This manual covers the 1994 BMW 540i, a distinguished executive sedan from the E34 generation. Renowned for its driver-focused engineering and impressive V8 performance, the 540i embodies BMW's commitment to "Sheer Driving Pleasure." This model, built on the robust E34 platform, offers a compelling combination of luxury, comfort, and dynamic handling, making it a standout in its segment. Its 4.0L V8 engine delivers robust power and smooth acceleration, complemented by advanced chassis design and available features like traction control, ensuring a refined driving experience. This comprehensive factory service manual provides detailed guidance for owners and technicians. It covers all essential aspects of the 1994 BMW 540i, including routine maintenance, complete engine and transmission overhauls, drivetrain, suspension, steering, brakes, and electrical systems. The manual offers step-by-step repair procedures, diagnostic troubleshooting for common issues such as M60 V8 chain guides and ABS sensors, technical specifications, and information on special tools. With over 500 pages of detailed information, this English-language resource is designed to facilitate effective maintenance and repair, ensuring the longevity and optimal performance of your vehicle. 🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: 540i Model Code: E34 Year: 1994 👋 Introduction Market Position Segment: Executive Sedan / Luxury Mid-size Sedan Target Audience: Affluent consumers seeking performance, luxury, and advanced engineering Competitive Analysis Key Competitors 1994: Mercedes-Benz E-Class (W124), Audi A6 (C4), Lexus LS 400, Cadillac DeVille Key Features Brand Philosophy: Sheer Driving Pleasure, driver-focused engineering Chassis Design: E34 platform, known for robust construction and excellent handling balance Powertrain Focus: Emphasis on smooth, powerful V8 engine performance 📋 Manual Details Coverage Areas Coverage Continents: Global (primarily North American and European market focus for E34 chassis) Coverage Regions: North America, Europe Page Count Approximate Page Count: 500+ Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, component repair, timing, lubrication, cooling Engine Management: Fuel injection (Bosch Motronic 5.2), ignition, emissions control, diagnostics Transmission Manual: ZF S5-310, component repair, clutch, fluid service Transmission Automatic: ZF 5HP30, component repair, torque converter, valve body, fluid service Drivetrain: Driveshafts, CV joints, differential (limited-slip option), rear axle Suspension: Front struts, rear multi-link, bushings, springs, shock absorbers, calibration Steering: Power steering system, steering rack, tie rods, troubleshooting Brakes: Hydraulic system, ABS (Anti-lock Braking System), disc brakes (front and rear), pad/rotor replacement, bleeding procedure Electrical System: Wiring diagrams, battery, charging system, starter, lighting, fuse/relay locations Body: Body panels, doors, windows, locks, seals, convertible top (if applicable), structural components Climate Control: HVAC system, A/C refrigerant, blower motor, climate control unit repair Interior: Seats, dashboard, trim panels, instrumentation Procedures Included Routine Maintenance: Oil change, filter replacement, spark plug service, fluid checks and changes Troubleshooting: Diagnostic procedures for common and uncommon faults across all systems Component Removal Installation: Step-by-step guides for major and minor component replacements Diagnostic Troubleshooting Codes: OBD-I codes and interpretation for the E34 generation Torque Specifications: Critical torque values for engine, chassis, and suspension components Special Tools: Identification and usage of BMW-specific tools required for repairs Technical Depth Depth Level: Comprehensive: from basic maintenance to full engine and transmission rebuilds Diagnostic Level: Advanced diagnostics, including electrical system troubleshooting and sensor analysis 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for professional printing Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Text Searchability: Searchable text content within PDF for quick information retrieval Printability Printable Pages: Printable in its entirety or select pages ⚙️ Engine Specifications Primary Engine Engine Code: M60B40 Engine Type: 4.0L V8 (32-valve DOHC) Bore X Stroke: 89.0 mm x 80.0 mm Displacement: 3982 cc (243 cu in) Compression Ratio: 10.0:1 Performance Horsepower: 282 hp @ 5800 rpm (SAE Net) Torque: 295 lb-ft @ 4500 rpm (SAE Net) Fuel System Fuel Delivery: Bosch Motronic 5.2 Electronic Fuel Injection (EFI) Recommended Fuel: Premium Unleaded Gasoline (91 octane or higher) Lubrication Oil Capacity W Filter: 7.0 Liters (7.4 US Quarts) Cooling System Coolant Capacity: 9.5 Liters (10.0 US Quarts) Ignition System Spark Plugs: NGK BKR6EK (or equivalent) 🔧 Transmission Standard Transmission Type Standard: ZF 5HP30 5-Speed Automatic Optional Transmission Type Optional: ZF S5-310 5-Speed Manual (Less common on 540i, more common on 530i of the era) Features Automatic Transmission Features: Electronic control, sport/economy modes Fluid Specifications Automatic Transmission Fluid: BMW ATF Dexron III (or equivalent) Fluid Capacity Automatic Transmission Fluid Capacity: Approximately 8.0 Liters (total system) Differential Rear Differential Fluid: BMW SAF-XJ (or GL-5 SAE 75W-140) 📐 Dimensions Exterior Wheelbase: 2760 mm (108.7 in) Length: 4710 mm (185.4 in) Width: 1750 mm (68.9 in) Height: 1410 mm (55.5 in) Weights Curb Weight: 1650 kg (3638 lbs) approx. Gross Vehicle Weight Rating: 2100 kg (4630 lbs) approx. Wheels Tires Standard Wheel Size: 15 x 7.0 inch Optional Wheel...