The 1999 BMW 540i, part of the esteemed E39 generation, represents a pinnacle of executive luxury and performance. This sedan is celebrated for its renowned BMW driving dynamics, powered by a potent 4.4L V8 engine, and offers a sophisticated interior and advanced engineering for its era. Positioned as a direct competitor to other premium mid-size sedans like the Mercedes-Benz E-Class and Audi A6, the 540i distinguishes itself with its potent powertrain, offering approximately 282 horsepower and 324 lb-ft of torque, and a refined driving experience that has earned consistent accolades, including appearances on Car and Driver's '10Best' lists. This comprehensive workshop repair service manual provides detailed guidance for all aspects of the 1999 BMW 540i, covering all engine and transmission types, trim levels, and the sedan body style. It is designed to assist owners, mechanics, and technicians in maintaining and repairing this luxury vehicle. The manual encompasses routine maintenance, in-depth troubleshooting and diagnostics, component replacement procedures, and essential technical specifications, including torque values and wiring diagrams. With extensive coverage of all major vehicle systems, from the engine mechanicals and fuel system to the brakes, suspension, and electrical components, this manual serves as an indispensable resource for ensuring the longevity and optimal performance of your BMW 540i. 🏷️ Basic Information Identification Make: BMW Model: 540i Model Variant: 540 Year: 1999 Codes Chassis Code: E39 👋 Introduction Market Position Vehicle Segment: Executive Sedan, Luxury Mid-size Sedan Competitive Analysis Primary Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS300, Jaguar S-Type. Key Features Distinctive Attributes: Renowned BMW driving dynamics, potent V8 engine, sophisticated interior, advanced engineering for its era. 📋 Manual Details Coverage Areas Engine Options Covered: All Engine Types for 1999 BMW 540i Transmission Options Covered: All Transmission Types for 1999 BMW 540i Trim Levels Covered: All Trim Levels for 1999 BMW 540i Body Styles Covered: Sedan (4-door) Page Count Estimated Page Count: High (Comprehensive Workshop Manual) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Management: Detailed diagnostics, repair procedures, specifications for engine control unit (ECU), sensors, actuators, ignition system, fuel injection system. Engine Mechanical: Comprehensive coverage of engine teardown, assembly, internal component specifications (pistons, rings, bearings, crankshaft, camshaft), cylinder head, valve train, timing systems. Cooling System: Radiator, water pump, thermostat, coolant hoses, fan clutch, expansion tank, bleeding procedures, pressure testing. Lubrication System: Oil pump, oil pan, oil filter, oil cooler, lubrication passages, oil pressure testing. Exhaust System: Exhaust manifolds, catalytic converter, muffler, oxygen sensors, exhaust hangers, leak detection. Fuel System: Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, fuel tank, evaporative emission control (EVAP) system. Transmission Automatic: Detailed overhaul procedures, valve body operation, torque converter, transmission control module (TCM), fluid specifications, fill procedures, shift solenoid testing. Transmission Manual: Clutch assembly, transmission gear ratios, input/output shafts, bearings, seals, shift linkage, lubrication. Drivetrain: Driveshafts, universal joints, CV joints, differential, axle shafts, wheel bearings. Brakes: Brake system diagnosis, ABS/DSC system, hydraulic components (master cylinder, brake lines, calipers, wheel cylinders), brake pads, rotors, drum brakes, parking brake system, bleeding procedures. Suspension Front: Control arms, ball joints, tie rod ends, sway bar, strut assembly, wheel bearings, steering knuckle, alignment specifications. Suspension Rear: Multilink suspension components, shock absorbers, springs, trailing arms, control arms, alignment specifications. Steering System: Power steering pump, steering gear/rack, power steering hoses, steering column, steering wheel, alignment. Electrical System Chassis: Lighting system (headlights, taillights, interior lights), horn, wipers, washers, power windows, power locks, mirrors, seats, sunroof. Electrical System Engine: Alternator, starter motor, battery, wiring harnesses, relays, fuses, ignition coils. Comfort Systems: Climate control (HVAC) system diagnosis and repair, blower motor, A/C compressor, refrigerant, heater core, evaporator, control panels. Body And Frame: Body panel removal and installation, door mechanisms, hood, trunk lid, bumpers, interior trim panels, glass replacement, rust prevention. Diagnostic Trouble Codes: Extensive listing of DTCs, their meanings, and troubleshooting flowcharts. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), fluid level checks and top-offs, spark plug replacement, belt inspections and replacement. Troubleshooting Diagnostics: Systematic approach to identifying and resolving common and uncommon faults, using diagnostic tools and symptom-based repair. Component Replacement: Step-by-step guides for replacing virtually every component on the vehicle. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Torque Specifications: Precise torque values for all critical fasteners. Wiring Diagrams: Detailed electrical schematics for all vehicle systems. Technical Depth Depth Of Coverage: Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and body repair. 📊 Manual Specifications File Format File Format: PDF Print Quality Image Resolution: High-resolution scans for clear diagrams and text. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: M62B44 Engine Type: 4.4L V8 (32-valve) Displacement: 4398 cc (268.3 cu...