🏷️ Basic Information Identification Make: BMW Model: 540i Model Code: E39 Product Name: BMW 540i 1997-2002 Workshop Service Repair Manual Generation Generation Code: E39 Generation Years: 1995-2003 (for E39 platform overall) Codes Chassis Code: E39 👋 Introduction Market Position Segment: Executive Sedan Luxury Level: Luxury, performance-oriented Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS, Jaguar S-Type Key Features Performance Focus: V8 engine power, balanced chassis, premium driving dynamics Technology Integration: Advanced electronics for the era, including navigation and stability control Build Quality: Renowned BMW build quality and materials 📋 Manual Details Coverage Areas Covered Years: 1997, 1998, 1999, 2000, 2001, 2002 Page Count Estimated Page Count: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: 4.4L V8 M62B44/TU Engine Management: DME (Digital Motor Electronics), VANOS, ignition system, fuel injection, emissions control Transmission: 5-speed Steptronic Automatic (GM 5L40-E), 5-speed Manual (ZF S5-31) Drivetrain: Rear-wheel drive (RWD), driveshafts, differential Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering system Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control) Electrical: Battery, alternator, starter, wiring diagrams, lighting, power windows, central locking, wipers, horn Body: Body panels, doors, hood, trunk, bumpers, glass, interior trim, seat adjustments HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, climate control Safety Systems: Airbag system, seat belts Chassis: Frame, subframes, structural components Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs Troubleshooting: Diagnostic procedures, fault code interpretation, common problem diagnosis Repair: Engine repair, transmission overhaul, suspension replacement, brake system service, electrical component repair Rebuilds: Engine rebuild procedures, transmission rebuilds Installation: Component installation and removal (e.g., starter, alternator, sensors) Diagnostics: OBD-II (On-Board Diagnostics) system, diagnostic tool usage Technical Depth Depth: Comprehensive, from basic maintenance to in-depth engine and transmission overhaul Detail Level: Detailed step-by-step instructions, torque specifications, special tool requirements Diagrams Illustrations: Includes detailed diagrams, schematics, and exploded views 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Printability: Printable pages Print Quality Image Resolution: High-resolution for clear diagrams and text Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: M62B44 / M62TUB44 Configuration: 4.4L Naturally Aspirated V8 Bore X Stroke: 92 mm x 82.7 mm Displacement: 4398 cc (4.4 Liters) Compression Ratio: 10.0:1 Valve Train: DOHC (Dual Overhead Camshafts), 4 valves per cylinder, Double VANOS Performance Horsepower: 282 hp @ 5400 rpm (M62B44), 290 hp @ 5400 rpm (M62TUB44) Torque: 324 lb-ft @ 3600 rpm (M62B44), 324 lb-ft @ 3600 rpm (M62TUB44) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Bosch Motronic DME Fuel Type: Premium Unleaded Gasoline (91 Octane or higher) Cooling System Coolant Capacity: Approx. 10.0 Liters (10.6 Quarts) Coolant Type: BMW Blue Antifreeze/Coolant 🔧 Transmission Standard Transmission Type: 5-speed Steptronic Automatic (GM 5L40-E) Optional Transmission Type: 5-speed Manual (ZF S5-31) - Less common in North America for 540i Features Automatic Modes: Sport and Manual (Steptronic) modes Fluid Specs Automatic Fluid Type: Dexron III or equivalent (e.g., GM P/N 88862419 or 1940773) Fluid Capacity Automatic Capacity: Approx. 8.5 Liters (8.9 Quarts) for complete refill 📐 Dimensions Exterior Length: 188.2 inches (4780 mm) Width: 71.5 inches (1816 mm) Height: 56.1 inches (1425 mm) Wheelbase: 111.4 inches (2830 mm) Weights Curb Weight: Approximately 3700-3900 lbs (1680-1770 kg) Gross Vehicle Weight Rating: Approximately 4700-4900 lbs (2130-2220 kg) Cargo Trunk Volume: 16.0 cubic feet (453 Liters) 🛡️ Safety Features Ratings NHTSA Front Impact: 5 Stars NHTSA Side Impact: 4 Stars Active Features Stability Control: Dynamic Stability Control (DSC) standard Traction Control: Automatic Stability Control (ASC+T) Braking System: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) Passive Features Airbags: Front airbags, optional front side airbags Seatbelts: Three-point seatbelts with pre-tensioners 💡 Technology Features Infotainment Navigation: Optional BMW Professional Navigation System (MK series units) Audio System: Optional Harman Kardon sound system, CD player, cassette player Driver Assistance Parking Sensors: Optional Park Distance Control (PDC) Cruise Control: Standard cruise control, optional Active Cruise Control (ACC) on some models Connectivity Phone Integration: Optional Bluetooth hands-free system Climate Control Climate System: Dual-zone automatic climate control 🔧 Maintenance Service Intervals Oil Change Interval: BMW Condition Based Service (CBS) system; typically 10,000-15,000 miles or annually, depending on driving conditions. Spark Plug Replacement: Around 100,000 miles (refer to manual for exact specification based on plug type) Coolant Flush: Every 2-3 years or 30,000-50,000 miles Fluid Specifications Engine Oil Spec: SAE 5W-30 or 5W-40 Synthetic Oil meeting BMW Longlife-98 (LL-98) or Longlife-01 (LL-01) specification Engine Oil Capacity: Approx. 6.5 Liters (6.9 Quarts) Brake Fluid Spec: DOT 4 Power Steering Fluid Spec: Pentosin CHF 11S or equivalent (BMW P/N 32131094316) Known Issues Common Issues Engine: Valley pan gasket leaks, VANOS solenoid failure, PCV system issues, oil consumption, starter motor failure...