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BMW 3 Series E46 Digital Workshop Repair Manual 1999-2005

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The 3 Series, chassis code E46, produced between 1999 and 2005, represents a significant chapter in the brand's legacy of crafting performance-oriented luxury vehicles. Renowned for its balanced chassis, precise...
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BMW 3 Series E46 Digital Workshop Repair Manual 1999-2005
The 3 Series, chassis code E46, produced between 1999 and 2005, represents a significant chapter in the brand's legacy of crafting performance-oriented luxury vehicles. Renowned for its balanced chassis, precise steering, and sophisticated multi-link rear suspension, the E46 offered a benchmark in its class for ride and handling. It competed directly with premium offerings from Mercedes-Benz, Audi, and Lexus, often earning accolades such as Car and Driver's '10Best' list for its exceptional driving dynamics. Available in various body styles including Sedan, Coupe, Convertible, and Touring wagon, and powered by a range of smooth inline-six and efficient four-cylinder engines, the E46 solidified the brand's reputation for engaging driving experiences and premium build quality. This comprehensive digital workshop repair manual covers all systems for the 3 Series E46 generation, encompassing all petrol and diesel engine variants, as well as the M3. It serves as an indispensable resource for repair, maintenance, diagnostics, rebuilding, refurbishment, and restoration. The manual provides in-depth guidance on powertrain, transmission, chassis, brakes, electrical systems, and body/interior components. It details routine maintenance procedures, diagnostic troubleshooting steps, component repair and replacement, and special procedures, offering extensive technical depth. This manual is designed to assist owners and technicians in accurately maintaining and repairing their vehicles, ensuring optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Model Years Covered:
1999-2005
👋 Introduction
Market Position
E46 Positioning:
The E46 generation solidified BMW's reputation for sporty handling, refined interiors, and engaging driving dynamics in the premium compact executive segment.
Competitive Analysis
Competitors:
Competed directly with the Mercedes-Benz C-Class, Audi A4, Lexus IS, and Jaguar X-Type.
Key Features Of E46
Driving Dynamics:
Renowned for its balanced chassis, precise steering, and sophisticated multi-link rear suspension, offering a benchmark in its class for ride and handling.
Engine Performance:
Offered a range of smooth and powerful inline-six engines, alongside efficient four-cylinder options, known for their responsiveness and characteristic BMW 'growl'.
Build Quality:
Exhibited strong build quality and premium interior materials, contributing to its desirability and longevity.
Manual Value Proposition
For Owners And Technicians:
This manual is invaluable for E46 owners seeking to perform their own maintenance and repairs, or for independent workshops aiming to service these vehicles accurately and efficiently.
📋 Manual Details
Coverage Areas
All Systems:
Yes
Engine Variants Covered:
All petrol and diesel variants for the E46 generation
Body Styles Covered:
Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (5-door wagon), M3
Page Count
Estimated Page Count:
Extensive, likely over 1000 pages given the scope of E46 models and systems.
Manual Type
Type:
Digital Workshop Repair Manual
Purpose:
Repair, maintenance, diagnostics, rebuilding, refurbishment, restoration
Language
Language:
English
Format
Format:
Digital (likely PDF or proprietary e-book format)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine management (DME), fuel system, exhaust system, cooling system, lubrication system
Transmission Drivetrain:
Manual and automatic transmissions, clutch, driveshafts, differentials, axles
Chassis Suspension:
Front and rear suspension, steering system, wheel bearings, hubs
Brakes:
Brake system components (calipers, rotors, pads, lines), ABS, DSC (Dynamic Stability Control), parking brake
Electrical Electronics:
Wiring diagrams, battery, charging system, starter, lighting, ignition, body control module (BCM), comfort electronics, instrument cluster, infotainment
Body Interior:
Body shell, doors, windows, locks, interior trim, seats, HVAC (Heating, Ventilation, and Air Conditioning)
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, brake fluid flush, coolant flush, belt inspection/replacement
Diagnostic Troubleshooting:
Symptom-based troubleshooting, fault code interpretation, component testing, electrical diagnostics
Component Repair Replacement:
Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper/master cylinder replacement, electrical component repair
Special Procedures:
Timing chain replacement (specific to certain engines), VANOS system repair, ABS/DSC module replacement and calibration, airbag system service
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid checks to full engine and transmission rebuilds, including electrical system troubleshooting and wiring diagrams.
Diagnostic Tools:
Likely references to BMW proprietary diagnostic tools (e.g., DIS, ISTA) and procedures for using generic OBD-II scanners.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, optimized for searchability and printing. May include interactive elements or linked diagrams.
Print Quality
Printability:
Designed to be printable page-by-page or by section, allowing for creation of a physical reference.
Binding Type
Binding For Printed:
N/A (Digital Format), but if printed, a robust binding like a spiral or perfect bound would be ideal for workshop use.
Paper Type
Paper For Printed:
N/A (Digital Format), but for workshop use, durable, matte finish paper would be preferred.
⚙️ Engine Specifications
Primary Engine Variants
Common Petrol Engines:
M52TU (2.0L, 2.5L, 2.8L inline-6), M54 (2.2L, 2.5L, 3.0L inline-6), N42/N46 (2.0L inline-4)
Common Diesel Engines:
M47 (2.0L 4-cylinder diesel), M57 (3.0L 6-cylinder diesel)
M54B30 Specs
Displacement:
2979 cc
Bore X Stroke:
84.0 mm x 89.6 mm
Compression Ratio:
10.2:1
Horsepower:
228 hp @ 6000 rpm
Torque:
214 lb-ft @ 3500 rpm
Performance
M3 S54B32 Hp:
333 hp @ 7900 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) with Bosch Motronic engine management
Fuel Type:
Premium Unleaded (91 Octane RON/AKI recommended for most variants)
Engine Management
Dme:
Digital Engine Electronics (DME) system, with detailed diagnostic procedures covered.
