🏷️ Basic Information

Make:

BMW

Model:

5 Series

Chassis Code:

E39

Body Style:

Sedan

Specific Model:

540i

Engine Code Typical:

M62B44 (4.4L V8)

👋 Introduction

Segment:

Executive/Luxury Sedan

Target Audience:

Discerning buyers seeking refinement, performance, and advanced technology.

Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (S160), Jaguar S-Type.

Driving Dynamics:

Renowned BMW handling and ride comfort, balanced chassis, rear-wheel drive bias.

Engine Variant:

Powerful 4.4L V8 engine (M62B44) offering strong torque and smooth power delivery.

Factory Origin:

Based on original factory service information, ensuring accuracy and completeness.

Value Proposition:

Essential resource for maintaining and repairing the E39 540i, saving time and money on professional servicing.

📋 Manual Details

Model Years:

1997, 1998, 1999, 2000, 2001, 2002

Estimated Pages:

Thousands (typically electronic manuals are comprehensive and can exceed 1000 pages when printed)

Type:

Service and Repair Manual

Language:

English

Format:

Electronic (likely PDF)

📖 Manual Coverage

Engine:

Engine mechanicals (M62B44 V8), lubrication system, cooling system, fuel system (including fuel injection), ignition system, exhaust system, engine management systems (DME), emissions control.

Transmission:

Automatic transmission (Steptronic) repair, diagnosis, fluid changes, and control systems.

Drivetrain:

Rear-wheel drive system, driveshaft, differential, axles, wheel bearings.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering system (including power steering), alignment specifications.

Brakes:

Brake system diagnosis, repair, fluid flushing, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pad and rotor replacement, parking brake.

Electrical:

Complete electrical system, battery, charging system, starter motor, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, ECU (Engine Control Unit) and module diagnostics, comfort electronics (windows, locks, mirrors, seats), climate control electronics.

Bodywork:

Body panel removal and installation, doors, hood, trunk, bumpers, glass replacement, interior trim, corrosion protection.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, refrigerant handling, compressor, evaporator, condenser, climate control module.

Interior:

Dashboard removal, instrument cluster, seats, airbags, seatbelts, sound system.

Maintenance:

Scheduled maintenance intervals, oil and filter changes, fluid level checks, spark plug replacement, air filter replacement, cabin air filter replacement.

Repair:

Engine component repair (e.g., VANOS, timing chain tensioners), transmission overhaul, brake component replacement, suspension component replacement, electrical component diagnosis and repair, body panel repair.

Troubleshooting:

Diagnostic trouble codes (DTCs), common fault diagnosis, electrical system troubleshooting, engine performance issues, HVAC problems.

Diagnostics:

On-Board Diagnostics (OBD-II) information, diagnostic tool usage, sensor testing, actuator testing.

Specifications:

Torque specifications for all fasteners, fluid capacities, component tolerances, alignment data, electrical system specifications.

Depth:

Comprehensive, covering from basic maintenance to in-depth component overhaul and advanced diagnostics, suitable for professional technicians and experienced DIY enthusiasts.

📊 Manual Specifications

File Type:

Likely PDF (Portable Document Format)

Searchability:

Searchable text content for quick access to information

Quality:

High-resolution diagrams, clear illustrations, and readable text, reflecting original factory manual standards.

Binding:

Not applicable for electronic format; if printed, would be professional binding (e.g., comb, spiral, or perfect bound).

Paper:

Not applicable for electronic format; if printed, typically high-quality paper suitable for technical documentation.

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated V8

Displacement:

4.4 Liters (4398 cc)

Bore X Stroke:

91.0 mm x 82.7 mm (typical for M62B44)

Compression Ratio:

10.0:1 (typical)

Valve Train:

DOHC (Dual Overhead Camshafts), 4 valves per cylinder

Valvetronic:

No (uses traditional throttle body)

Vanos:

Double VANOS (Variable Valve Timing)

Horsepower:

Approximately 282 hp @ 5400 rpm (DIN)

Torque:

Approximately 317 lb-ft (430 Nm) @ 3600 rpm (DIN)

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Engine Management:

BMW Digital Motor Electronics (DME) 7.1 (or similar)

🔧 Transmission

Type:

5-speed Steptronic Automatic Transmission (GM 5L40-E / 5HP19)

Type:

5-speed Manual Transmission (Getrag 420G)

Steptronic:

Allows manual selection of gears via shifter or steering wheel buttons (on some models).

Automatic Transmission Fluid:

BMW ATF LT-3 (or equivalent specified fluid for the 5HP19/5L40-E)

Automatic Transmission Capacity:

Approximately 9.5 liters (2.5 US gallons) for a complete fluid service including torque converter.

5Hp19 Ratios:

1st: 3.23, 2nd: 2.14, 3rd: 1.41, 4th: 1.00, 5th: 0.75, Reverse: 2.37 (typical, verify with manual)

📐 Dimensions

Length:

4,770 mm (187.8 in)

Width:

1,798 mm (70.8 in)

Height:

1,436 mm (56.5 in)

Wheelbase:

2,830 mm (111.4 in)

Front Track:

1,511 mm (59.5 in)

Rear Track:

1,525 mm (60.0 in)

Curb Weight:

Approximately 1,675 kg (3,693 lbs) for automatic transmission models.

