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BMW 3 Series (E46) 325xi Coupe 1999-2005 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E46 Specific Model Variant: 325xi Coupe Production Years Covered: 1999-2005 Codes Engine Code Common: M54B25 👋 Introduction Market Position...
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BMW 3 Series (E46) 325xi Coupe 1999-2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Specific Model Variant:
325xi Coupe
Production Years Covered:
1999-2005
Codes
Engine Code Common:
M54B25
👋 Introduction
Market Position
Vehicle Class:
Compact Executive Car (Sport Sedan/Coupe)
Target Demographic:
Enthusiasts seeking a balance of performance, luxury, and practicality
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class (W203), Audi A4 (B6/B7), Lexus IS300, Infiniti G35
Key Features
Driving Dynamics:
Renowned for balanced chassis, precise steering, and engaging driving experience
Powertrain:
Smooth and powerful inline-six engines, sophisticated xDrive all-wheel-drive system for the 325xi
Interior Quality:
Premium materials, driver-focused cockpit, solid build quality
Design:
Timeless and iconic Chris Bangle-era design, aggressive coupe profile for the 325xi Coupe
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
Digital (likely PDF, though not explicitly stated in product info)
Completeness:
Comprehensive
Page Count
Estimated Page Count:
1000+
📖 Manual Coverage
Systems Covered
Engine:
M54B25 (2.5L Inline-6), including cooling, lubrication, fuel delivery, ignition, and emissions
Transmission:
All-wheel drive (xDrive) system, SMG (Sequential Manual Gearbox), Automatic Transmission (GM 5L40-E), Manual Transmission (Getrag 420G/ZF GS6-37BZ)
Drivetrain:
Front and rear differentials, transfer case, driveshafts, CV joints
Suspension:
Front struts, rear multi-link suspension, springs, shocks, control arms, sway bars
Brakes:
Front and rear disc brakes (ABS, DSC), brake fluid, lines, calipers, rotors, pads
Steering:
Power steering system, steering rack, tie rods, steering column
Electrical:
12V battery system, alternator, starter, fuses, relays, wiring diagrams, lighting, power accessories, immobilizer system
Bodywork:
Body panels, doors, windows, sunroof, interior trim, bumpers, hinges, latches
HVAC:
Air conditioning, heating, ventilation, climate control system
Diagnostics:
On-Board Diagnostics (OBD-II) procedures, fault code interpretation, sensor testing
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs, brake inspections
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides
Component Repair:
Detailed instructions for removing, inspecting, repairing, and reinstalling major components (engine, transmission, suspension, brakes, electrical modules, etc.)
Rebuilding:
Engine rebuild procedures, transmission overhaul, differential rebuilds
Specifications:
Torque specifications, clearances, measurements, diagnostic parameters
Wiring Diagrams:
Comprehensive electrical schematics for all major systems
Body And Interior:
Repair and replacement of body panels, interior trim pieces, glass, and seals
Technical Depth
Level Of Detail:
Expert-level, covering complete overhauls and complex diagnostics
Diagrams And Illustrations:
Extensive use of exploded views, diagrams, and photographs for clarity
Special Tools:
Identification and usage instructions for necessary specialized BMW tools
📊 Manual Specifications
File Format
File Type:
Likely PDF (standard for digital manuals)
Searchability:
Expected to be text-searchable if PDF
Printability:
Typically printable
Print Quality
Image Resolution:
High resolution for clear diagrams and images
Binding Type
Binding:
N/A (digital format)
Paper Type
Paper Quality:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, Naturally Aspirated
Engine Code:
M54B25
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
10.2:1
Valvetrain:
DOHC, 24 valves, VANOS (Variable Valve Timing)
Performance
Horsepower:
184 hp @ 6000 rpm
Torque:
175 lb-ft (237 Nm) @ 3500 rpm
Fuel System
Fuel Type:
Premium Unleaded (91+ Octane Recommended)
Fuel Delivery:
Multi-point Fuel Injection (Bosch Motronic ME 9.2)
Ignition System:
