The BMW 540i, model year 2001, chassis code E39, is a premium sport sedan renowned for its exceptional engineering and performance, embodying BMW's commitment to being "The Ultimate Driving Machine." This generation, produced from 1996 to 2003, is celebrated for its superior handling, refined driving dynamics, and luxury appointments, often recognized with accolades such as Car and Driver's 10 Best. Powered by a robust 4.4L V8 engine producing 290 horsepower and 324 lb-ft of torque, it offers an engaging driving experience, complemented by either a 5-speed Steptronic automatic transmission or a rare 6-speed manual. Its design emphasizes a balance of sportiness and comfort, making it a compelling choice in its segment. This comprehensive workshop repair service manual, written in English, serves as an indispensable resource for maintaining and repairing the BMW 540i (E39). It covers all models, engines, trims, and transmission types, offering detailed information on general maintenance, troubleshooting, engine and transmission service, brake systems, electrical systems, suspension, steering, cooling, fuel injection, and more. With professional technician-level depth, including diagnostic procedures, disassembly and assembly instructions, and critical notes, this manual empowers owners and technicians to perform a wide range of tasks, from routine service to complex repairs, ensuring the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: BMW Model: 540i Year: 2001 Chassis Code: E39 👋 Introduction Market Position Positioning: Premium sport sedan Competitive Analysis Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS Key Features Brand Promise: The Ultimate Driving Machine Value Proposition: Comprehensive DIY repair and maintenance resource to save significant costs 📋 Manual Details Coverage Areas Coverage: All Models/Engines/Trim/Transmissions Types Page Count Page Count: Hundreds of Pages (estimated based on description) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems: General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle Procedures Included Procedures: Diagnostic, Repair, Maintenance, Disassembly, Assembly, Cleaning, Reinstalling, Troubleshooting steps, Detailed substeps, Notes, Cautions, Warnings Technical Depth Depth: Professional Technician Level, Complete Informational Book, Detailed diagrams and information 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Full Printable Binding Type Binding Type: Digital Download (No physical binding) Paper Type Paper Type: N/A (Digital) Zoom Capability Zoom: YES Delivery Method Delivery: Instant Download Requirements Requirements: Adobe PDF Reader & WinZip Compatibility Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: M62B44TU (Technical Update) Engine Type: 4.4L V8 Performance Horsepower: 290 hp @ 5400 rpm Torque: 324 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Sequential Multi-Point Fuel Injection (SFI) Valve Train Valve Train: DOHC, 4 valves per cylinder Cooling System Cooling System Type: Pressurized liquid cooling 🔧 Transmission Standard Transmission Type: 5-speed automatic (Steptronic) Optional Transmission Type Optional: 6-speed manual (Rare, limited availability for 540i M-Sport) Features Transmission Features: Steptronic manual shifting mode for automatic transmission 📐 Dimensions Exterior Length: 190.2 in (4831 mm) Width: 71.0 in (1803 mm) Height: 57.0 in (1448 mm) Wheelbase Wheelbase: 113.7 in (2888 mm) Weights Curb Weight: approx. 3,850 - 4,000 lbs (1746 - 1814 kg) 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars NHTSA Side Impact: 4/5 Stars Active Features Active Safety: ABS, DSC (Dynamic Stability Control), Traction Control Passive Features Passive Safety: Front airbags, Side-impact airbags, Pre-tensioned seatbelts, Reinforced chassis 💡 Technology Features Infotainment Infotainment System: BMW Business CD or Professional CD/Cassette system, optional navigation system (CCC precursor). Driver Assistance Driver Assistance Features: Park Distance Control (PDC), Cruise Control Connectivity Connectivity Features: Optional cellular phone integration (early Bluetooth or wired systems) 🔧 Maintenance Service Intervals Oil Change Interval: BMW Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually. Spark Plug Replacement: Approximately every 60,000 miles Fluid Specifications Engine Oil Type: SAE 5W-30 Synthetic (BMW Longlife-01 approved) Coolant Type: BMW Blue Coolant (G48) or equivalent ethylene glycol-based coolant with corrosion inhibitors Transmission Fluid Type Auto: Dexron III/VI or ZF Lifeguardfluid 5 Known Issues Common Issues: Vanos system leaks, cooling system hoses and water pump failures, ABS/DSC module failures, VANOS solenoid failure, oil pan gasket leaks, PCV system issues. Preventative Maintenance: Regular inspection of cooling system, VANOS seals, and vacuum lines. 📚 Vehicle History Brand Heritage Brand Heritage: BMW, founded in 1916, renowned for performance, luxury, and engineering excellence. Model Evolution Model Evolution: The E39 generation (1995-2003) represented a significant advancement in BMW's mid-size luxury sedan segment, known for its superior handling and refined driving dynamics. Production Production Period: 1996-2003 (E39 generation) Production Location Manufacturing Plants: Dingolfing, Germany; Rosslyn, South Africa 🏆 Awards & Recognition Recognitions Car And Driver Awards: Car and Driver 10 Best (multiple years during E39 generation) Type Of Recognition: Automotive Journalism and Consumer Recognition