Systems Covered:
Engine mechanical, Engine electrical, Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system, Drivetrain, Transmission (automatic), Brakes (hydraulic, ABS), Steering, Suspension, Climate control, Body electrical, Bodywork, Interior, Chassis, HVAC, SRS (Airbag) systems.
Type:
Factory Service Repair Manual
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of the M62B44 V8 engine, including cylinder heads, block, pistons, connecting rods, crankshaft, camshafts, timing components, valves, and seals.
Engine Electrical:
Detailed wiring diagrams, troubleshooting guides for engine control units (ECU), sensors (crankshaft position, camshaft position, MAF, O2, etc.), ignition coils, starter, alternator, and battery system.
Transmission:
Service and repair procedures for the ZF 5HP30 5-speed automatic transmission, including hydraulic control, torque converter, clutch packs, valve body, electronic control, fluid specifications, and capacities.
Brakes:
Comprehensive coverage of the hydraulic braking system, including ABS (Anti-lock Braking System) and DSC (Dynamic Stability Control), brake fluid specifications, caliper overhaul, rotor replacement, brake pad specifications, and bleeding procedures.
Suspension Steering:
Detailed diagrams and repair instructions for front and rear suspension components, including control arms, shock absorbers, springs, bushings, power steering system, steering rack, and wheel alignment specifications.
Routine Maintenance:
Oil and filter changes, air filter replacement, cabin filter replacement, spark plug replacement, fuel filter replacement, coolant flush and fill, brake fluid flush, and differential fluid change.
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts, OBD-II diagnostic trouble codes (DTCs) and their meanings, electrical system diagnostics, and engine performance issues.
Component Overhaul:
Detailed instructions for the overhaul of major components such as cylinder heads, pistons, transmission valve body, brake calipers, power steering rack, and alternator.
Body And Trim:
Procedures for interior and exterior trim removal and installation, door panel removal, bumper replacement, headlight and taillight replacement, and glass replacement.
Depth:
Extensive technical detail covering from basic fluid changes and component replacements to complete engine and transmission rebuilds, including torque specifications, clearances, and special tool requirements.
Transmission Type:
5-speed Automatic (ZF 5HP30)
Manual Transmission Availability:
Not commonly available for the 540i in North America for this model year; primarily automatic.
Sport Mode:
Yes (Tiptronic-style manual shifting capability)
Transmission Fluid Type:
ATF LT-3 (BMW part number 83 22 0 030 949 or equivalent)
Transmission Fluid Capacity:
Approximately 9.5 liters (pan refill) / 12.5 liters (total)
NHTSA Front Impact Driver:
4 stars (for pre-1998 era testing)
NHTSA Front Impact Passenger:
4 stars (for pre-1998 era testing)
ABS:
Standard (BMW Advanced ABS)
Traction Control:
Standard (ASR - Automatic Stability Control)
Stability Control:
Optional/Available (DSC - Dynamic Stability Control)
Airbags:
Driver and front passenger airbags, optional side airbags.
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners.
Head Unit:
BMW Business CD or Professional RDS CD/Cassette Player. Optional navigation system (MKII).
Audio System:
Standard 8-speaker system. Optional premium Hi-Fi system with amplifier and subwoofer.
Cruise Control:
Standard electronic cruise control.
Parking Assistance:
Optional rear parking sensors (Park Distance Control - PDC).
Telematics:
Optional BMW Assist telematics service (may be discontinued).
Climate Control:
Standard automatic climate control with dual-zone temperature settings.
Oil Change Interval:
Varies by driving conditions and oil quality, typically 7,500-10,000 miles or annually. Consult the vehicle's Condition Based Service (CBS) system if equipped or the owner's manual for precise intervals.
Transmission Fluid Change Interval:
BMW initially stated 'lifetime' fluid, but proactive changes every 60,000-80,000 miles are highly recommended by enthusiasts and mechanics for transmission longevity.
Spark Plug Replacement:
Approx. 100,000 miles (depending on plug type and condition).
Engine Oil Type:
SAE 5W-30 or 5W-40 Synthetic, meeting BMW LL-01 or LL-98 specifications (e.g., Castrol Syntec, Mobil 1).
Engine Oil Capacity:
8.5 US Quarts (8.0 Liters)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) mixed 50/50 with distilled water.
Common Problems:
VANOS (Variable Valve Timing) system issues (oil leaks, rattling), coolant expansion tank leaks, water pump failure, alternator bearing failure, starter failure, oil pan gasket leaks, ignition coil failures, mass air flow sensor (MAF) issues, and early E39 door handle exterior trim separation.
Symptom Examples:
Rough idle, loss of low-end torque, rattling sound on startup (VANOS), overheating (coolant system), intermittent starting (starter/alternator).
