BMW 3 Series (E46) 325i Sedan 1999-2005 Service Repair Manual

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Tipo: Car

Proveedor:

SKU: 150071

Etiquetas: 1999 2000 2001 2002 2003 2004 2005 3 Series 325i Sedan BMW Car Cars E46

Variantes de producto

Descripción

The BMW 3 Series E46 Sedan, produced from 1999 to 2005, represents a pinnacle of compact executive sedan engineering, renowned for its sporting dynamics, premium interior, and reliable M54 inline-six engine. This generation is celebrated for its balanced chassis, offering exceptional handling characteristics that embody a commitment to driving enjoyment. The 325i model, in particular, provides a compelling blend of performance and refinement, making it a highly sought-after vehicle for both daily commuting and spirited driving. Its design and engineering reflect a commitment to quality and driver engagement, establishing it as a benchmark in its class. This comprehensive Workshop Service Repair Manual is designed to provide in-depth, factory-level knowledge for the BMW 3 Series E46, specifically covering the 325i Sedan models from 1999-2005. It details a vast array of maintenance procedures, from routine oil changes to complex engine and transmission rebuilds. The manual thoroughly covers engine mechanicals, fuel and exhaust systems, drivetrain, suspension, steering, and brakes, as well as the electrical system, body, and HVAC. With step-by-step instructions, detailed diagrams, and diagnostic troubleshooting procedures, this resource empowers both professional technicians and DIY enthusiasts to accurately maintain, diagnose, and repair their vehicle, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Model:

3 Series

Chassis Code:

Body Style:

Sedan

Engine Variant:

Model Years Covered:

1999-2005

Codes

Engine Code Range:

M54B25 (common)

👋 Introduction

Market Position

Market Segment:

Compact Executive Sedan

Key Selling Points:

Sporting dynamics, premium interior, reliable engineering

Competitive Analysis

Primary Competitors:

Audi A4, Mercedes-Benz C-Class, Lexus IS

Key Features

Chassis Design:

E46 platform known for its balanced chassis and excellent handling characteristics.

Engine Technology:

M54 inline-six engine, known for smooth power delivery and durability.

Manual Value Proposition:

Provides in-depth factory knowledge for accurate diagnostics and repairs, empowering owners and technicians.

📋 Manual Details

Coverage Areas

General Maintenance:

Engine Repair:

Transmission Repair:

Drivetrain Repair:

Suspension Repair:

Steering Repair:

Brake System Repair:

Electrical System Diagnosis Repair:

Body And Chassis Repair:

Heating Ventilation Air Conditioning HVAC:

Body Control Modules Bcm:

Diagnostic Troubleshooting Procedures:

Wiring Diagrams:

Page Count

Estimated Pages:

Hundreds (Specific count not provided in source, but indicative of comprehensive coverage)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshaft, valve train

Engine Management:

Engine control unit (ECU), fuel injection, ignition system, emissions control

Cooling System:

Radiator, water pump, thermostat, cooling fans, coolant specifications

Lubrication System:

Oil pump, oil pan, oil filter, oil specifications

Fuel System:

Fuel pump, fuel injectors, fuel filter, fuel tank, fuel pressure

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, oxygen sensors

Manual Transmission:

Clutch, gearbox, shifter mechanism, lubricant specifications

Automatic Transmission:

Torque converter, planetary gear sets, valve body, transmission fluid specifications

Drive Axles:

CV joints, drive shafts, differential

Suspension Front:

Struts, control arms, ball joints, sway bar

Suspension Rear:

Multi-link suspension, shock absorbers, control arms

Steering System:

Steering rack, power steering pump, steering column

Brake System Front:

Brake calipers, rotors, pads, brake fluid

Brake System Rear:

Brake calipers, rotors, pads, parking brake mechanism

Anti-Lock Braking System ABS:

ABS control module, wheel speed sensors

Body Electrical System:

Lighting, power windows, door locks, mirrors

Instrument Panel:

Gauges, warning lights, onboard computer

Audio System:

Radio, speakers, amplifiers

Comfort Controls:

Climate control, heated seats

Safety Systems:

Airbags, seatbelts, pre-tensioners

Body Structure:

Frame, chassis components, body panels

Body Hardware:

Doors, hood, trunk, fenders, bumpers

Paint And Trim:

Body panel repair, paint codes

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, spark plug replacement

Troubleshooting Guides:

Step-by-step diagnostic procedures for common problems

Component Disassembly Assembly:

Detailed instructions for removing and reinstalling parts

Rebuild Procedures:

Engine and transmission rebuild specifications

Electrical Component Testing:

Testing methods for sensors, actuators, and control modules

Wheel Alignment:

Specifications and adjustment procedures

Air Conditioning Service:

Refrigerant handling, system diagnostics, component replacement

Brake Bleeding:

Procedures for various brake systems, including ABS

Timing Belt Replacement:

