The 2001 model year represents a premium luxury sedan celebrated for its potent 4.4-liter V8 engine, delivering approximately 290 horsepower, and engaging driving dynamics. As part of the E39 generation, this model is distinguished by its high-quality interior, advanced technology for its era, and a sophisticated design that earned it accolades, including recognition on Car and Driver's Ten Best lists. Engineered for performance and comfort, the 540i offers a compelling blend of luxury sedan refinement and sporty handling, making it a standout in its competitive segment against vehicles like the Mercedes-Benz E-Class and Audi A6. This comprehensive workshop manual provides essential information for maintaining and repairing the 2001 540i. It covers a wide array of systems, including detailed engine mechanical and electrical diagnostics, fuel and emission control systems, transmission service for both automatic and manual variants, suspension, steering, and brake systems. Additionally, the manual details bodywork, interior components, HVAC, and the electrical system. It offers step-by-step maintenance procedures, troubleshooting guides with diagnostic flowcharts, and all necessary technical specifications, including fluid requirements and service intervals, making it an invaluable resource for both DIY enthusiasts and professional technicians. 🏷️ Basic Information Identification Make: BMW Model: 540i Model Variant: 540 Year: 2001 Codes Chassis Code: E39 👋 Introduction Market Position Positioning: Premium luxury sedan renowned for performance, comfort, and advanced engineering. Competitive Analysis Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type. Key Features Distinctiveness: Powerful V8 engine, engaging driving dynamics, high-quality interior, sophisticated technology for its era. Value Proposition For Owners: Empowers owners with the knowledge to perform maintenance and repairs, saving significant costs compared to dealership services. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service, Repair, and Troubleshooting Secondary Coverage: Maintenance, Diagnostics, Wiring Schematics, Specifications Page Count Estimated Page Count: Detailed section breakdowns suggest a comprehensive manual, likely exceeding 1000 pages. Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, internal components, timing, lubrication, cooling. Engine Electrical: Ignition system, starting and charging, sensors, actuators, ECU troubleshooting. Emission Control: EVAP system, catalytic converters, emissions sensors, diagnostic trouble codes. Fuel System: Fuel pump, injectors, fuel pressure regulator, fuel tank, diagnosis. Clutch System: Clutch assembly, hydraulic system, release bearing, diagnosis. Manual Transaxle: Gearbox removal and installation, internal components, shift linkage, lubrication. Automatic Transaxle: Transmission fluid, torque converter, valve body, electronic control, troubleshooting. Driveshaft And Axle: U-joints, CV joints, driveshaft removal, axle shaft seals. Suspension System: Front and rear suspension components, control arms, struts, springs, alignment specifications. Steering System: Steering rack, power steering pump, steering column, tie rods, diagnosis. Restraint System: Airbag system components, seat belts, SRS module, troubleshooting. Brake System: Brake pads, rotors, calipers, ABS system, hydraulic lines, bleeding procedures. Body Interior Exterior: Body panel removal, interior trim, door mechanisms, seals, glass. Body Electrical System: Lighting, power windows, central locking, mirrors, instrument cluster, body control modules. HVAC: Air conditioning system, heater core, blower motor, climate control unit, refrigerant. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, spark plug replacement, oil changes. Repair: Component replacement, subsystem overhauls, reassembly procedures. Troubleshooting: Diagnostic flowcharts, common fault identification, symptom-based diagnosis. Diagnostics: OBD-II diagnostics, error code interpretation, sensor testing. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds. Target Audience: DIY mechanics with basic skills to professional technicians. 📊 Manual Specifications File Format Format: PDF Compatibility: All versions of Windows and Mac Print Quality Printability: Yes, all pages are printable. Graphic Quality: Includes diagrams, illustrations, and wiring schematics. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code: M62TU (4.4L V8) Displacement: 4.4 Liters (4398 cc) Configuration: V8, 32-valve (4 valves per cylinder) Induction: Naturally Aspirated Performance Horsepower: Approximately 290 hp @ 5400 RPM Torque: Approximately 324 lb-ft @ 3600 RPM Fuel System Injection Type: Electronic Fuel Injection (EFI) / Bosch Motronic Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) 🔧 Transmission Standard Type: 5-speed Steptronic Automatic Transmission Optional Type: 6-speed Manual Transmission (less common for 540i in this year) Features Steptronic: Manual shifting mode for driver engagement. 📐 Dimensions Exterior Length: Approximately 191.1 inches (4854 mm) Width: Approximately 71.5 inches (1816 mm) Height: Approximately 57.0 inches (1448 mm) Weights Curb Weight: Approximately 3700-3900 lbs (1678-1769 kg), varies with options. Gross Vehicle Weight Rating: Typically around 4700 lbs (2132 kg). 🛡️ Safety Features Ratings NHTSA Frontal Crash: Likely received good ratings for its era, though specific 2001 data can be scarce. Active Features ABS: Standard Anti-lock Braking System Traction Control: Standard Automatic Stability Control (ASC+T) Stability Control: Standard Dynamic Stability Control (DSC) Passive Features Airbags: Frontal airbags, side airbags (standard). Seatbelts: Pretensioner front seat belts, three-point rear seat belts. 💡 Technology Features Infotainment Head Unit: BMW Business...