BMW E46 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series (E46) Year: 2004 Generation Generation Name: E46 Generation Years: 1998-2006 (Globally) 👋 Introduction Market Position Market Segment: Premium compact executive sedan/coupe/convertible/wagon....

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Art.-Nr: 146190

Stichworte: 2004 3 Series BMW Car Cars E46

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Beschreibung

🏷️ Basic Information

Identification

Make:

Model:

3 Series (E46)

Year:

Generation

Generation Name:

Generation Years:

1998-2006 (Globally)

👋 Introduction

Market Position

Market Segment:

Premium compact executive sedan/coupe/convertible/wagon.

Competitive Analysis

Competitors 2004:

Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS300, Infiniti G35.

Key Features

Driver Focus:

Renowned for its engaging driving dynamics, balanced chassis, and driver-centric cockpit.

Powertrain Options:

Available with a range of inline-four and inline-six M54 engines known for smoothness and performance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for BMW E46 2004 models.

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, searchable)

📖 Manual Coverage

Systems Covered

Engine Management:

Detailed diagnostics, component testing, and repair procedures for DME (Digital Motor Electronics).

Fuel System:

Fuel pump, injectors, pressure regulation, fuel tank, EVAP system diagnosis and repair.

Cooling System:

Radiator, water pump, thermostat, hoses, fan clutch/electric fan, coolant specifications.

Exhaust System:

Catalytic converters, mufflers, oxygen sensors, exhaust manifold diagnosis and replacement.

Ignition System:

Spark plugs, ignition coils, crank and cam position sensors, troubleshooting.

Transmission Manual:

Clutch assembly, gearbox removal/installation, internal component repair, fluid specifications.

Transmission Automatic:

GM 5L40-E / ZF 5HP19 / ZF 6HP19 (depending on engine variant) - control modules, solenoid testing, fluid specifications, torque converter.

Drivetrain Rear Axle:

Differential, driveshafts, CV joints, limited-slip differential (if equipped), fluid specifications.

Suspension Front:

MacPherson struts, control arms, ball joints, bushings, sway bar, alignment specifications.

Suspension Rear:

Multi-link independent suspension, shock absorbers, control arms, bushings, alignment specifications.

Steering System:

Power steering pump, steering rack, tie rods, steering column, fluid type.

Braking System:

Brake discs, calipers, pads, ABS system, DSC (Dynamic Stability Control), EBD (Electronic Brake-force Distribution), fluid type and bleeding procedures.

Wheel Speed Sensors:

Diagnosis and replacement for ABS/DSC functionality.

Electrical System General:

Battery, alternator, starter motor, wiring diagrams, fuse/relay locations.

Body Electrical:

Lighting systems (headlights, taillights, interior), power windows, locks, mirrors, sunroof, horn.

Climate Control:

HVAC system, A/C compressor, refrigerant, blower motor, climate control modules, cabin filter.

Infotainment Audio:

Radio, CD player, speakers, amplifier (if equipped), antenna system.

Instrument Cluster:

Gauge operation, warning lights, troubleshooting.

Srs Airbag System:

Airbag modules, sensors, control unit, diagnostic procedures.

Security System E46:

Immobilizer system (EWS), remote key functions, alarm system.

Body Panels:

Hood, fenders, doors, trunk lid removal and installation, hinge adjustment.

Glass And Seals:

Windshield, side windows, rear window, seals, weatherstripping.

Interior Trim:

Dashboard, door panels, headliner, seats, carpet removal and installation.

Lighting Exterior:

Headlight aim, bulb replacement, taillight assembly, fog lights.

Lighting Interior:

Dome light, vanity mirrors, footwell lighting, trunk light.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin), spark plug replacement, brake fluid flush, coolant flush.

Component Removal Installation:

Step-by-step guides for all major components across all systems.

Disassembly Assembly:

Detailed instructions for internal components of engines, transmissions, and other assemblies.

Troubleshooting Diagnostics:

Symptom-based diagnostics, fault code interpretation (OBD-II), electrical system tracing.

Repair Procedures:

Specific repair instructions for common failures and wear items.

Specifications And Tolerances:

Torque values, clearances, alignment settings, and other critical specifications.

Wiring Diagrams:

Comprehensive electrical schematics for all circuits.

