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BMW 540 540i 1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 540i Year: 1999 Codes Chassis Code: E39 👋 Introduction Market Position Target Audience: BMW 540i (E39) owners, DIY enthusiasts, professional technicians Competitive Analysis Manual Superiority: Actual genuine factory manual, not third-party; provides professional technician-level knowledge Key Features Content Style: Step-by-step instructions, notes, cautions, warnings, detailed illustrations, drawings, photos, enlarged insets Usability: Easy to use, no advanced computer skills required, printable on demand 📋 Manual Details Coverage Areas Coverage Scope: Complete factory service and repair Page Count Estimated Page Count: Hundreds (exact number not specified, but described as comprehensive) Manual Type Manual Classification: Factory Service Repair Manual Language Primary Language: English Format File Format: PDF Download Delivery Method: Instant download link provided after purchase completion 📖 Manual Coverage Systems Covered Engine Service: Engine service, repair, fuel injection, engine control system Transmission Service: Transmission service and repair Brake System: Brake system service and repair Electrical System: Electrical system diagnostics and repair, wiring diagrams Suspension Steering: Suspension, steering, chassis, body Cooling Fuel Emission: Cooling system, fuel injection/fuel system, emission system Comfort Restraint: Heater/Air Conditioning, Restraint System, Interior Drivetrain: Differential, Drive Axle Interior Systems: Interior trim, climate control, seating mechanisms Procedures Included Maintenance Tasks: General maintenance, periodic lubrication Troubleshooting: Troubleshooting guide, problem diagnosis and correction Wiring Diagrams: Detailed wiring diagrams for electrical systems, facilitating diagnostics Technical Depth Diagnostic Level: Advanced diagnostics, in-depth repair procedures Rebuild Capability: Full repair, maintenance, rebuilding, refurbishing, restoration Diagnostic Tools Coverage: Implied coverage of diagnostic procedures relevant to BMW's diagnostic systems (e.g., OBD-II, although specific tool references are not detailed) 📊 Manual Specifications File Format PDF Quality: High resolution, searchable Searchability: Yes, via Adobe PDF Reader's search function Print Quality Printability: Fully printable (individual pages, chapters, or entire manual) Binding Type Binding Method: N/A (Digital PDF) Paper Type Digital Storage: Save to hard drive, burn to CD-ROM ⚙️ Engine Specifications Primary Engine Engine Type: V8 Engine Displacement: 4.4 Liters (M62B44/TU) Performance Horsepower Approximate: 282 hp @ 5400 rpm Torque Approximate: 324 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Multi-point fuel injection (Bosch Motronic ME 7.2 likely) Engine Control ECU Type: Engine Control Unit (ECU) details and diagnostics covered Engine Control Coverage: Detailed explanation of Engine Control System functions and troubleshooting 🔧 Transmission Standard Transmission Type Standard: 5-speed Automatic (Steptronic) Optional Transmission Type Optional: 5-speed Manual Features Transmission Coverage: Service and repair procedures for both automatic and manual transmissions 📐 Dimensions Exterior Length: 191.1 inches (4854 mm) Width: 71.3 inches (1811 mm) Height: 56.5 inches (1435 mm) Weights Curb Weight Approximate: 3,770 lbs (1710 kg) Wheelbase: 113.7 inches (2888 mm) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-star (1999 model year specific rating) NHTSA Frontal Impact Passenger: 4-star (1999 model year specific rating) Active Features Traction Control: Standard (ASC+T - Automatic Stability Control + Traction) ABS: Standard (Anti-lock Braking System) Passive Features Airbags: Frontal airbags for driver and passenger; optional side airbags Restraint System Coverage: Manual covers restraint system components and diagnostics 💡 Technology Features Infotainment Infotainment System: BMW Professional Radio/Cassette or CD player, optional navigation system (MK III or IV) Driver Assistance Cruise Control: Standard electronic cruise control Connectivity Phone Integration: Optional Bluetooth preparation and hands-free system 🔧 Maintenance Service Intervals Oil Change Interval Approximate: 10,000-15,000 miles or 12 months (flexible service interval system - CBS) Spark Plug Replacement Approximate: Every 60,000 miles (Long Life Platinum/Iridium plugs) Transmission Fluid Change Interval Approximate: Typically at 60,000-100,000 miles (consult manual for specific recommendation) Fluid Specifications Engine Oil Type: SAE 5W-30 Synthetic (BMW Longlife-01 approved or equivalent) Coolant Type: BMW Blue Antifreeze/Coolant (G48 or equivalent) Brake Fluid Type: DOT 4 Transmission Fluid Automatic: Dexron III / Mercon (or BMW approved equivalent - consult manual for specific part numbers) Differential Fluid Type: Synthetic 75W-90 GL-5 Known Issues Common E39 Issues 1: Oil leaks (valve cover gaskets, oil pan gasket), cooling system components (water pump, hoses, thermostat), VANOS system issues Common E39 Issues 2: ABS/DSC sensor failures, front suspension components wear (control arms, bushings), ignition coil failures Common E39 Issues 3: Pixelated instrument cluster display, sunroof drain blockages leading to water ingress 📚 Vehicle History Brand Heritage Bmw History: Long-standing reputation for performance, luxury, and engineering excellence Model Evolution E39 Generation: E39 generation (1995-2003), known for its advanced chassis and driving dynamics. Production Production Location: Dingolfing, Germany 🏆 Awards & Recognition Recognitions Car And Driver Best: Car and Driver's 10Best list multiple times in its generation (E39 platform)
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Sku: 73650
