🏷️ Basic Information

Make:

BMW

Model:

3 Series

Chassis Code:

E46

Specific Model Variant:

325xi Sedan

Production Years:

1999-2005

👋 Introduction

Segment:

Entry-level Luxury Sedan / Compact Executive Sedan

Target Audience:

Enthusiast owners, independent repair shops, and DIY mechanics seeking in-depth knowledge of the E46 325xi.

Key Competitors:

Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS300, Infiniti G35.

Bmw Value Proposition:

Sporting dynamics, refined handling, rear-wheel-drive bias (though this is AWD), premium interior, and advanced engineering.

Powertrain Advantage:

The M54B25 inline-six engine offers smooth power delivery and a distinctive BMW sound. The xDrive AWD system provides enhanced traction and stability, especially in adverse weather conditions.

Chassis Dynamics:

Renowned for its balanced chassis, communicative steering, and capable suspension providing a engaging driving experience.

Manual Advantage:

Provides DIY enthusiasts and independent shops with the factory-level detail required to maintain and repair this complex vehicle efficiently and accurately.

📋 Manual Details

Primary Coverage:

Service, Maintenance, and Repair

Vehicle Types Covered:

Sedan

Specific Models Covered:

BMW 325xi Sedan (E46)

Estimated Page Count:

1500+

Type:

Comprehensive Service and Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, and overhaul procedures for all major engine components including cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, and cooling system.

Engine Management And Emissions:

Diagnosis and repair of fuel injection, ignition system, sensor inputs (MAF, MAP, O2, Crank/Cam position), ECU operation, emissions control systems (EVAP, EGR), and catalytic converter operation.

Transmission Manual:

Service and repair procedures for the Getrag 5-speed manual transmission, including clutch replacement, gear selection mechanisms, and fluid specifications.

Transmission Automatic:

Diagnosis and repair of the ZF 5HP19 (or similar) 5-speed automatic transmission, including torque converter, valve body, mechatronics, solenoids, fluid changes, and troubleshooting electronic control modules.

Drivetrain AWD:

Specific procedures for the xDrive all-wheel-drive system, including the center differential, transfer case, drive shafts, and front/rear differential service and repair.

Suspension And Steering:

Detailed overhaul of front and rear suspension components (struts, shocks, control arms, bushings, sway bars), power steering system (pump, rack and pinion), wheel alignment specifications, and wheel bearing replacement.

Brakes:

Service for ABS system, brake fluid flush, disc brake component replacement (pads, rotors, calipers), parking brake adjustment, and diagnostic procedures for brake system faults.

Electrical System:

Comprehensive wiring diagrams for all circuits, fuse and relay locations, diagnostic procedures for common electrical faults, battery and charging system service, lighting system repair, and accessory electrical component troubleshooting.

Body And Chassis:

Panel removal and installation, door mechanisms, window regulators, sunroof operation, interior trim removal, body repair guidelines, and collision repair information.

HVAC Climate Control:

Refrigerant handling, A/C system diagnostics, blower motor, evaporator, condenser, heater core replacement, and climate control module troubleshooting.

Safety Systems:

Airbag system (SRS) diagnostics, component replacement, and safety precautions. Seat belt mechanisms and troubleshooting.

Scheduled Maintenance:

Detailed step-by-step instructions for all recommended maintenance services, including oil changes, filter replacements, fluid checks and changes, spark plug replacement, and inspections.

Troubleshooting Guides:

Systematic diagnostic procedures for identifying and resolving common and complex problems, including symptom-based troubleshooting trees and fault code explanations.

Component Replacement:

Detailed instructions for replacing all major and minor components, from routine items like wiper blades to complex assemblies like engines and transmissions.

Rebuild Instructions:

Comprehensive guidelines for overhauling major sub-assemblies such as engines, transmissions, and differentials.

Technical Specifications Data:

Torque specifications, fluid capacities and types, engine timing parameters, electrical resistance values, and other critical data for accurate repairs.

Wiring Diagrams:

Complete, detailed, and clearly labeled wiring diagrams for all vehicle electrical systems, facilitating accurate diagnosis and repair.

Exploratory Procedures:

Detailed 'exploded view' diagrams illustrating the proper assembly and disassembly order of components.

Depth:

Extremely high. Covers everything from basic fluid changes and filter replacements to full engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repairs.

Diagnostic Capabilities:

Detailed procedures for using diagnostic tools (e.g., BMW ISTA/D or similar principles) and interpreting diagnostic trouble codes (DTCs).

Special Tools:

Identifies and describes the use of specialized tools required for specific repair procedures.

📊 Manual Specifications

File Type:

PDF

Searchability:

Fully searchable text for quick access to information.

Printability:

Printable pages for use in a workshop environment.

Resolution:

High-resolution images, diagrams, and text for clarity.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code:

M54B25

Engine Type:

Naturally Aspirated Inline-6 (Straight-6)

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

10.2:1

Horsepower:

184 hp @ 6000 rpm

Torque:

175 lb-ft (237 Nm) @ 3500 rpm

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane Recommended)

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug (COP) or coil-near-plug setup.

Valvetrain:

Dual Overhead Camshafts (DOHC), 24 Valves, VANOS (Variable Valve Timing) on intake camshaft.

