Target Audience:
BMW owners seeking DIY repair, maintenance, and diagnostic information.
Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type
Manual Advantages:
Officially licensed, digital format for quick access, detailed diagrams and illustrations, specific to the 2002 540i model.
Major Systems:
Engine, Drivetrain, Suspension, Brakes, Electrical, HVAC, Body, Interior
Type:
Service and Repair Manual Software
Format:
Digital Software (Likely PDF or proprietary application)
Powertrain:
Engine mechanical (M62TU V8), fuel, ignition, cooling, exhaust, lubrication, engine management (DME)
Drivetrain:
Automatic Transmission (Steptronic GM 5L40-E), Rear Differential, Driveshafts, Axles
Suspension Steering:
Front & Rear Suspension (Multi-link), Steering system (Servotronic), Wheel alignment
Brakes:
Front & Rear Disc Brakes (ABS, DSC, EBD), Parking Brake
Electrical:
Battery, Alternator, Starter, Lighting, Instrumentation, Power windows/locks, Central locking, Wiper system, SRS Airbag system, ECU diagnostics
Comfort Convenience:
Climate Control (IHKA), Power seats, Sunroof, Audio system, Navigation system (optional)
Body Chassis:
Body panels, Doors, Bumpers, Hood, Trunk, Exterior trim, Interior trim
Maintenance:
Oil change, Filter replacement (oil, air, cabin), Spark plug replacement, Coolant flush, Brake fluid flush, Transmission fluid service
Troubleshooting:
Diagnostic trouble code (DTC) interpretation, Symptom-based troubleshooting for engine, transmission, electrical systems
Repair Rebuild:
Engine component replacement (e.g., water pump, thermostat, belts, hoses, ignition coils, spark plugs), Transmission service, Brake component replacement (pads, rotors, calipers), Suspension component replacement (shocks, struts, bushings), Electrical component testing and replacement
Diagnostics:
OBD-II scanning, Sensor testing, Actuator testing, Module programming (requires specific BMW diagnostic tools not typically included in manual software)
Depth:
Comprehensive, covering routine maintenance to major component overhauls and electrical diagnostics.
Engine Code:
M62TU (Technically Updated)
Engine Type:
4.4L V8 DOHC 32-valve
Horsepower:
290 hp @ 5400 rpm
Torque:
324 lb-ft @ 3600 rpm
Fuel Delivery:
Sequential Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
ECM Type:
Bosch Motronic (likely ME7.2 variant)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 or equivalent)
Coolant Capacity:
Approx. 10.6 quarts (10.0 liters)
Transmission Type:
5-Speed Automatic (GM 5L40-E)
Manual Transmission:
Available on some models/markets (e.g., 6-speed Getrag S6S 420G), but the 540i primarily featured the automatic.
Transmission Modes:
Steptronic (manual shifting capability)
Automatic Transmission Fluid:
Dexron III (or equivalent specified for 5L40-E)
Automatic Transmission Fluid Capacity:
Approx. 8.5 quarts (8.0 liters) for complete refill
NHTSA Front Impact:
5-Star
NHTSA Side Impact:
4-Star
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Standard (ASC+T - Automatic Stability Control + Traction)
Stability Control:
Standard (DSC - Dynamic Stability Control)
Airbags:
Frontal airbags, Side-impact airbags, Optional side-curtain airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Display:
Central Information Display (CID) screen for climate, audio, navigation, and vehicle status.
Audio System:
BMW Business CD or Professional CD/RDS, optional Hi-Fi or Logic7 sound systems.
Navigation:
Optional MKIII or MKIV navigation system with CD-ROM maps.
Parking Sensors:
Optional Park Distance Control (PDC) front and rear.
Phone Integration:
Optional Bluetooth or car phone preparation.
Cruise Control:
Standard, adaptive cruise control (optional) not typically on 2002 models.
Keyless Entry:
Standard with remote central locking.
Oil Change Interval:
Variable, typically around 7,500-10,000 miles or 12-24 months, depending on driving conditions and oil quality (as indicated by the Condition Based Service system).
Coolant Flush Interval:
Every 2-4 years or 30,000-50,000 miles.
Transmission Service Interval:
Recommended around 50,000-70,000 miles for fluid and filter change, though BMW often stated 'lifetime fill' for sealed transmissions.
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-98 approved synthetic oil, typically 0W-40 or 5W-40.
Engine Oil Capacity:
Approx. 6.9 quarts (6.5 liters) with filter change
Brake Fluid Specification:
DOT 4
Power Steering Fluid:
Pentosin CHF 11S or equivalent
Cooling System Weaknesses:
Plastic expansion tank, radiator hoses, and water pump can degrade over time, leading to leaks.
Vibration Issues:
Driveshaft center support bearing, rear differential mounts, and control arm bushings are common wear items that can cause vibrations.
Ignition System:
Ignition coils and spark plugs are wear items; failure can lead to misfires.
ABS Asc Dse Errors:
Wheel speed sensors and ABS pump failures are not uncommon.
Brand Focus:
BMW is renowned for its 'Ultimate Driving Machine' ethos, emphasizing performance, luxury, and engineering precision.
E39 Generation:
The E39 (1995-2003) represented a significant advancement in BMW's 5 Series, featuring improved aerodynamics, chassis dynamics, and technology.
540I Positioning:
The 540i was the top-tier V8 model for the E39 generation, offering a balance of luxury, performance, and everyday usability.
Production Years:
The E39 generation was produced from 1995 to 2003. The 2002 model year falls within this period.
Car And Driver 10 Best:
The E39 generation of the BMW 5 Series, including the 540i, was frequently recognized on Car and Driver's 10Best list during its production run.
Consumer Reports Reliability:
Historically, E39 BMWs have shown average to above-average reliability, with some common wear items requiring proactive maintenance. Detailed reliability ratings depend on specific year and options.