Although M54 is chain-driven, related timing component checks are likely covered

Torque Specifications:

Detailed torque values for critical fasteners across all systems

Technical Depth

Depth:

Comprehensive Factory Level

Target Audience:

Professional Technicians & DIY Mechanics

Detail Level:

Step-by-step instructions with highly detailed exploded pictures and diagrams

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Full Printable

Zoom Capability:

Yes (Zoom IN/OUT)

Binding Type

Binding Type:

Digital Download (Printable)

Paper Type

Paper Type:

N/A (Digital format)

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

Operating System Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B25

Engine Type:

Naturally Aspirated Inline 6-Cylinder

Displacement:

2494 cc (2.5 Liters)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

10.2:1

Performance

Horsepower Hp:

189 hp @ 6000 rpm (approximate)

Torque Lb-Ft:

245 Nm (181 lb-ft) @ 3500 rpm (approximate)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Bosch Motronic

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Engine Management

ECU Type:

MS43 or MS45 (depending on model year)

Timing System

Timing Mechanism:

Double VANOS (Variable Valve Timing) and timing chain

🔧 Transmission

Standard

Type:

5-Speed Manual (Getrag GS5-39DZ)

Optional

Type:

5-Speed Automatic (GM A5S360R/RHW or ZF 5HP19)

Features

Clutch:

Hydraulically actuated single-plate dry clutch

Transmission Fluid Manual:

BMW MTF LT-2 (or equivalent)

Transmission Fluid Automatic:

Dexron III / Mercon (or equivalent, check specific model year)

📐 Dimensions

Exterior

Length:

4471 mm (176.0 in)

Width:

1739 mm (68.5 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2760 mm (108.7 in)

Weights

Curb Weight:

~1500 kg (3307 lbs) - varies by transmission and options

Gross Vehicle Weight Rating Gvwr:

Approx. 1970 kg (4343 lbs)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

5-Star (for models with specific safety features)

NHTSA Frontal Impact Passenger:

5-Star (for models with specific safety features)

IIHS Moderate Overlap Frontal Offset:

Good (for many E46 models)

Active Features

Traction Control:

Available (ASC+T)

Dynamic Stability Control:

Available (DSC)

Anti-Lock Braking System:

Standard (ABS)

Passive Features

Airbags:

Frontal airbags, optional side airbags

Seatbelts:

3-point seatbelts with pretensioners

Body Structure:

Reinforced safety cell, crumple zones

💡 Technology Features

Infotainment

Head Unit:

Factory BMW Business or Professional CD/Radio systems, often with optional navigation.

Audio Options:

Various speaker configurations, optional Harman Kardon sound system.

Driver Assistance

Cruise Control:

Standard on most models.

Parking Sensors:

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

Connectivity

Auxiliary Input:

Not standard; aftermarket solutions often required for modern device connectivity.

Bluetooth:

Optional on later models or via aftermarket integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 miles or 12-24 months, as indicated by the Condition Based Service (CBS) system or recommended by manual.

Air Filter Replacement:

Check every 15,000 miles, replace every 30,000 miles or as needed.

Cabin Filter Replacement:

Every 15,000 miles or annually.

Spark Plug Replacement:

Approx. 100,000 miles for iridium spark plugs (check specific type).

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 or 5W-40 (BMW LL-01 approved synthetic)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)

Power Steering Fluid:

Pentosin CHF 11S or ATF Dexron III

Brake Fluid:

DOT 4

Known Issues

Cooling System:

Plastic expansion tank cracks, water pump failure (especially plastic impeller type), thermostat housing leaks.

Engine M54:

CCV (Crankcase Ventilation) system failures leading to oil leaks and rough running, VANOS solenoid failures, VANOS oil line leaks, oil filter housing gasket leaks.

Suspension:

Worn control arm bushings, ball joints, rear subframe mounting point fatigue/cracking.

Electrical:

Window regulator failures, blower motor resistor failure, alternator issues, ABS/DSC sensor failures, coolant level sensor failures.

Interior:

Headliner sagging, pixelated instrument cluster displays, door panel creaking.

📚 Vehicle History

Brand Heritage

Brand Philosophy:

BMW's 'Ultimate Driving Machine' heritage, focusing on performance and driver engagement.

Model Evolution

E46 Generation:

The E46 replaced the E36 3 Series and was produced from 1998 to 2006, with significant updates throughout its lifecycle.

325I Positioning:

The 325i was positioned as a mid-range model within the E46 lineup, offering a balance of performance and refinement, succeeding the 323i.

Production

Production Years:

1999-2005 for the 325i Sedan variant.

Manufacturing Locations:

Primary production at BMW's Dingolfing plant, Germany, with other plants globally.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E46 3 Series was a frequent recipient of Car and Driver's 10 Best list during its production run.

Automotive Journalism Accolades:

Widely praised for its driving dynamics, ride comfort, and build quality by numerous automotive publications.