🏷️ Basic Information Identification Make: BMW Model: 540i Year: 2002 Generation Chassis Code: E39 Codes Engine Code Primary: M62TU B44 👋 Introduction Market Position Segment: Executive Sedan Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160) Key Features Powertrain Options: V8 Engine (540i) Driving Dynamics: Renowned BMW handling and performance characteristics. Luxury Appointments: High-quality interior materials and advanced features for its era. 📋 Manual Details Coverage Areas Coverage Summary: All Models, Engines, Trim, and Transmission Types for the 2002 BMW 540i. Page Count Estimated Page Count: Hundreds of pages Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: Compatible with All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Service And Repair: YES Transmission Service And Repair: YES Brake System: YES Electrical System: YES Wiring Diagrams: YES Suspension: YES Steering: YES Cooling System: YES Fuel Injection And Fuel System: YES Emission System: YES Heating And Air Conditioning: YES Engine Control System: YES Chassis And Body: YES Restraint System: YES Interior Systems: YES Differential And Drive Axle: YES Procedures Included General Maintenance: YES Troubleshooting: YES Periodic Lubrication: YES Diagnostic Procedures: YES Disassembly And Assembly: YES Cleaning And Reinstallation: YES Repair Procedures: YES Technical Depth Depth: Comprehensive, covering all aspects from routine maintenance to in-depth repairs and diagnostics, mirroring factory technician standards. Diagrams And Illustrations: Detailed diagrams, drawings, and photos are included to guide through repair procedures. Troubleshooting Complexity: Combines troubleshooting with electrical service procedures and detailed wiring diagrams for comprehensive issue diagnosis. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Full Printable Zoom Capability: YES Binding Type Binding: Digital Download (No physical binding) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated V8 Engine Code: M62TU B44 Displacement: 4.4 Liters (4398 cc) Performance Horsepower: 290 hp @ 5400 rpm Torque: 324 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Sequential Multi-Point Fuel Injection (SFI) Fuel Type: Premium Unleaded Gasoline Internal Components Valvetrain: Dual Overhead Camshafts (DOHC), 4 valves per cylinder Block Material: Aluminum Alloy Head Material: Aluminum Alloy 🔧 Transmission Standard Transmission Type: 5-speed Automatic (Steptronic) Optional Transmission Type Optional: 6-speed Manual (on select markets/models) Features Steptronic Functionality: Allows manual gear selection. 📐 Dimensions Exterior Length: 188.2 inches Width: 71.5 inches Height: 57.0 inches Wheelbase: 111.4 inches Weights Curb Weight: Approx. 3700-3800 lbs (depending on transmission and options) 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated for 2002 model year in easily accessible data, but generally performed well for its era. Active Features Traction Control: Automatic Stability Control (ASC+T) Braking System: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) Passive Features Airbags: Driver and front passenger airbags, side-impact airbags. Seatbelts: Pretensioning seatbelts with force limiters. 💡 Technology Features Infotainment Navigation System: Available BMW Professional Navigation System (MKIII or MKIV) Audio System: Available Hi-Fi or Harman Kardon premium sound systems. Driver Assistance Parking Sensors: Available Park Distance Control (PDC) front and rear. Connectivity Telematics: BMW Assist with Tele Aid emergency calling available on some models. Convenience Features Climate Control: Dual-zone automatic climate control. 🔧 Maintenance Service Intervals Oil Change Interval: Variable, based on BMW's Condition Based Service (CBS) system. Typically around 10,000-15,000 miles or 12-24 months. Spark Plug Replacement: Around 100,000 miles for iridium spark plugs, as specified by BMW for the M62TU. Fluid Specifications Engine Oil Type: BMW Longlife-01 (LL-01) or LL-04 compliant synthetic oil, typically SAE 0W-40 or 5W-30. Coolant Type: BMW Blue Antifreeze/Coolant (G48 ethylene glycol based). Transmission Fluid Automatic: BMW ATF Dexron III or equivalent (check specific service bulletin for precise fill). Brake Fluid Type: DOT 4. Known Issues Cooling System Component Failure: Plastic coolant expansion tanks, hoses, and water pumps can degrade over time. Thermostat failures are also common. Vibration Issues: Driveshaft center support bearing, guibo (flex disc), and differential bushings can wear, leading to vibrations, especially under acceleration or deceleration. Oil Leaks: Valve cover gaskets, oil pan gaskets, and front crank seal leaks are common due to age and heat. ABS Wheel Speed Sensor Failure: Often leads to ABS and DSC warning lights. Sensors are prone to failure due to heat and contamination. Window Regulator Failure: Plastic components within the window regulator mechanism can break. Pixel Loss In Display: Instrument cluster and infotainment displays can suffer from dead pixels. 📚 Vehicle History Brand Heritage Brand Focus: BMW, Bayerische Motoren Werke AG, is renowned for producing luxury and performance automobiles, with a strong emphasis on driving dynamics ('The Ultimate Driving Machine'). Model Evolution E39 Generation: The 2002 model year falls within the second generation (E39) of the BMW 5 Series, produced from 1995 to 2003. The 540i was positioned as a high-performance, luxury variant within this generation. Production Production...