🏷️ Basic Information

Make:

BMW

Model:

540i

Model Code:

E39

Year:

2002

Engine Code Primary:

M62TU V8

👋 Introduction

Vehicle Segment:

Executive Sedan / Mid-size Luxury Sedan

Key Competitors:

Mercedes-Benz E-Class (W211), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type

Target Audience:

Enthusiasts, DIY mechanics, professional technicians seeking in-depth repair knowledge

Value Proposition:

Provides factory-accurate information crucial for maintaining and repairing the BMW 540i (E39) to OEM standards.

📋 Manual Details

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

Estimated Page Count:

Hundreds (Exact count varies based on specific factory publication, typically 1000+ pages for comprehensive coverage)

📖 Manual Coverage

Engine:

Complete engine overhaul, disassembly, assembly, diagnosis, component testing (e.g., VANOS, ignition system, fuel injection, cooling system)

Transmission:

Automatic transmission (e.g., GM 5L40-E) repair, overhaul, diagnosis, fluid specifications, solenoids, torque converter

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), rotor/pad replacement, caliper service, bleeding procedures

Suspension:

Front and rear suspension components, struts, shocks, control arms, bushings, alignment specifications, steering rack

Electrical:

Wiring diagrams, component locations, fuse box layouts, starter, alternator, battery, lighting, power windows, central locking, diagnostic trouble codes (DTCs)

Bodywork:

Body panel removal/installation, door mechanisms, interior trim, bumpers, glass replacement, rust prevention and repair

Climate Control:

HVAC system diagnosis, refrigerant handling, compressor service, blower motor, climate control unit troubleshooting

Fuel System:

Fuel pump, injectors, fuel pressure regulator, fuel tank service, evaporative emission control (EVAP) system

Exhaust System:

Exhaust manifold, catalytic converter, muffler, oxygen sensors, exhaust leak diagnosis

Cooling System:

Radiator, coolant pump, thermostat, hoses, expansion tank, pressure testing, coolant specifications

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides

Repair:

Step-by-step repair instructions for virtually every component and system on the vehicle

Installation:

Instructions for installing new or replacement parts and accessories

Diagnostics:

Guidance on using diagnostic tools (e.g., BMW ISTA/D or similar), interpreting sensor data, and identifying fault codes

Depth Level:

Comprehensive (covers everything from basic maintenance to full engine/transmission rebuilds and advanced electrical diagnostics)

📊 Manual Specifications

File Format Type:

PDF

Searchability:

Searchable text for quick information retrieval

Print Capability:

Printable (entire manual or selected pages)

Binding Type Digital:

N/A (Digital Download)

Paper Type Digital:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated V8

Displacement:

4.4 Liters (4398 cc)

Valvetrain:

DOHC (Double Overhead Camshaft), 4 valves per cylinder (32 valves total)

Engine Management System:

Bosch Motronic (e.g., ME 7.2)

Horsepower:

290 hp @ 5400 rpm (approx.)

Torque:

324 lb-ft @ 3600 rpm (approx.)

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MFI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Variable Valve Timing:

Double VANOS (Variable Valve Timing for both intake and exhaust camshafts)

🔧 Transmission

Transmission Type:

5-speed Automatic (GM 5L40-E)

Transmission Type Optional:

5-speed Manual (Getrag 420G) - typically found on M Sport or specific 540i models

Traction Control:

Standard (ASR/ASC+T)

Stability Control:

Standard (DSC - Dynamic Stability Control)

Automatic Transmission Fluid:

BMW ATF LT-3 or equivalent (Dexron III/Mercon compatible, check manual for exact specs)

📐 Dimensions

Length:

191.1 inches (4854 mm)

Width:

71.0 inches (1803 mm)

Height:

57.7 inches (1466 mm)

Wheelbase:

113.4 inches (2881 mm)

Curb Weight:

Approx. 3700-3800 lbs (1680-1725 kg)

🛡️ Safety Features

NHTSA Front Impact:

4 Stars (Driver), 4 Stars (Passenger) - for E39 generation (specific 2002 ratings may vary)

IIHS Side Impact:

Good (for E39 generation, check specific year for definitive ratings)

Active Safety Systems:

Dynamic Stability Control (DSC), Traction Control (ASC+T), ABS (Anti-lock Braking System), Electronic Brakeforce Distribution (EBD), Cornering Brake Control (CBC)

Passive Safety Features:

Front airbags, front side-impact airbags, front and rear head protection system (HPS), crumple zones, reinforced door beams, seatbelt pre-tensioners

💡 Technology Features

Infotainment System:

BMW Business CD or Professional CD/Radio systems, often with optional GPS Navigation system (MKIV).

Speaker System:

Standard 10-speaker Hi-Fi system or optional Harman Kardon premium audio.

Driver Assistance Features:

Cruise Control, Parking Distance Control (PDC) - front and rear sensors.

Connectivity Options:

Optional Bluetooth integration (UHV - Universal Hands-free system), BMW Assist telematics.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000-15,000 miles or 12-24 months, dependent on driving conditions and oil used (refer to manual for specific CBS recommendations).

Transmission Fluid Interval:

BMW historically stated 'lifetime' for automatic transmission fluid, but independent experts and many owners recommend fluid and filter changes every 60,000-100,000 miles.

Coolant Interval:

First change at 2 years/25,000 miles, subsequent changes every 2 years/25,000 miles (using BMW Blue coolant).

Engine Oil Specification:

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

Engine Oil Capacity:

Approx. 7.5 liters (7.9 US quarts) with filter change.

Coolant Specification:

BMW Blue Antifreeze/Coolant (G48 type)

Brake Fluid Specification:

DOT 4 (BMW recommendation, check manual for specific DOT rating and change interval).

Common Issues Engine:

Oil leaks (valve cover gaskets, oil pan gasket), VANOS solenoid issues, ignition coil failure, water pump leaks, PCV system issues.

Common Issues Suspension:

Worn control arm bushings, sagging springs, worn shock absorbers/struts, steering rack leaks.

Common Issues Electrical:

ABS/DSC sensor failures, alternator issues, headlight leveling system problems, window regulator failures, LCM (Light Control Module) issues.

Common Issues Cooling:

Plastic coolant expansion tanks becoming brittle and cracking, thermostat housing leaks, water pump impeller failure.

📚 Vehicle History

Bmw Philosophy:

Sheer Driving Pleasure, focus on performance, luxury, and engineering excellence.

E39 Generation Introduction:

Introduced in 1995 (Europe) / 1997 (North America), as the successor to the E34.

E39 Facelift:

Received a significant facelift in 2000, introducing updated headlights ('angel eyes'), taillights, bumpers, and interior refinements. The 2002 model year falls within this facelifted period.

Production Years E39:

1995-2003

Manufacturing Locations:

Dingolfing, Germany (primary), Spartanburg, USA (some variants)

🏆 Awards & Recognition

Car And Driver 10 Best:

The E39 5 Series (including the 540i) was a perennial contender and often named to Car and Driver's 10Best list during its production run, lauded for its balance of performance, luxury, and handling.

Jd Power Initial Quality:

Consistently ranked well in its segment for initial quality and dependability during its time, reflecting BMW's commitment to build quality.