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BMW 3 Series E46 Workshop Service & Repair Manual 1999-2005 # 1

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The 3 Series, generation code E46, represents a significant chapter in the legacy of producing premium compact executive vehicles. Produced from 1999 to 2005, this model line, available as a...
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BMW 3 Series E46 Workshop Service & Repair Manual 1999-2005 # 1
The 3 Series, generation code E46, represents a significant chapter in the legacy of producing premium compact executive vehicles. Produced from 1999 to 2005, this model line, available as a Sedan, Coupe, Convertible, and Sport Wagon, is renowned for its exceptional driving dynamics, embodying the philosophy of being 'The Ultimate Driving Machine.' Featuring a rear-wheel drive biased chassis with optional all-wheel drive, and powered by a range of potent inline-six gasoline engines (such as the M54 series) and efficient diesel options, the E46 3 Series offered an engaging and refined driving experience that earned it multiple accolades, including placement on Car and Driver's 10Best list. This comprehensive workshop manual provides extensive coverage for the 3 Series E46 models produced between 1999 and 2005. It details all major systems, including gasoline and diesel engines, manual and automatic transmissions, suspension, steering, brakes, electrical systems, and body components. The manual includes step-by-step maintenance procedures, detailed repair instructions, troubleshooting guides with diagnostic flowcharts, and essential technical specifications. Designed for expert-level understanding, this resource is an indispensable tool for owners, mechanics, and technicians seeking to maintain, diagnose, and repair their E46 3 Series with precision and confidence.
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Generation
Generation Code:
E46
Codes
Model Years Covered:
1999-2005
👋 Introduction
Market Position
Segment:
Premium Compact Executive Sedan/Coupe/Convertible/Wagon
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS (XE10), Acura TL (UA4/UA5)
Key Features
Platform:
Rear-wheel drive biased chassis with optional xDrive all-wheel drive.
Driving Dynamics:
Renowned for balanced handling, responsive steering, and engaging driving experience ('The Ultimate Driving Machine').
Body Styles:
Available as Sedan (E46/4), Coupe (E46/2), Convertible (E46/C), and Sport Wagon (E46/3).
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service & Repair
Page Count
Estimated Page Count:
Extensive (typically 2000+ pages for full E46 manuals)
Manual Type
Type:
Comprehensive Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
All gasoline and diesel engines (e.g., M52, M54, M43, M47, M57)
Transmission:
Manual and Automatic Transmissions (e.g., Getrag GS53Z, ZF 5HP19, ZF 6HP19)
Suspension Steering:
Front and Rear Suspension, Steering System, Power Steering
Brakes:
Hydraulic System, ABS, DSC, Brake Pads, Rotors, Lines, Parking Brake
Body:
Body Panels, Frame, Doors, Hood, Trunk, Bumpers, Trim
Body Equipment:
Seats, Interior Trim, Sunroof, Mirrors, Convertible Top Mechanisms
Electrical System:
Battery, Alternator, Starter, Lighting, Fuses, Relays, ECU, Body Control Module (BCM)
Equipment Accessories:
HVAC, Audio System, Navigation, Cruise Control, Seat Adjustment, Window Regulators
Diagnostics:
OBD-II (On-Board Diagnostics), Fault Codes, Diagnostic Procedures
Procedures Included
Maintenance:
Routine Service, Oil Changes, Filter Replacements, Fluid Flushes, Spark Plugs
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Repair
Troubleshooting:
Diagnostic Flowcharts, Common Problems, Symptom-Based Troubleshooting
Installation:
Component Replacement, Accessory Installation
Technical Depth
Depth:
Expert Level (from basic maintenance to full component rebuilds and electrical system diagnostics)
📊 Manual Specifications
File Format
Format Details:
Searchable PDF with selectable text, allowing easy navigation and printing.
