The BMW 540i, model year 2002, represents the pinnacle of executive luxury and performance within the E39 generation. This model is distinguished by its potent M62TU B44 4.4-liter V8 engine, delivering 290 horsepower and 324 lb-ft of torque, paired with either a 5-speed Steptronic automatic or an optional 6-speed manual transmission. Renowned for its exceptional driving dynamics, a hallmark of BMW engineering, the 540i also features high-quality interior appointments and advanced technologies for its era, including available navigation and premium sound systems. Its robust construction and sophisticated design made it a strong competitor in the executive sedan segment, often earning accolades such as Car and Driver's 10Best. This comprehensive workshop repair service manual provides extensive coverage for all models, engines, trims, and transmission types of the 2002 BMW 540i. It details a wide array of systems, including engine, transmission, brakes, electrical, suspension, steering, cooling, fuel, emissions, HVAC, chassis, body, and restraint systems. The manual is meticulously organized to assist owners, mechanics, and technicians with general maintenance, periodic lubrication, disassembly and assembly procedures, cleaning and reinstallation, repair procedures, and diagnostic troubleshooting. With detailed diagrams, illustrations, and in-depth technical information, this manual serves as an indispensable resource for maintaining and repairing the vehicle to factory standards. 🏷️ Basic Information Identification Make: BMW Model: 540i Year: 2002 Generation Chassis Code: E39 Codes Engine Code Primary: M62TU B44 👋 Introduction Market Position Segment: Executive Sedan Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160) Key Features Powertrain Options: V8 Engine (540i) Driving Dynamics: Renowned BMW handling and performance characteristics. Luxury Appointments: High-quality interior materials and advanced features for its era. 📋 Manual Details Coverage Areas Coverage Summary: All Models, Engines, Trim, and Transmission Types for the 2002 BMW 540i. Page Count Estimated Page Count: Hundreds of pages Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: Compatible with All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Service And Repair: YES Transmission Service And Repair: YES Brake System: YES Electrical System: YES Wiring Diagrams: YES Suspension: YES Steering: YES Cooling System: YES Fuel Injection And Fuel System: YES Emission System: YES Heating And Air Conditioning: YES Engine Control System: YES Chassis And Body: YES Restraint System: YES Interior Systems: YES Differential And Drive Axle: YES Procedures Included General Maintenance: YES Troubleshooting: YES Periodic Lubrication: YES Diagnostic Procedures: YES Disassembly And Assembly: YES Cleaning And Reinstallation: YES Repair Procedures: YES Technical Depth Depth: Comprehensive, covering all aspects from routine maintenance to in-depth repairs and diagnostics, mirroring factory technician standards. Diagrams And Illustrations: Detailed diagrams, drawings, and photos are included to guide through repair procedures. Troubleshooting Complexity: Combines troubleshooting with electrical service procedures and detailed wiring diagrams for comprehensive issue diagnosis. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Full Printable Zoom Capability: YES Binding Type Binding: Digital Download (No physical binding) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated V8 Engine Code: M62TU B44 Displacement: 4.4 Liters (4398 cc) Performance Horsepower: 290 hp @ 5400 rpm Torque: 324 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Sequential Multi-Point Fuel Injection (SFI) Fuel Type: Premium Unleaded Gasoline Internal Components Valvetrain: Dual Overhead Camshafts (DOHC), 4 valves per cylinder Block Material: Aluminum Alloy Head Material: Aluminum Alloy 🔧 Transmission Standard Transmission Type: 5-speed Automatic (Steptronic) Optional Transmission Type Optional: 6-speed Manual (on select markets/models) Features Steptronic Functionality: Allows manual gear selection. 📐 Dimensions Exterior Length: 188.2 inches Width: 71.5 inches Height: 57.0 inches Wheelbase: 111.4 inches Weights Curb Weight: Approx. 3700-3800 lbs (depending on transmission and options) 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated for 2002 model year in easily accessible data, but generally performed well for its era. Active Features Traction Control: Automatic Stability Control (ASC+T) Braking System: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) Passive Features Airbags: Driver and front passenger airbags, side-impact airbags. Seatbelts: Pretensioning seatbelts with force limiters. 💡 Technology Features Infotainment Navigation System: Available BMW Professional Navigation System (MKIII or MKIV) Audio System: Available Hi-Fi or Harman Kardon premium sound systems. Driver Assistance Parking Sensors: Available Park Distance Control (PDC) front and rear. Connectivity Telematics: BMW Assist with Tele Aid emergency calling available on some models. Convenience Features Climate Control: Dual-zone automatic climate control. 🔧 Maintenance Service Intervals Oil Change Interval: Variable, based on BMW's Condition Based Service (CBS) system. Typically around 10,000-15,000 miles or 12-24 months. Spark Plug Replacement: Around 100,000 miles for iridium spark plugs, as specified by BMW for the M62TU. Fluid Specifications Engine Oil Type: BMW Longlife-01 (LL-01) or LL-04 compliant synthetic oil, typically SAE 0W-40 or 5W-30. Coolant Type: BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)....