2001 BMW 540i Service and Repair Manual

This factory service and repair manual for the 2001 BMW 540i covers a car offered in two shapes on one drivetrain: a four-door sedan and a four-door wagon, both carrying the naturally aspirated 4.4L DOHC V8 on gasoline, in a single Base trim. Because the wagon shares its running gear with the sedan, the engine, transmission and chassis procedures apply to both, while the body and glass material separates where the rear structure differs. Specifications, torque values, wiring diagrams and diagnostics follow that split throughout.

Engines covered

• 4.4L V8 — DOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sedan
• 4-door wagon

Trims covered

• Base

Known issues on the 2001 540i. Four recalls sit on the federal record for this year. Two describe the same fault: an auxiliary cooling fan motor that can overload the circuitry in its control unit, stopping the fan and letting the engine overheat. Another covers an optional sports steering wheel whose air bag inflator can degrade with heat and humidity until it bursts and throws metal fragments. The last covers a control module that may fire the bags or the battery safety terminal with no crash at all. Owners logged fifteen complaints, led by the electrical system at five and air bags at four.