requirements:
Adobe PDF Reader & WinZip
Operating Systems:
All Versions of Windows & Mac
Engine Type:
4.0L V8 (M60B40)
Horsepower:
Approx. 282 hp @ 5800 rpm (for M60B40)
Torque:
Approx. 295 lb-ft @ 4500 rpm (for M60B40)
Fuel Delivery:
Multi-point fuel injection (Bosch Motronic ECU)
Coolant Type Specification:
BMW Blue Antifreeze (G48 ethylene glycol based)
Oil Type Specification:
SAE 5W-30 or 5W-40 Synthetic (e.g., Castrol Syntec, BMW High Performance Synthetic)
Ignition System:
Distributorless ignition (DIS) with individual coil packs.
Type:
5-speed Automatic (e.g., ZF 5HP30)
Type:
5-speed Manual (Getrag 420G, though less common for the 540i in this generation, often found in M5 models but the manual covers all variants)
Automatic Modes:
Sport and Economy modes
Automatic Transmission Fluid:
BMW ATF LT71141 (ZF Approved)
Length:
Approx. 191.1 inches
Width:
Approx. 70.1 inches
Height:
Approx. 55.9 inches
Curb Weight:
Approx. 3700-3800 lbs
Wheelbase:
Approx. 111.4 inches
Passive Safety Features:
Front airbags, crumple zones, reinforced passenger compartment.
Driver Assistance:
Anti-lock Braking System (ABS) standard.
Audio System:
Factory premium sound system, optional CD changer.
Traction Control:
Automatic Stability Control (ASC) or ASC+T (Traction Control) optional on some models.
HVAC Features:
Automatic climate control (optional) with recirculation mode and cabin microfilter.
Oil Change:
Every 7,500-10,000 miles or annually with synthetic oil, as per specific vehicle conditions and driving habits. (Refer to manual for exact interval based on oil quality and driving).
Spark Plugs:
Refer to manual, typically around 60,000 miles for platinum or iridium plugs.
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Brake Fluid:
DOT 4 (BMW Part No. 81 22 9 400 343)
Power Steering Fluid:
Pentosin CHF 11S (BMW Part No. 81 22 9 407 305)
Differential Fluid:
SAE 75W-90 Synthetic Gear Oil (API GL-5 compliant)
Cooling System:
Plastic coolant expansion tanks can become brittle and crack; water pump failure is also common. M60 engines are known for potential head gasket issues if overheated.
Electrical:
Vanous electrical gremlins can occur due to age, including faulty door lock actuators, window regulators, and ABS/ASC sensor issues.
Fuel System:
Fuel pump failure and clogged fuel injectors can occur.
Suspension:
Wear in control arm bushings, ball joints, and shock absorbers is typical for vehicles of this age.
Bmw Philosophy:
German luxury and performance, focus on driving dynamics ('The Ultimate Driving Machine').
E34 Generation:
The E34 generation (1988-1996) represented BMW's executive sedan, known for its sophisticated engineering and driver-focused cockpit. The 540i introduced the powerful V8 engine to the 5 Series line-up.
Manufacturing Location:
Germany
Car And Driver 10Best:
The E34 generation 5 Series, including variants like the 540i, frequently appeared on Car and Driver's 10Best lists in its era for its balance of luxury, performance, and handling.
