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BMW 325I 325XI Service Repair Manual 1999-2005

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i / 325xi Generation Generation Code: E46 Generation Years: 1998-2006 (Global); 1999-2005 (US Market) Codes Chassis Codes: E46 (Sedan/Touring),...
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Sku: 319613
BMW 325I 325XI Service Repair Manual 1999-2005
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Model Variant:
325i / 325xi
Generation
Generation Code:
E46
Generation Years:
1998-2006 (Global); 1999-2005 (US Market)
Codes
Chassis Codes:
E46 (Sedan/Touring), E46/2 (Coupe), E46/3 (Sports Wagon), E46/5 (Hatchback/Compact), E46/4 (Convertible)
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Wagon/Coupe/Convertible
Positioning:
Premium sport sedan known for driving dynamics, build quality, and sophisticated engineering.
Competitive Analysis
Primary Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35, Acura TL.
Key Features
Driving Dynamics:
Renowned for balanced chassis, responsive steering, and engaging driving experience.
Build Quality:
Exceptional German engineering and high-quality materials, contributing to durability and a premium feel.
Powertrain Options:
Smooth inline-six engines delivering a refined power delivery.
📋 Manual Details
Coverage Areas
Vehicle Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Covered Models:
325i (RWD), 325xi (AWD)
Page Count
Estimated Page Count:
Over 2500 Pages (typical for comprehensive workshop manuals)
Manual Type
Manual Type:
Workshop Repair and Service Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, valve train, pistons, crankshaft, connecting rods, lubrication system, cooling system, fuel injection, emissions control.
Engine Electrical:
Ignition system, starter motor, alternator, ECU (Engine Control Unit) diagnostics, sensor testing, wiring diagrams.
Transmission:
Manual and Automatic Transmission repair, clutch system, torque converter, gearbox internals, shift mechanisms, transmission control module (TCM).
Drivetrain:
Front axle, rear axle, differential, driveshafts, CV joints, transfer case (for xi models).
Suspension Steering:
Front suspension (MacPherson struts, control arms), rear suspension (multi-link), shock absorbers, springs, power steering system, steering rack, wheel alignment specifications.
Brakes:
Front and rear brake systems (vented discs), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid specifications, bleeding procedures, caliper and rotor replacement.
Electrical Body:
Lighting systems, power windows, power locks, central locking, sunroof, wipers, horn, instrument cluster, body control module (BCM).
Climate Control:
HVAC (Heating, Ventilation, and Air Conditioning) system, refrigerant handling, compressor, evaporator, heater core, climate control unit diagnostics.
Safety Systems:
Airbag system (SRS), seatbelt pre-tensioners, diagnostic procedures for safety components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, cabin), spark plug replacement, coolant flushes, brake fluid replacement, interval checks.
Engine Repair:
Head gasket replacement, timing chain/belt service, piston ring replacement, bearing inspection, engine rebuild procedures.
Transmission Repair:
Clutch replacement, automatic transmission overhaul, seal replacements, mechatronic unit repair (where applicable).
Suspension Steering Repair:
Control arm bushings replacement, shock/strut replacement, steering rack repair/replacement, tie rod end replacement.
Brake System Repair:
Brake pad and rotor replacement, caliper overhaul, ABS sensor replacement, brake line repair/replacement.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, component testing, ECU module diagnostics and programming (basic level).
Bodywork Repair:
Panel replacement, door mechanism repair, bumper repair, glass replacement.
Troubleshooting:
Diagnostic flowcharts, common fault codes and their meanings, step-by-step troubleshooting guides for various systems.
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds).
Diagnostics Coverage:
Detailed diagnostic procedures, including component testing, sensor readings, and interpretation of fault codes.
Specifications:
Torque specifications, clearances, fluid capacities, electrical values, alignment data.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Likely searchable text, allowing for quick keyword-based information retrieval.
