Target Audience:
Professional automotive technicians, experienced DIY mechanics, BMW enthusiasts
Value Proposition:
Provides dealership-level service information, enabling cost savings on repairs and maintenance and empowering owners to perform their own work.
Safety Emphasis:
Highlights safety warnings, cautions, and notes essential for safe operation and repair procedures.
Accuracy And Reliability:
Stated to contain the most reliable information, aiming for accuracy and completeness for any repair needs.
Applicable Years:
1997, 1998, 1999, 2000, 2001, 2002
Covered Models:
BMW 540i, 540i Sport, 540i Touring (if applicable to the 540 designation within E39 for these years)
Estimated Page Count:
Comprehensive (Specific page count not provided in product info, but implies extensive coverage)
Manual Type:
Workshop Service Manual
Engine:
Complete repair, overhaul, diagnostics, tuning, lubrication system, fuel system, ignition system, cooling system, exhaust system
Transmission:
Removal, installation, repair, overhaul, fluid specifications
Electrical System:
Wiring diagrams, component testing, diagnostics, EWS (Immobilizer), ABS, DSC, body electronics, lighting
Bodywork:
Body panel removal/installation, interior trim, glass, seals, collision repair information (general)
Suspension And Steering:
Component identification, removal/installation, diagnostics, alignment specifications
Brakes:
Brake system diagnostics, repair, fluid specifications, ABS, DSC integration
HVAC System:
Diagnosis and repair of heating, ventilation, and air conditioning systems
Maintenance:
Routine maintenance, tune-ups, fluid changes, filter replacements, scheduled servicing
Repair And Overhaul:
Complete repair and overhaul procedures for all major vehicle systems, including engine and transmission disassembly/reassembly
Diagnostics:
Troubleshooting guides, diagnostic flowcharts, symptom-based diagnostics, OBD-II (On-Board Diagnostics) information
Installation And Removal:
Step-by-step instructions for component removal and installation
Depth Of Coverage:
Comprehensive: Covers everything from routine maintenance to full engine and transmission rebuilds, suitable for professional technicians and knowledgeable DIY enthusiasts.
Special Tool Identification:
References and illustrations of required BMW special tools with their corresponding part numbers.
Proprietary Component Information:
Includes instructions for proprietary BMW components and integrated procedures for third-party manufactured components used in the vehicle.
Engine Type:
V8, Naturally Aspirated
Engine Code Families:
M62 (e.g., M62B44)
Displacement:
4.4 Liters (4398 cc)
Horsepower Range:
Approximately 282-290 hp (depending on year and specific market)
Torque Range:
Approximately 317-324 lb-ft (depending on year and specific market)
Fuel Delivery:
Electronic Fuel Injection (EFI), Bosch Motronic (likely)
Fuel Type:
Premium Unleaded Gasoline (91+ octane)
Valvetrain:
Dual Overhead Camshafts (DOHC), 4 valves per cylinder
Block Material:
Aluminum Alloy
Head Material:
Aluminum Alloy
Transmission Type Standard:
5-speed Automatic (Steptronic)
Transmission Type Optional:
6-speed Manual (for some markets/variants)
Automatic Transmission Features:
Steptronic manual shifting mode
Automatic Transmission Fluid:
Dexron III or equivalent (refer to manual for specific BMW fluid P/N)
Manual Transmission Fluid:
BMW MTF LT-1 or LT-2 (refer to manual for specific P/N)
Length:
Approx. 190.6 inches (4841 mm)
Width:
Approx. 71.1 inches (1806 mm)
Height:
Approx. 57.1 inches (1450 mm)
Wheelbase:
Approx. 111.4 inches (2830 mm)
Curb Weight Range:
Approx. 3700 - 3900 lbs (1678 - 1769 kg)
Gross Vehicle Weight Rating:
Varies by model and configuration (refer to manual for specifics)
NHTSA Frontal Impact:
4-star driver, 4-star passenger (1997-1999 models)
IIHS Side Impact:
Acceptable (Good for later models with updated side airbags)
ABS:
Standard Anti-lock Braking System
Dsc:
Dynamic Stability Control (DSC) standard on most 540 models
Airbags:
Frontal airbags, side airbags (optional/standard depending on year/trim)
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Child Seat Anchors:
LATCH system (standard from 2001 model year)
Infotainment System:
BMW Professional Radio, available with optional CD changer, navigation system (MK III/IV), and premium audio systems (e.g., Harman Kardon).
Cruise Control:
Standard cruise control, potentially with adaptive features on later models.
Parking Assistance:
Optional rear parking sensors (Park Distance Control - PDC).
Cellular Integration:
Optional Bluetooth hands-free system (Tele Aid/BMW Assist on some models).
Climate Control:
Automatic climate control with dual-zone temperature control.
Lighting:
Xenon (HID) headlights with automatic leveling and washers (optional/standard depending on year/trim).
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically around 10,000-15,000 miles or annually, depending on driving conditions. Manual will detail exact intervals.
Transmission Fluid Change:
BMW initially claimed 'lifetime' fluid for automatic transmissions, but recommended service intervals of 60,000-100,000 miles are now common practice. Manual will specify.
Engine Oil Type:
SAE 5W-30 or 0W-40 Synthetic (BMW Longlife-01 or LL-04 specification recommended. Manual will confirm)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based). Manual will specify the correct BMW part number.
Brake Fluid Type:
DOT 4 (Low Viscosity - LV) brake fluid. Manual will specify the correct BMW part number.
Common Wear Items:
Vibration dampers (harmonic balancers), cooling system components (water pump, thermostat, hoses), VANOS system, oil pan gaskets, vacuum lines, fuel pump, ignition coils, spark plugs, window regulators, door handle microswitches, strut mounts, control arms.
Typical Diagnostics:
Misfires, rough idle, power loss, cooling system leaks, oil leaks, ABS/DSC warning lights, drivetrain vibrations.
Brand Focus:
BMW, renowned for its 'Ultimate Driving Machine' slogan, emphasizing performance, luxury, and engineering.
E39 Introduction:
The E39 generation of the 5 Series was introduced in 1995 (as a 1997 model in North America) and ran until 2003, representing a significant advancement in luxury, technology, and chassis dynamics.
540I Positioning:
The 540i was positioned as the performance-oriented sedan within the E39 lineup, featuring a powerful V8 engine and often enhanced suspension and braking components.
Production Locations:
Primarily manufactured in Dingolfing, Germany.
Car And Driver Awards:
Car and Driver 10Best list multiple times during its production run, a testament to its engineering and performance.
Consumer Reports Ratings:
Generally well-regarded for performance and handling, though can have average to below-average reliability ratings in later years due to complex electronics and potential maintenance issues.
Manufacturer Certification:
Official BMW workshop manual content, providing manufacturer-approved repair procedures and specifications.
