The BMW 540i, model variant 540, chassis code E39, represents the pinnacle of executive luxury sedans from its production era. Introduced in 2001, this vehicle is celebrated for its renowned handling and performance, powered by a smooth and potent 4.4L Naturally Aspirated V8 engine that produces 290 horsepower and 324 lb-ft of torque. Its interior quality, featuring premium materials and refined design, along with optional advanced technology like the Professional Navigation System, solidifies its standing against competitors such as the Mercedes-Benz E-Class and Audi A6. Engineered with the philosophy of "Sheer Driving Pleasure," the 540i offers a compelling blend of dynamic capability and sophisticated comfort, making it a distinguished choice in its segment. This comprehensive Factory Service Repair Manual, written in English, provides in-depth coverage for all systems of the 540i (E39). Spanning hundreds of pages, it details everything from routine maintenance, such as oil changes and fluid checks, to complete engine and transmission overhauls, including specific procedures for the M62TU V8 engine and both the GM 5L40-E automatic and ZF manual transmissions. The manual offers extensive troubleshooting guidance, component replacement steps, and critical technical specifications, including torque values, clearances, and detailed wiring diagrams. This resource is designed to empower owners, mechanics, and technicians to effectively maintain, diagnose, and repair their vehicle, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: BMW Model: 540i Model Variant: 540 Year: 2001 Codes Chassis Code: E39 👋 Introduction Market Position Segment: Executive Luxury Sedan Competitive Analysis Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS Key Features Driving Dynamics: Renowned BMW handling and performance Powertrain: Smooth and powerful V8 engine Interior Quality: Premium materials and refined cabin design 📋 Manual Details Coverage Areas All Systems: Yes Page Count Estimated Pages: Hundreds Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnostics, repair procedures Engine Management: DME (Digital Motor Electronics), sensors, actuators, fault codes Fuel System: Fuel pump, injectors, fuel pressure regulation, EVAP system Cooling System: Radiator, water pump, thermostat, hoses, fans Exhaust System: Catalytic converters, mufflers, exhaust manifolds, O2 sensors Transmission Automatic: GM 5L40-E: Diagnostics, repair, fluid changes, electronic controls Transmission Manual: ZF 5-speed: Clutch, gearbox overhaul, fluid service Drivetrain: Driveshafts, differential, axle shafts, wheel bearings Suspension: Front/rear suspension components, springs, shocks, control arms, bushings Steering: Power steering system, steering rack, tie rods, steering column Brakes: ABS, DSC, EBC, brake pads, rotors, calipers, hydraulic system, bleeding procedures Electrical System: Battery, alternator, starter, wiring diagrams, fuses, relays Lighting System: Headlights, taillights, interior lights, LCM (Light Control Module) Climate Control: HVAC system, blower motor, A/C compressor, refrigerant, climate control unit Infotainment: Radio, navigation system (MK III/MK IV), amplifier, speakers, CD changer Body And Interior: Door panels, seats, dashboard, trim, exterior body panels Safety Systems: Airbags, seatbelt pre-tensioners, SRS module Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, spark plugs Troubleshooting: Diagnostic charts, symptom-based repairs, fault code interpretation Component Replacement: Step-by-step guides for major and minor components Engine Rebuild: Disassembly, inspection, reassembly of the V8 engine Transmission Overhaul: Complete teardown and rebuilding of automatic and manual transmissions Brake System Service: Pad/rotor replacement, caliper service, brake fluid flush Electrical Diagnostics: Wiring diagram interpretation, component testing Climate Control Repair: Leak detection, component replacement, system recharging Bodywork Repair: Panel alignment, dent repair, rust treatment (conceptual coverage) Technical Depth Depth: Comprehensive (from basic maintenance to full rebuilds and advanced diagnostics) Diagnostic Codes: OBD-II codes and BMW-specific fault codes Torque Specifications: Detailed torque values for all fasteners Clearances And Tolerances: Specifications for engine components, bearings, etc. Wiring Diagrams: Detailed electrical schematics for all systems 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, printable pages Binding Type Binding Style: N/A (Digital Download - Printable) Paper Type Paper Recommendation: Standard printer paper (user selectable) Searchability Text Search: Searchable text content ⚙️ Engine Specifications Primary Engine Engine Code: M62TU (Technically Upgraded) Engine Type: 4.4L Naturally Aspirated V8 Performance Horsepower: 290 hp @ 5400 rpm Torque: 324 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (Bosch Motronic ME 7.2) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Engine Details Bore X Stroke: 94.0 mm x 79.5 mm Compression Ratio: 10.0:1 Valvetrain: Dual Overhead Camshafts (DOHC), 4 valves per cylinder Variable Valve Timing: VANOS (Variable Valve Timing System) 🔧 Transmission Standard Type: 5-speed Automatic (GM 5L40-E) Optional Type: 5-speed Manual (ZF S5-31/S5-32) Features Automatic Modes: Steptronic (manual shifting capability) Fluid Specifications Automatic Fluid Type: BMW ATF LT-3 (Dexron III compatible) 📐 Dimensions Exterior Length: 188.3 inches (4783 mm) Width: 71.0 inches (1803 mm) Height: 57.1 inches (1450 mm) Wheelbase: 113.7 inches (2890 mm) Weights Curb Weight: Approx. 3750-3850 lbs (1700-1750 kg) 🛡️ Safety Features Ratings NHTSA Frontal Impact: 4-Star (Driver and Passenger) Active Features Traction Control: ASC+T (Automatic Stability Control + Traction) Stability Control:...