Print Quality
Print Readability:
Designed for clear reading and printing, with diagrams and schematics rendered accurately.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Family:
M54
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Displacement Liters:
3.0 L
Displacement Cc:
2979 cc
Bore X Stroke:
84.0 mm x 89.6 mm
Compression Ratio:
10.2:1
Engine Management:
Digital Motor Electronics (DME) MS 43 / MS 45
Performance
Horsepower Hp:
225 hp @ 5900 rpm
Torque Lb Ft:
214 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic
Fuel Type:
Premium Unleaded Gasoline (91+ Octane Recommended)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (Getrag GS5-39DZ)
Optional
Transmission Type:
5-Speed Steptronic Automatic (GM A5S360R/Z)
Features
Drivetrain:
RWD (325i), AWD (xDrive on 325xi)
📐 Dimensions
Exterior
Wheelbase In:
107.4 inches (Sedan/Coupe/Convertible), 108.3 inches (Touring)
Length In:
177.4 - 181.1 inches (depending on body style)
Width In:
69.1 - 70.1 inches
Height In:
55.5 - 56.7 inches
Weights
Curb Weight Lbs:
3350 - 3600 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5 Stars
NHTSA Side Impact:
4 Stars (driver), 5 Stars (passenger)
IIHS Moderate Overlap:
Good
Active Features
Stability Control:
Dynamic Stability Control (DSC) standard
Traction Control:
Automatic Stability Control and Traction (ASC+T)
Braking System:
Anti-lock Braking System (ABS), Electronic Brake Force Distribution (EBD)
Passive Features
Airbags:
Front airbags, side airbags (front occupants), optional head airbags.
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners and force limiters.
💡 Technology Features
Infotainment
Head Unit Options:
BMW Business CD, BMW Professional CD RDS, optional Navigation system (CCC or MKIV based).
Audio System:
Harman Kardon premium audio system optional.
Driver Assistance
Cruise Control:
Standard cruise control, some models might have adaptive cruise control (less common for this era).
Parking Assist:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Phone Integration:
Optional Bluetooth hands-free system with integrated cradle or adapter.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically around 10,000-15,000 miles or 12-24 months, depending on driving conditions.
Spark Plug Replacement:
Around 100,000 miles (long-life iridium plugs).
Coolant Flush:
Every 2-4 years or 30,000-50,000 miles.
Brake Fluid Flush:
Every 2 years
Fluid Specifications
Engine Oil Type:
Synthetic API SN or newer, BMW Longlife-01 (LL-01) approved, SAE 5W-30 or 5W-40 recommended. Check owner's manual for exact specs.
Engine Oil Capacity Qts:
6.5 US quarts (with filter change)
Coolant Type:
BMW Blue Antifreeze (G48), mixed 50/50 with distilled water.
Transmission Fluid Manual:
SAE 75W-90 Synthetic Gear Oil (e.g., Pentosin MTF 2.0 or equivalent GL-4/GL-5 rated).
Transmission Fluid Automatic:
BMW ATF LT-3 (e.g., Pentosin ATF 1 or equivalent) – critical for longevity.
Brake Fluid Type:
DOT 4 High Performance Synthetic Brake Fluid
Known Issues
Cooling System:
Plastic expansion tank failures, water pump and thermostat housing leaks (especially the plastic impeller on early water pumps).
Suspension:
Front control arm bushings (vibrations/clunks), rear shock mounts, subframe bushings.
Engine M54:
PCV (Positive Crankcase Ventilation) system clogging leading to oil leaks and rough running, VANOS (Variable Valve Timing) solenoid issues.
Electrical:
Window regulator failures, LCM (Light Module Control) issues, blower motor resistor failures.
Exhaust:
Cracked exhaust manifold on some M54 engines.
📚 Vehicle History
Brand Heritage
Brand Legacy:
BMW, Bayerische Motoren Werke AG, founded in 1916, renowned for performance, luxury, and driving pleasure.
Model Evolution
E46 Introduction:
The E46 generation succeeded the E36 3 Series and was introduced globally starting in 1998. It marked a significant step forward in design, technology, and driving refinement.
325I Positioning:
The 325i represented the mid-range gasoline engine offering within the E46 lineup, positioned between the 323i/328i (earlier models) and the higher-performance 330i.
Production
Production Dates Usdm:
1999-2005
Manufacturing Locations:
Primarily Dingolfing, Germany; also plants in South Africa, Mexico, and Austria.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E46 3 Series (including variants like the 325i) was a frequent recipient of Car and Driver's 10Best list during its production run, lauded for its performance and handling.
Ratings
Consumer Reports Reliability:
Generally rated as average to good for its class, with common issues related to specific components as noted in the maintenance section.
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