This workshop service manual covers the 540i (E39 chassis code) produced between 1997 and 2002. The 540i is an executive sedan renowned for its powerful 4.4L V8 engine, producing approximately 282 horsepower and 324 lb-ft of torque, and its sophisticated blend of luxury appointments and driving dynamics, often lauded by automotive publications. Engineered for performance and comfort, this model offered advanced features for its era, including optional navigation systems, high-quality audio, and automatic climate control, positioning it as a strong competitor in the luxury sedan market. This comprehensive manual provides detailed information essential for the maintenance, diagnosis, and repair of your 540i. It includes extensive coverage of all major systems, including the powertrain (engine, transmission, drivetrain, fuel, exhaust), chassis (suspension, steering, brakes), electrical systems, and body/interior components. Within its 1002 pages, you will find scheduled maintenance procedures, detailed repair and rebuild instructions, troubleshooting guides with diagnostic trees, and installation procedures for various components. Technical specifications, torque values, wiring diagrams, and clear illustrations are also included to assist owners, mechanics, and technicians in ensuring the optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: BMW Model: 540i Model Variant: 540 Generation Chassis Code: E39 Codes Engine Code Primary: M62B44 Engine Code Variant Tu: M62TUB44 👋 Introduction Market Position Segment: Executive Sedan Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS Key Features Powertrain Emphasis: Powerful V8 engine, refined driving dynamics Luxury Appointments: High-quality interior materials, advanced features for its era 📋 Manual Details Coverage Areas Applicable Model Years: 1997, 1998, 1999, 2000, 2001, 2002 Page Count Total Pages: 1002 Manual Type Type: Workshop Service Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (M62 V8), Transmission (5-speed automatic, 6-speed manual), Drivetrain (Rear-wheel drive), Fuel System, Exhaust System Chassis: Suspension (Front/Rear), Steering, Brakes (ABS, DSC), Wheels and Tires Electrical: Engine Control Unit (ECU), Lighting System, Instrumentation, Audio System, Power Accessories (Windows, Seats, Mirrors), Diagnostic System (OBD-II) Body And Interior: Body Panels, Doors, Bumpers, Exterior Trim, Interior Trim, Seats, HVAC System Procedures Included Maintenance: Scheduled Maintenance (Oil Changes, Filter Replacements, Fluid Checks), Tune-ups, Belt and Hose Inspection/Replacement Repair And Rebuild: Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Electrical Component Diagnosis and Repair Troubleshooting: Diagnostic Procedures, Symptom-based Troubleshooting Guides, Error Code Interpretation Installation And Removal: Component Removal and Installation (e.g., Alternator, Starter, Water Pump, Radiator, Headlights) Technical Depth Diagnostics: Detailed diagnostic trees, sensor data interpretation, ECU function explanations Specifications: Torque values, fluid capacities, wear limits, electrical specifications, diagnostic parameters Illustrations And Diagrams: Step-by-step pictorial guides, exploded views, wiring diagrams, schematic diagrams 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Yes, all pages are printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirements Reader: Adobe Reader Compatibility Operating Systems: Windows, Mac, Linux OS ⚙️ Engine Specifications Primary Engine Engine Type: 4.4L DOHC 32-valve V8 Engine Code: M62TUB44 (for later models, earlier may be M62B44) Performance Horsepower Approx: 282 hp @ 5400 rpm Torque Approx: 324 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (Bosch Motronic) Recommended Fuel: Premium Unleaded Gasoline (91 octane or higher) Cooling System Coolant Capacity Approx: 9.5 liters (10.0 quarts) Lubrication Oil Capacity Approx: 7.0 liters (7.4 quarts) Recommended Oil Viscosity: 5W-30 Synthetic 🔧 Transmission Standard Type: 5-speed Steptronic Automatic Transmission (e.g., GM 5L40-E) Optional Type: 6-speed Manual Transmission (Getrag 420G) Features Steptronic Functionality: Manual shift mode available for driver control Fluid Specs Automatic Transmission Fluid: Dexron III or equivalent (refer to manual for specific BMW P/N) Manual Transmission Fluid: BMW recommended synthetic gear oil (e.g., 75W-90) 📐 Dimensions Exterior Length: Approx. 4,819 mm (189.7 in) Width: Approx. 1,801 mm (70.9 in) Height: Approx. 1,437 mm (56.6 in) Weights Curb Weight Approx: 1,670 - 1,750 kg (3,682 - 3,858 lb) Wheelbase: Approx. 2,830 mm (111.4 in) Wheels And Tires Standard Wheel Size: 16-inch or 17-inch alloy wheels Standard Tire Size: 225/55R16 or 235/45R17 Bolt Pattern: 5x120 mm 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-star (for similarly equipped models of the era) NHTSA Frontal Impact Passenger: 4-star (for similarly equipped models of the era) Active Features Traction Control: Automatic Stability Control (ASC) or Dynamic Stability Control (DSC) Braking System: Anti-lock Braking System (ABS) standard, optional Electronic Brake Force Distribution (EBD) Passive Features Airbags: Frontal airbags (driver and passenger), optional side airbags Seatbelts: Three-point seatbelts with pretensioners 💡 Technology Features Infotainment Navigation System: Optional BMW Business or Professional Navigation System (MKIII or MKIV based) Audio System: Hi-Fi or Logic7 audio systems available, cassette player and CD changer common Driver Assistance Cruise Control: Standard electronic cruise control Parking Sensors: Optional rear Park Distance Control (PDC) Connectivity Bluetooth: Optional Bluetooth interface (often required an adapter for earlier models) Comfort Features Climate Control: Automatic dual-zone climate control Seating: Power adjustable...