The BMW 540i, chassis code E34, represents a pinnacle of luxury executive sedan engineering from 1994, embodying BMW's philosophy of "The Ultimate Driving Machine." Powered by the robust M60B40 naturally aspirated V8 engine, this model delivers an impressive 282 horsepower and 400 Nm of torque, paired with either a 5-speed manual or an optional 5-speed automatic transmission. Its design, part of the E34 generation's move towards more aerodynamic styling, competed with luxury stalwarts like the Mercedes-Benz E-Class and Audi A6. This vehicle is distinguished by its focus on performance, refined handling, and a suite of driver-centric features, making it a sought-after model for enthusiasts and those appreciating automotive excellence. This comprehensive workshop repair service manual provides essential information for the maintenance and repair of all BMW 540i (E34) models from 1994. Covering a vast array of systems including engine, transmission, brakes, electrical, suspension, steering, cooling, fuel, emissions, HVAC, chassis, body, interior, and drivetrain, this manual is an indispensable resource. It details general maintenance, periodic lubrication, troubleshooting procedures, diagnostic information, and step-by-step repair, disassembly, assembly, and reinstallation processes, all presented with clear diagrams and illustrations. This professional-level guide ensures that owners and technicians can effectively maintain and repair the vehicle, preserving its performance and longevity. 🏷️ Basic Information Identification Make: BMW Model: 540i Year: 1994 Codes Chassis Code: E34 Engine Code: M60B40 👋 Introduction Market Position Segment: Luxury Executive Sedan Target Audience: BMW 540i (E34) owners, independent repair shops, DIY enthusiasts Competitive Analysis Key Competitors Era: Mercedes-Benz E-Class (W124), Audi A6 (C4), Lexus GS Key Features Authenticity: Original BMW Workshop Service Manual Completeness: Complete and intact, no missing or corrupt parts/pages Usability: Easy to follow directions, numbered instructions, clear diagrams Cost Savings: Enables DIY repairs to save significant money on labor costs Format Advantage: Digital PDF allows for printing specific sections, eliminating physical wear and tear 📋 Manual Details Coverage Areas Primary Coverage: BMW 540i (E34) 1994 All Models Included: Yes (All Models/Engines/Trim/Transmissions Types) Page Count Estimated Pages: Hundreds (Specific count not provided, but indicated as comprehensive) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Service, Repair, Engine Control System Transmission: Service, Repair Brakes: Brake System Service and Repair Electrical: Electrical System, Wiring Diagrams, Diagnostic and Repair Procedures Suspension Steering: Suspension, Steering Cooling Fuel Emissions: Cooling System, Fuel Injection/Fuel System, Emission System HVAC: Heater/Air Conditioner Chassis Body: Chassis/Body Interior Safety: Interior, Restraint System Drivetrain: Differential/Drive, Axle Procedures Included Maintenance: General Maintenance, Periodic Lubrication Troubleshooting: Troubleshooting Repair: Detailed repair procedures with substeps, notes, cautions, and warnings Diagnostics: Comprehensive diagnostic information for electrical systems and general troubleshooting Assembly Disassembly: Disassembly, Assembly, and Reinstallation Procedures Technical Depth Depth: Professional/Technician Level (Same manual used in local service/repair shops) Illustrations: Detailed illustrations, drawings, photos, and enlarged insets for parts identification 📊 Manual Specifications File Format File Type: PDF Portability: Instant Download Print Quality Printability: Full Printable Zoom Functionality: Zoom IN/OUT capability Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF - can be printed on any paper) Software Requirements PDF Reader: Adobe PDF Reader Compression Utility: WinZip (for downloaded file) Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated V8 Engine Code: M60B40 Displacement: 3982 cc (4.0 Liters) Bore X Stroke: 84 mm x 90 mm Compression Ratio: 10.0:1 Valve Train: DOHC, 4 Valves per Cylinder Performance Horsepower: 282 hp (210 kW) @ 5800 rpm Torque: 295 lb-ft (400 Nm) @ 4500 rpm Fuel System Fuel Delivery: Bosch Motronic M4.0 Electronic Fuel Injection Fuel Type: Premium Unleaded Gasoline (91+ Octane) Cooling System Coolant Capacity: Approx. 10.5 Liters (11.1 US Quarts) Lubrication Oil Capacity: Approx. 6.5 Liters (6.9 US Quarts) with filter Recommended Oil Viscosity: SAE 5W-30 or 5W-40 Synthetic (check owner's manual for specific BMW approval) 🔧 Transmission Standard Type: 5-Speed Manual (S5D 320Z / Getrag 265) Optional Type: 5-Speed Automatic (Steptronic - EGS) Features Automatic Features: Electronic Gear Selection (EGS), Sport Mode Fluid Specifications Automatic Transmission Fluid: BMW ATF LT-3 (or equivalent Dexron III type) Manual Transmission Fluid: BMW Manual Transmission Fluid (e.g., SAF-XJ 75W-140 or equivalent API GL-4/GL-5) 📐 Dimensions Exterior Length: 4,719 mm (185.8 in) Width: 1,798 mm (70.8 in) Height: 1,410 mm (55.5 in) Wheelbase: 2,760 mm (108.7 in) Weights Curb Weight: Approx. 1,700 kg (3,748 lbs) - Manual Transmission Gross Weight: Approx. 2,150 kg (4,740 lbs) 🛡️ Safety Features Ratings Crash Test Results: N/A (Limited comprehensive testing for this era available publicly) Active Features ABS: Standard Anti-lock Braking System (ABS) Passive Features Airbags: Driver and Front Passenger Airbags Seatbelts: Pretensioning Seatbelts 💡 Technology Features Infotainment Radio Options: BMW Bavaria C III or Blaupunkt aftermarket units (optional) On Board Computer: Optional On-Board Computer (OBC) with features like trip computer, fuel consumption, and system checks. Driver Assistance Cruise Control:...