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BMW 3 series E461999-2005 Service Repair Manual

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The 3 Series E46, produced from 1999 to 2005, established itself as a benchmark in the sport sedan segment, celebrated for its exceptional driving dynamics, refined inline-four and inline-six engines,...
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BMW 3 series E461999-2005 Service Repair Manual
The 3 Series E46, produced from 1999 to 2005, established itself as a benchmark in the sport sedan segment, celebrated for its exceptional driving dynamics, refined inline-four and inline-six engines, and premium interior appointments. This generation of the 3 Series, available in sedan, coupe, convertible, and touring body styles, was lauded for its balanced chassis and engaging rear-wheel-drive performance, earning it consistent recognition, including multiple appearances on Car and Driver's 10Best lists. Its engineering quality and a wide array of powertrain options, from the efficient 320i to the potent M3, catered to a discerning driver seeking a blend of luxury, sportiness, and everyday usability. This comprehensive Service and Repair Manual provides in-depth coverage for the 3 Series E46, encompassing all gasoline and diesel engines, manual and automatic transmissions, and drivetrain variations. It details maintenance procedures, troubleshooting guides, diagnostic strategies, and repair instructions for all major systems, including brakes, suspension, steering, electrical components, and comfort systems. The manual's factory-level detail is designed to assist both owners performing their own maintenance and professional technicians, ensuring the longevity and optimal performance of your E46 through clear, accurate, and thorough guidance.
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Codes
Product Name:
BMW 3 Series E46 1999-2005 Service Repair Manual
👋 Introduction
Market Position
Positioning:
The E46 3 Series represented the sport sedan benchmark, offering a blend of performance, luxury, and handling.
Competitive Analysis
Competitors:
Audi A4, Mercedes-Benz C-Class, Lexus IS, Infiniti G35
Key Features
Driving Dynamics:
Renowned for balanced chassis, RWD dynamics, and engaging driving experience.
Engine Options:
Wide range of inline-4 and inline-6 engines known for smoothness and power delivery.
Build Quality:
Solid build quality and premium interior materials typical of BMW.
Body Styles:
Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon, 5-door)
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service, repair, and maintenance for BMW E46 chassis vehicles
Page Count
Estimated Pages:
Thousands (as it's a digital compilation of factory data)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
File Format:
Portable Document Format (PDF)
Print Quality
Quality:
High-resolution, allowing for clear text and image zoom
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
📖 Manual Coverage
Systems Covered
Engine:
All gasoline and diesel engines (e.g., M52TU, M54, M43, M44, M57, M47)
Transmission:
Manual (Getrag 250G), Automatic (GM A5S360R, A5S320Z, Steptronic)
Drivetrain:
Rear-wheel drive (RWD), All-wheel drive (xDrive) for applicable models
Suspension:
Front MacPherson struts, Rear multi-link suspension, Sport suspension options
Brakes:
Front and rear disc brakes, ABS, DSC (Dynamic Stability Control), Parking brake
Steering:
Hydraulic power steering, Servotronic
Electrical:
Complete wiring diagrams, fuse box layouts, component locations, diagnostic procedures
Body And Chassis:
Body repair, panel replacement, structural integrity, rust prevention
Comfort Systems:
HVAC (Heating, Ventilation, Air Conditioning), Power windows, Power seats, Sunroof
Safety Systems:
Airbags, Seatbelt pretensioners, Restraint systems
Infotainment And Electronics:
Radio, Navigation system, Instrument cluster, OBC (On-Board Computer)
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, brake fluid flush, spark plug replacement
Troubleshooting:
Diagnostic fault codes (DTCs), symptom-based troubleshooting guides
Repair:
Component removal and installation, engine rebuild, transmission overhaul, suspension component replacement, electrical system repair
Diagnostics:
Engine management system diagnostics, ABS/DSC diagnostics, SRS diagnostics, body electronics diagnostics
Specifications:
Torque specifications, clearances, diagnostic values, fluid capacities
Technical Depth
Depth:
Factory-level detail, suitable for DIY enthusiasts and professional technicians
Scope:
From routine maintenance to major component overhauls and complex diagnostics
⚙️ Engine Specifications
Primary Engine
320I Engine:
M52TU B20: 2.0L I6, 148 hp @ 6000 rpm, 190 Nm @ 3600 rpm
