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BMW M3 2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: M3 Year: 2002 Codes Chassis Code: E46 Engine Code Primary: S54 👋 Introduction Market Position Positioning: High-performance sports sedan/coupe, targeting driving enthusiasts. Competitive...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
M3
Year:
2002
Codes
Chassis Code:
E46
Engine Code Primary:
S54
👋 Introduction
Market Position
Positioning:
High-performance sports sedan/coupe, targeting driving enthusiasts.
Competitive Analysis
Competitors:
Porsche 911, Mercedes-Benz C63 AMG (later models), Audi RS4 (later models), Chevrolet Corvette.
Key Features
Performance Focus:
Engineered for track performance and exhilarating road driving.
Handling:
Renowned for precise steering, balanced chassis, and advanced suspension technology.
Engine Characteristics:
High-revving, naturally aspirated inline-six with individual throttle bodies.
📋 Manual Details
Coverage Areas
Coverage:
Complete factory service and repair
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine disassembly, inspection, repair, and reassembly for S54B32.
Engine Management:
DME (Digital Motor Electronics), sensor diagnostics, actuators, Vanos, throttle bodies, fuel injection, ignition system.
Transmission:
SMG (Sequential Manual Gearbox) and manual gearbox (Getrag 420G) service, repair, and diagnostics.
Drivetrain:
Clutch, differential (limited-slip differential - LSD), driveshafts, axle shafts.
Suspension:
Front and rear suspension components, alignment specifications, shock absorbers, springs, control arms, bushings.
Brakes:
Brake system diagnostics, component replacement (calipers, rotors, pads, lines), ABS, DSC (Dynamic Stability Control).
Steering:
Power steering system, steering rack, tie rods, steering column.
Electrical:
Complete wiring diagrams, component location, diagnosis of electrical faults, fuse/relay information.
Body And Chassis:
Body panel removal and installation, interior trim, chassis components, body structure repair (limited).
HVAC:
Heating, Ventilation, and Air Conditioning system service and repair.
Safety Systems:
Airbag system diagnosis and repair, seatbelt mechanisms.
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, spark plug replacement.
Troubleshooting:
Diagnostic flowcharts, common fault identification, and resolution for various systems.
Repair:
Step-by-step repair procedures for all major mechanical and electrical components.
Diagnostics:
Detailed procedures for using diagnostic tools (e.g., DIS, ISTA) and interpreting fault codes.
Specifications:
Torque specifications for all fasteners, engine bearing clearances, valve clearances.
Technical Depth
Depth:
Comprehensive, from basic fluid checks to full engine rebuilds and complex electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Searchability
Text Search:
Yes, fully searchable text for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-6
Engine Code:
S54B32
Displacement:
3.2 Liters (3246 cc)
Bore X Stroke:
87.0 mm x 91.0 mm
Compression Ratio:
11.5:1
Valve Train:
DOHC, 24 valves, Double VANOS
Performance
Horsepower:
333 hp @ 7900 rpm
Torque:
262 lb-ft (355 Nm) @ 4900 rpm
Redline:
8000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic ME7.2)
Fuel Type:
Premium Unleaded Gasoline (91+ octane)
Intake System:
Individual Throttle Bodies (ITBs)
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual (Getrag 420G)
Optional
Transmission Type:
6-Speed Sequential Manual Gearbox (SMG II)
Features
Differential:
M Variable Lock Differential (Limited-Slip)
Clutch Manual:
Hydraulically actuated, single-plate dry clutch
Clutch Smg:
Hydraulically actuated, single-plate dry clutch with electro-hydraulic actuation.