🔧 Transmission
Standard Transmission
Standard Gearbox:
5-speed manual (Getrag GS5-39DZ for most inline-6 models)
Optional Transmission
Optional Gearbox:
5-speed Steptronic automatic (GM A5S360R/A5S390R), 6-speed manual (ZF GS6-37BZ for M3)
Features
Clutch Type:
Hydraulically actuated single-plate dry clutch
Automatic Transmission Features:
Steptronic manual shift mode, electronically controlled for smooth shifts.
Fluid Specs
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent (e.g., Pentosin MTF 2)
Automatic Transmission Fluid:
ATF LT 71141 or equivalent (e.g., Pentosin ATF 3)
📐 Dimensions
Exterior Sedan
Length:
Approx. 4471 mm (176.0 in)
Width:
Approx. 1739 mm (68.5 in)
Height:
Approx. 1415 mm (55.7 in)
Exterior Coupe
Wheelbase:
Approx. 2725 mm (107.3 in)
Exterior Convertible
Curb Weight:
Varies by model, typically 1500-1700 kg (3300-3750 lbs)
Cargo
Trunk Volume Sedan:
Approx. 440 liters (15.5 cu ft)
Weights
Gvw:
Gross Vehicle Weight varies by model, typically around 1900-2100 kg.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for applicable models/years)
IIHS Side Impact:
Good (for applicable models/years)
Active Features
Stability Control:
Dynamic Stability Control (DSC) standard on most models from mid-generation onwards.
Traction Control:
Automatic Stability Control and Traction (ASC+T)
Braking:
Anti-lock Braking System (ABS) standard. Ventilated front discs, solid rear discs.
Passive Features
Airbags:
Front airbags, front side airbags, optional rear side airbags.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners and force limiters.
Rollover Protection:
Automatic pop-up roll bars for convertible models.
💡 Technology Features
Infotainment
Head Unit Options:
BMW Business CD, BMW Professional RDS, optional navigation systems (MKIV).
Audio System:
Standard 10-speaker system, optional Harman Kardon audio upgrade.
Driver Assistance
Parking Sensors:
Optional Park Distance Control (PDC) rear parking sensors.
Cruise Control:
Standard cruise control on most models.
Connectivity
Bluetooth Integration:
Optional Bluetooth hands-free interface available on later models, integrated with the head unit.
Lighting
Headlights:
Halogen headlights standard, optional Xenon HID headlights with automatic leveling and headlight washers.
Climate Control
HVAC:
Manual climate control or optional automatic climate control (ACC) with integrated cabin microfilter.
🔧 Maintenance
Service Intervals General
Oil Service:
BMW Condition Based Service (CBS) system, typically around 15,000 miles or 12 months. Manual specifies checks and replacements based on driving conditions.
Spark Plugs:
Typically every 60,000-100,000 miles depending on engine variant and spark plug type (e.g., iridium).
Coolant Flush:
Every 2-4 years or 30,000-50,000 miles, depending on coolant type and manufacturer recommendations.
Fluid Specifications
Engine Oil Capacity:
Varies by engine, e.g., 6.5 liters (6.9 US quarts) for M54B30.
Engine Oil Viscosity:
Typically 5W-30 or 5W-40 synthetic oil meeting BMW LL-01 specifications.
Brake Fluid:
DOT 4 Low Viscosity (LV) brake fluid.
Power Steering Fluid:
Pentosin CHF 11S or equivalent hydraulic fluid.
Known Issues
Ccv System:
Crankcase Ventilation (CCV) system failure, leading to oil leaks and rough idle, particularly on M54 engines.
Cooling System:
Plastic coolant expansion tank can become brittle and crack. Water pump impeller can fail. Thermostat housing leaks.
Vanos System:
Variable Valve Timing (VANOS) solenoids and seals can degrade, causing rough idle, loss of power, and poor fuel economy.
Subframe Mounts:
Rear subframe mounting points can crack or tear from the chassis due to stress, especially on harder-driven cars.
Oil Pan Gaskets:
Oil pan gaskets and valve cover gaskets are common sources of oil leaks due to aging seals.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW, founded in 1916, has a long-standing heritage of producing performance-oriented luxury vehicles, particularly known for its inline-six engines and superior driving dynamics.
Model Evolution
E46 Lineage:
The E46 succeeded the highly successful E36 3 Series and was itself succeeded by the E90/E91/E92/E93 generation. It represented a significant evolution in design, technology, and engineering over its predecessor.
M3 Introduction:
The E46 M3, introduced in 2000, is considered one of the all-time great M cars, featuring the legendary S54 naturally aspirated inline-six engine.
Production
Production Period:
1998 (pre-series) - 2006 (for certain export markets, main production ended earlier)
Production Locations
Manufacturing Plants:
Primarily produced at BMW's main plant in Munich, Germany, and also at plants in Dingolfing, Germany, and Regensburg, Germany.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E46 3 Series was a frequent recipient of Car and Driver's '10Best' list, recognized for its exceptional driving dynamics and overall value.
Ward 10 Best Engines:
BMW's M54 inline-six engines, particularly the 3.0L, were often lauded by publications like Ward's AutoWorld for their smoothness and performance.
Ratings
Jd Power Initial Quality:
Generally received good ratings for initial quality and dependability within its class, though specific model years and powertrains may vary.
Certifications
Euro Ncap Safety:
Achieved a 4-star Euro NCAP rating for adult occupant protection.
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