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BMW E46 3 series 1999-2005 Service Repair Manual 2000 2001 2002 2003 2004

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Codes Chassis Code: E46 Generation Code: E46 Generation Generation Name: Fourth Generation 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Convertible/Wagon Target...
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BMW E46 3 series 1999-2005 Service Repair Manual 2000 2001 2002 2003 2004
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Codes
Chassis Code:
E46
Generation Code:
E46
Generation
Generation Name:
Fourth Generation
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe/Convertible/Wagon
Target Audience:
Enthusiast owners, independent repair shops, DIY mechanics
Competitive Analysis
Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS
Key Features
Driving Dynamics:
Renowned for its 'Ultimate Driving Machine' reputation, balanced chassis, rear-wheel drive platform
Engine Options:
Range of refined inline-six and inline-four gasoline engines
Build Quality:
High-quality materials and assembly typical of BMW
📋 Manual Details
Coverage Areas
Years Covered:
1999-2005
Page Count
Estimated Pages:
Over 1000
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, timing, lubrication, cooling, fuel injection, exhaust
Engine Electrical:
Ignition system, starter, alternator, ECU diagnostics, sensors, wiring diagrams
Transmission Manual:
Clutch, gearbox repair, shifting mechanisms, fluid specifications
Transmission Automatic:
Gearbox overhaul, valve body, torque converter, fluid specifications, shift control modules
Drivetrain:
Driveshafts, CV joints, differential, wheel bearings, subframes
Suspension:
Front and rear suspension components, struts, shocks, control arms, bushings, springs
Steering:
Power steering system, steering rack, steering column, wheel alignment specifications
Brakes:
Front and rear brake systems, ABS, DSC, brake fluid specifications, bleeding procedures, rotor/pad replacement
Body And Chassis:
Body panel removal/installation, door mechanisms, glass, seals, structural components
Electrical Systems:
Lighting, power windows, central locking, mirrors, interior electronics, fuse/relay locations
Climate Control:
HVAC system, AC compressor, refrigerant, blower motor, control modules
Infotainment And Comfort:
Radio, navigation (if equipped), speaker systems, seat adjustment, interior trim
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, fluid level checks, brake checks
Troubleshooting:
Diagnostic flowcharts, common fault codes, symptom-based diagnosis
Repair Procedures:
Step-by-step guides for component removal, installation, and repair
Diagnostics:
OBD-II scanning, sensor testing, electrical circuit analysis
Component Replacement:
Detailed instructions for replacing major and minor components
Adjustments:
Clutch adjustment, parking brake adjustment, idle speed adjustment
Technical Depth
Depth Of Information:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds)
Diagnostic Level:
Advanced diagnostics, including electrical troubleshooting and component-level testing
Wiring Diagrams:
Detailed and specific electrical wiring diagrams for all systems
Torque Specifications:
Exact torque values for all fasteners
Special Tools:
Identification and usage of BMW-specific tools required for certain procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (text-searchable)
Printable:
Yes (designed for digital access, but can be printed)
Print Quality
Illustration Clarity:
High (clear, step-by-step illustrations and diagrams)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Family:
M54 (most common gasoline engines), M43 (earlier models)
Engine Variants Covered:
2.5L (M54B25), 3.0L (M54B30), 2.0L (M54B22), 2.5L (M52TUB25, earlier models), 2.8L (M52TUB28, earlier models), 2.0L (M43B20)
Performance
Horsepower Range:
148 hp (2.0L) to 231 hp (3.0L)
Torque Range:
155 lb-ft (2.0L) to 221 lb-ft (3.0L)
Fuel System
Fuel Delivery:
Multi-point fuel injection (Bosch Motronic ME 7.2 or similar)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Engine Management