Special Tools And Procedures:

Identification of BMW-specific tools and unique repair methods.

Technical Depth

Depth:

Factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format Details:

Likely a PDF file, optimized for digital viewing and printing. Searchable text is a key feature of factory manuals.

Print Quality

Print Quality Recommendation:

High-resolution images and clear diagrams ensure readability when printed.

Binding Type

Binding Type Description:

For physical copies, typically coil-bound or perfect-bound for durability and lay-flat use.

Paper Type

Paper Type Recommendation:

Durable, matte-finish paper is ideal for workshop environments to reduce glare and resist oil/grease.

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

M54B22, M54B25, M54B30 (inline-six); N42B18, N46B20 (inline-four)

Performance

Horsepower Range:

143 hp (N42) to 231 hp (M54B30)

Torque Range:

190 Nm (N42) to 300 Nm (M54B30)

Fuel System

Fuel Injection Type:

Sequential Electronic Fuel Injection (SEFI)

Recommended Fuel:

Premium Unleaded Gasoline (91 AKI or higher)

Engine Management

Dme Model:

MS43 or MS45 (depending on engine and transmission)

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Getrag 250G

Optional

Optional Transmission Auto:

5-speed Automatic GM 5L40-E (RWD); 5-speed Automatic ZF 5HP19 (xDrive); 6-speed Automatic ZF 6HP19 (post-facelift models with M54)

Features

Steptronic:

Available on automatic transmissions for manual shifting.

Fluid Specifications

Automatic Transmission Fluid:

BMW ATF LT-3 (e.g., Pentosin ATF1 or equivalent)

Manual Transmission Fluid:

BMW MTF LT-2 (e.g., Castrol Syntrans B 75W-80 or equivalent)

📐 Dimensions

Exterior

Body Styles:

Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon, 5-door)

Weights

Curb Weight Range:

Approx. 1450 kg - 1700 kg (depending on body style and engine)

🛡️ Safety Features

Ratings

IIHS Frontal Impact:

Good (for applicable models)

NHTSA Side Impact:

5-star (for applicable models)

Active Features

Standard Anti-lock Braking System

Standard Dynamic Stability Control (on most models)

Passive Features

Airbags:

Front, side, and curtain airbags (availability varies by model year and trim)

Seatbelts:

Pretensioning seatbelts with force limiters

💡 Technology Features

Infotainment

Head Unit Options:

BMW Business CD, BMW Professional CD, Navigation systems (MKIII/MKIV)

Driver Assistance

Parking Assist:

Optional rear parking sensors (Park Distance Control - PDC).

Connectivity

Bluetooth:

Optional, via aftermarket adapters or specific factory options (e.g., TCU upgrade).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil used (refer to Condition Based Service).

Spark Plug Interval:

60,000-100,000 miles (depending on plug type - iridium recommended)

Brake Fluid Flush Interval:

Every 2 years, regardless of mileage.

Fluid Specifications

Engine Oil Specification:

BMW Longlife-01 (LL-01) or LL-04 (depending on region/fuel) 0W-30 or 5W-30 synthetic oil.

Coolant Specification:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)

Power Steering Fluid:

Pentosin CHF 11S or ZF Servolenkungsspezifikation (green)

Known Issues

Cooling System Leaks:

Cracked plastic expansion tank, failing water pump (plastic impeller), thermostat housing leaks.

Vanos System:

Failure of the Variable Valve Timing system (solenoids, seals) leading to rough idle and power loss.

Oil Pan Gasket Leaks:

Common leak point, especially on higher mileage vehicles.

Subframe Mounts:

Cracking and separation of rear subframe mounting points, particularly in coupes and convertibles.

Window Regulator Failure:

Common issue with plastic components breaking.

ABS Wheel Speed Sensors:

Frequent failures leading to ABS/DSC warning lights.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure - emphasis on performance, handling, and driver engagement.

Model Evolution

E46 Predecessor:

E36 3 Series

E46 Successor:

E90 (Sedan/Wagon), E92 (Coupe), E93 (Convertible)

Production

Production Years E46:

1998-2006

Manufacturing Locations:

Germany (Dingolfing, Regensburg), Austria, South Africa, Mexico, Thailand

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

3 Series models frequently featured on Car and Driver's 10Best list during its production run.