BMW 325xi 2003 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325xi Year: 2003 Codes Chassis Code: E46 Engine Code: M54B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Wagon Target Audience: Enthusiasts, DIY mechanics,...

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Type: Car

Vendor:

Sku: 421439

Tags: 2003 325xi BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

325xi

Year:

Codes

Chassis Code:

Engine Code:

M54B25

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Wagon

Target Audience:

Enthusiasts, DIY mechanics, professional technicians working on E46 3-series

Competitive Analysis

Key Competitors 2003:

Audi A4 Quattro, Mercedes-Benz C-Class 4MATIC, Lexus IS300

Key Features Vehicle

Drivetrain:

BMW's intelligent xDrive all-wheel-drive system

Engine Technology:

Smooth and responsive M54 inline-6 engine with VANOS (Variable Valve Timing)

Key Features Manual

Comprehensiveness:

Covers virtually every aspect of vehicle repair and maintenance

Diagnostic Emphasis:

Strong focus on diagnostic procedures and troubleshooting common electrical and mechanical faults

📋 Manual Details

Coverage Areas

Primary Focus:

Service and Repair

Secondary Focus:

Maintenance, Troubleshooting, Rebuilding, Refurbishment, Restoration

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

File Format:

Searchable PDF

Print Quality:

High-resolution, clear text and diagrams

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, assembly, tuning, diagnosis, M54B25 inline-6

Drivetrain:

All-wheel drive (xDrive) system, differentials (front, rear), driveshafts, CV joints

Transmission:

Automatic (Steptronic) and Manual transmissions, clutch, torque converter, seals, linkages

Suspension:

Front and rear suspension components, struts, shocks, control arms, bushings, springs, sway bars, alignment specifications

Brakes:

Front and rear brake systems (discs and pads), ABS, DSC (Dynamic Stability Control), hydraulic lines, master cylinder, calipers

Steering:

Power steering system, steering rack, pump, hoses, tie rods, steering column

Cooling System:

Radiator, coolant hoses, water pump, thermostat, expansion tank, cooling fan

Fuel System:

Fuel pump, fuel injectors, fuel filter, fuel lines, EVAP system

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, oxygen sensors

Electrical System:

Battery, alternator, starter motor, wiring diagrams, lighting, fuses, relays, ignition system

Comfort Systems:

HVAC (Heating, Ventilation, Air Conditioning), climate control, blower motor, evaporator, condenser

Body And Chassis:

Body panel removal and installation, doors, hood, trunk, interior trim, chassis components

Diagnostics:

OBD-II (On-Board Diagnostics) troubleshooting, fault codes, diagnostic procedures, BMW ISTA/D integration (conceptual)

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and flushes, spark plug replacement, belt inspection/replacement

Troubleshooting:

Step-by-step diagnostic guides for common and uncommon issues

Repair And Rebuild:

Detailed instructions for component removal, repair, and reinstallation

Component Testing:

Procedures for testing sensors, actuators, and electronic modules

Torque Specifications:

All critical fastener torque values for engine, chassis, and body components

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission overhauls

Detail Level:

Highly detailed, often with OEM-level procedures and specifications

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B25

Engine Type:

Naturally Aspirated Inline-6

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

10.2:1

Performance

Horsepower:

184 hp @ 6000 rpm

Torque:

230 Nm (169 lb-ft) @ 3500 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Engine Management

Siemens MS43 (typical)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (Getrag GS5-39DZ)

Optional

Type:

5-speed Automatic Transmission with Steptronic (GM A5S360R / A5S390R)

Features

Drivetrain Layout:

xDrive All-Wheel Drive

Fluid Specifications

Manual Transmission Fluid:

BMW MTF LT-2 (or equivalent, e.g., Castrol SAF-XO)

Automatic Transmission Fluid:

Esso LT 71141 (or equivalent, e.g., Pentosin ATF LT-2)

📐 Dimensions

Exterior Sedan

Length:

4471 mm (176.0 in)

Width:

1739 mm (68.5 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2760 mm (108.7 in)

Front Track:

1471 mm (57.9 in)

Rear Track:

1496 mm (58.9 in)

Weights

Curb Weight Manual:

~1570 kg (3461 lbs)

Curb Weight Automatic:

~1590 kg (3505 lbs)

Cargo

Trunk Volume:

440 Liters (15.5 cu ft)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

4/5 Stars (Driver/Passenger)

NHTSA Side Impact:

4/5 Stars (Front/Rear Passengers)

Active Features

Standard Anti-lock Braking System

Standard Dynamic Stability Control

Traction Control:

Standard Traction Control (ASC+T)

Passive Features

Airbags:

Frontal airbags, front side-impact airbags, optional front and rear head protection system (HPS)

Seatbelts:

3-point inertia-reel seatbelts with pretensioners

Chassis:

Reinforced safety cell structure

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD, BMW Professional RDS, or optional navigation system

Audio System:

Standard 6-speaker system, optional Harman Kardon Logic 7 system

Driver Assistance

Stability Control:

DSC (Dynamic Stability Control)

Cruise Control:

Standard cruise control

Connectivity

Bluetooth:

Optional Bluetooth preparation with mobile phone integration

Aux Input:

Optional (often requires modification or specific models)

🔧 Maintenance

Service Intervals

Oil Change Interval:

10,000-15,000 miles or 1 year (flexible service interval system, CBS)

Spark Plug Replacement:

Every 60,000-100,000 miles (depending on spark plug type, e.g., iridium)

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil:

SAE 5W-30 Synthetic (BMW Longlife-01 or LL-01FE compliant)

Coolant:

BMW Blue Antifreeze/Coolant (G48 specification)

Power Steering Fluid:

BMW Power Steering Fluid (e.g., Pentosin CHF 11S or G002000)

Known Issues

Ccv System:

Crankcase Ventilation (CCV) system failure leading to oil leaks and rough idle

Oil Pan Gasket:

Oil pan gasket leaks

Cooling System Leaks:

Plastic cooling system components (expansion tank, hoses, water pump) can become brittle and leak

Window Regulators:

Failure of power window regulators

ABS Asc Sensors:

Wheel speed sensor failures leading to ABS/DSC warning lights

Ignition Coils:

Weak or failing ignition coils causing misfires

Vibration Issues:

Driveshaft guibo (flex disc) wear, differential mounts, or engine mounts can cause vibrations

📚 Vehicle History

Brand Heritage

Brand Focus:

Performance luxury vehicles, engineering excellence

Model Evolution

Generation:

E46 (Third Generation 3 Series, 1998-2006)

Introduction Year:

2003 (for 325xi model)

Production

Manufacturing Location:

Germany (primarily Dingolfing)

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

E46 3 Series often featured on Car and Driver's 10 Best List in various years/configurations