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1994 BMW 540I CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT BMW REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service

A/C & HEATER SERVICE PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
BMW -> Wiring Diagrams -> Fans
Vehicle: 1994 BMW 540I 4.0 V8 GAS
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BRAKE SERVICE PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
Anti-lock Brakes -> System Service -> Brake System Bleed -> Component Replacement -> Control Unit, Replace -> Front Speed Sensor, Replace -> Hydraulic Unit, Replace -> Rear Speed Sensor, Replace
Vehicle: 1994 BMW 540I 4.0 V8 GAS
Brake System Bleed
Refer to "Hydraulic Brake Systems," for procedures.
Component Replacement
Hydraulic Unit, Replace
- Disconnect battery ground cable.
- Remove coolant expansion tank.
- Remove brake lines from hydraulic unit as follows: front left; front right; rear left; rear right.
- Remove brake hydraulic lines from master cylinder to hydraulic unit.
- Remove cover from top of hydraulic cover, then loosen, but do not remove, bolts for hydraulic unit.
- Remove retaining screws and pull off multiple pin connector and disconnect ground wire.
- Pull up on the front of the hydraulic unit, then disconnect t...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
BMW -> Fuel Filter Replacement -> Except X3 & Z4 -> Fuel System Pressure Relief -> Models w/Fitting Or Union Bolt Connection -> Models w/Fuel Hose Connection -> Removal & Installation
Vehicle: 1994 BMW 540I 4.0 V8 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while it relearns its adaptive strategy.
Fuel System Pressure Relief
- Obtain the vehicle owner's radio theft protection code.
- Remove the fuel pump relay(s).
- Start the engine and allow it to stall.
- Crank engine for 10 seconds to ensure the fuel pressure has been...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assembly -> Disassembly
Vehicle: 1994 BMW 540I 4.0 V8 GAS
Disassembly
- Raise and support vehicle.
- Remove propeller shaft assembly.
- Remove hose straps.
- Lift out circlip.
- Pull off constant velocity joint complete with dust cover.
- Press knurled head bolts and washers out of constant velocity joint.
- Press off dust cover.
Assembly
- Pack new constant velocity joint with 60 grams of grease (HWB). Do not pack the inner race with cage since the balls would fall ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
Starter, Replace
Vehicle: 1994 BMW 540I 4.0 V8 GAS
- Disconnect battery ground cable and drain cooling system.
- Mark position of starter leads, remove retaining nut and disconnect electrical connectors from starter.
- Disconnect coolant hose shrouding start...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
Cabin Air Filter Service -> BMW -> 1992-95 5 Series
Vehicle: 1994 BMW 540I 4.0 V8 GAS
Service interval is determined by the service indicator.
- Obtain the radio anti-theft code prior to disconnecting the battery ground cable.
- Disconnect the battery ground cable.
- Lift out the glove compartment clips, then pull off the retaining straps.
- Detach the tabs located at the righthand and lefthand sides of the glove compartment.
- Remove the glove compartment.
- Remove the screws retaining the lefthand and righthand side carpeted console trim panels.
- Remove the trim panel from above the glove compartment.
- Remove the two air duct attaching screws, then the air duct.
- Remove the cabin air...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
BMW -> Anti-Lock Brake System Warning Lamp ->
Vehicle: 1994 BMW 540I 4.0 V8 GAS
The Anti-Lock warning lamp is used to warn of a system fault. It will be lit during engine start-up, but should go out when the self-diagnostic system determines that the system is functioning properly. If the ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1994 BMW 540I 4.0 V8 GAS
Lower
- Drain coolant into a suitable container.
- Reposition hose clamp at radiator and remove hose.
- Reposition hose clamp at water pump and remove hose.
- Remove hose from vehicle.
- Reverse procedure to i...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1994 BMW 540I AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1994 BMW 540I 4.0 V8 GAS
- Remove fan cowl by lifting out expansion rivets on both sides.
- Secure fan pulley with suitable securing tool, or equivalent, then remove fan. Fan has lefthand handed threads.
- Loosen tensioner lock bolts, then turn tensioner with suitable wrench to receive tens...
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COMPONENT LOCATION DIAGRAMS FOR 1994 BMW 540I AUTOMOBILES
Component location diagrams for most 1994 BMW 540I cars and light trucks sold in the U.S. from 1990+.
![]() Components on diagram: |
![]() Components on diagram: |
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WIRING DIAGRAMS FOR 1994 BMW 540I AUTOMOBILES
OEM drawn wiring diagrams for most 1994 BMW 540I cars and light trucks sold in the U.S.
![]() Components on diagram: |
![]() Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1994 BMW 540I AUTOMOBILES
OEM TSB listings for most 1994 BMW 540I cars and light trucks sold in the U.S. from 1985+.
Document: Tools and Equipment Vehicle: 1994 BMW 540I 4.0 V8 GAS Auto Systems: |
Document: Tools and Equipment Vehicle: 1994 BMW 540I 4.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1994 BMW 540I AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1994 BMW 540I cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1994 BMW 540I cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1994 BMW 540I cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1994 BMW 540I cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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