This manual covers the 1999 BMW 5 Series, specifically the 540i model, built on the E39 chassis. Renowned for its engineering prowess and the philosophy of 'The Ultimate Driving Machine,' the 540i represents BMW's commitment to performance, luxury, and driver engagement within the executive sedan segment. Key selling points include its powerful 4.4-liter V8 engine, refined handling, and a sophisticated interior, making it a competitive offering against rivals like the Mercedes-Benz E-Class and Audi A6 of its era. This generation of the 5 Series, produced from 1995 to 2003, was recognized for its advancements in chassis dynamics and technology, earning accolades such as Car and Driver's 10Best Cars. This comprehensive Service Repair Workshop Manual provides detailed information essential for the maintenance and repair of your 1999 BMW 540i. It covers a wide array of systems, including the engine, transmission, drivetrain, suspension, steering, brakes, electrical system, HVAC, and body. Within its extensive pages, you will find step-by-step repair procedures, diagnostic guidance, troubleshooting flowcharts, and technical specifications for all major components. This manual is an invaluable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their vehicle through accurate service and repair practices. 🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: 540i Year: 1999 Codes Chassis Code: E39 Engine Code Family: M62 👋 Introduction Market Position Segment: Executive Sedan Competitors 1999: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS300, Volvo S80 Competitive Analysis Key Selling Points: Performance (V8 engine), refined handling, luxury interior, advanced technology for its era Key Features Model Emphasis: Focus on the 540i variant, highlighting its V8 engine and premium features. 📋 Manual Details Coverage Areas Covered Systems: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Interior, Emissions, Diagnostics, Troubleshooting Page Count Estimated Page Count: Approximately 1000-2000 pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures, component testing, torque specifications, timing, lubrication, cooling system Engine Management: DME (Digital Motor Electronics) system, sensor diagnostics, fuel injection, ignition timing, emissions control Transmission Automatic: GM 5L40-E (S5D 320Z for manual transmission variant, though 540i typically automatic), overhaul, fluid specifications, diagnostic codes, control modules Suspension: Front struts, rear multi-link, bushings, control arms, shock absorbers, spring replacement, wheel alignment procedures Steering: Power steering system, steering rack, tie rods, steering column, diagnostic and repair procedures Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid type, bleeding procedures, component replacement Electrical System: Wiring diagrams, fuse box locations, relay assignments, starter, alternator, battery, lighting, power windows, central locking, diagnostic connector (OBD-II) HVAC: Climate control system, blower motor, A/C compressor, refrigerant, heater core, diagnostic and repair Body And Interior: Panel removal and installation, door mechanisms, seat adjustments, trim components, sound insulation Emissions Control: Oxygen sensors, catalytic converter, EVAP system, EGR system (if applicable) Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, belt inspections/replacement Diagnostic Procedures: Troubleshooting common faults, fault code retrieval and interpretation (OBD-II), component testing using multimeters and oscilloscopes Repair Procedures: Detailed step-by-step instructions for component replacement and repair, including engine, transmission, suspension, brake, and electrical components Installation Procedures: Installation guidelines for various replacement parts and accessories Technical Depth Depth Of Information: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics and troubleshooting flowcharts. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (typically, depending on PDF creation) Print Quality Printability: Printable pages for easy reference in a workshop environment Binding Type Binding: Not applicable (digital download) Paper Type Paper Quality: Not applicable (digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated V8 Engine Code: M62B44 Displacement: 4.4 Liters (4398 cc) Performance Horsepower: 282 hp @ 5400 rpm Torque: 324 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Features Valve Train: DOHC (Dual Overhead Camshafts), 32 Valves Bore X Stroke: 92.0 mm x 82.7 mm Compression Ratio: 10.0:1 🔧 Transmission Standard Transmission Type Standard: 5-speed Automatic (GM 5L40-E / S5D 320Z) Optional Transmission Type Optional: 5-speed Manual (Getrag 420G - rarer option for 540i) Features Automatic Features: Steptronic (manual shift mode), electronic control 📐 Dimensions Exterior Length: 190.7 inches (4844 mm) Width: 71.5 inches (1816 mm) Height: 57.1 inches (1450 mm) Wheelbase: 111.4 inches (2830 mm) Weights Curb Weight: Approx. 3700-3800 lbs (1680-1725 kg) Gross Vehicle Weight Rating: Approx. 4780 lbs (2170 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (1999 Model Year Data) NHTSA Front Impact Passenger: 4 Stars (1999 Model Year Data) Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Standard (ASC+T - Automatic Stability Control...