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BMW 3 Series 99-05 E46 Repair/Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E46 Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Body Styles Covered: Sedan, Coupe, Convertible, Sports Wagon...
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Type: Car
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Sku: 146960
BMW 3 Series 99-05 E46 Repair/Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Body Styles Covered:
Sedan, Coupe, Convertible, Sports Wagon (Touring), M3 Coupe/Convertible
Codes
Manual Product Code:
Not Specified (Placeholder for potential retail SKU)
👋 Introduction
Market Position
Vehicle Segment:
Compact Executive Car (Entry-level luxury sedan/coupe).
Target Audience:
Enthusiasts, DIY mechanics, owners seeking in-depth knowledge for maintenance and repair.
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35, Acura TL.
Key Features
Vehicle Focus:
Sporty handling, premium build quality, refined engines, driver-centric cockpit.
Manual Value Proposition
Value To Owner:
Empowers owners to perform maintenance, diagnose issues, and undertake repairs, saving on labor costs and fostering a deeper understanding of their vehicle.
📋 Manual Details
Coverage Areas
Manual Type:
Repair and Service Manual
Language:
English
Format:
Digital (e.g., PDF, e-book)
Page Count
Estimated Page Count:
Over 2000 pages (Typical for comprehensive E46 service manuals)
Manual Type
Manual Scope:
Comprehensive Repair and Service Information
📖 Manual Coverage
Systems Covered
Engine:
4-cylinder (M43, N42, N46), 6-cylinder (M52TU, M54, S54 M3), Diesel (M47, M57) engine overhauls, diagnostics, tuning, cooling systems, exhaust systems, fuel delivery, ignition systems, oil systems.
Transmission:
Manual (Getrag 250, ZF S5-31) and Automatic (GM A4S270R, A5S325Z, ZF 5HP19, 5HP24) transmission service, clutch replacement, differential service, driveshaft maintenance, hydraulic systems.
Suspension:
Front strut assembly, rear multi-link suspension, shock absorber replacement, spring replacement, control arm bushings, sway bar links, wheel bearing replacement, steering rack service.
Brakes:
Front and rear brake pad and rotor replacement, caliper service, brake fluid flush and bleed, ABS/DSC system diagnostics and repair, parking brake adjustment.
Electrical:
Wiring diagrams for all systems, alternator and starter service, battery testing and replacement, lighting systems, power windows, mirrors, seats, central locking, instrument cluster, fuse and relay identification and testing, ECU diagnostics.
Bodywork:
Exterior panel removal and installation (hood, doors, fenders, bumpers), interior trim panel removal, door mechanism repair, glass replacement, convertible top mechanisms, body panel alignment, rust repair guidance.
Climate Control:
HVAC system diagnosis, blower motor replacement, evaporator and condenser service, refrigerant recharge, heater core replacement, A/C system leak testing.
Fuel System:
Fuel pump replacement, fuel filter replacement, fuel injector cleaning and replacement, fuel tank service, fuel pressure testing.
Exhaust System:
Exhaust manifold repair/replacement, catalytic converter replacement, muffler service, exhaust hanger replacement.
Cooling System:
Radiator replacement, water pump service, thermostat replacement, coolant flush, hoses and pipe inspection and replacement.
Procedures Included
Maintenance:
Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid level checks and top-offs, brake fluid flushes, coolant flushes, drive belt inspection and replacement.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, DTC (Diagnostic Trouble Code) interpretation and resolution, symptom-based troubleshooting guides.
Repair:
Detailed instructions for component removal, repair, and reinstallation for all major vehicle systems, including engine rebuilds, transmission overhauls, suspension and steering repairs, brake system overhauls, and electrical component replacement.
Installation:
Guidance for installing aftermarket parts or performing major component upgrades (e.g., performance exhaust, suspension components).
Diagnostics:
On-board diagnostics (OBD-II) procedures, sensor testing, actuator testing, use of diagnostic tools (e.g., BMW ISTA/EDiABAS, generic OBD-II scanners).
Technical Depth
Depth:
Comprehensive. Covers everything from basic routine maintenance and fluid changes to complete engine and transmission rebuilds, complex electrical system diagnostics, and bodywork repairs. Includes detailed torque specifications and component tolerances.
📊 Manual Specifications
File Format
File Type:
Likely PDF or similar digital format for easy searching and printing.
Searchability:
High (typically OCR-enabled PDFs allow full text search).
Print Quality
Illustrations:
High-quality diagrams, schematics, and photographs for procedural clarity.
