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BMW 3 Series E46 Factory Manual 1999-2005

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This manual covers the 3 Series, chassis code E46, produced between 1999 and 2005. Known for its performance-oriented, driver-focused nature, the 3 Series is a compact executive car renowned for...
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SKU: 127526
BMW 3 Series E46 Factory Manual 1999-2005
This manual covers the 3 Series, chassis code E46, produced between 1999 and 2005. Known for its performance-oriented, driver-focused nature, the 3 Series is a compact executive car renowned for its balanced chassis, responsive steering, and engaging driving experience. Throughout its generation, it offered a range of smooth inline-four and inline-six gasoline engines, and was available in sedan, coupe, convertible, and sports wagon body styles. The E46 frequently earned accolades such as '10Best' awards, reflecting its esteemed position in the automotive market and its competitive standing against rivals like the Mercedes-Benz C-Class and Audi A4. This comprehensive factory service manual provides detailed information for the repair and maintenance of your 3 Series. It covers all major aspects, including powertrain, drivetrain, chassis, electrical systems, and body components. Within its extensive pages, you will find step-by-step procedures for routine maintenance, diagnostics, component removal and installation, and even complete engine and transmission rebuilds. The manual also details the use of specialized tools and provides crucial technical specifications, fluid requirements, and troubleshooting guides, empowering owners and technicians to effectively maintain and repair their vehicle.
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Model Years Covered:
1999-2005
👋 Introduction
Market Position
Segment:
Compact executive car
Brand Perception:
Performance-oriented, luxury, driver-focused
Competitive Analysis
Key Rivals:
Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35
Key Features
Driving Dynamics:
Renowned for balanced chassis, rear-wheel drive bias, responsive steering, and engaging driving experience.
Engine Lineup:
Offered a range of inline-four and inline-six gasoline engines, known for smoothness and power delivery.
Body Styles:
Sedan (4-door), Coupe (2-door), Convertible (2-door), Sports Wagon (Touring/Wagon - 5-door).
📋 Manual Details
Coverage Areas
Primary Focus:
Comprehensive repair and maintenance
Breadth Of Coverage:
All major repair and maintenance aspects
Page Count
Estimated Page Count:
Varies by specific model/engine, typically 2000+ pages for a complete factory set
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, potentially downloadable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition, exhaust, cooling, lubrication, emissions control
Drivetrain:
Transmission (manual and automatic), clutch, driveshafts, differential, axles
Chassis:
Suspension (front and rear), steering system, brakes (hydraulic, ABS, DSC)
Electrical:
Body electrical, lighting, instruments, comfort systems, infotainment, engine management electronics, diagnostic connectors (OBD-II)
Body:
Body construction, exterior trim, interior trim, doors, windows, roof, climate control (HVAC)
Procedures Included
Maintenance:
Routine checks, fluid changes, filter replacements, spark plug service, brake pad/rotor replacement
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, wiring diagrams, component testing
Repair:
Component removal and installation, engine rebuilds, transmission overhauls, suspension component replacement, electrical component repair
Special Tools:
Identification and usage of BMW-specific tools
Technical Depth
Depth:
Comprehensive: from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF with searchable text and high-resolution diagrams.
Print Quality
Diagram Resolution:
High-resolution, clear and legible technical diagrams and illustrations.
Binding Type
Physical Binding:
N/A (Digital Format)
Paper Type
Physical Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Common Gasoline Engines:
2.5L I6 (M54B25), 3.0L I6 (M54B30), 2.0L I4 (M43B20 - early models), 2.8L I6 (M52TUB28 - early models), 2.2L I6 (M54B22)
Common Diesel Engines:
2.0L I4 Turbo-Diesel (M47), 3.0L I6 Turbo-Diesel (M57)
Performance
Horsepower Range:
Approx. 140 hp (2.0L I4) to 231 hp (3.0L I6 - M54B30), up to 333 hp for M3 variants.
Torque Range:
Approx. 140 lb-ft to 220 lb-ft for standard models, higher for M3.
Fuel System
Injection Type:
Sequential Multi-Point Fuel Injection (MPI)
Fuel Requirement:
Premium Unleaded gasoline (91 AKI or higher recommended)
🔧 Transmission
Standard
Manual Transmission:
5-speed Getrag (e.g., GS5-39DZ) or 6-speed Getrag (e.g., GS6-37BZ for later models/performance variants).