ECU:
MS43, MS45
🔧 Transmission
Standard
Type Standard:
5-speed Manual (Getrag 260/6, GS5-39DZ)
Optional
Type Optional:
5-speed Automatic (GM A5S360R, A5S390R)
Features
Drive Type:
Rear-wheel drive (RWD), Optional xDrive All-wheel drive (AWD) on select models (e.g., 325xi, 330xi)
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 (or equivalent API GL-4/GL-5, SAE 75W-90)
Automatic Transmission Fluid:
Dexron III or equivalent (e.g., Dexron VI for later models, check specific vehicle)
📐 Dimensions
Exterior
Body Styles:
Sedan (E46/4), Coupe (E46/2), Convertible (E46/2C), Wagon/Touring (E46/3), Compact (E46/5 - 316ti, 318ti)
Wheelbase Sedan Coupe:
108.7 inches (2760 mm)
Wheelbase Wagon Convertible:
107.4 inches (2729 mm)
Weights
Curb Weight Range:
Approx. 3100 - 3500 lbs (1400 - 1600 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for Sedans/Coupes in 2001 model year)
IIHS Top Safety Pick:
Good (for Sedans/Coupes in relevant years)
Active Features
Traction Control:
Available ASC+T (Automatic Stability Control and Traction)
Stability Control:
Available DSC (Dynamic Stability Control)
Passive Features
Airbags:
Driver, passenger, side airbags (front), optional rear side airbags
Seatbelts:
3-point inertia-reel seatbelts with front pretensioners and force limiters
💡 Technology Features
Infotainment
Head Unit Options:
BMW Business CD, BMW Professional CD, BMW Navigation System Professional (CCC system later in production)
Audio System:
Standard 6-speaker system, optional Harman Kardon premium audio
Driver Assistance
Parking Assistance:
Optional Park Distance Control (PDC) front and rear
Connectivity
Bluetooth:
Optional Bluetooth hands-free interface (via ULF module)
Convenience
Cruise Control:
Standard
Automatic Climate Control:
Optional dual-zone automatic climate control
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable: typically 7,500-15,000 miles or 12-24 months, depending on driving conditions and oil quality (Condition Based Service - CBS)
Brake Fluid Flush:
Every 2 years (regardless of mileage)
Coolant Replacement:
Initial fill for life, but recommended flush/replacement every 4-5 years or 50,000-60,000 miles
Spark Plug Replacement:
Approx. 60,000 - 100,000 miles (depending on plug type: copper, platinum, iridium)
Fluid Specifications
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-04 compliant synthetic oil, viscosity typically 5W-30 or 0W-30 (check owner's manual for specific engine)
Engine Oil Capacity:
Approx. 6.5 quarts (6.1 liters) for 6-cylinder engines; 4.5 quarts (4.3 liters) for 4-cylinder engines (check specific model)
Coolant Specification:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) mixed with distilled water at 50/50 ratio
Power Steering Fluid:
Pentosin CHF 11S (or equivalent high-quality hydraulic fluid)
Known Issues
Cooling System:
Plastic expansion tank cracking, water pump failure (especially plastic impeller), thermostat housing leaks
Suspension:
Front control arm bushings (vibrations, wandering), rear trailing arm bushings, sway bar links/bushings
Electrical:
Vanos solenoid failure, CCV (Crankcase Ventilation) system failure leading to oil leaks and rough idle, ABS/DSC sensor issues, door seal water ingress
Interior:
Headliner sagging, worn seat bolsters, pixelated instrument cluster displays
Engine Oil Leaks:
Valve cover gasket, oil pan gasket, rear main seal
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Model Evolution
Predecessor:
BMW E36 3 Series
Successor:
BMW E90 3 Series
Production
Production Years:
1997-2006 (Global)
Manufacturing Locations:
Germany (Munich, Dingolfing), Austria, South Africa, USA (Spartanburg)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Included on Car and Driver's 10Best list multiple times during its production run
Ward 10Best Engines:
The M54 inline-six engines were frequently recognized by Ward's AutoWorld's 10Best Engines.
Ratings
Consumer Reports:
Generally good, with some models receiving higher reliability ratings than others, often citing specific common issues.
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