🏷️ Basic Information

Make:

BMW

Model:

5 Series

Model Variant:

540i

Year:

2002

Chassis Code:

E39

👋 Introduction

Vehicle Class:

Executive Sedan / Luxury Mid-size Sedan

Target Demographic:

Affluent professionals seeking performance, luxury, and sophisticated engineering.

Key Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type

Engine Performance:

Powerful V8 engine, refined ride quality, driver-oriented cockpit.

Driving Dynamics:

Balanced chassis, precise steering, and comfortable yet engaging handling characteristics.

Luxury Appointments:

Premium interior materials, advanced features for its era, and a quiet cabin.

📋 Manual Details

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Management:

Detailed diagnostics, testing, and repair procedures for the M62 V8 engine, including VANOS, ignition, fuel injection, and emissions control systems.

Drivetrain:

Comprehensive coverage of the automatic (Steptronic) and manual transmissions, including removal, installation, component overhaul, and fluid specifications.

Suspension Steering:

Detailed information on front and rear suspension systems, including springs, shock absorbers, control arms, bushings, power steering system diagnostics and repair.

Brakes:

Complete procedures for brake system service, including ABS, DSC, brake fluid replacement, rotor and pad replacement, and caliper overhaul.

Electrical System:

Extensive coverage of the entire electrical system, including wiring diagrams, component testing, fuse and relay identification, lighting, power windows, mirrors, seats, and comfort modules.

Climate Control:

Diagnosis and repair of the automatic climate control system, including A/C refrigerant handling, compressor, condenser, evaporator, and blower motor.

Body And Interior:

Procedures for body panel repair, interior trim removal and installation, door mechanisms, and trunk lid operation.

Scheduled Maintenance:

Detailed recommendations for routine maintenance services, including oil changes, filter replacements, fluid checks, and inspections at specified intervals.

Troubleshooting Diagnostics:

Systematic troubleshooting guides for common and complex issues, including symptom-based diagnostics and fault code interpretation.

Engine Overhaul:

Complete instructions for engine disassembly, inspection, rebuilding, and reassembly, including torque specifications and component clearances.

Transmission Repair:

Step-by-step guides for transmission repair, including clutch replacement, seal servicing, and valve body diagnostics.

Brake System Service:

Detailed instructions for brake pad and rotor replacement, brake caliper service, and bleeding the brake system.

Electrical Component Replacement:

Guidance on replacing various electrical components such as alternators, starter motors, sensors, and control modules.

Depth Level:

Comprehensive

Target Audience:

Professional mechanics and experienced DIY enthusiasts

Diagnostic Tools:

Includes information relevant to using diagnostic tools like BMW's ISTA/D or compatible OBD-II scanners for fault code retrieval and live data analysis.

📊 Manual Specifications

Format Type:

PDF

Searchability:

Searchable text enabled for quick information retrieval

Printability:

Printable pages for offline use

Image Resolution:

High-resolution diagrams and illustrations for clarity

Physical Format Hint:

Digital Download (PDF)

Digital Format Details:

Optimized for digital viewing on computers, tablets, and smartphones

⚙️ Engine Specifications

Engine Code:

M62TU B44

Engine Type:

4.4L V8, Naturally Aspirated

Displacement Liters:

4.4

Bore X Stroke Mm:

92.0 x 82.7

Compression Ratio:

10.0:1

Valve Train:

DOHC, 4 valves per cylinder, Double VANOS (Variable Valve Timing)

Horsepower Hp At Rpm:

290 hp @ 5400 rpm

Torque Lb-Ft At Rpm:

324 lb-ft @ 3600 rpm

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Engine Oil Type:

BMW Longlife-01 Approved Synthetic SAE 5W-30 or 5W-40

Engine Oil Capacity Quarts:

7.0 (with filter change)

Coolant Capacity Quarts:

9.5

🔧 Transmission

Transmission Type:

5-speed Steptronic Automatic Transmission

Transmission Type Optional:

5-speed Manual Transmission (Less Common)

Steptronic Functionality:

Allows manual gear selection via selector lever or steering wheel buttons.