📐 Dimensions
Exterior
Length:
4488 mm (176.7 in)
Width:
1788 mm (70.4 in)
Height:
1365 mm (53.7 in)
Wheelbase:
2760 mm (108.7 in)
Front Track:
1519 mm (59.8 in)
Rear Track:
1524 mm (60.0 in)
Weights
Curb Weight Manual:
1570 kg (3461 lbs)
Curb Weight Smg:
1575 kg (3472 lbs)
Gross Weight Rating:
2030 kg (4475 lbs)
Cargo
Trunk Volume:
420 Liters (14.8 cu ft)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (Driver/Passenger)
IIHS Side Impact:
Acceptable
IIHS Rear Impact:
Acceptable
Active Features
Traction Control:
ASC+T (Automatic Stability Control + Traction)
Stability Control:
DSC (Dynamic Stability Control) - standard on M3
Braking Assist:
ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution)
Headlight System:
Xenon Adaptive Headlights (Optional)
Passive Features
Airbags:
Frontal airbags (driver & passenger), Side airbags (front)
Seat Belts:
3-point inertia-reel seatbelts with pretensioners and force limiters
Body Structure:
High-strength steel chassis with reinforced A-pillars and safety cage construction.
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD or Professional CD radio with optional navigation system.
Audio System:
Harman Kardon premium audio system (optional).
Driver Assistance
Stability Control:
DSC (Dynamic Stability Control) with MDM (M Dynamic Mode) for sportier intervention limits.
Parking Assistance:
Rear Park Distance Control (PDC) (optional).
Connectivity
Auxiliary Input:
Available via aftermarket adapters for audio input.
Telematics
Bmw Assist:
Optional telematics system providing emergency services and assistance.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable, indicated by Condition Based Service (CBS) system. Typically 10,000-15,000 miles or annually.
Air Filter Replacement:
Approximately 30,000 miles or as indicated by CBS.
Cabin Filter Replacement:
Approximately 15,000 miles or annually.
Spark Plug Replacement:
Approximately 60,000 miles (NGK BKR6EQUP recommended).
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil:
BMW M Twin Power Turbo SAE 10W-60 (or equivalent API SJ/CF, ACEA A3/B3).
Coolant:
BMW Blue Coolant (G48 Ethylene Glycol based), 50/50 mix with distilled water.
Brake Fluid:
DOT 4
Transmission Fluid Manual:
Pentosin MTF LT-2 (BMW Part # 83 22 0 309 299)
Transmission Fluid Smg:
Pentosin CHF 11S (BMW Part # 81 22 9 407 276) for hydraulic system.
Differential Fluid:
BMW Hypoid Getriebeol G2 (SAF-XJ) SAE 75W-140 (BMW Part # 83 22 2 365 987)
Known Issues
Rod Bearings:
Increased wear potential on connecting rod bearings, especially with aggressive driving or infrequent oil changes. Manual recommends checking and potentially replacing with updated bearings.
Vanos:
VANOS (Variable Valve Timing) system solenoid issues can lead to rough idle, poor performance, and fault codes.
Subframe Mounts:
Cracking or failure of rear subframe mounting points due to chassis stress.
Smg Pump:
SMG II hydraulic pump failures can result in transmission malfunction.
📚 Vehicle History
Brand Heritage
Brand Philosophy:
Bayerische Motoren Werke AG (BMW) is renowned for its 'Ultimate Driving Machine' philosophy, emphasizing performance, engineering, and driver engagement.
Model Evolution
E46 M3 Introduction:
The E46 M3 succeeded the E36 M3, representing a significant leap in performance and technology.
E46 M3 Key Developments:
Introduction of the S54 engine, available SMG II transmission, and chassis refinements for enhanced dynamics.
Production
Production Years:
2000-2006 (E46 M3)
Manufacturing Location:
Regensburg, Germany
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Car and Driver 10Best list multiple times during its production run.
Motortrend Car Of The Year:
No specific award, but highly regarded in segment reviews.
Ratings
Driving Dynamics:
Consistently praised by automotive journalists for exceptional handling, steering feel, and engine responsiveness.
Certifications
Emissions Standards:
Meets relevant emissions standards for the model year (e.g., LEV).