🏷️ Basic Information Identification Make: BMW Model: 540i Year: 1990 Codes Chassis Code: E34 👋 Introduction Market Position Segment: Luxury Sedan / Executive Car Target Audience: Enthusiasts, DIY mechanics, professional automotive technicians specializing in BMW vehicles Competitive Analysis Competitors 1990: Mercedes-Benz E-Class (W124), Audi V8 Quattro, Lexus LS 400 Key Features Vehicle Positioning: The BMW 540i (E34) was positioned as a high-performance executive sedan, blending luxury, driving dynamics, and advanced engineering. Manual Value Proposition: Provides the comprehensive, factory-level detail necessary to maintain and repair this sophisticated vehicle, preserving its performance and value. 📋 Manual Details Coverage Areas General Coverage: Full Service and Repair Specific Systems Covered: Engine, Drivetrain, Suspension, Steering, Brakes, Electrical Systems, HVAC, Body, Interior, Diagnostics Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, component testing, timing procedures, fuel delivery, ignition system, cooling system Engine Management: DME (Digital Motor Electronics) troubleshooting, sensor identification and testing, actuator diagnosis, fault code interpretation Transmission Manual: Clutch, gearbox disassembly and assembly, gear shift linkage, overhaul procedures Transmission Automatic: ZF 4HP22/4HP24 service, torque converter, valve body, electronic control unit (ECU) interface, fluid service Suspension Front: MacPherson strut overhaul, control arms, ball joints, bushings, spring replacement Suspension Rear: Multi-link rear axle service, trailing arms, control arms, bushings, shock absorber replacement Steering: Power steering system service, hydraulic pump, steering rack overhaul, tie rod ends Brakes Front: Ventilated disc brake service, caliper overhaul, pad replacement, rotor replacement Brakes Rear: Disc brake service, caliper overhaul, pad replacement, rotor replacement, parking brake mechanism Brake Control: ABS (Anti-lock Braking System) diagnosis and component testing, hydraulic modulator service Electrical Charging: Alternator testing and replacement, battery service, charging system diagnostics Electrical Starting: Starter motor testing and replacement, ignition switch, wiring harness diagnostics Lighting: Headlight, taillight, interior lighting service, bulb replacement, wiring Comfort Controls HVAC: Climate control system diagnostics, blower motor, evaporator, heater core, refrigerant service, A/C system repair Body Exterior: Panel alignment, door, hood, trunk latch mechanisms, trim piece replacement Body Interior: Seat removal and installation, dashboard disassembly, carpet replacement, headliner service Body Glass: Windshield, side glass, rear glass removal and installation, seal replacement Body Safety Systems: Airbag system (SRS) diagnosis, component identification, safety restraint system servicing Procedures Included Preventative Maintenance: Oil changes, filter replacements, spark plug service, fluid checks and changes Diagnostic Procedures: Step-by-step troubleshooting guides, symptom-based diagnostics, use of diagnostic tools and equipment Repair Procedures: Component removal and installation, part replacement, adjustment procedures Rebuilding Procedures: Detailed instructions for engine, transmission, and major component rebuilds Refurbishment Restoration: Guidance on restoring classic E34 models, including bodywork, interior, and mechanicals Wiring Diagrams: Comprehensive electrical wiring schematics for all vehicle systems Troubleshooting Charts: Detailed charts correlating symptoms to potential causes and repair actions Technical Depth Depth: Expert-level, covering everything from basic fluid changes to full engine and transmission rebuilds Diagnostic Capability: In-depth diagnostic procedures for all electronic control units (ECU) and sensors Specification Detail: Includes torque specifications, tolerances, clearances, and all necessary technical data for repairs 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF with clear images and text Printable: Printable pages for workshop use Print Quality Image Clarity: Sharp, clear diagrams and photographs Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: M60B40 Engine Type: 4.0L V8, DOHC, 32 valves Bore X Stroke: 84 mm x 90 mm Compression Ratio: 10.0:1 Block Material: Aluminum Alloy Head Material: Aluminum Alloy Performance Horsepower Hp: 282 hp @ 5800 rpm (DIN) Torque Lb-Ft: 295 lb-ft @ 4500 rpm (DIN) Fuel System Fuel Delivery: Bosch Motronic MLE Electronic Fuel Injection (EFI) Fuel Type: Premium Unleaded Gasoline (91 RON or higher) Engine Oil Capacity: 7.5 Liters (8 US Quarts) with filter Cooling System Coolant Capacity: 10.0 Liters (10.6 US Quarts) 🔧 Transmission Standard Type: ZF 4HP24 Automatic Transmission Optional Type: Getrag 5-Speed Manual Transmission (S6S-250G) Features Automatic Features: Electronic control, Sport and Economy modes Fluid Capacity Automatic Capacity: Approximately 8.0 Liters (8.5 US Quarts) Fluid Specifications Automatic Fluid Type: BMW ATF LT 71141 or equivalent Fluid Capacity Manual Capacity: Approximately 1.8 Liters (1.9 US Quarts) Fluid Specifications Manual Fluid Type: BMW MTF LT-2 or equivalent (GL-4 rated) 📐 Dimensions Exterior Length: 4720 mm (185.8 in) Width: 1751 mm (68.9 in) Height: 1410 mm (55.5 in) Wheelbase: 2799 mm (110.2 in) Weights Curb Weight Approx: 1750 kg (3858 lbs) 🛡️ Safety Features Ratings Crash Test Performance: As per 1990 standards, featuring robust safety cage construction. Active Features ABS: Standard Anti-lock Braking System (ABS) Passive Features Airbags: Driver-side airbag (standard on most models), optional passenger airbag Seat Belts: Front and rear seat belts, pre-tensioners for front belts 💡 Technology Features Infotainment Audio System: BMW Bavaria C Business/Professional RDS cassette radio with optional CD changer. Onboard Computer:...