🏷️ Basic Information

Make:

BMW

Model:

540i

Model Variant:

540

Year:

1997-2002

Chassis Code:

E39

👋 Introduction

Target Audience:

BMW 540i (E39) owners, DIY mechanics, professional technicians

Value Proposition:

Provides professional-level repair knowledge, enabling significant savings on labor costs ($50-$60 per hour)

Accuracy:

Actual genuine factory manual, not third-party

Usability:

Easy to use, searchable PDF, printable pages for convenient on-the-job reference

Completeness:

Covers all aspects of repair and maintenance for all styles

📋 Manual Details

Covered Models:

BMW 540i (E39 chassis)

Covered Years:

1997, 1998, 1999, 2000, 2001, 2002

Estimated Pages:

Hundreds of pages (specific count not provided, but described as comprehensive)

Type:

Factory Service Repair Manual

Source:

Official Factory Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine Service/Repair, Transmission Service/Repair, Differential/Drive, Axle

Chassis And Suspension:

Brake System, Suspension, Steering, Chassis/Body

Electrical And Electronics:

Wiring Diagram, Electrical System, Engine Control System

Comfort And Climate:

Cooling System, Fuel Injection/Fuel System, Emission System, Heater/Air Conditioning

Interior And Safety:

Restraint System, Interior

Maintenance:

General Maintenance, Periodic Lubrication, Scheduled Service

Repair And Rebuild:

Step-by-step repair procedures for all covered systems, complete rebuilds

Diagnostics:

Troubleshooting, Advanced Troubleshooting Guide, Diagnostic Procedures

Depth:

Comprehensive, detailed, covering fundamentals to advanced repair, same information as professional technicians

📊 Manual Specifications

Format:

PDF

Compatibility:

Windows and Mac operating systems

Printability:

Fully printable (individual pages or entire manual)

Binding:

Digital download (user prints and binds as desired)

Paper Type:

N/A (Digital)

Delivery:

Instant Download after payment

Reader:

Adobe PDF Reader

⚙️ Engine Specifications

Engine Code:

M62B44 (4.4L V8)

Displacement:

4.4 Liters (4398 cc)

Horsepower Approx:

282 hp @ 5400 rpm (E39 M62 variant)

Torque Approx:

324 lb-ft @ 3600 rpm (E39 M62 variant)

Induction:

Sequential Multi-Point Fuel Injection (SFI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

ECU:

BMW's DME (Digital Motor Electronics) - specific model varies by year and region

Coolant Type:

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

Coolant Capacity Approx:

10.5 Liters (11.1 US Quarts)

🔧 Transmission

Type:

5-Speed Steptronic Automatic Transmission (GM 5L40-E)

Type:

6-Speed Manual Transmission (Getrag S6S 420G)

Steptronic:

Allows manual gear selection via shifter or steering wheel buttons (depending on specific option/year)

Automatic Fluid:

Dexron III (or equivalent ATF specification, consult manual for specific BMW fluid PN)

Manual Fluid:

BMW Manual Transmission Fluid (MTF-LT-2 or equivalent)

📐 Dimensions

Length:

Approx. 191.0 inches (4851 mm)

Width:

Approx. 71.5 inches (1816 mm)

Height:

Approx. 57.3 inches (1455 mm)

Wheelbase:

Approx. 115.4 inches (2931 mm)

Curb Weight Approx:

3,800 - 4,000 lbs (1724 - 1814 kg), varies by transmission and options

🛡️ Safety Features

NHTSA Front Impact:

Not explicitly rated for these years, but generally good for the era

Traction Control:

Available, often as Automatic Stability Control (ASC) or Dynamic Stability Control (DSC)

ABS:

Standard Anti-lock Braking System

Airbags:

Front airbags, optional side airbags

💡 Technology Features

Head Unit:

BMW Professional RDS radio with cassette and CD player, optional navigation system (e.g., Mk II/Mk III system)

Display:

Central instrument cluster display, optional green monochrome or color LCD for navigation/vehicle information

Cruise Control:

Standard electronic cruise control

Bluetooth:

Not standard, optional dealer-installed or aftermarket kits available

Headlights:

Halogen headlights, optional Xenon (HID) headlights with auto-leveling

🔧 Maintenance

Oil Change:

BMW Condition Based Service (CBS) system, typically around 7,500-15,000 miles or annually. Consult manual for specific CBS parameters.

Spark Plugs:

Typically 60,000 - 100,000 miles (depending on plug type - platinum/iridium) - consult manual for exact interval and part number.

Coolant Flush:

Every 2-4 years or specified mileage (consult manual).

Engine Oil Type:

SAE 5W-30 or 5W-40 Synthetic Engine Oil meeting BMW LL-01 specification (e.g., Castrol Syntec, Mobil 1).

Engine Oil Capacity:

7.5 Liters (7.9 US Quarts) with filter change.

Brake Fluid:

DOT 4 low-viscosity brake fluid (BMW part number often 82111468074 or similar).

Power Steering Fluid:

BMW Power Steering Fluid (e.g., Pentosin CHF 11S, BMW part number 32131134011).

Vanos Seals:

Degradation of VANOS (Variable Valve Timing) piston ring seals leading to rough idle, low-end torque loss, and rattle on startup.

Oil Pan Gasket:

Common leaks from the oil pan gasket and rear main seal due to age and material degradation.

Cooling System Components:

Plastic coolant expansion tank can become brittle and crack, radiator hoses can degrade, water pump and thermostat can fail.

Differential Bearings:

Premature wear of differential mounting bearings, causing noise and vibration.

ABS/Asc/Dsc Module:

Failure of the ABS/ASC/DSC control module (often referred to as the "red triangle" light) is a common electrical fault.

📚 Vehicle History

Brand Philosophy:

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

E39 Introduction:

The E39 generation of the 5 Series was introduced in 1995 (as a 1996 model) in Europe and late 1996 in North America. The 540i model, with its V8 engine, was a flagship offering.

M62 Engine:

The M62 V8 engine was introduced in the E39, evolving from the M60. Key updates included the move to an aluminum block and Nikasil cylinder liners (later Alusil in some markets/years due to concerns over fuel quality). The 4.4L variant was standard for the 540i.

Production Location:

Dingolfing Plant, Germany

Production Period:

1996-2003 (for E39 generation)

🏆 Awards & Recognition

Car And Driver 10 Best:

The E39 5 Series generation was frequently recognized on Car and Driver's 10 Best lists for its handling, performance, and luxury, including the 540i variants.

Owner Satisfaction:

Generally high owner satisfaction for driving dynamics and build quality, though maintenance costs can be a factor.