Gross Weight Rating:

Approximately 2,150 kg (4,740 lbs)

Trunk Volume:

Approximately 500 liters (17.7 cu ft)

Wheel Bolt Pattern:

5 x 120 mm

Typical Wheel Size:

16-inch, 17-inch, or 18-inch alloy wheels

Typical Tire Sizes:

205/55R16, 225/55R16 (front), 235/50R17 (rear), 235/40R18 (front), 265/35R18 (rear) - vary by trim and options. Check manual for specific fitments.

🛡️ Safety Features

NHTSA Front Impact:

Not specifically rated by NHTSA for this exact year/model. BMW generally aimed for high safety standards.

IIHS Side Impact:

Not specifically rated by IIHS for this exact year/model. E39 generation known for good structural integrity.

Airbags:

Front airbags (driver and passenger), optional side airbags.

Seatbelts:

3-point inertia-reel seatbelts with pretensioners and force limiters.

Body Structure:

Reinforced safety cell, crumple zones.

ABS:

Standard Anti-lock Braking System (ABS).

Dsc:

Standard Dynamic Stability Control (DSC) or Traction Control System (ASR) depending on model year and region.

Headlights:

Halogen projector headlights, optional Xenon High-Intensity Discharge (HID) headlights with automatic leveling.

💡 Technology Features

Head Unit:

BMW Business CD, BMW Professional CD, or optional BMW Navigation system with integrated radio and CD player.

Display:

Central LCD display on dashboard for climate control, radio, and navigation information (often suffers from dead pixels).

Audio System:

Standard BMW 6-speaker system, optional premium Hi-Fi system (e.g., Harman Kardon).

Cruise Control:

Standard cruise control.

Parking Sensors:

Optional rear Park Distance Control (PDC).

Phone Integration:

Optional Bluetooth or cellular phone preparation with hands-free system.

Seats:

Standard comfort seats, optional sport seats, power adjustment with memory for driver's seat, heated seats.

Climate Control:

Automatic climate control with dual-zone temperature settings, optional rear climate control.

🔧 Maintenance

Oil Change Interval:

BMW's 'Condition Based Service' (CBS) system will indicate based on driving style, but typically around 7,500-15,000 miles or annually. Refer to manual for exact CBS logic or fixed intervals if applicable.

Engine Oil Type:

BMW Longlife-01 (LL-01) or LL-98 approved synthetic oil, typically 5W-30 or 5W-40. Refer to manual for exact specification.

Engine Oil Capacity:

Approximately 7.5 liters (7.9 US quarts) with filter change for the M62B44.

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) or equivalent.

Spark Plug Replacement:

Around 60,000 miles (check manual for specific type and interval). Typically NGK BKR6EQUP or Bosch FGR7DQP.

Automatic Transmission Service:

Fluid and filter change recommended between 50,000 to 100,000 miles, depending on driving conditions and manufacturer recommendation (often considered 'lifetime' by some, but proactive changes are advised).

Cooling System:

Plastic coolant expansion tank, water pump, and radiator hoses are prone to degradation and leaks.

Engine Oil Leaks:

Valve cover gaskets, oil pan gaskets, and crank seal leaks are common with age.

Vanos:

VANOS solenoids and seals can fail, leading to rough idle and power loss, particularly at low RPMs.

Timing Chain Tensioners:

Plastic timing chain tensioners (on earlier M62 engines) can degrade and fail, leading to rattling noises and potential catastrophic engine damage. Later M62TU engines use metal tensioners.

Ccv System:

Crankcase Ventilation (CCV) system can become clogged, leading to oil leaks and pressure buildup.

ABS Sensors:

ABS wheel speed sensors are a common failure point, leading to ABS and DSC warning lights.

Pixel Display:

Instrument cluster LCD display ('dead pixels') issues are prevalent on many E39s.

Power Window Regulators:

Power window regulators can fail, often due to plastic wear.

📚 Vehicle History

Bmw Legacy:

BMW's reputation for 'The Ultimate Driving Machine,' engineering excellence, and sporting sedans.

E39 Introduction:

The E39 generation of the 5 Series was introduced in 1995 (as a 1996 model in Europe) and replaced the E34 generation. It was praised for its improved handling, comfort, and build quality.

E39 Facelift:

The E39 received a significant facelift in 2000 (for the 2001 model year), introducing updated headlights (angel eyes), taillights, bumpers, and interior refinements. The 540i specifically continued with the M62 engine, though some later models saw minor revisions.

Production Years E39:

1995-2003

Production Location:

Primarily Dingolfing, Germany.

🏆 Awards & Recognition

Car And Driver Best:

Car and Driver magazine frequently listed the E39 5 Series (including various engine variants) on its annual '10Best Cars' list during its production run, praising its balance of sport and luxury.

Auto Motor Und Sport:

Often received high marks in comparisons and awards from European automotive publications for its driving dynamics and build quality.

Overall Reputation:

Widely regarded as one of the best driving and most robustly built sedans of its era, earning a strong enthusiast following.