Print Quality
Quality:
High-resolution graphics, clear diagrams, and sharp text for easy readability.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Common Engines:
M54B22 (2.2L I6), M54B25 (2.5L I6), M54B30 (3.0L I6), M52TUB25 (2.5L I6), M52TUB28 (2.8L I6), S54B32 (3.2L I6 - M3)
Performance
M54B30 Output:
225 hp @ 6000 rpm, 214 lb-ft @ 3500 rpm
S54B32 Output:
333 hp @ 7900 rpm, 262 lb-ft @ 4900 rpm (M3)
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI), VANOS (Variable Valve Timing)
Technical Specs
Engine Management:
Bosch Motronic DME (Digital Engine Electronics) variants
🔧 Transmission
Standard
Base Transmission:
5-speed Manual (Getrag GS53Z, later ZF GS6-37BZ on some models)
Optional
Automatic Options:
5-speed Automatic (ZF 5HP19), 6-speed Automatic (ZF 6HP19 on later models, especially 330i/xi)
Features
Clutch Type:
Hydraulically actuated single dry plate clutch (manual)
Transmission Fluid Spec:
Manual: ATF Dexron III/VI or specialist manual transmission fluid. Automatic: ATF Dexron III/VI, or specific ZF fluids (e.g., Lifeguard Fluid 5 for 5HP19, Lifeguard Fluid 6 for 6HP19).
📐 Dimensions
Exterior
Sedan Length:
Approx. 4,471 mm (176.0 in)
Coupe Length:
Approx. 4,471 mm (176.0 in)
Convertible Length:
Approx. 4,488 mm (176.7 in)
Wagon Length:
Approx. 4,471 mm (176.0 in)
Weights
Curb Weight Range:
Approx. 1450 kg - 1650 kg (depending on model and options)
Wheelbase:
Approx. 2,725 mm (107.3 in)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for models tested)
IIHS Side Impact:
Good (for models tested)
Active Features
Stability Control:
Dynamic Stability Control (DSC) or Dynamic Traction Control (DTC)
Braking Assist:
Anti-lock Braking System (ABS), Electronic Brake Force Distribution (EBD)
Passive Features
Airbags:
Frontal airbags, Side airbags, available Head Protection System (HPS)
Structure:
Advanced crumple zones, reinforced passenger cell
💡 Technology Features
Infotainment
Available Systems:
BMW Business CD, BMW Professional RDS, optional CD Changer, optional Navigation system (MK III/IV).
Driver Assistance
Systems:
Park Distance Control (PDC), Cruise Control, Rain-sensing wipers, Automatic headlights.
Connectivity
Features:
Optional Bluetooth phone integration (via TCU module), Sirius Satellite Radio readiness.
🔧 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 Blue Coolant, typically every 4 years or 100,000 miles for initial fill.
Fluid Specifications
Engine Oil:
SAE 5W-30 or 5W-40 meeting BMW Longlife-01 (LL-01) or LL-04 specifications (check owner's manual/oil cap for precise spec).
Power Steering Fluid:
BMW CHF 11S or equivalent Pentosin PSF.
Known Issues
Cooling System:
Plastic coolant expansion tank can become brittle and crack. Water pump failure (plastic impeller)
Vanos:
Vanos seals and solenoids can fail, leading to rough idle and loss of low-end torque.
Subframe Mounts:
Rear subframe mounting points can crack the chassis, especially on higher-mileage vehicles. (Crucial check)
Oil Pan Gasket:
Common source of oil leaks on M54 engines.
Window Regulators:
Plastic components in window regulator mechanisms are prone to failure.
📚 Vehicle History
Brand Heritage
Philosophy:
BMW's long-standing commitment to performance, engineering, and driver engagement.
Model Evolution
Predecessor:
BMW E36 3 Series
Successor:
BMW E90 3 Series (Sedan/Wagon), E92 3 Series (Coupe), E93 3 Series (Convertible)
Production
Production Period:
1998-2006 (with 2005 being the final model year for most markets)
Manufacturing Locations:
Germany (Dingolfing, Munich), South Africa (Rosslyn), Thailand, Egypt, Russia, Brazil, China, India.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
3 Series (E46) named to Car and Driver's 10Best list multiple times during its production run.
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