Binding Type
Physical Manual Binding:
Not Applicable (Digital Format)
Paper Type
Physical Manual Paper:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Common Engines Gasoline:
2.5L I6 (M54B25), 3.0L I6 (M54B30), 3.2L I6 (S54B32 - M3)
Common Engines Diesel:
2.0L I4 (M47TU), 3.0L I6 (M57)
Performance
M54B25 Horsepower:
189 hp @ 6000 rpm
M54B25 Torque:
175 lb-ft @ 3500 rpm
M54B30 Horsepower:
225 hp @ 6000 rpm
M54B30 Torque:
214 lb-ft @ 3500 rpm
S54B32 Horsepower M3:
333 hp @ 7900 rpm (US Spec)
S54B32 Torque M3:
262 lb-ft @ 4900 rpm (US Spec)
Fuel System
Fuel Injection:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane recommended for most models)
Engine Management
ECU Type:
MS43, MS45.1 (depending on engine and year)
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual (Getrag 250, ZF S5-31 for M3)
Optional
Optional Transmission Type:
5-speed automatic (GM A4S270R, A5S325Z), 6-speed manual (SMG II for M3)
Features
Transmission Fluid M54 Auto:
BMW ATF LT-3 (ZF LifeguardFluid 5)
Clutch Type:
Dry single-plate clutch (manual transmission)
Differential
Differential Type:
Open differential (some M3 models feature limited-slip differential - LSD)
📐 Dimensions
Exterior
Wheelbase:
108.7 inches (2760 mm) for Sedan/Touring, 107.4 inches (2728 mm) for Coupe/Convertible
Overall Length:
Approx. 177.4 - 180.3 inches (4506 - 4580 mm) depending on body style
Wheel Bolt Pattern:
5x120mm
Wheel Size Range:
15-19 inches (standard 16/17 inch, M3 typically 18/19 inch)
Weights
Curb Weight Range:
Approx. 3200 - 3700 lbs (1450 - 1680 kg) depending on model and equipment
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 stars (for applicable models/years)
IIHS Side Impact:
Good (for applicable models/years)
Active Features
Active Safety Systems:
ABS (Anti-lock Braking System), ASC+T (Automatic Stability Control + Traction), DSC (Dynamic Stability Control) on later/higher trims.
Passive Features
Passive Safety Features:
Front airbags (driver/passenger), Side curtain airbags (optional/later models), Seatbelt pretensioners, Crumple zones.
💡 Technology Features
Infotainment
Infotainment System:
BMW Business CD, BMW Professional CD, optional Navigation system (MKIII/MKIV DVD-based).
Audio Features:
CD player, AM/FM radio, optional Harman Kardon premium sound system, cassette player (early models).
Driver Assistance
Driver Assistance Features:
Cruise control, Park Distance Control (PDC) (optional), Rain-sensing wipers (optional).
Connectivity
Connectivity Options:
Optional Bluetooth phone integration (UHF module), CD changer preparation.
Lighting
Headlight Types:
Halogen reflector, Xenon HID (optional), LED taillights (facelift models).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles or 12 months (depending on driving conditions and oil used, often indicated by the Condition Based Service - CBS system).
Brake Fluid Change Interval:
Every 2 years.
Coolant Change Interval:
BMW Blue or Green Antifreeze/Coolant concentrate, change every 4-5 years or as indicated.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 or 5W-40 synthetic oil meeting BMW LL-01 or LL-04 specifications (check owner's manual for specific engine recommendations).
Power Steering Fluid:
BMW ATF DEXRON III or equivalent.
Coolant Type:
BMW Blue Antifreeze (G48) or Green Antifreeze concentrate, mixed 50/50 with distilled water.
Known Issues
Common E46 Issues:
Cracked rear subframe mounting points, cooling system failure (water pump, thermostat, expansion tank), VANOS system issues, oil consumption (especially M54 engines), heater core leaks, CCV system failure (crankcase ventilation), rear shock mount fatigue, oil pan gasket leaks, window regulator failures, ABS/DSC sensor failures.
M3 Specific Issues:
Rod bearing wear (S54 engine), throttle actuator issues, VANOS solenoid failures.
Part Numbers
Oil Filter M54:
Mann-Filter HU 830/1 x, Mahle KL 072 019 012 019
Air Filter M54:
Mann-Filter C 25 328
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Sheer Driving Pleasure, focus on performance, handling, and driver engagement.
Model Evolution
E46 Introduction:
Launched in 1998 (as a 1999 model), replacing the E36 3 Series. Known for significant improvements in chassis rigidity, suspension design, and interior refinement.
E46 Facelift:
Mid-cycle refresh (LCI - Life Cycle Impulse) introduced in late 2001 for the 2002 model year, featuring updated headlights, taillights, bumpers, and interior trim.
Production
Production Locations:
Mainly Germany (Dingolfing, Munich), with some production in other countries.
Production Total Units:
Over 3 million units produced globally across all body styles.
🏆 Awards & Recognition
Recognitions
Car And Driver Award:
Car and Driver's 10Best list multiple times during its production run (notably 2000-2003).
Ward S Auto World Engine Award:
M54 engines (3.0L variant) recognized for refinement and performance.
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