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BMW 323 323i 2004 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: 323i Model Variant: 323 Year: 2004 Codes Chassis Code: E46 Engine Code Suffix: B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Competitors:...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
323i
Model Variant:
323
Year:
2004
Codes
Chassis Code:
E46
Engine Code Suffix:
B25
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35
Key Features
Driving Dynamics:
Renowned for BMW's signature 'Ultimate Driving Machine' handling and balance
Powertrain:
Smooth and responsive inline-six engine
Build Quality:
High-quality interior materials and solid construction
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service, repair, and diagnostic procedures
Included Sections:
Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Exterior, Interior
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing systems (VANOS), lubrication, cooling
Engine Electrical:
Ignition system, fuel injection system (DME - Digital Motor Electronics), sensors, actuators, ECU diagnostics
Transmission:
Manual and Automatic Transmission (GM 5L40-E) service, repair, overhaul, fluid specifications, control modules
Drivetrain:
Clutch, driveshafts, differential, axles, wheel bearings
Suspension:
Front and rear suspension components (struts, shock absorbers, control arms, ball joints, bushings), alignment specifications
Steering:
Power steering system, steering rack, tie rods, steering column
Brakes:
Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), hydraulic system, bleeding procedures
Electrical System:
Wiring diagrams, fuse box locations, lighting, power windows, mirrors, central locking, battery, starter, alternator
HVAC:
Air conditioning system, heater core, blower motor, climate control module, refrigerant handling
Body Exterior:
Body panels, doors, hood, trunk, bumpers, glass, seals, rust prevention
Body Interior:
Seats, dashboard, trim panels, airbags, seatbelts, interior lighting
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for common issues
Repair:
Detailed step-by-step repair instructions for all major components and systems
Diagnostics:
OBD-II (On-Board Diagnostics II) procedures, fault code interpretation, sensor testing, diagnostic tool usage
Disassembly Reassembly:
Complete procedures for removing, inspecting, repairing, and reinstalling components
Technical Depth
Depth:
Expert-level, suitable for professional mechanics and advanced DIY enthusiasts
Diagnostic Tools:
Information on using BMW-specific diagnostic tools (e.g., DIS, ISTA) and general OBD-II scanners
Wiring Diagrams:
Detailed, system-specific wiring schematics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable
Printability:
Printable
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M54B25
Engine Type:
Naturally Aspirated Inline-6 Cylinder
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
82.0 mm x 79.5 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
184 hp @ 6000 rpm
Torque:
237 Nm (175 lb-ft) @ 3500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic ME7.2)
Fuel Type:
Premium Unleaded (91 octane or higher recommended)
Emission Control:
Secondary Air Injection System, Catalytic Converters
Engine Features
Valvetrain:
Double Overhead Camshafts (DOHC), 24 Valves, Double VANOS (Variable Valve Timing)
Cooling System:
Pressurized liquid cooling system with electric fan
Lubrication System:
Wet sump lubrication, oil filter, oil cooler (if equipped)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (Getrag S5D 320Z)
Optional
Transmission Type:
5-speed Automatic (GM 5L40-E)
Features
Clutch Type:
Hydraulically operated single dry plate clutch (Manual)
Automatic Control:
Electronic control, Steptronic (manual shifting mode)
📐 Dimensions
Exterior
Length:
4471 mm (176.0 inches)
Width:
1739 mm (68.5 inches)
Height:
1414 mm (55.7 inches)
Wheelbase:
2760 mm (108.7 inches)
Weights
Curb Weight Manual:
1450 kg (3197 lbs)
Curb Weight Automatic:
1490 kg (3285 lbs)
Gross Vehicle Weight Rating:
1900 kg (4189 lbs)
Wheel Bolt Pattern:
5 x 120 mm
Wheel Size:
16-inch or 17-inch alloy wheels
Tire Size Standard:
205/55 R16 (Front), 225/50 R16 (Rear)
Cargo
Trunk Volume:
440 Liters (15.5 cubic feet)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star
NHTSA Front Impact Passenger:
5-Star
IIHS Side Impact:
Good (for vehicles equipped with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System
Dsc:
Standard Dynamic Stability Control
Traction Control:
Standard Automatic Stability Control + Traction (ASC+T)
Passive Features
Airbags:
Frontal airbags, optional front side-impact airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system (where applicable)
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD or Professional CD/Cassette radio, optional CD changer
Navigation:
Optional BMW Professional Navigation System (MK4 unit)
Driver Assistance
Parking Sensors:
Optional Rear Park Distance Control (PDC)
Cruise Control:
Standard Cruise Control
Connectivity
Bluetooth:
Optional Bluetooth mobile phone integration (often requiring a separate cradle)
Comfort Features
Climate Control:
Optional Automatic Climate Control with digital display
🔧 Maintenance
Service Intervals
Oil Change Interval:
Approximately every 7,500-15,000 miles or as indicated by the Condition Based Service (CBS) system
Brake Fluid Change:
Every 2 years (regardless of mileage)
Coolant Change:
Every 3-4 years or as recommended by BMW (BMW Blue Coolant)
Spark Plug Replacement:
Around 60,000 - 100,000 miles, depending on spark plug type
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic (BMW LL-01 approved)
Engine Oil Capacity:
6.5 Liters (6.9 US Quarts)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)
Brake Fluid Type:
DOT 4 (BMW Heavy Duty Brake Fluid)
Transmission Fluid Manual:
BMW MTF LT-2 (Manual Transmission Fluid) or equivalent
Transmission Fluid Automatic:
Esso LT 71141 (or Pentosin ATF 1)
Known Issues
Oil Leaks:
Valve cover gasket, oil filter housing gasket, oil pan gasket, CCV (Crankcase Ventilation) system leaks
Cooling System:
Water pump failure (plastic impeller), thermostat housing leaks, expansion tank leaks, radiator leaks
Suspension:
Control arm bushings (mentally crack), rear subframe bushings, thrust arm bushings
Electrical:
Heated oxygen sensor (O2 sensor) failures, VANOS solenoid issues, ABS/DSC wheel speed sensor failures
Interior:
Pixelated instrument cluster displays, dead pixels in infotainment screens
Common Repairs
Ccv System:
Regular replacement or modification of the CCV system is recommended to prevent oil leaks and rough idling
Vanos System:
VANOS solenoids and seals can fail, leading to rough idle, poor performance, and increased fuel consumption
📚 Vehicle History
Brand Heritage
Heritage:
BMW's legacy of engineering excellence and sporty driving experience
Model Evolution
E46 Generation:
Fourth generation of the BMW 3 Series, known for refined styling and improved dynamics
323I Positioning:
Positioned below the 325i and 330i, offering a balance of performance and value
Production
Production Years:
1999-2006 (E46 generation)
Manufacturing Location:
Germany, South Africa, Thailand, Brazil, Russia, China
🏆 Awards & Recognition
Recognitions
Model Awards:
Car and Driver's 10Best (1999, 2000, 2001 - for the E46 generation)
Bmw Brand Reputation:
Consistently recognized for engineering, performance, and luxury
Ratings
Consumer Reports Reliability:
Varied, with common issues requiring proactive maintenance