🔧 Transmission

Transmission Type:

5-Speed Manual (Getrag 260/5 or similar)

Transmission Type:

5-Speed Steptronic Automatic (ZF 5HP19FLA or similar)

Drivetrain:

xDrive All-Wheel Drive (AWD) with variable torque distribution.

Manual Transmission Fluid:

BMW recommends MTF LT-2 or equivalent (e.g., Castrol SYNTRANS) for manual transmissions. Capacity typically 1.6-1.8 liters.

Automatic Transmission Fluid:

ZF LifeguardFluid 5 or equivalent (e.g., Pentosin ATF1) for automatic transmissions. Capacity typically 7-8 liters for a complete drain and fill.

📐 Dimensions

Length:

4471 mm (176.0 inches)

Width:

1739 mm (68.5 inches)

Height:

1412 mm (55.6 inches)

Wheelbase:

2760 mm (108.7 inches)

Curb Weight:

Approx. 1550 kg (3417 lbs)

Gross Vehicle Weight Rating:

Approx. 2040 kg (4500 lbs)

🛡️ Safety Features

NHTSA Frontal Crash Rating:

5-Star (for driver and front passenger)

IIHS Front Small Overlap:

Good (for later models, E46 generally rated well)

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Standard Automatic Stability Control (ASC+T) or Dynamic Stability Control (DSC) depending on year/option.

Airbags:

Driver and front passenger airbags, optional side-impact airbags.

Seatbelts:

3-point inertia-reel seatbelts with front-seat pretensioners.

Body Structure:

Reinforced safety cage and crumple zones.

💡 Technology Features

Radio System:

BMW Business CD or BMW Professional CD radio with options for CD changer and navigation system (CCC later in production).

Display:

Optional onboard computer display in the instrument cluster providing vehicle status and basic navigation prompts.

Cruise Control:

Standard cruise control system.

Parking Sensors:

Optional Park Distance Control (PDC) sensors.

Bluetooth:

Optional Bluetooth hands-free system for phone connectivity.

Usb:

Not typically equipped with factory USB ports; aftermarket solutions may exist.

🔧 Maintenance

Oil Change Interval:

BMW's Condition Based Service (CBS) system typically recommends oil changes based on driving conditions, but generally around 10,000-15,000 miles or annually. Check CBS indicator.

Air Filter Replacement:

Recommended every 30,000-45,000 miles or as indicated by vehicle performance.

Cabin Air Filter Replacement:

Recommended every 15,000-30,000 miles or annually.

Spark Plug Replacement:

M54 engines typically use long-life spark plugs. Recommended replacement at 100,000 miles (e.g., NGK BKR6EQUP or BMW OE equivalent).

Brake Fluid Flush:

Recommended every 2 years, regardless of mileage.

Coolant Flush:

BMW Blue Antifreeze (G48 type) with distilled water. Recommended initial change at 4 years, then every 2 years thereafter.

Engine Oil:

BMW Longlife-01 (LL-01) or BMW Longlife-04 (LL-04) approved synthetic oil, typically SAE 0W-30 or 5W-30. Oil capacity: 6.5 liters (6.9 US quarts).

Coolant:

BMW Blue Antifreeze (G48) mixed with distilled water at a 50/50 ratio.

Brake Fluid:

DOT 4 Low Viscosity (LV) or DOT 4 Plus approved brake fluid.

Power Steering Fluid:

BMW approved hydraulic fluid (e.g., Pentosin CHF 11S or similar)

Vibration Issues:

Cracked engine mounts, worn driveshaft center support bearing, and driveshaft flex discs are common causes of vibrations.

Cooling System Failures:

Plastic cooling system components (expansion tank, radiator, water pump impeller) can become brittle and fail. Thermostat housing leaks are also common.

Oil Leaks:

Valve cover gasket, oil filter housing gasket, and oil pan gasket are prone to leaking over time.

Oil Sludge:

M54 engines can be susceptible to oil sludge if maintenance is neglected. Regular oil changes with correct oil are crucial.

ABS Wheel Speed Sensor Failure:

ABS and DSC warning lights on the dashboard often indicate a failing wheel speed sensor.

Window Regulator Failure:

The plastic clips and cables for the window regulators are a common failure point, causing windows to drop or operate poorly.

Heater Core Leaks:

Heater core leaks can manifest as coolant smells in the cabin or a foggy windshield.

📚 Vehicle History

Bmw Philosophy:

BMW's long-standing reputation for building driver-focused, sporty, and well-engineered vehicles.

E46 Generation Introduction:

The E46 generation, introduced in 1998 (for model year 1999 in North America), represented a significant evolution from the E36, offering improved chassis dynamics, more refined interiors, and advanced technology.

325Xi Introduction:

The 325xi variant, featuring the xDrive all-wheel-drive system, was introduced to provide enhanced all-weather capability and market appeal in regions with challenging climates.

Production Period:

1999-2005

Manufacturing Locations:

Primary manufacturing plant in Dingolfing, Germany, with some assembly possibly occurring in other BMW facilities globally.

🏆 Awards & Recognition

Car And Driver 10Best:

The E46 3 Series platform, in various configurations, was frequently recognized on Car and Driver's 10Best lists during its production run, highlighting its exceptional driving dynamics and overall quality.

Wardsauto 10Bestengines:

The M54 inline-six engine was a multiple recipient of Ward's 10 Best Engines awards, celebrated for its smoothness, power delivery, and mechanical refinement.