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BMW 540I CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT BMW REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about BMW 540I car and truck
repair procedures including BMW engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your BMW 540I automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR BMW 540I AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported BMW 540I cars and light trucks from 1990+
BMW -> Manual A/C & Heater System Diagnosis & Testing -> Precautions -> Air Bag System Disarming & Arming -> Battery Ground Cable -> Product Compatibility -> R-134a Systems
Vehicle: 2002 BMW 540I 4.4 V8 GAS
R-134a Systems
R-134a is a non-toxic, non-flammable, clear, odorless, liquefied gas.
R-134a refrigerant is not compatible with R-12 refrigerant. Even small amounts of R-12 in an R-134a system can cause lubricant contamination, improper air conditioning performance or compressor failure. Never add R-12 to an R-134a system.
New service ports have been added to compressor to prevent charging system with R-12 refrigerant. R-134a systems require a special compressor lubricant.
Avoid breathing R-134a refrige...
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BRAKE SERVICE PROCEDURES FOR BMW 540I AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported BMW 540I cars and light trucks from 1990+.
Hydraulic Brake Systems -> Tightening Specifications
Vehicle: 2001 BMW 540I Sport Wagon 4.4 V8 GAS
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FUEL FILTER REPLACEMENT PROCEDURES FOR BMW 540I AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported BMW 540I cars and light trucks sold in the U.S. for 1980+.
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: 2003 BMW 540I Sport Wagon 4.4 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 BMW 540I AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported BMW 540I cars and light trucks from 1990+.
CV AXLE SHAFT, Replace -> Rear
Vehicle: 1998 BMW 540I 4.4 V8 GAS
Rear
- Raise and support vehicle, then remove rear tire and wheel assembly.
- Remove rear axle.
- Remove axle nut.
- Press halfshaft off hub using a su...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR BMW 540I AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported BMW 540I cars and light trucks sold in the U.S. from mid 1990's+.
Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Trouble Code Identification
Vehicle: 2002 BMW 540I 4.4 V8 GAS
Accessing Diagnostic Trouble Codes
Connect a suitable scan tool the DLC (Data Link Connector). Follow the scan tool manufacturers instructions.
Diagnostic Trouble Code Identificati...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR BMW 540I AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported BMW 540I cars and light trucks from 1990+.
Starter, Replace
Vehicle: 1999 BMW 540I 4.4 V8 GAS
- Raise and support vehicle.
- Remove mounting bolts and splash guards.
- Remove mounting bolts and catalytic converter heat shields.
- Disconnect righthand oxygen sensor connector from transmission clip.
- Remove nuts and disconnect start...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR BMW 540I AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported BMW 540I cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> BMW -> 1996-2005 5 Series
Vehicle: 2002 BMW 540I 4.4 V8 GAS
Service interval is determined by the service indicator.
- Open the hood.
- Turn quick-release fastener approximately, 90° counterclockwise. Unlatch the cabin air filter cover retainers.
- Remove the cabin air fi...
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MAINTENANCE LAMP RESET PROCEDURES FOR BMW 540I AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported BMW 540I cars and light trucks sold in the U.S. from 1990+.
BMW -> Anti-Lock Brake System Warning Lamp ->
Vehicle: 1998 BMW 540I 4.4 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 BMW 540I AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported BMW 540I cars and light trucks from 1990+
Radiator, Replace
Vehicle: 1998 BMW 540I 4.4 V8 GAS
- Raise and support vehicle, then drain coolant into suitable container.
- Remove air cleaner cover.
- Remove expansion tank cap.
- Remove vent screw.
- Remove mounting bolts and splash guard.
- Remove drain hose.
- Disconnect coolant level sensor.
- Disconnect expansion hose.
- Disconnect retainer,...
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SERPENTINE BELT SERVICE PROCEDURES FOR BMW 540I AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported BMW 540I cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2003 BMW 540I Sport Wagon 4.4 V8 GAS
- If reusing belt, mark rotational direction for installation.
- Lock belt pulley in position using suitable holding tool, then remove mounting nut using suitable wrench. Nut has lefthand threads.
- Remove fan clutch.
- Remove engine splash shield.
- Tighten a...
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COMPONENT LOCATION DIAGRAMS FOR BMW 540I AUTOMOBILES
Component location diagrams for most BMW 540I cars and light trucks sold in the U.S. from 1990+.
 Top Center of Engine Compartment Diagram for 2002 BMW 540I 4.4 V8 GASComponents on diagram: |
 Left of Spare Wheel under Trim Panel Diagram for 2001 BMW 540I 4.4 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR BMW 540I AUTOMOBILES
OEM drawn wiring diagrams for most BMW 540I cars and light trucks sold in the U.S.
 2002 BMW 540I 4.4 V8 GAS Wiring DiagramComponents on diagram: |
 2003 BMW 540I 4.4 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR BMW 540I AUTOMOBILES
OEM TSB listings for most BMW 540I cars and light trucks sold in the U.S. from 1985+.
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Document: NAVIGATION SYSTEM OPERATING SOFTWARE - REVISED Vehicle: 2001 BMW 540I Sport Wagon 4.4 V8 GAS Auto Systems: |
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Document: BRAKE ROTOR MINIMUM THICKNESS Vehicle: 1999 BMW 540I 4.4 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR BMW 540I AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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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