Distributorless Electronic Ignition (Coil-on-Plug)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (Getrag 420G or ZF GS6-37BZ for later models)
Optional
Transmission Type:
5-Speed SMG (Sequential Manual Gearbox)
Features
Drivetrain:
xDrive All-Wheel Drive System (Permanent AWD with a default RWD bias)
📐 Dimensions
Exterior
Length:
Approx. 177.4 inches (4506 mm)
Width:
Approx. 68.7 inches (1745 mm)
Height:
Approx. 53.7 inches (1364 mm)
Wheelbase:
Approx. 107.3 inches (2725 mm)
Weights
Curb Weight:
Approx. 3550-3750 lbs (1610-1700 kg), depending on transmission and options
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (Driver/Passenger) for the E46 Coupe
IIHS Side Impact:
Good (for models equipped with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System
Dsc:
Dynamic Stability Control (includes Traction Control)
Akebono Brakes:
Optional larger front brakes on later models or M-Sport package
Passive Features
Airbags:
Front airbags, optional side-impact airbags, optional head protection system (HPS)
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters
Body Structure:
Reinforced safety cell, crumple zones
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD/Radio, BMW Professional CD/Radio, optional Navigation systems (MKIV)
Speakers:
Standard 6 or 10-speaker Hi-Fi system, optional Harman Kardon system
Driver Assistance
Parking Sensors:
Optional Rear Park Distance Control (PDC)
Connectivity
Bluetooth:
Optional Bluetooth integration for mobile phones (often via cradle)
Voice Control:
Optional voice command system for navigation and audio functions
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically every 10,000-15,000 miles or as indicated by the vehicle's computer
Brake Fluid Flush:
Every 2 years, regardless of mileage
Coolant Flush:
BMW recommends long-life coolant, often specified for 3-5 years or higher mileage intervals
Spark Plug Replacement:
Typically around 60,000-100,000 miles for the M54 engine, depending on plug type and vehicle usage
Fluid Specifications
Engine Oil:
SAE 5W-30 or 5W-40 Synthetic Engine Oil meeting BMW LL-01 or LL-04 specifications
Coolant:
BMW Blue Antifreeze/Coolant (G48) or equivalent ethylene glycol-based coolant
Brake Fluid:
DOT 4 Low Viscosity (LV) Brake Fluid
Transmission Fluid Automatic:
Dexron III/VI or equivalent ATF (for GM 5L40-E)
Transmission Fluid Manual:
SAE 75W-90 Synthetic Gear Oil (API GL-4 or GL-5)
Power Steering Fluid:
ATF Dexron III or Pentosin CHF 11 S (verify based on specific vehicle options)
Known Issues
Ccv System:
Crankcase Ventilation (CCV) system failures, leading to oil leaks, rough idle, and increased oil consumption
Cooling System:
Plastic coolant expansion tank cracks, water pump failures, thermostat housing leaks
Oil Leaks:
Valve cover gasket leaks, oil pan gasket leaks, oil filter housing gasket leaks (often due to failing O-rings)
Suspension:
Wear in control arm bushings, ball joints, and rear trailing arm bushings
Window Regulators:
Common failures of power window regulators and motors
ABS Wheel Speed Sensors:
Failure of ABS/DSC wheel speed sensors leading to warning lights
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Long-standing reputation for performance, luxury, and engineering excellence ('The Ultimate Driving Machine')
Model Evolution
E46 Generation:
Fourth generation of the 3 Series, succeeding the E36 and preceding the E90/E92
Introduction Of AWD:
Introduction of the xDrive all-wheel-drive system on select models, including the 325xi
Coupe Body Style:
Continued the successful coupe variant, known for its sporty aesthetics
Production
Manufacturing Locations:
Germany (primarily Dingolfing)
Sales Figures:
Highly successful generation, contributing significantly to BMW's global sales
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
E46 3 Series models frequently appeared on Car and Driver's 10Best lists during its production run
Ratings
Consumer Reports:
Generally received good reliability ratings, though specific model years and common issues should be noted
Certifications
Automotive Engineering:
Praised for its chassis tuning, suspension geometry, and engine refinement by automotive journalists.
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