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BMW 325xi 1999-2005 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 325xi Chassis Code: E46 Generation Generation Identifier: E46 (Second Generation 3 Series) Codes Platform Code: E46 👋 Introduction Market Position Vehicle Class: Compact...
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BMW 325xi 1999-2005 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325xi
Chassis Code:
E46
Generation
Generation Identifier:
E46 (Second Generation 3 Series)
Codes
Platform Code:
E46
👋 Introduction
Market Position
Vehicle Class:
Compact Executive Sedan/Wagon
Competitive Analysis
Key Competitors:
Audi A4 Quattro, Mercedes-Benz C-Class 4MATIC, Lexus IS300.
Key Features
Driving Dynamics:
Renowned for BMW's signature handling, balanced chassis, and the stability of the xDrive all-wheel-drive system.
Powertrain:
Smooth inline-six engines known for their refinement and linear power delivery.
Build Quality:
Typical BMW build quality with premium materials and solid construction for its era.
Manual Value Proposition
Target Audience:
DIY mechanics, independent repair shops, and BMW enthusiasts seeking in-depth knowledge.
📋 Manual Details
Coverage Areas
Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Workshop Repair and Service Manual
Language
Language:
English
Format
Format:
PDF Download
File Format
File Type:
PDF
Print Quality
Printability:
High-resolution, optimized for printing or screen viewing.
Binding Type
Binding Method:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnostics, timing, cooling system, lubrication system, emissions control.
Engine Electrical:
Ignition system, fuel injection system (DME), starter, alternator, battery, wiring diagrams.
Transmission:
Automatic and Manual transmissions: Removal, installation, overhaul, fluid specifications, shift control.
Drivetrain:
xDrive all-wheel drive system, differential, driveshafts, CV joints, transfer case.
Suspension:
Front and rear suspension components, struts, shocks, control arms, bushings, wheel alignment specifications.
Steering:
Power steering system, steering rack, steering column, linkages.
Brakes:
Front and rear brake systems (ABS, DSC), rotors, calipers, pads, hydraulic system, parking brake.
Electrical System:
Body control module (BCM), lighting, wipers, horn, central locking, power windows, mirrors, instrument cluster.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant, blower motor, compressor.
Body And Interior:
Body panels, doors, hood, trunk, bumpers, interior trim, seats, airbags.
Diagnostics And Troubleshooting:
OBD-II diagnostics, fault codes, diagnostic procedures for all major systems.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection.
Component Replacement:
Detailed instructions for replacing engine components, transmission, suspension parts, brakes, electrical modules.
Troubleshooting Guides:
Systematic approaches to diagnosing and resolving common and uncommon vehicle issues.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Technical Data Tables:
Torque specifications, clearances, fluid capacities, electrical specifications.
Technical Depth
Depth Level:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including advanced diagnostics.
⚙️ Engine Specifications
Primary Engine
Engine Type:
M54B30 Inline 6-Cylinder
Engine Displacement:
2979 cc (3.0 Liters)
Bore X Stroke:
84.0 mm x 89.6 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
225 hp @ 5900 rpm
Torque:
214 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (EFI) - Bosch Motronic ME 7.2
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
Engine Management
ECU Type:
Bosch Motronic ME 7.2
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (Getrag S5D 320Z)
Optional
Transmission Type:
5-Speed Automatic (ZF 5HP19)
Features
Transmission Fluid Type:
ATF Dexron III/VI for automatic, Manual gearbox oil (specific BMW spec, e.g., ATF Dextron III H)
Transfer Case:
BMW xDrive all-wheel-drive system with center differential.
📐 Dimensions
Exterior
Wheelbase:
2760 mm (108.7 inches)
Length:
4471 mm (176.0 inches)
Width:
1739 mm (68.5 inches)
Height:
1372 mm (54.0 inches)
Weights
Curb Weight:
Approx. 1565 kg (3450 lbs)
Gross Vehicle Weight Rating:
Approx. 2000 kg (4400 lbs)
Cargo
Trunk Volume:
430 liters (15.2 cubic feet) for sedan
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars (Driver), 5 Stars (Passenger)
Active Features
Traction Control:
Dynamic Stability Control (DSC)
ABS:
Anti-lock Braking System (ABS)
All Wheel Drive:
BMW xDrive permanent all-wheel drive with Variable Torque Distribution (VTD)
Passive Features
Airbags:
Front dual-stage airbags, front side-impact airbags.
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters.
💡 Technology Features
Infotainment
Infotainment System:
Optional: BMW Professional Radio, CD player, optional navigation system (MKIII/MKIV).
Driver Assistance
Traction And Stability Control:
Dynamic Stability Control (DSC) and Traction Control (ASC+T).
Connectivity
Connectivity Features:
Optional: BMW Assist telematics, hands-free Bluetooth (later models).
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) typically recommends every 10,000-15,000 miles or 12-24 months, depending on driving conditions.
Spark Plug Replacement:
Every 60,000 - 100,000 miles (depending on plug type, e.g., iridium)
Coolant Flush:
Every 30,000 - 60,000 miles or 2-4 years.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or equivalent SAE 5W-30 or 5W-40 synthetic oil.
Engine Oil Capacity:
6.5 liters (6.9 US quarts) with filter change.
Coolant Type:
BMW Blue Ethylene Glycol Coolant (50/50 mix with distilled water).
Brake Fluid Type:
DOT 4
Known Issues
Ccv System:
Crankcase Ventilation (CCV) system failure leading to oil consumption and smoke.
Cooling System:
Plastic cooling system components (expansion tank, water pump, thermostat housing) prone to cracking.
Oil Leaks:
Valve cover gasket, oil filter housing gasket, and oil pan gasket commonly leak.
Suspension Wear:
Front control arm bushings (bushings and ball joints), rear trailing arm bushings, and tie rod ends are common wear items.
Window Regulators:
Plastic clips in the window regulator mechanism are known to break.
Part Numbers
Oil Filter Part Number Example:
Mann-Filter HU 832/1, Mahle OX 37
Cabin Air Filter Part Number Example:
Mann-Filter CU 2557
📚 Vehicle History
Brand Heritage
Brand Legacy:
BMW's long history of producing driver-focused vehicles with superior engineering and performance.
Model Evolution
E46 Introduction:
The E46 generation replaced the E36 in 1998 and represented a significant step forward in design, technology, and refinement.
325Xi Introduction:
The 'xi' designation signifies BMW's xDrive all-wheel-drive system, introduced to the 3 Series lineup to enhance traction and stability, particularly in adverse weather conditions.
Production
Production Period:
1999-2005 for the E46 generation 325xi.
Manufacturing Locations:
Primarily Dingolfing and Regensburg, Germany.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E46 3 Series was frequently recognized on Car and Driver's '10Best' lists during its production run for its driving dynamics and value.
Ratings
General Reputation:
Widely regarded as one of the best-driving sedans of its era, praised for handling and refinement.
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