Automatic Transmission Fluid Type:

BMW ATF LT-3 (or equivalent specifications, check manual for exact part number)

Manual Transmission Fluid Type:

GL-4 SAE 75W-90 (check manual for exact specification and part number)

📐 Dimensions

Length Inches:

191.1

Width Inches:

71.0

Height Inches:

56.6

Wheelbase Inches:

111.4

Front Track Inches:

60.6

Rear Track Inches:

60.8

Curb Weight Lbs:

3792 - 3968 (depending on transmission and options)

Gross Vehicle Weight Rating Lbs:

4960

Payload Capacity Lbs:

1168

Trunk Volume Cubic Feet:

17.1

Standard Wheel Size:

16 x 7.0

Optional Wheel Size:

17 x 8.0 (Style 42 or M Parallel Spoke)

Standard Tire Size:

225/55R16

Optional Tire Size:

235/45R17 (front), 255/40R17 (rear) for 17-inch wheels

Bolt Pattern:

5x120

Center Bore Mm:

72.5

🛡️ Safety Features

NHTSA Frontal Crash Test Driver:

4 Stars

NHTSA Frontal Crash Test Passenger:

4 Stars

IIHS Frontal Offset Score:

Good (for vehicles tested in its era)

ABS:

Standard Anti-lock Braking System

Dsc:

Standard Dynamic Stability Control

Traction Control:

Standard Automatic Stability Control + Traction (ASC+T)

Airbags:

Frontal airbags for driver and passenger, front side-impact airbags.

Seatbelts:

3-point inertia-reel seatbelts with pretensioners for all occupants.

Body Structure:

Reinforced safety cage construction.

💡 Technology Features

Audio System:

BMW Professional RDS stereo system with CD player, AM/FM radio. Optional premium sound systems (e.g., Harman Kardon).

Navigation System:

Optional BMW business or professional navigation system with CD-ROM based maps.

Telematics:

Optional BMW Assist telematics system for emergency services and roadside assistance.

Cruise Control:

Standard electronically controlled cruise control.

Parking Assistance:

Optional rear park distance control (PDC).

Cd Changer:

Optional trunk-mounted 6-disc CD changer.

Phone Integration:

Optional integrated cellular phone system (older analog or early digital).

🔧 Maintenance

Oil Change Interval:

Variable Service Interval Indicator (VSI) system. Typically every 7,500 to 15,000 miles or 12-24 months, depending on driving conditions.

Air Filter Replacement:

Recommended every 30,000 miles or as indicated by VSI.

Cabin Air Filter Replacement:

Recommended every 15,000 miles or annually.

Spark Plug Replacement:

Typically around 60,000-100,000 miles for iridium spark plugs (check specific recommendation).

Coolant Flush:

Recommended every 2-4 years or as per VSI.

Brake Fluid Type:

DOT 4 Low Viscosity (LV)

Power Steering Fluid Type:

Pentosin CHF 11S or Pentosin CHF 202 (check manual for specific compatibility)

Cooling System:

Water pump failure, thermostat housing leaks, radiator expansion tank cracks, and VANOS line leaks are common. The M62TU has a plastic thermostat housing which is prone to cracking.

Oil Leaks:

Valve cover gaskets, oil pan gaskets, and O-ring seals on the oil filter housing and oil cooler can develop leaks.

ABS Asc Wheel Speed Sensors:

Wheel speed sensors can fail, leading to ABS and ASC warnings on the dashboard.

Ignition Coils:

Individual ignition coils can fail, causing misfires.

Electrical Connectors:

Corrosion or loose connections in various electrical connectors can cause intermittent issues.

Headliner Sagging:

Common in many E39 models due to adhesive failure.

📚 Vehicle History

Bmw Philosophy:

Focus on 'The Ultimate Driving Machine' - emphasizing performance, handling, and driver engagement.

E39 Generation Introduction:

The E39 generation 5 Series was introduced in 1995 (for the 1996 model year in Europe) and replaced the E34. The 540i was a key model in this generation.

E39 Facelift:

The E39 received a significant facelift in 2000 (for the 2001 model year), which included updated headlights (angel eyes), taillights, front and rear bumpers, and interior refinements. The 2002 model benefits from these updates.

Production Years E39:

1995-2003

Manufacturing Locations:

Dingolfing, Germany; also assembled in certain other locations globally.

🏆 Awards & Recognition

Car And Driver 10Best:

The E39 generation 5 Series, including variants like the 540i, was a frequent recipient of Car and Driver's 10Best awards during its production run, recognized for its exceptional blend of performance, luxury, and handling.

Automotive Journalism Reputation:

Widely praised by automotive journalists for its sophisticated engineering, driving dynamics, and build quality.

Industry Recognition:

Considered a benchmark in the luxury sedan segment for its time.