Optional
Automatic Transmission:
5-speed ZF Steptronic automatic transmission (e.g., 5HP19FLA).
Features
Clutch Type:
Hydraulically actuated single-plate dry clutch (for manual).
Differential:
Open differential standard, limited-slip differential (LSD) optional on some models/M-Sport packages.
📐 Dimensions
Exterior
Wheelbase:
Approx. 107.4 inches (2728 mm)
Overall Length:
Approx. 177.4 - 183.7 inches (4506 - 4665 mm) depending on body style
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 55.7 - 57.3 inches (1415 - 1455 mm) depending on body style
Weights
Curb Weight:
Approx. 3100 - 3500 lbs (1400 - 1600 kg) depending on engine and body style.
Cargo
Trunk Volume:
Approx. 14.1 cu ft (400 L) for sedan.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Generally good frontal and side impact ratings for its era, check specific year/model for detailed reports.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Traction Control System (TCS) and Dynamic Stability Control (DSC) on most models.
Passive Features
Airbags:
Front dual-stage airbags, optional side airbags, optional curtain airbags (later models/convertibles).
Seatbelts:
3-point seat belts with pretensioners and force limiters.
💡 Technology Features
Infotainment
Head Unit:
Various BMW Business CD, Professional CD, and optional Navigation systems.
Audio System:
Standard 6-speaker system, optional Harman Kardon audio upgrade.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Sensors:
Optional rear Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional Bluetooth preparation with hands-free system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 15,000 miles (12,000 to 24,000 km) or annually, depending on driving conditions and oil specification (as per Condition Based Service - CBS).
Spark Plug Replacement:
Around 60,000 to 100,000 miles (100,000 to 160,000 km) depending on spark plug type (e.g., iridium).
Coolant Flush:
Every 2-4 years or 30,000-60,000 miles (50,000-100,000 km).
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) synthetic oil, typically 5W-30 or 5W-40 viscosity. Check specific engine for exact grade and capacity (e.g., ~6.5 qts for 3.0L I6).
Coolant:
BMW Blue or Purple coolant (G48 ethylene glycol based), typically a 50/50 mix with distilled water. Capacity approx. 8.5 qts.
Brake Fluid:
DOT 4 Low Viscosity (LV) brake fluid.
Transmission Fluid Manual:
MTF LT-2 or similar BMW approved manual transmission fluid.
Transmission Fluid Automatic:
ZF Lifeguardfluid 5 (or equivalent approved fluid). Crucial for longevity, requires specialized procedure for changing/checking level.
Known Issues
Cooling System:
Plastic coolant expansion tanks can become brittle and crack; water pumps (especially plastic impeller versions) are prone to failure; thermostat housings can leak.
Suspension:
Front control arm bushings (RTABs - Rear Trailing Arm Bushings) wear out leading to poor handling; rear subframe bushings can tear; front strut mounts.
Engine:
Oil leaks from valve cover gaskets and oil filter housings are common; VANOS (Variable Valve Timing) solenoids/seals can cause rough idle or power loss; CCV (Crankcase Ventilation) system can clog and cause oil pressure issues/leaks.
Electrical:
ABS/DSC module failures; alternator failures; window regulator failures; door lock actuator issues.
Exhaust:
Muffler bearings (colloquial term for the rubber hangers) can degrade; exhaust manifold cracks on some early M54 engines.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Model Evolution
Generation:
Fourth generation of the 3 Series compact executive car, succeeding the E36 and preceding the E90.
Key Updates:
Significant chassis redesign, improved suspension geometry, updated engines (particularly the M54 inline-six), enhanced electronics, and a more refined interior.
Production
Production Years:
1998 (introduced late 1997 for 1998 model year in some markets) through 2006 (for sedan/wagon).
Manufacturing Locations:
Primary manufacturing in Munich, Germany; Dingolfing, Germany; and Regensburg, Germany. Assembly also occurred in other global locations.
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
The E46 3 Series models, particularly the 330i and M3, were frequent recipients of Car and Driver's '10Best' awards.
Consumers Reports:
Varied reliability ratings over its production run, with some model years and powertrains performing better than others. The manual highlights common issues to watch for.
Certifications
Euro Ncap:
Achieved strong safety ratings for its time, typically 4 or 5 stars, depending on the specific test and equipment.
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