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

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E46 Body Style: Sedan Engine Variant: 325i Model Years Covered: 1999-2005 Codes Engine Code Range: M54B25 (common) 👋 Introduction...
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UGS: 150071
BMW 3 Series (E46) 325i Sedan 1999-2005 Service Repair ManualBMW 3 Series (E46) 325i Sedan 1999-2005 Service Repair ManualBMW 3 Series (E46) 325i Sedan 1999-2005 Service Repair ManualBMW 3 Series (E46) 325i Sedan 1999-2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Body Style:
Sedan
Engine Variant:
325i
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:
Yes
Engine Repair:
Yes
Transmission Repair:
Yes
Drivetrain Repair:
Yes
Suspension Repair:
Yes
Steering Repair:
Yes
Brake System Repair:
Yes
Electrical System Diagnosis Repair:
Yes
Body And Chassis Repair:
Yes
Heating Ventilation Air Conditioning HVAC:
Yes
Body Control Modules Bcm:
Yes
Diagnostic Troubleshooting Procedures:
Yes
Wiring Diagrams:
Yes
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:
PDF
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:
PDF
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.
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