🏷️ Basic Information Identification Make: BMW Model: 540i Year: 1991 Codes Chassis Code: E34 Engine Code: M60B40 👋 Introduction Market Position Segment: Luxury Executive Sedan Competitive Analysis Competitors: Mercedes-Benz E-Class, Audi 100/A6, Lexus LS400 Key Features Vehicle Highlights: Powerful V8 engine, refined luxury interior, advanced engineering for its era Manual Value Purpose: Empowering owners and technicians with the knowledge to maintain and repair the 540i 📋 Manual Details Coverage Areas Coverage Type: Full Service Repair Page Count Estimated Page Count: 1500+ Manual Type Manual Format: Comprehensive Repair Manual Language Language: English Format Physical Format: Print 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, component replacement, timing, valve adjustment Engine Electrical: Ignition system, fuel injection (DME), sensor diagnostics, wiring diagrams Transmission: Manual (Getrag 265) and Automatic (ZF 4HP22) service, repair, and diagnostics Drivetrain: Driveshaft, differential, axles, CV joints Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment Brakes: Hydraulic system, ABS diagnostics and repair, caliper overhaul, pad/rotor replacement Steering: Power steering system, steering rack, tie rods, steering column Fuel System: Fuel pump, injectors, pressure regulator, fuel tank service Cooling System: Radiator, water pump, thermostat, hoses, coolant specifications Exhaust System: Catalytic converter, mufflers, pipes, hangers HVAC: Air conditioning, heating, climate control system Electrical Systems: Lighting, wipers, horn, power windows, central locking Body And Chassis: Body panels, doors, windows, trim, structural components Diagnostic Troubleshooting: Detailed fault code interpretation, symptom-based diagnosis Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, spark plugs Major Repairs: Engine rebuilds, transmission overhauls, cylinder head service Component Replacement: Detailed step-by-step guides for all major components Troubleshooting Guides: Systematic approaches to identifying and resolving common and uncommon issues Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Torque Specifications: Essential torque values for critical fasteners Special Tools: Identification of specialized tools required for specific procedures Technical Depth Depth Level: Expert/Professional Level Diagnostic Capability: Advanced diagnostics and troubleshooting for complex electronic systems Rebuild Procedures: Complete rebuild instructions for major mechanical assemblies 📊 Manual Specifications File Format File Type: Physical Book Print Quality Print Resolution: High-quality, crisp printing Binding Type Binding: Durable, lay-flat binding Paper Type Paper Quality: Heavy-duty, oil-resistant paper ⚙️ Engine Specifications Primary Engine Engine Type: V8 Displacement: 4.0 Liters (3982 cc) Bore X Stroke: 84.0 mm x 90.0 mm Compression Ratio: 8.8:1 Valvetrain: DOHC, 4 valves per cylinder Performance Horsepower: 282 hp @ 5800 rpm (DIN) Torque: 295 lb-ft @ 4500 rpm (DIN) Fuel System Induction: Bosch Motronic M4.0 Electronic Fuel Injection (EFI) Fuel Type: Unleaded Premium Gasoline (91+ Octane) Engine Cooling Coolant Type: BMW Blue Antifreeze (G48) or equivalent, 50/50 mix with distilled water Engine Oil Oil Type: SAE 5W-30 Synthetic (BMW Longlife-98 specification) Oil Capacity: 6.5 Liters (6.9 US Quarts) with filter change Ignition Spark Plugs: Bosch Super Plus F7DC0 or equivalent, gap 0.032" (0.8 mm) 🔧 Transmission Standard Transmission Type: 5-Speed Manual (Getrag Type D - 265) Optional Transmission Type: 4-Speed Automatic (ZF 4HP22 EH) Features Manual Gear Ratios: 1st: 4.23:1, 2nd: 2.52:1, 3rd: 1.67:1, 4th: 1.24:1, 5th: 1.00:1, Reverse: 3.90:1 Automatic Features: Electronic Hydraulic control (EH), Sport/Economy modes Fluid Specifications Manual Transmission Fluid: SAE 75W-90 Synthetic Gear Oil (API GL-4) Automatic Transmission Fluid: BMW ATF LT 71141 or ZF TE-ML 11B/11A 📐 Dimensions Exterior Length: 4735 mm (186.4 in) Width: 1749 mm (68.9 in) Height: 1412 mm (55.6 in) Wheelbase: 2797 mm (110.1 in) Weights Curb Weight: Approx. 1630 kg (3594 lbs) Manual / 1660 kg (3660 lbs) Automatic Gross Vehicle Weight Rating: Approx. 2100 kg (4630 lbs) 🛡️ Safety Features Ratings NHTSA Crash Test Ratings: Not officially rated by NHTSA for this era, but known for robust chassis construction Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional ASC+T (Automatic Stability Control + Traction) Passive Features Airbags: Driver-side airbag standard, passenger airbag optional on later models/markets Seatbelts: 3-point inertia-reel seatbelts front and rear 💡 Technology Features Infotainment Audio System: Standard BMW AM/FM stereo with cassette, optional premium sound systems (e.g., HiFi, Bavaria C Business/Professional) Driver Assistance Cruise Control: Standard electronic cruise control Connectivity Phone Integration: Optional cellular phone preparation with external antenna 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 12 months, whichever comes first (using appropriate synthetic oil) Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km) Spark Plug Replacement: Every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type Coolant Flush: Every 2 years or 30,000 miles (48,000 km) Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 Power Steering Fluid: BMW CHF 11S or Pentosin 11S Known Issues Common Wear Items: E34 specific cooling system components (plastic expansion tank, water pump impeller), rear axle bushings, front control arm bushings, idle control valve, oxygen sensors. M60 Engine Specific: Timing chain guides (can become brittle and break), VANOS solenoid seals (if equipped on later M60s),...