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BMW

BMW 540 540i 1997 1998 1999 2000 2001 2002 Service Manual

BMW 540 540i 1997 1998 1999 2000 2001 2002 Service Manual

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Vehicle data plateRef 57556
Brand
BMW
Vehicle
Tractors
Models covered
540, 540i, Agriculture, Case
Years
1997, 1998, 1999, 2000, 2001, 2002
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

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  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
BMW
Model:
540i
Model Variant:
540
Generation
Chassis Code:
E39
Codes
Engine Code Primary:
M62B44
Engine Code Variant Tu:
M62TUB44
👋 Introduction
Market Position
Segment:
Executive Sedan
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS
Key Features
Powertrain Emphasis:
Powerful V8 engine, refined driving dynamics
Luxury Appointments:
High-quality interior materials, advanced features for its era
📋 Manual Details
Coverage Areas
Applicable Model Years:
1997, 1998, 1999, 2000, 2001, 2002
Page Count
Total Pages:
1002
Manual Type
Type:
Workshop Service Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (M62 V8), Transmission (5-speed automatic, 6-speed manual), Drivetrain (Rear-wheel drive), Fuel System, Exhaust System
Chassis:
Suspension (Front/Rear), Steering, Brakes (ABS, DSC), Wheels and Tires
Electrical:
Engine Control Unit (ECU), Lighting System, Instrumentation, Audio System, Power Accessories (Windows, Seats, Mirrors), Diagnostic System (OBD-II)
Body And Interior:
Body Panels, Doors, Bumpers, Exterior Trim, Interior Trim, Seats, HVAC System
Procedures Included
Maintenance:
Scheduled Maintenance (Oil Changes, Filter Replacements, Fluid Checks), Tune-ups, Belt and Hose Inspection/Replacement
Repair And Rebuild:
Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Electrical Component Diagnosis and Repair
Troubleshooting:
Diagnostic Procedures, Symptom-based Troubleshooting Guides, Error Code Interpretation
Installation And Removal:
Component Removal and Installation (e.g., Alternator, Starter, Water Pump, Radiator, Headlights)
Technical Depth
Diagnostics:
Detailed diagnostic trees, sensor data interpretation, ECU function explanations
Specifications:
Torque values, fluid capacities, wear limits, electrical specifications, diagnostic parameters
Illustrations And Diagrams:
Step-by-step pictorial guides, exploded views, wiring diagrams, schematic diagrams
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Yes, all pages are printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Software Requirements
Reader:
Adobe Reader
Compatibility
Operating Systems:
Windows, Mac, Linux OS
⚙️ Engine Specifications
Primary Engine
Engine Type:
4.4L DOHC 32-valve V8
Engine Code:
M62TUB44 (for later models, earlier may be M62B44)
Performance
Horsepower Approx:
282 hp @ 5400 rpm
Torque Approx:
324 lb-ft @ 3600 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic)
Recommended Fuel:
Premium Unleaded Gasoline (91 octane or higher)
Cooling System
Coolant Capacity Approx:
9.5 liters (10.0 quarts)
Lubrication
Oil Capacity Approx:
7.0 liters (7.4 quarts)
Recommended Oil Viscosity:
5W-30 Synthetic
🔧 Transmission
Standard
Type:
5-speed Steptronic Automatic Transmission (e.g., GM 5L40-E)
Optional
Type:
6-speed Manual Transmission (Getrag 420G)
Features
Steptronic Functionality:
Manual shift mode available for driver control
Fluid Specs
Automatic Transmission Fluid:
Dexron III or equivalent (refer to manual for specific BMW P/N)
Manual Transmission Fluid:
BMW recommended synthetic gear oil (e.g., 75W-90)
📐 Dimensions
Exterior
Length:
Approx. 4,819 mm (189.7 in)
Width:
Approx. 1,801 mm (70.9 in)
Height:
Approx. 1,437 mm (56.6 in)
Weights
Curb Weight Approx:
1,670 - 1,750 kg (3,682 - 3,858 lb)
Wheelbase:
Approx. 2,830 mm (111.4 in)
Wheels And Tires
Standard Wheel Size:
16-inch or 17-inch alloy wheels
Standard Tire Size:
225/55R16 or 235/45R17
Bolt Pattern:
5x120 mm
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4-star (for similarly equipped models of the era)
NHTSA Frontal Impact Passenger:
4-star (for similarly equipped models of the era)
Active Features
Traction Control:
Automatic Stability Control (ASC) or Dynamic Stability Control (DSC)
Braking System:
Anti-lock Braking System (ABS) standard, optional Electronic Brake Force Distribution (EBD)
Passive Features
Airbags:
Frontal airbags (driver and passenger), optional side airbags
Seatbelts:
Three-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Navigation System:
Optional BMW Business or Professional Navigation System (MKIII or MKIV based)
Audio System:
Hi-Fi or Logic7 audio systems available, cassette player and CD changer common
Driver Assistance
Cruise Control:
Standard electronic cruise control
Parking Sensors:
Optional rear Park Distance Control (PDC)
Connectivity
Bluetooth:
Optional Bluetooth interface (often required an adapter for earlier models)
Comfort Features
Climate Control:
Automatic dual-zone climate control
Seating:
Power adjustable front seats with memory, heated seats optional
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles or 12 months, using synthetic oil. Vehicle condition based service (CBS) system may influence this.
Major Service Points:
Spark plug replacement (around 60,000-100,000 miles), coolant flush, transmission fluid/filter service (often considered lifetime by some, but periodic changes recommended for longevity).
Fluid Specifications
Coolant Type:
BMW Blue or G48 Antifreeze/Coolant
Brake Fluid Type:
DOT 4
Power Steering Fluid:
BMW ATF Dexron III or Pentosin CHF 11S (verify with manual)
Known Issues
Cooling System:
Plastic coolant expansion tank prone to cracking, water pump failure, thermostat issues.
Engine M62:
Vanos (Variable Valve Timing) seal leaks, valve cover gasket leaks, oil pan gasket leaks, potential for secondary air injection system issues.
Electrical:
Alternator failure, headlight condensation, blower motor resistor failure, ABS/DSC sensor issues.
Suspension:
Worn control arm bushings, ball joints, strut mount bearings, rear subframe bushings.
📚 Vehicle History
Brand Heritage
Bmw Focus:
Performance, luxury, and driving dynamics ('The Ultimate Driving Machine')
Model Evolution
E39 Generation:
Introduced in 1995 (for 1996 model year), E39 represented a significant step forward in refinement and technology over its predecessor (E34).
Facelift Impact:
Facelifted models (typically from 2001 onwards) featured updated headlights (angel eyes), taillights, and minor interior/exterior styling tweaks.
Production
Manufacturing Locations:
Germany (Dingolfing plant)
Production Years
E39 Production Span:
1995-2003
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E39 generation of the 5 Series (including 540i) was frequently recognized on Car and Driver's 10Best lists for its driving dynamics and overall excellence.
Ratings
Reliability Reputation:
Generally considered reliable for its class, but requires diligent maintenance and addressing common E39 issues proactively.
Certifications
Certification:
Certified for safety and emissions standards relevant to its production years in various global markets.

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Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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