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BMW 325i & 325xi Complete Workshop Service Repair Manual 1999 2000 2001 2002 2003 2004 2005

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Specific Models Covered: 325i, 325xi Body Styles Covered: Sedan (E46), Sports Wagon (E46) Generation Generation Code: E46 Production Years: 1999, 2000,...
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BMW 325i & 325xi Complete Workshop Service Repair Manual 1999 2000 2001 2002 2003 2004 2005
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Specific Models Covered:
325i, 325xi
Body Styles Covered:
Sedan (E46), Sports Wagon (E46)
Generation
Generation Code:
E46
Production Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Codes
Engine Code Common:
M54B25
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Wagon
Reputation:
Renowned for driving dynamics, build quality, and sophisticated engineering.
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35
Key Features
Driving Experience:
Balanced handling, responsive steering, powerful inline-six engine.
All Wheel Drive:
Availability of the 'xi' models with BMW's xDrive all-wheel-drive system for enhanced traction.
Interior Quality:
Premium materials, ergonomic design, driver-focused cockpit.
📋 Manual Details
Coverage Areas
Major Systems:
Engine Mechanical, Engine Fuel & Emission Control, Engine Electrical System, Drivetrain, Suspension, Steering, Brakes, Body, HVAC, Electrical System, Wiring Diagrams
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine M54B25, Transmission (5-speed manual, 5-speed automatic), Drivetrain (RWD, AWD xDrive)
Chassis:
Front & Rear Suspension, Steering System, Brake System (ABS, DSC)
Electrical:
Engine Control Module (ECM), Ignition System, Lighting, Instruments & Gauges, Body Electronics, Infotainment, SRS Airbag System
Body And Interior:
Body Panels, Doors, Windows, Seats, Climate Control (HVAC)
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes
Repair:
Engine overhaul, transmission service, suspension component replacement, brake caliper rebuild, electrical component troubleshooting and replacement
Diagnostics:
Troubleshooting guides, fault code interpretation, diagnostic procedures for all major systems
Installation:
Component installation and replacement procedures
Technical Depth
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval
Print Quality
Quality:
High-resolution, clear images and diagrams
Binding Type
Binding:
Not applicable (downloadable digital format)
Paper Type
Paper:
Not applicable (downloadable digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Engine Code:
M54B25
Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
184 hp @ 6000 rpm
Torque:
175 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (SFI)
Recommended Fuel:
Premium Unleaded Gasoline (91 octane or higher)
Technical Features
Valve Train:
Dual Overhead Camshafts (DOHC), 24 Valves, VANOS (Variable Valve Timing)
Block Material:
Aluminum Alloy
Head Material:
Aluminum Alloy
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (Getrag GS5-39DZ)
Optional
Transmission Type:
5-Speed Automatic (Steptronic)
Features
Automatic Features:
Sequential shifting, comfort and sport modes (depending on model year and options)
Fluid Type
Automatic Transmission Fluid:
BMW ATF LT-3 (or equivalent DEXRON III/VI for some earlier models, consult manual for specifics)
Manual Transmission Fluid:
BMW MTF-LT-1 or MTF-LT-2 (or equivalent GL-4 gear oil)
Differential Fluid
Rear Differential Fluid:
Hypoid Gear Oil API GL-5 SAE 75W-90
📐 Dimensions
Exterior
Wheelbase:
107.0 inches (2718 mm)
Length:
177.4 inches (4506 mm) for Sedan
Width:
68.5 inches (1740 mm)
Height:
55.7 inches (1415 mm) for Sedan
Interior
Front Headroom:
Approx. 38.4 inches
Rear Headroom:
Approx. 37.7 inches
Cargo
Trunk Volume:
Approx. 11.2 cubic feet (Sedan)
Weights
Curb Weight:
Approx. 3300-3500 lbs (depending on drivetrain and options)
Gross Vehicle Weight Rating:
Approx. 4500-4700 lbs
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (Driver & Passenger)
IIHS Side Impact:
Good (for comparable models/years)
Active Features
Traction Control:
Dynamic Stability Control (DSC) - standard on most models
Anti Lock Brakes:
Anti-lock Braking System (ABS) - standard
Brake Assist:
Optional on some models
Passive Features
Airbags:
Frontal airbags, front side airbags, optional head protection airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Child Seat Anchors:
LATCH system (Lower Anchors and Tethers for Children)
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD, BMW Professional CD, optional Navigation System (CCC or MKIV era).
Audio System:
Standard BMW Hi-Fi, optional Harman Kardon audio system.
Driver Assistance
Cruise Control:
Standard cruise control, adaptive cruise control unavailable on these specific models.
Parking Sensors:
Optional Park Distance Control (PDC).
Connectivity
Bluetooth:
Optional Bluetooth hands-free system on later models.
Aux Input:
Optional aux-in jack for audio devices on later models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable, typically 10,000-15,000 miles or annually, as indicated by the vehicle's Condition Based Service (CBS) system or manufacturer recommendation.
Air Filter Replacement:
Every 30,000-50,000 miles or as needed based on driving conditions.
Cabin Filter Replacement:
Every 15,000-30,000 miles or annually.
Spark Plug Replacement:
Typically 60,000-100,000 miles for iridium spark plugs, check manual for exact specification.
Coolant Flush:
Every 30,000-60,000 miles or 3-5 years.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or LL-04 approved synthetic oil, typically 5W-30 or 0W-30.
Engine Oil Capacity:
Approx. 6.5 US quarts (6.1 Liters) with filter change.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48, ethylene glycol based).
Brake Fluid Type:
DOT 4 (BMW High Performance DOT 4)
Known Issues
Crankcase Ventilation System:
Clogged PCV valve and breather hoses can lead to oil leaks and rough running.
Cooling System:
Plastic coolant expansion tank can become brittle and crack; water pump and thermostat failures are common.
Oil Pan Gasket:
Common source of oil leaks, often requires subframe removal for replacement.
Rear Main Seal:
Another common area for oil leaks, especially on higher mileage vehicles.
Suspension Components:
Worn control arm bushings, ball joints, and sway bar links can lead to rattling noises and poor handling.
Window Regulators:
Plastic components can break, causing windows to fall into the doors.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long history of producing performance-oriented, driver-focused luxury vehicles.
Model Evolution
E46 Generation:
The E46 generation (1998-2006) is widely considered one of BMW's most successful and well-regarded generations of the 3 Series, praised for its chassis balance and styling.
Production
Manufacturing Locations:
Primarily Germany (Dingolfing, Regensburg), with some assembly in other global locations.
Sales Performance:
The E46 3 Series was a significant sales success globally, solidifying BMW's position in the premium compact executive segment.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E46 3 Series was a frequent recipient of Car and Driver's '10Best' lists during its production run, recognized for its outstanding driving dynamics.
Ward'S Auto World 10 Best Engines:
The M54 engine family, including the 3.0L variant, received accolades for its smoothness and performance.
Ratings
Consumer Reports:
Generally rated highly for performance and handling, with some common issues noted for reliability in specific areas like cooling systems and oil leaks.
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