The BMW 540i, model designation E39, represents a pinnacle of German engineering and performance within the premium sport sedan segment. Produced between 1997 and 2002, this vehicle is powered by a robust 4.4-liter V8 engine, offering approximately 290-310 horsepower and 320-340 lb-ft of torque, delivered through either a 5-speed manual or an optional Steptronic automatic transmission. Renowned for its exceptional driving dynamics, luxurious interior, and solid build quality, the 540i was positioned as a direct competitor to esteemed models such as the Mercedes-Benz E-Class and Audi A6, appealing to those who value both performance and refinement in their daily driving experience. This comprehensive service repair workshop manual provides essential information for the maintenance and repair of the BMW 540i (E39) for model years 1997 through 2002. It covers a wide array of systems, including detailed procedures for engine mechanical and electrical components, fuel and emission control systems, clutch, manual and automatic transmissions, driveshafts, suspension, steering, brakes, and bodywork. The manual also details interior and exterior electrical systems, HVAC, and restraint systems. For owners and technicians, this resource offers step-by-step instructions for routine maintenance, troubleshooting common issues, component repair and replacement, and in-depth diagnostics, all supported by diagrams, illustrations, and critical technical specifications to ensure optimal vehicle upkeep and performance. 🏷️ Basic Information Identification Make: BMW Model: 540i Model Designation: E39 Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002 Codes Engine Codes: M62B44 (Naturally Aspirated) 👋 Introduction Market Position Positioning: Premium sport sedan, competitor to Mercedes-Benz E-Class and Audi A6. Competitive Analysis Key Competitors: Mercedes-Benz W210 E-Class, Audi C5 A6, Lexus GS. Key Features Vehicle Appeal: Performance, luxury, driving dynamics, build quality. Manual Benefit: Enables informed decision-making with technicians and empowers DIY repairs, saving significant costs. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: PDF Download Document Delivery: Digital Download Intended Audience: Professional Technicians and DIY Enthusiasts 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, assembly, timing, cooling, lubrication. Engine Electrical: Ignition system, starting and charging system, sensors, actuators, ECU diagnostics. Emission Control: Catalytic converter, oxygen sensors, EVAP system, EGR system. Fuel System: Fuel pump, injectors, fuel pressure regulator, fuel tank, fuel lines. Clutch System: Clutch disc, pressure plate, release bearing, clutch hydraulic system. Manual Transaxle: Gearbox overhaul, component replacement, shift mechanism. Automatic Transaxle: Transmission fluid changes, torque converter, valve body, solenoids, electronic control. Driveshaft Axle: Driveshaft, universal joints, CV joints, rear axle assembly. Suspension System: Front and rear suspension components, shock absorbers, springs, control arms, bushings. Steering System: Power steering pump, steering rack, tie rods, steering column. Restraint System: Airbags, seatbelts, SRS module diagnostics. Brake System: Front and rear brake calipers, rotors, pads, ABS system, hydraulic lines. Body Interior Exterior: Door panels, seats, dashboard, trim, exterior body panels, glass. Body Electrical: Lighting, power windows, central locking, mirrors, wipers, horn. HVAC System: Air conditioning compressor, evaporator, condenser, heater core, blower motor, climate control unit. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement. Troubleshooting: Diagnostic charts, symptom-based repair procedures, error code interpretation. Repair: Component removal, installation, adjustment, calibration. Diagnostics: Component testing, circuit analysis, data stream interpretation. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds. Visuals Included: Diagrams, illustrations, wiring schematics. Specification Level: Detailed torque specifications, clearances, fluid capacities, pressure readings. 📊 Manual Specifications File Format Compatibility: Windows and macOS Reader Requirement: Adobe PDF Reader Print Quality Printability: Fully printable, individual pages Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: V8, Naturally Aspirated Engine Displacement: 4.4 Liters (4398 cc) Engine Code: M62B44TU (post-1998 update) Performance Horsepower Output: Approx. 290-310 hp (depending on year and specific tuning) Torque Output: Approx. 320-340 lb-ft Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) 🔧 Transmission Standard Transmission Type: 5-speed Manual (Getrag 420G) / 5-speed Automatic (Steptronic) Optional Optional Transmission: 5-speed Automatic with Steptronic manual shift mode Features Automatic Features: Adaptive transmission control, Steptronic manual shifting capability. 📐 Dimensions Exterior Wheelbase: Approx. 113.4 inches (2881 mm) Length: Approx. 190.6 inches (4841 mm) Width: Approx. 71.5 inches (1816 mm) Height: Approx. 57.0 inches (1448 mm) Weights Curb Weight: Approx. 3600-3800 lbs (1633-1724 kg) Gross Vehicle Weight Rating: Approx. 4700 lbs (2132 kg) 🛡️ Safety Features Ratings NHTSA Overall Rating: Information not readily available for specific year/model ratings in this format. Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Dynamic Stability Control (DSC) or Traction Control System (TCS). Passive Features Airbags: Frontal airbags, available side-impact airbags. Body Structure: Reinforced safety cage construction. 💡 Technology Features Infotainment Head Unit: BMW Business or Professional CD/Radio system, optional navigation system (e.g., MK III). Display: Central information display in instrument cluster and on the dashboard (often...