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BMW 540 540i 1999 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
540i
Year:
1999
Codes
Chassis Code:
E39
👋 Introduction
Market Position
Target Audience:
BMW 540i (E39) owners, DIY enthusiasts, professional technicians
Competitive Analysis
Manual Superiority:
Actual genuine factory manual, not third-party; provides professional technician-level knowledge
Key Features
Content Style:
Step-by-step instructions, notes, cautions, warnings, detailed illustrations, drawings, photos, enlarged insets
Usability:
Easy to use, no advanced computer skills required, printable on demand
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete factory service and repair
Page Count
Estimated Page Count:
Hundreds (exact number not specified, but described as comprehensive)
Manual Type
Manual Classification:
Factory Service Repair Manual
Language
Primary Language:
English
Format
File Format:
PDF Download
Delivery Method:
Instant download link provided after purchase completion
📖 Manual Coverage
Systems Covered
Engine Service:
Engine service, repair, fuel injection, engine control system
Transmission Service:
Transmission service and repair
Brake System:
Brake system service and repair
Electrical System:
Electrical system diagnostics and repair, wiring diagrams
Suspension Steering:
Suspension, steering, chassis, body
Cooling Fuel Emission:
Cooling system, fuel injection/fuel system, emission system
Comfort Restraint:
Heater/Air Conditioning, Restraint System, Interior
Drivetrain:
Differential, Drive Axle
Interior Systems:
Interior trim, climate control, seating mechanisms
Procedures Included
Maintenance Tasks:
General maintenance, periodic lubrication
Troubleshooting:
Troubleshooting guide, problem diagnosis and correction
Wiring Diagrams:
Detailed wiring diagrams for electrical systems, facilitating diagnostics
Technical Depth
Diagnostic Level:
Advanced diagnostics, in-depth repair procedures
Rebuild Capability:
Full repair, maintenance, rebuilding, refurbishing, restoration
Diagnostic Tools Coverage:
Implied coverage of diagnostic procedures relevant to BMW's diagnostic systems (e.g., OBD-II, although specific tool references are not detailed)
📊 Manual Specifications
File Format
PDF Quality:
High resolution, searchable
Searchability:
Yes, via Adobe PDF Reader's search function
Print Quality
Printability:
Fully printable (individual pages, chapters, or entire manual)
Binding Type
Binding Method:
N/A (Digital PDF)
Paper Type
Digital Storage:
Save to hard drive, burn to CD-ROM
⚙️ Engine Specifications
Primary Engine
Engine Type:
V8
Engine Displacement:
4.4 Liters (M62B44/TU)
Performance
Horsepower Approximate:
282 hp @ 5400 rpm
Torque Approximate:
324 lb-ft @ 3600 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (Bosch Motronic ME 7.2 likely)
Engine Control
ECU Type:
Engine Control Unit (ECU) details and diagnostics covered
Engine Control Coverage:
Detailed explanation of Engine Control System functions and troubleshooting
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Automatic (Steptronic)
Optional
Transmission Type Optional:
5-speed Manual
Features
Transmission Coverage:
Service and repair procedures for both automatic and manual transmissions
📐 Dimensions
Exterior
Length:
191.1 inches (4854 mm)
Width:
71.3 inches (1811 mm)
Height:
56.5 inches (1435 mm)
Weights
Curb Weight Approximate:
3,770 lbs (1710 kg)
Wheelbase:
113.7 inches (2888 mm)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4-star (1999 model year specific rating)
NHTSA Frontal Impact Passenger:
4-star (1999 model year specific rating)
Active Features
Traction Control:
Standard (ASC+T - Automatic Stability Control + Traction)
ABS:
Standard (Anti-lock Braking System)
Passive Features
Airbags:
Frontal airbags for driver and passenger; optional side airbags
Restraint System Coverage:
Manual covers restraint system components and diagnostics
💡 Technology Features
Infotainment
Infotainment System:
BMW Professional Radio/Cassette or CD player, optional navigation system (MK III or IV)
Driver Assistance
Cruise Control:
Standard electronic cruise control
Connectivity
Phone Integration:
Optional Bluetooth preparation and hands-free system
🔧 Maintenance
Service Intervals
Oil Change Interval Approximate:
10,000-15,000 miles or 12 months (flexible service interval system - CBS)
Spark Plug Replacement Approximate:
Every 60,000 miles (Long Life Platinum/Iridium plugs)
Transmission Fluid Change Interval Approximate:
Typically at 60,000-100,000 miles (consult manual for specific recommendation)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic (BMW Longlife-01 approved or equivalent)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 or equivalent)
Brake Fluid Type:
DOT 4
Transmission Fluid Automatic:
Dexron III / Mercon (or BMW approved equivalent - consult manual for specific part numbers)
Differential Fluid Type:
Synthetic 75W-90 GL-5
Known Issues
Common E39 Issues 1:
Oil leaks (valve cover gaskets, oil pan gasket), cooling system components (water pump, hoses, thermostat), VANOS system issues
Common E39 Issues 2:
ABS/DSC sensor failures, front suspension components wear (control arms, bushings), ignition coil failures
Common E39 Issues 3:
Pixelated instrument cluster display, sunroof drain blockages leading to water ingress
📚 Vehicle History
Brand Heritage
Bmw History:
Long-standing reputation for performance, luxury, and engineering excellence
Model Evolution
E39 Generation:
E39 generation (1995-2003), known for its advanced chassis and driving dynamics.
Production
Production Location:
Dingolfing, Germany
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Car and Driver's 10Best list multiple times in its generation (E39 platform)
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