This manual covers the 540i, chassis code E39, produced between 1997 and 2002. Powered by the M62B44 V8 engine, this model embodies the philosophy of the "Ultimate Driving Machine," blending performance, luxury, and engineering excellence. The 540i, a top-tier offering in its generation, was renowned for its engaging driving dynamics and sophisticated comfort, earning frequent accolades such as Car and Driver's 10Best awards. It was manufactured in Germany, reflecting a commitment to quality and precision. This comprehensive Workshop Service Repair Manual in English provides in-depth coverage for all styles of the 540i (E39). It is designed to assist both do-it-yourself enthusiasts and experienced mechanics in maintaining and repairing the vehicle. The manual includes detailed step-by-step instructions, complete disassembly procedures, diagnostic protocols, and technical specifications for all major systems, including engine, transmission, brakes, electrical, suspension, and HVAC. With hundreds of photos and illustrations, this manual offers an inexpensive and efficient way to keep your vehicle operating at its peak. 🏷️ Basic Information Identification Make: BMW Model: 540i Chassis Code: E39 Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002 Codes Engine Code Primary: M62B44 👋 Introduction Market Position Target Audience: Do-it-yourselfers and experienced mechanics Key Features Value Proposition: Inexpensive way to keep vehicle working properly, saves on shipping and waiting time Delivery Method: Instant download link after payment 📋 Manual Details Coverage Areas All Styles Covered: True Page Count Estimated Page Count: Hundreds (specific number not provided, but described as comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download Print Quality Printable: Printable in its entirety or just the pages you need, without any restriction Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) 📖 Manual Coverage Systems Covered Engine Service Repair: Yes Transmission Service Repair: Yes Brake System: Yes Electrical System: Yes Wiring Diagrams: Yes Suspension: Yes Steering: Yes Cooling System: Yes Fuel Injection: Yes Fuel System: Yes Emission System: Yes Heater Air Conditioning: Yes Engine Control System: Yes Chassis Body: Yes Restraint System: Yes Interior: Yes Differential Drive: Yes Axle: Yes General Maintenance: Yes Troubleshooting: Yes Periodic Lubrication: Yes Procedures Included Step By Step Instructions: Yes Complete Disassembly Procedures: Yes Detailed Substeps: Yes Diagnostic Procedures: Yes Technical Depth Depth: Complete Official Full Factory Service Repair (suitable for DIY and experienced mechanics) Illustrations Photos Illustrations: Hundreds of photos and illustrations Enlarged Inset Illustrations: Yes Navigation Numbered Table Of Contents: Yes ⚙️ Engine Specifications Primary Engine Engine Type: V8, Naturally Aspirated Displacement: 4.4 Liters (4398 cc) Engine Code: M62B44 Performance Horsepower Approximate: 282 hp @ 5400 rpm (for 1997-2001 models) Torque Approximate: 324 lb-ft @ 3600 rpm (for 1997-2001 models) Fuel System Fuel Delivery: Electronic Fuel Injection (Bosch Motronic) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management Engine Control Unit: BMW M-ASK / Professional Navigation System (CCC in later E39 models) 🔧 Transmission Standard Transmission Type Standard: 5-speed Automatic (Steptronic) Optional Transmission Type Optional: 6-speed Manual (available on some models/markets, particularly 540i/6-speed variants) Features Steptronic Functionality: Yes (manual shifting mode) 📐 Dimensions Exterior Wheelbase: 115.4 inches (2931 mm) Length: 191.0 inches (4851 mm) Width: 71.0 inches (1803 mm) Height: 57.4 inches (1458 mm) Weights Curb Weight Approximate: 3700 - 3900 lbs (depending on transmission and options) 🛡️ Safety Features Passive Features Airbags: Frontal airbags (driver and passenger), side airbags (optional/standard depending on year/trim) Seatbelts: Three-point inertia-reel seat belts with pre-tensioners Active Features Antilock Braking System: Standard ABS Traction Control: Standard ASC+T (Automatic Stability Control + Traction) or DSC (Dynamic Stability Control) 💡 Technology Features Infotainment Head Unit Options: BMW Business CD, BMW Professional RDS, Navigation system (M-ASK or CCC) Speaker System: Standard Hi-Fi system, optional Harman Kardon Logic 7 surround sound Driver Assistance Parking Assistance: Optional Rear Park Distance Control (PDC) Connectivity Bluetooth: Optional Bluetooth integration available on later models 🔧 Maintenance Service Intervals Oil Change Interval Recommendation: Every 7,500 - 15,000 miles or 12 months, depending on oil quality and driving conditions (refer to manual for exact CBS settings) Fluid Specifications Engine Oil Type: Full Synthetic SAE 5W-30 or 5W-40, meeting BMW Longlife-01 specification (e.g., Castrol Syntec or equivalent) Coolant Type: BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) Brake Fluid Type: DOT 4 (low viscosity, e.g., DOT 4 LV) Transmission Fluid Automatic: Dexron III or Dexron VI (check specific transmission type and BMW service bulletins for definitive specs) Transmission Fluid Manual: BMW MTF LT-2 or equivalent high-quality manual transmission fluid Known Issues Common Problem Oil Leaks: Valve cover gaskets, oil pan gasket, oil filter housing gasket Common Problem Cooling System: Plastic coolant expansion tank, water pump, thermostat housing failures Common Problem Vanos System: Degradation of VANOS seals leading to rough idle, loss of low-end torque Common Problem Spark Plugs Ignition: Coil-on-plug ignition failures, spark plug replacement often recommended around 60,000-100,000 miles Common Problem Suspension:...