🏷️ Basic Information

Make:

BMW

Model:

540i

Year:

2002

Platform Chassis Code:

E39

👋 Introduction

Segment:

Executive Sedan

Target Audience:

Owners seeking to perform DIY maintenance and repairs, independent repair shops

Competitors 2002:

Mercedes-Benz E-Class (W211 generation starting mid-year), Audi A6 (C5), Lexus GS (JZS160)

Engine Performance:

Strong V8 power, refined driving dynamics

Luxury Appointments:

High-quality interior materials, advanced features for its time

Completeness:

Extremely comprehensive, covering nearly all aspects of vehicle repair and maintenance

Clarity:

Detailed diagrams, clear step-by-step instructions

📋 Manual Details

Primary Coverage:

Full Service and Repair

Diagnostic Coverage:

Comprehensive diagnostic procedures

Rebuild Coverage:

Engine, transmission, and differential rebuilds

Refurbish Restore Coverage:

Procedures for refurbishing and restoring components

Estimated Page Count:

1500+

Type:

Service and Repair Manual

Source Origin:

Likely derived from official BMW service information

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, inspection, repair, and overhaul

Engine Management:

Fuel injection, ignition system, emissions control, ECU diagnostics

Transmission Manual:

Manual transmission removal, disassembly, repair, and installation

Transmission Automatic:

Automatic transmission (e.g., GM 5L40-E) removal, disassembly, repair, and installation

Drivetrain:

Driveshafts, CV joints, differential, axle shafts

Suspension Front:

MacPherson strut, control arms, ball joints, bushings, steering linkage

Suspension Rear:

Multi-link independent suspension, shock absorbers, springs, bushings

Brakes Front:

Disc brake system, calipers, pads, rotors, hydraulic lines

Brakes Rear:

Disc brake system, calipers, pads, rotors, parking brake mechanism

Steering:

Power steering system, steering column, steering gear/rack

Electrical Charging:

Alternator, battery, charging system diagnostics

Electrical Starting:

Starter motor, ignition switch, starting system diagnostics

Lighting:

Headlights, taillights, interior lighting, bulb replacement

HVAC:

Air conditioning, heating, ventilation, climate control system

Body Exterior:

Doors, hood, trunk, fenders, bumpers, trim, glass replacement

Body Interior:

Seats, dashboard, door panels, headliner, trim panels

Infotainment:

Radio, navigation system (e.g., MKIV), speaker system

Safety Systems:

Airbag system, seat belts, ABS, traction control (ASC+T/DSC)

Routine Maintenance:

Oil change, filter replacement, fluid checks and top-offs, spark plug replacement

Troubleshooting:

Diagnostic flowcharts, common symptom analysis, fault code interpretation

Component Replacement:

Detailed instructions for replacing most wear items and major components

Overhaul Procedures:

Step-by-step guides for complete engine and transmission overhauls

Wiring Diagrams:

Comprehensive electrical system wiring diagrams

Specifications Data:

Torque specifications, clearances, fluid capacities, electrical values

Depth:

Comprehensive (from basic maintenance to complete engine rebuilds)

Diagnostic Level:

Advanced diagnostics with specific fault code meanings and troubleshooting trees

Rebuild Detail:

Detailed component measurement, machining specifications, and assembly procedures

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text for quick information retrieval

Resolution:

High-resolution images and diagrams

Print Readability:

Optimized for clear printing of text and diagrams

Binding:

N/A (Digital format)

Paper:

N/A (Digital format)

⚙️ Engine Specifications

Engine Code:

M62TU (Technical Update)

Configuration:

4.4L (4398cc) V8, DOHC, 32 valves

Bore X Stroke:

94.0 mm x 79.5 mm

Compression Ratio:

10.0:1

Horsepower:

290 hp @ 5400 rpm

Torque:

324 lb-ft @ 3600 rpm

Induction:

Sequential Multi-Point Fuel Injection (MPI), Dual MAF sensors

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

ECU Type:

Bosch Motronic ME 7.2

🔧 Transmission

Type:

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

Type:

6-speed Manual Transmission (Getrag S6-37)

Automatic Modes:

Sport and Manual (Steptronic) modes

Automatic Fluid:

Dexron III / Mercon (or BMW ATF LT-2 / 83 22 0 024 359)

Automatic Capacity:

Approx. 9.5 liters (9.0 US quarts) for a complete fill

Manual Capacity:

Approx. 1.3 liters (1.4 US quarts) of ATF Fluid (e.g., Dexron III)

📐 Dimensions

Length:

188.8 inches (4795 mm)

Width:

70.2 inches (1783 mm)

Height:

57.4 inches (1458 mm)

Wheelbase:

113.4 inches (2880 mm)

Curb Weight Auto:

3770 lbs (1710 kg)

Curb Weight Manual:

3704 lbs (1680 kg)

Trunk Volume:

15.0 cu ft (425 L)

🛡️ Safety Features

NHTSA Front Impact:

5-Star (Driver and Passenger)

NHTSA Side Impact:

4-Star (Front Passenger), 5-Star (Rear Passenger)

Traction Control:

Automatic Stability Control (ASC) / Dynamic Stability Control (DSC)

Antilock Brakes:

Anti-lock Braking System (ABS)

Brake Assist:

Brake Force Display (BFD)

Airbags:

Frontal airbags (driver and passenger), Side airbags (front)

Seat Belts:

Front pretensioners, Rear three-point seat belts

💡 Technology Features

Navigation System:

BMW Professional Navigation System (MKIV) with CD-ROM maps.

Audio System:

Hi-Fi stereo system with CD player, optional Harman Kardon sound system available.

Climate Control:

Automatic dual-zone climate control with pollen filter.

Cruise Control:

Standard cruise control.

Parking Sensors:

Optional Parking Distance Control (PDC) front and rear.

Bluetooth:

Optional Bluetooth mobile phone preparation available.

Telematics:

Optional BMW Assist telematics system.

🔧 Maintenance

Oil Change Interval:

BMW Condition Based Service (CBS) system typically recommends oil changes every 10,000-15,000 miles or based on driving conditions.

Major Service Intervals:

Spark plugs (approx. 100,000 miles), Coolant flush (approx. 2-4 years), Transmission fluid (often considered 'lifetime' but recommended service every 50,000-100,000 miles, especially for automatic).

Engine Oil:

SAE 5W-30 Synthetic (BMW Longlife-01 or LL-01 FE approved)

Coolant:

BMW Blue Antifreeze/Coolant (G48 specification) or equivalent G48 ethylene glycol-based coolant mixed 50/50 with distilled water.

Brake Fluid:

DOT 4 (BMW recommendation is typically DOT 4 PLUS)

Engine Oil Capacity:

Approx. 6.5 liters (6.9 US quarts) with filter change

Coolant Capacity:

Approx. 9.5 liters (10.0 US quarts)

Cooling System:

Plastic coolant expansion tanks are prone to cracking, water pump failure (plastic impeller can disintegrate), coolant hose leaks.

Valve Cover Gaskets:

Leaking valve cover gaskets are common, leading to oil consumption and smell.

ABS Wheel Speed Sensors:

Failure of ABS/DSC sensors can trigger warning lights.

Oil Pan Gaskets:

Oil pan gasket leaks are also frequent.

Alternator Bracket Seals:

Oil leaks from the alternator bracket seals.

Mass Air Flow Sensor:

MAF sensor contamination can lead to rough idling and poor performance.

Ccv System:

Crankcase Ventilation (CCV) system failure leading to oil consumption, rough idle, and potential vacuum leaks.

📚 Vehicle History

Bmw Reputation:

Known for 'The Ultimate Driving Machine', luxury, performance, and engineering excellence.

E39 Generation:

The E39 generation (1995-2003) is highly regarded for its balance of luxury, technology, and driving dynamics.

E39 Updates:

The 2001-2003 E39 models received significant updates including refreshed styling (angel eyes headlights, revised taillights), new engines (M54 for 6-cyl, M62TU for V8), and updated interior features.

Production Years:

1996-2003 (E39 generation)

Assembly Location:

Dingolfing, Germany

🏆 Awards & Recognition

Car And Driver Ten Best:

The E39 5 Series was a consistent recipient of Car and Driver's '10Best' awards during its production run, including for the 2002 model year.

Consumer Reports:

Generally rated well for performance and luxury, with some common electronic and mechanical issues noted.

Safety Certifications:

Compliant with US Federal Motor Vehicle Safety Standards (FMVSS) for 2002 model year.