The BMW 540i, produced between 1997 and 2002 under the E39 chassis code, represents a pinnacle of automotive engineering, embodying BMW's philosophy of "Sheer Driving Pleasure." This executive sedan, powered by a robust 4.4-liter V8 engine, offered a compelling blend of luxury, performance, and advanced technology for its era. Frequently recognized for its exceptional handling and build quality, the 540i was a flagship model, providing a dynamic driving experience with features like available Dynamic Stability Control and premium interior appointments. Its design and engineering have cemented its status as a desirable vehicle for enthusiasts and those seeking sophisticated transportation. This comprehensive factory service repair manual provides in-depth information for the BMW 540i (E39 chassis) from 1997 to 2002. It covers all essential aspects of maintenance, repair, and diagnostics, including detailed procedures for the powertrain, chassis, suspension, and electrical systems. Within its hundreds of pages, you will find step-by-step repair instructions, troubleshooting guides, technical specifications, and safety guidelines, offering the same level of detail to professional technicians. This manual is an indispensable resource for owners, DIY mechanics, and service professionals aiming to maintain and restore the optimal performance and longevity of their BMW 540i. 🏷️ Basic Information Identification Make: BMW Model: 540i Model Variant: 540 Year: 1997-2002 Generation Chassis Code: E39 👋 Introduction Market Position Target Audience: BMW 540i (E39) owners, DIY mechanics, professional technicians Competitive Analysis Value Proposition: Provides professional-level repair knowledge, enabling significant savings on labor costs ($50-$60 per hour) Key Features Accuracy: Actual genuine factory manual, not third-party Usability: Easy to use, searchable PDF, printable pages for convenient on-the-job reference Completeness: Covers all aspects of repair and maintenance for all styles 📋 Manual Details Coverage Areas Covered Models: BMW 540i (E39 chassis) Covered Years: 1997, 1998, 1999, 2000, 2001, 2002 Page Count Estimated Pages: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Type: Factory Service Repair Manual Source: Official Factory Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine Service/Repair, Transmission Service/Repair, Differential/Drive, Axle Chassis And Suspension: Brake System, Suspension, Steering, Chassis/Body Electrical And Electronics: Wiring Diagram, Electrical System, Engine Control System Comfort And Climate: Cooling System, Fuel Injection/Fuel System, Emission System, Heater/Air Conditioning Interior And Safety: Restraint System, Interior Procedures Included Maintenance: General Maintenance, Periodic Lubrication, Scheduled Service Repair And Rebuild: Step-by-step repair procedures for all covered systems, complete rebuilds Diagnostics: Troubleshooting, Advanced Troubleshooting Guide, Diagnostic Procedures Technical Depth Depth: Comprehensive, detailed, covering fundamentals to advanced repair, same information as professional technicians 📊 Manual Specifications File Format Format: PDF Compatibility: Windows and Mac operating systems Print Quality Printability: Fully printable (individual pages or entire manual) Binding Type Binding: Digital download (user prints and binds as desired) Paper Type Paper Type: N/A (Digital) Delivery Method Delivery: Instant Download after payment Software Requirements Reader: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Code: M62B44 (4.4L V8) Performance Displacement: 4.4 Liters (4398 cc) Horsepower Approx: 282 hp @ 5400 rpm (E39 M62 variant) Torque Approx: 324 lb-ft @ 3600 rpm (E39 M62 variant) Fuel System Induction: Sequential Multi-Point Fuel Injection (SFI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management ECU: BMW's DME (Digital Motor Electronics) - specific model varies by year and region Cooling System Coolant Type: BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) or equivalent Coolant Capacity Approx: 10.5 Liters (11.1 US Quarts) 🔧 Transmission Standard Type: 5-Speed Steptronic Automatic Transmission (GM 5L40-E) Optional Type: 6-Speed Manual Transmission (Getrag S6S 420G) Features Steptronic: Allows manual gear selection via shifter or steering wheel buttons (depending on specific option/year) Fluid Specifications Automatic Fluid: Dexron III (or equivalent ATF specification, consult manual for specific BMW fluid PN) Manual Fluid: BMW Manual Transmission Fluid (MTF-LT-2 or equivalent) 📐 Dimensions Exterior Length: Approx. 191.0 inches (4851 mm) Width: Approx. 71.5 inches (1816 mm) Height: Approx. 57.3 inches (1455 mm) Wheelbase Wheelbase: Approx. 115.4 inches (2931 mm) Weights Curb Weight Approx: 3,800 - 4,000 lbs (1724 - 1814 kg), varies by transmission and options 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated for these years, but generally good for the era Active Features Traction Control: Available, often as Automatic Stability Control (ASC) or Dynamic Stability Control (DSC) ABS: Standard Anti-lock Braking System Passive Features Airbags: Front airbags, optional side airbags 💡 Technology Features Infotainment Head Unit: BMW Professional RDS radio with cassette and CD player, optional navigation system (e.g., Mk II/Mk III system) Display: Central instrument cluster display, optional green monochrome or color LCD for navigation/vehicle information Driver Assistance Cruise Control: Standard electronic cruise control Connectivity Bluetooth: Not standard, optional dealer-installed or aftermarket kits available Lighting Headlights: Halogen headlights, optional Xenon (HID) headlights with auto-leveling 🔧 Maintenance Service Intervals Oil Change: BMW Condition Based Service (CBS) system, typically around 7,500-15,000 miles or annually. Consult manual for specific...