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BMW M3 2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: M3 Year: 2004 Chassis Code: E46 Codes Engine Code: S54B32 👋 Introduction Market Position Positioning: High-performance luxury sports sedan/coupe, a benchmark in its...
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BMW M3 2004 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
M3
Year:
2004
Chassis Code:
E46
Codes
Engine Code:
S54B32
👋 Introduction
Market Position
Positioning:
High-performance luxury sports sedan/coupe, a benchmark in its class for driving dynamics and engineering.
Competitive Analysis
Competitors:
Mercedes-Benz C55 AMG, Audi S4, Porsche 911 (as a performance benchmark)
Key Features
Design Philosophy:
Driver-focused, motorsport-derived technology, balanced chassis, powerful naturally aspirated engine.
Performance Focus:
Engineered for exhilarating performance, precise handling, and track capability.
📋 Manual Details
Coverage Areas
Manual Type:
Full Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
Page Count
Page Count:
Extensive (typically 1000+ pages for BMW M models)
📖 Manual Coverage
Systems Covered
Engine:
3.2L S54 inline-6, including Vanos, valvetrain, lubrication, cooling, fuel injection, ignition, engine management (DME)
Transmission:
6-speed manual (Getrag 420G), clutch system, driveline, differential
Brakes:
Front & rear disc brakes, ABS, DSC, brake fluid service
Suspension Steering:
Front & rear suspension components, struts, shocks, control arms, bushings, power steering system
Electrical:
Battery, charging system, starter, lighting, fuses, relays, ECUs, wiring diagrams, body control module (BCM)
Bodywork Interior:
Body panels, doors, windows, locks, seats, HVAC system, interior trim, convertible top (if applicable)
Diagnostics:
OBD-II diagnostics, fault code retrieval, troubleshooting procedures, specific BMW diagnostic tools (e.g., DIS, ISTA/D)
Procedures Included
Maintenance:
Oil changes, filter replacements (oil, air, cabin), spark plug replacement, coolant flushes, brake fluid bleeding, differential fluid change, general inspections
Repair:
Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper service, alternator replacement, starter motor repair, sensor replacement
Troubleshooting:
Step-by-step diagnostic flowcharts for common and uncommon issues, electrical system fault finding, drivability problems
Rebuild Refurbish:
Detailed instructions for complete engine, transmission, and differential rebuilds, including torque specifications and clearances
Restoration:
Guidance on component refurbishment, material specifications, and procedures relevant to returning the vehicle to original condition
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and drivetrain rebuilds, including advanced diagnostics and electronic system repairs.
📊 Manual Specifications
File Format
File Format:
PDF (searchable text, layered diagrams if original source)
Print Quality
Print Quality:
High resolution for clear diagrams and text
Binding Type
Binding Type:
N/A (for digital format)
Paper Type
Paper Type:
N/A (for digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline 6-cylinder
Engine Code:
S54B32
Displacement:
3.2 Liters (3246 cc)
Bore X Stroke:
87.0 mm x 91.0 mm
Compression Ratio:
11.5:1
Valvetrain:
DOHC, 4 valves per cylinder, Double VANOS (variable valve timing)
Performance
Horsepower:
333 hp @ 7900 rpm
Torque:
262 lb-ft @ 4900 rpm
Redline:
8000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), individual throttle bodies (ITBs)
Fuel Type:
Premium Unleaded (91+ octane recommended)
🔧 Transmission
Standard
Type:
6-Speed Manual
Manufacturer:
Getrag
Model:
420G
Optional
Type:
SMG (Sequential Manual Gearbox)
Version:
SMG II (with paddle shifters)
Features
Drivetrain:
Rear-Wheel Drive (RWD)
Differential:
Limited Slip Differential (LSD)
📐 Dimensions
Exterior
Coupe Length:
177.7 inches (4514 mm)
Coupe Width:
70.1 inches (1780 mm)
Coupe Height:
53.7 inches (1365 mm)
Convertible Length:
177.7 inches (4514 mm)
Convertible Width:
70.1 inches (1780 mm)
Convertible Height:
54.4 inches (1382 mm)
Wheelbase:
107.5 inches (2731 mm)
Weights
Curb Weight Coupe:
3,415 lbs (1549 kg)
Curb Weight Convertible:
3,704 lbs (1680 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (Driver/Passenger)
IIHS Side Impact:
Good (for comparable models of the era)
Active Features
Stability Control:
Dynamic Stability Control (DSC)
Traction Control:
Automatic Stability Control + Traction (ASC+T)
ABS:
Anti-lock Braking System (ABS)
Passive Features
Airbags:
Frontal airbags, side airbags (front seats), knee airbags (driver)
Seatbelts:
Pretensioners and force limiters
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD or Professional CD radio with cassette player, optional navigation system (MKIV).
Audio System:
Optional Harman Kardon sound system.
Driver Assistance
Parking Sensors:
Optional Park Distance Control (PDC)
Cruise Control:
Standard cruise control system.
Connectivity
Bluetooth:
Optional Bluetooth phone integration (with specific cradles).
Telematics:
Optional BMW Assist telematics system.
🔧 Maintenance
Service Intervals
Oil Change:
BMW Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually. Check oil level frequently.
Spark Plugs:
Typically every 60,000 miles (refer to manual for specific type and gap)
Coolant Flush:
Every 2-3 years or 30,000-45,000 miles
Brake Fluid:
Every 2 years (DOT 4)
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) certified synthetic oil, SAE 0W-40 or 5W-40 recommended. Capacity: approx. 6.5 liters (6.9 US quarts)
Coolant:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based), mixed 50/50 with distilled water. Capacity: approx. 8.0 liters (8.5 US quarts)
Brake Fluid:
DOT 4 High Performance
Transmission Fluid Manual:
MTF LT-2 (Manual Transmission Fluid), 2.1 liters (2.2 US quarts)
Differential Fluid:
SAF-XJ (Synthetic Axle Fluid XJ), 1.0 liter (1.1 US quarts)
Known Issues
Rod Bearings:
Increased wear, particularly on early S54 engines. Regular inspection and replacement recommended for high-mileage or hard-driven vehicles.
Vanos System:
Degradation of seals and pump can lead to reduced performance and rough idling. Solenoid failure is also common.
Subframe Mounts:
Cracking or separation of rear subframe mounting points due to chassis stress.
Throttle Actuators:
Failure of electric throttle actuators (on ITBs) can cause driveability issues.
Cooling System:
Water pump failure (plastic impeller), thermostat issues, and radiator leaks are not uncommon.
📚 Vehicle History
Brand Heritage
Bmw Motorsport:
BMW M GmbH (formerly M-Technik) lineage, known for racing homologation and performance vehicles.
Model Evolution
E46 M3 Introduction:
Launched in 2000 for the 2001 model year, successor to the E36 M3.
E46 M3 Variants:
Available as Coupe and Convertible. Special editions include CSL (Coupe Sport Lightweight).
Production
Production Years:
2000-2006
Manufacturing Location:
Regensburg, Germany
🏆 Awards & Recognition
Recognitions
Car And Driver Otr:
Car and Driver's 10Best list multiple times.
Motor Trend:
Highly praised by automotive journalists for its driving dynamics and performance.
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