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

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325xi Codes Chassis Code: E46 Engine Code Range: M54B25 👋 Introduction Market Position Positioning: The E46 generation 3 Series,...
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Sku: 172628
BMW 325XI-3 Series (E46) 1999-2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Model Variant:
325xi
Codes
Chassis Code:
E46
Engine Code Range:
M54B25
👋 Introduction
Market Position
Positioning:
The E46 generation 3 Series, particularly the 325xi, represented BMW's entry into the premium compact executive sedan/wagon segment, emphasizing sporty handling, sophisticated engineering, and a driver-centric experience with the added benefit of all-wheel drive for enhanced traction.
Competitive Analysis
Competitors:
Competed against models like the Audi A4 Quattro, Mercedes-Benz C-Class (C230/C240), and Lexus IS300 during its production run.
Key Features
Distinctive Attributes:
Rear-wheel-drive bias in the xDrive AWD system, balanced chassis, refined inline-six engine, premium interior materials, and advanced (for the era) electronic driver aids.
📋 Manual Details
Coverage Areas
Coverage Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Covered Models:
325xi (All-Wheel Drive)
Page Count
Estimated Page Count:
~1500+
Manual Type
Type:
Comprehensive Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF), potentially printed
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Drivetrain, Transmission, Cooling System, Fuel System, Exhaust System
Chassis:
Suspension, Steering, Brakes (including ABS/DSC), Wheels and Tires
Electrical:
Engine Control Module (ECM), Body Control Module (BCM), Lighting, Instruments, Audio System, Power Accessories, Ignition System, Charging System, Diagnostic Trouble Codes (DTCs)
Body And Interior:
Body Panels, Doors, Glass, Seats, HVAC, Interior Trim, Safety Restraints (Airbags/Seatbelts)
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes (Oil, Coolant, Brake Fluid, Power Steering Fluid), Filter Replacements, Spark Plug Replacement, Belt Replacement
Repair:
Engine Overhaul/Rebuild, Transmission Removal/Installation, Suspension Component Replacement, Brake System Service, Electrical Component Diagnosis and Repair, Body Panel Repair
Diagnostics:
Troubleshooting Guides, Symptom-based Diagnostics, Wiring Diagrams, Component Testing Procedures
Special Procedures:
Wheel Alignment, Tire Balancing, Clutch Service (if applicable), Differential Service, Transfer Case Service (for AWD)
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, with detailed electrical schematics and diagnostic information)
📊 Manual Specifications
File Format
File Type:
Likely PDF, Searchable Text
Print Quality:
High-resolution, enabling clear printing of diagrams and text
Binding Type
Binding:
N/A (for digital format); Likely perfect bound or spiral bound for printed versions
Paper Type
Paper Quality:
N/A (for digital format); Typically heavy-duty paper for printed workshop manuals
⚙️ Engine Specifications
Primary Engine
Engine Family:
M54
Engine Type:
Naturally Aspirated Inline-6 (Straight-6)
Displacement:
2.5 Liters (2494 cc)
Engine Code:
M54B25
Performance
Horsepower:
184 hp @ 6000 rpm (approx.)
Torque:
175 lb-ft @ 3500 rpm (approx.)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with Electronic Throttle Control (ETC)
Recommended Fuel:
Premium Unleaded (91 octane or higher recommended)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (Getrag S5D 320Z/Z32)
Optional
Type:
5-speed Steptronic Automatic Transmission (GM A5S325Z)
Features
Drivetrain Type:
All-Wheel Drive (xDrive)
Transfer Case:
Center differential with planetary gear set
📐 Dimensions
Exterior
Wheelbase:
107.1 inches (2720 mm)
Length:
177.4 inches (4507 mm)
Width:
68.5 inches (1740 mm)
Height:
55.4 inches (1407 mm)
Weights
Curb Weight:
~3500-3600 lbs (depending on body style and options)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 stars (driver/passenger, 1999-2005 models)
IIHS Front Offset:
Good (for models tested)
Active Features
Stability Control:
Dynamic Stability Control (DSC) standard
Traction Control:
Automatic Stability Control and Traction (ASC+T) standard
ABS:
Anti-lock Braking System (ABS) standard
Passive Features
Airbags:
Frontal airbags for driver and front passenger; optional side airbags
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners
💡 Technology Features
Infotainment
Audio System:
BMW Business CD or Professional CD/Cassette/RDS radio with optional CD changer and Harman Kardon premium audio.
Navigation:
Optional BMW Professional Navigation System (MKIV unit).
Driver Assistance
Parking Assistance:
Optional Rear Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional Bluetooth preparation with cradle.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system; typically 7,500-15,000 miles or annually, whichever comes first.
Spark Plug Replacement:
Approximately every 100,000 miles (M54 engines use long-life spark plugs).
Coolant Flush:
Every 2-4 years or as indicated by CBS.
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) approved synthetic oil, typically 5W-30 or 0W-30.
Coolant:
BMW Blue Coolant (G48 ethylene glycol based) mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 or DOT 4 Plus approved.
Power Steering Fluid:
BMW Pentosin CHF 11 S or equivalent.
Known Issues
Cooling System:
Plastic expansion tank cracks, water pump impeller failure (often plastic), thermostat housing leaks, radiator leaks.
Engine M54:
CCV (Crankcase Ventilation) system failure leading to oil leaks and rough idle, VANOS (Variable Valve Timing) solenoid leaks or failure, oil filter housing gasket (OFHG) leaks, rear main seal leaks.
Suspension:
Front control arm bushings wear out, rear subframe bushings can tear, ball joint wear.
Electrical:
Window regulator failures, headlight condensation, ABS/DSC sensor failures, pixelation on the instrument cluster display.
Body:
Rust can be an issue in certain climates, especially around wheel arches and rocker panels.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for producing driver-focused luxury vehicles with superior handling dynamics and innovative engineering.
Model Evolution
E46 Introduction:
The E46 generation replaced the E36 3 Series and was introduced in 1998 for the 1999 model year. It was praised for its improved chassis rigidity, refined ride quality, and updated styling.
Production
Production Years:
1999-2005 (for E46 generation)
Manufacturing Locations:
Primarily Dingolfing, Germany; some assembly in other BMW plants globally.
🏆 Awards & Recognition
Recognitions
Car And Driver:
Car and Driver 10Best list multiple times during its production run.
Ward Auto:
Engine awards for the M54 inline-six.
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