323I Engine:
M52TU B25: 2.5L I6, 168 hp @ 5500 rpm, 245 Nm @ 3950 rpm
325I Engine:
M54 B25: 2.5L I6, 189 hp @ 6000 rpm, 245 Nm @ 3500 rpm
328I Engine:
M52TU B28: 2.8L I6, 190 hp @ 5300 rpm, 280 Nm @ 3950 rpm
330I Engine:
M54 B30: 3.0L I6, 225 hp @ 6000 rpm, 300 Nm @ 3500 rpm
M3 Engine:
S54 B32: 3.2L I6, 333 hp @ 7900 rpm, 320 Nm @ 4900 rpm
320D Engine:
M47 D20: 2.0L I4 Turbo Diesel, 134 hp @ 4000 rpm, 280 Nm @ 1750 rpm
330D Engine:
M57 D30: 3.0L I6 Turbo Diesel, 181 hp @ 4000 rpm, 390 Nm @ 1750 rpm
Performance
0 60 Mph 330I:
Approx. 6.4 seconds
0 60 Mph M3:
Approx. 4.8 seconds
Fuel System
Injection Type:
Multi-point fuel injection (MPI), Common Rail Direct Injection (CRDi) for diesel
Required Octane:
Premium Unleaded (91+ AKI) for gasoline engines
🔧 Transmission
Standard
Transmission Standard:
5-speed Manual (Getrag 250G)
Optional
Transmission Optional:
5-speed Automatic (GM A5S360R/A5S320Z) with Steptronic manual shifting
Features
Traction Control:
ASC+T (Automatic Stability Control + Traction) or DSC (Dynamic Stability Control)
Final Drive Ratio:
Varies by model and transmission; e.g., 3.38:1 for 330i manual
📐 Dimensions
Exterior
Sedan Length:
Approx. 4471 mm (176.0 in)
Sedan Width:
Approx. 1739 mm (68.5 in)
Sedan Height:
Approx. 1415 mm (55.7 in)
Wheelbase:
Approx. 2760 mm (108.7 in)
Cargo
Sedan Trunk Volume:
Approx. 410 L (14.5 cu ft)
Weights
Curb Weight 330I Manual:
Approx. 1500 kg (3307 lbs)
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
4/5 Stars (for earlier models)
IIHS Frontal Offset:
Good (for early models)
Active Features
Stability Control:
Standard on most models (ASC+T or DSC)
ABS:
Standard
Passive Features
Airbags:
Frontal airbags, Optional side airbags
Seatbelts:
3-point seat belts with pretensioners
💡 Technology Features
Infotainment
Head Unit Options:
Various BMW Business CD, Professional CD, and CD/Navigation units.
Navigation System:
Optional MK III or MK IV navigation systems.
Driver Assistance
Parking Sensors:
Optional rear park distance control (PDC).
Cruise Control:
Standard on most models.
Connectivity
Phone Integration:
Optional Bluetooth phone preparation with cradle.
Auxiliary Input:
Available on some later models or via aftermarket adapters.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil type (based on BMW's Condition Based Service - CBS system).
Spark Plug Replacement:
Approx. every 60,000-100,000 miles for iridium plugs, depending on engine variant.
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Spec:
BMW Longlife-01 (LL-01) or LL-04 (for diesel with DPF) compliant synthetic oil, e.g., 5W-30 or 5W-40.
Coolant Spec:
BMW Antifreeze/Coolant Concentrate (Blue) mixed with distilled water in a 50/50 ratio.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, e.g., 75W-90 Synthetic.
Transmission Fluid Automatic:
BMW ATF LT-3 (or equivalent like Dexron III/VI for some models). Service interval often 'filled for life' but recommended for change.
Brake Fluid Spec:
DOT 4 (low viscosity, e.g., DOT 4 LV).
Known Issues
Cooling System:
Plastic expansion tank, water pump (often plastic impeller), and thermostat housing can become brittle and leak.
Vanos System:
Applicable to M52TU and M54 engines, VANOS solenoids and seals can fail, leading to rough idle, loss of power, and poor fuel economy.
Oil Pan Gasket And Valve Cover Gasket:
Commonly leak oil due to age and material degradation.
Subframe Mounts:
Rear subframe mounting points can crack due to stress, leading to clunking noises and poor handling.
Ccv System:
Crankcase Ventilation system can clog, leading to oil leaks and increased oil consumption.
Window Regulators:
Plastic components can break, causing windows to fail to operate.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for producing driver-focused luxury sports sedans.
Model Evolution
E46 Introduction:
The E46 replaced the E36 generation and was produced from 1998 to 2006 (depending on market and body style).
Facelift:
A significant facelift occurred for the 2002 model year, with updated exterior styling (headlights, taillights, bumpers) and interior refinements.
Production
Manufacturing Locations:
Primarily Germany, with some assembly in South Africa, Mexico, and Egypt.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The 3 Series (E46) was a frequent recipient of Car and Driver's 10Best list, solidifying its class-leading status.
Motor Trend Car Of The Year:
While not a specific win for E46, the 3 Series line consistently received accolades for performance and luxury.
Ratings
Consumer Reports Reliability:
Generally rated as average to above average, though specific issues like VANOS and cooling system components were noted.
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