🏷️ Basic Information

Make:

BMW

Model:

540i

Year:

1990

Chassis Code:

E34

Engine Code Common:

M60B40

👋 Introduction

Positioning:

The BMW 540i (E34) represented the pinnacle of performance and luxury in the mid-size executive sedan segment for its era, directly competing with Mercedes-Benz E-Class and Audi V8.

Competitors:

Mercedes-Benz W124 E-Class (particularly the 400E/500E), Audi V8 Quattro.

Vehicle Highlights:

Powerful V8 engine, sophisticated suspension, luxurious interior, renowned BMW driving dynamics, advanced (for the time) electronics.

Value Proposition:

This factory manual provides BMW-specific, accurate, and comprehensive information crucial for proper maintenance, diagnosis, and repair of the 1990 540i, essential for preserving its performance and value.

📋 Manual Details

Coverage:

Complete factory service and repair information for the 1990 BMW 540i (E34 chassis).

Pages:

Hundreds of pages (specific count not provided, but indicative of comprehensive coverage).

Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, lubrication, cooling, exhaust, engine management (DME), transmission (automatic).

Chassis:

Suspension (front and rear), steering, brakes (ABS, hydraulic, parking), driveline (rear-wheel drive).

Electrical:

Wiring diagrams, battery, charging system, starting system, lighting, instruments, control modules (DME, ABS, etc.), comfort systems.

Body:

Exterior body panels, interior trim, doors, windows, sunroof, HVAC system, seats.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, belt inspections.

Repair:

Engine component removal/installation (e.g., cylinder heads, pistons, crankshaft), transmission service, brake caliper replacement, suspension bushing replacement, HVAC component repair.

Diagnostics:

Troubleshooting guides for common issues, diagnostic trouble codes (DTCs) interpretation (for DME and ABS), wiring diagram interpretation for fault finding.

Specifications:

Torque specifications for all critical fasteners, clearances, timing procedures, electrical system voltage and resistance checks.

Depth:

Comprehensive, covering everything from basic fluid checks and filter changes to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical system troubleshooting.

📊 Manual Specifications

File Type:

PDF

Printability:

High-resolution, allowing for clear printing of individual pages or the entire manual.

Binding Description:

Not applicable as it is a digital download; however, designed for easy printing and binding.

Recommended Paper:

Standard copier paper (8.5" x 11" or A4) suitable for digital printing.

Text Search:

Likely to be searchable text, enabling quick access to specific information.

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated V8

Engine Code:

M60B40

Displacement:

3.982 cc (4.0 Liters)

Bore X Stroke:

84 mm x 89.6 mm

Compression Ratio:

10.0:1

Horsepower Net:

282 hp (210 kW) @ 5800 rpm

Torque Net:

295 lb-ft (400 Nm) @ 4500 rpm

Fuel Delivery:

Bosch Motronic M3.3 fuel injection

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Engine Control Unit:

DME (Digital Motor Electronics)

Ignition System:

Distributorless ignition with two ignition coils

🔧 Transmission

Transmission Type:

4-speed Automatic (ZF 4HP-22 EH)

Optional Transmission:

5-speed Manual (Getrag 265/5 - rare for 540i in North America)

Automatic Features:

Electronic shift control, Sport/Economy mode selection.

Automatic Transmission Fluid:

BMW ATF JWS 3309 (or equivalent like Dexron III for older specs, consult manual for definitive)

📐 Dimensions

Wheelbase:

2763 mm (108.8 inches)

Length:

4720 mm (185.8 inches)

Width:

1751 mm (68.9 inches)

Height:

1380 mm (54.3 inches)

Curb Weight:

1750 kg (3858 lbs) - approximate, varies with options.

Gross Vehicle Weight Rating:

Not specified, but typical for the class.

Trunk Volume:

Approximately 450 liters (15.9 cubic feet)

🛡️ Safety Features

Safety Certification:

Not directly comparable to modern NHTSA/Euro NCAP ratings; relied on passive safety systems and robust construction.

ABS:

Standard Anti-lock Braking System (ABS III)

Traction Control:

Optional ASC (Automatic Stability Control) or ASC+T on some later models, but likely not standard on all 1990 540i.

Airbags:

Driver's side airbag standard; passenger airbag optional or not available on all models.

Seatbelts:

3-point inertia-reel seatbelts front and rear, with pretensioners for front occupants.

Body Structure:

Reinforced passenger safety cell, crumple zones.

💡 Technology Features

Audio System:

Factory BMW sound system, often with cassette player and optional CD changer preparation. Speaker quality varies by trim.

Navigation:

Optional early-generation BMW navigation system available on some models.

Cruise Control:

Standard electronic cruise control.

Parking Assistance:

Rear Park Distance Control (PDC) was an optional feature introduced on later E34 models, potentially available on some 1990 vehicles.

Connectivity Options:

Limited by modern standards. Primarily focused on basic car functions. Some models might have had early cellular phone integration kits.

🔧 Maintenance

Oil Change Interval:

Typically 7,500 to 10,000 miles (12,000 to 16,000 km) or annually, depending on driving conditions. Refer to manual for specific conditions.

Spark Plug Replacement:

Approximately 30,000 to 60,000 miles (48,000 to 96,000 km), depending on plug type. Manual will specify exact interval and plug type.

Coolant Flush:

Typically every 2 to 4 years or 30,000 to 60,000 miles.

Engine Oil:

SAE 5W-30 or 5W-40 synthetic recommended. Refer to manual for BMW LL-01 or equivalent approvals for the M60 engine.

Coolant:

BMW Blue or equivalent G48 ethylene glycol-based coolant (50/50 mix with distilled water).

Brake Fluid:

DOT 4 or DOT 5.1 (consult manual for BMW specifications).

Power Steering Fluid:

BMW Power Steering Fluid (Pentosin CHF 11S or equivalent, manual will specify).

Common Problems:

Cooling system leaks (water pump, hoses, expansion tank), VANOS seal issues (on later M60 variants), oil pan gasket leaks, oil separator issues (PCV system), sagging headliner, aging plastic and rubber components, potential fuel pump and injector issues.

V8 Specific Issues:

M60 engines can suffer from premature timing chain guide wear (though less common than on M62). Correct oil viscosity and regular changes are critical for longevity.

📚 Vehicle History

Bmw Philosophy:

BMW's reputation for 'The Ultimate Driving Machine' established through engineering excellence, performance, and driver engagement.

E34 Generation:

The E34 generation (1988-1996) represented a significant step forward in technology and design for the BMW 5 Series, blending performance with luxury.

Introduction Of V8:

The V8 engine option (M60) was introduced in 1992 for the E34 chassis with the 530i and 540i models, making the 1990 model year description slightly anachronistic if it refers to V8 power for that exact year. However, this manual specifically targets the 1990 model year, implying it covers the 6-cylinder variants (e.g., 525i, 535i) for that specific year, or is a generalized manual for the chassis that later received the V8. Given the product name, it strongly suggests coverage for the V8 variant as introduced later in the E34's lifecycle, possibly a typo or a manual that covers the platform broadly and details the 540i engine as it became available in the E34 platform.

Production Years E34:

1988-1996

Manufacturing Location:

Dingolfing, Germany

🏆 Awards & Recognition

Automotive Journalism:

The E34 generation 5 Series, including variants like the 540i, was consistently praised by automotive critics for its blend of performance, luxury, and handling.

Comparative Awards:

Often featured on "best of" lists for executive sedans during its production run.

Quality Ratings:

BMW's commitment to build quality was a strong selling point, contributing to the model's reputation for durability when properly maintained.