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BMW 325i-3 Series (E46) 1999-2005 Service Repair Manual

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Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i Generation Chassis Code: E46 Codes Production Years: 1999-2005 Introduction Market Position Positioning: The BMW 3 Series (E46) established itself...
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BMW 325i-3 Series (E46) 1999-2005 Service Repair Manual
Basic Information
Identification
Make: BMW
Model: 3 Series
Model Variant: 325i
Generation
Chassis Code: E46
Codes
Production Years: 1999-2005
Introduction
Market Position
Positioning: The BMW 3 Series (E46) established itself as a benchmark for compact luxury sport sedans, offering a compelling blend of performance, refinement, and driving dynamics.
Competitive Analysis
Competitors: Competed directly with models like the Mercedes-Benz C-Class, Audi A4, Lexus IS, and Infiniti G35.
Key Features
Driving Dynamics: Renowned for its balanced chassis, precise steering, and engaging handling characteristics, often praised as one of the best-driving cars of its era.
Build Quality: Typical BMW build quality, with a premium interior and solid construction.
Engine Options: Offered a range of smooth and powerful inline-six engines, with the 325i featuring a highly regarded M54B25 variant.
Manual Details
Coverage Areas
Vehicle Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005
Vehicle Models Covered: BMW 325i (E46)
Page Count
Estimated Pages: 1000+
Manual Type
Type: Service and Repair Manual
Language
Language: English
Format
Digital Format: PDF (Digital Download)
Manual Coverage
Systems Covered
Engine Mechanical: Complete overhaul, component testing, timing, lubrication, cooling
Engine Management: Fuel injection, ignition system, emissions control, sensors, actuators, DME (Digital Motor Electronics)
Transmission Manual: Clutch, gearbox overhaul, shifting mechanisms, fluid service
Transmission Automatic: Control unit, valve body, torque converter, fluid service, shift solenoid testing
Drivetrain: Driveshafts, CV joints, differential, wheel bearings
Suspension: Front and rear suspension components, shock absorbers, struts, bushings, alignment specifications
Steering: Power steering system, steering rack, tie rods, steering column
Brakes: Hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pad/rotor replacement, caliper service, bleeding procedures
Electrical System: Battery, alternator, starter, wiring diagrams, fuses, relays, lighting, horn
Body And Interior: Body panel removal/installation, door mechanisms, interior trim, seats, headliner, HVAC (Heating, Ventilation, and Air Conditioning)
Comfort Systems: Climate control, power windows, power seats, central locking, sunroof
Diagnostics: OBD-II (On-Board Diagnostics) procedures, diagnostic trouble codes (DTCs), fault finding
Procedures Included
Routine Maintenance: Oil changes, filter replacements, spark plug service, fluid checks and changes
Troubleshooting: Step-by-step diagnostic guides for common and complex issues
Repair And Rebuild: Detailed instructions for component disassembly, repair, and reassembly
Diagnostic Tools: Information on using scan tools and specialized BMW diagnostic equipment
Technical Depth
Depth: Comprehensive: Covers from basic maintenance to in-depth engine and transmission overhauls, electrical system diagnostics, and bodywork repairs.
Manual Specifications
File Format
Quality: High-resolution, clear text and images
Searchability: Fully searchable PDF document
Print Quality
Printable: Printable pages for workshop use
Binding Type
Binding: Not Applicable (Digital Download)
Paper Type
Paper: Not Applicable (Digital Download)
Engine Specifications
Primary Engine
Engine Code: M54B25
Configuration: Inline 6-cylinder
Displacement: 2.5 Liters (2494 cc)
Valvetrain: DOHC (Double Overhead Camshafts), 24 valves (4 per cylinder)
Bore X Stroke: 84.0 mm x 75.0 mm
Compression Ratio: 10.2:1
Performance
Horsepower: 184 hp @ 6000 rpm
Torque: 232 Nm (171 lb-ft) @ 3500 rpm
Fuel System
Induction: Multi-point fuel injection (MPI)
Fuel Type: Premium Unleaded Gasoline (91+ Octane Recommended)
Fluid Specifications
Engine Oil Capacity: 6.5 Liters (6.9 US Quarts) with filter change
Engine Oil Type: SAE 5W-30 Synthetic (BMW Longlife-01 recommended)
Coolant Type: BMW Blue Antifreeze/Coolant (G48 type)
Transmission
Standard
Transmission Type: 5-speed Manual Transmission (Getrag GS5-39DZ)
Optional
Transmission Type: 5-speed Automatic Transmission (Steptronic)
Features
Manual Gear Ratios: 1st: 4.23, 2nd: 2.52, 3rd: 1.67, 4th: 1.23, 5th: 1.00, Reverse: 3.93
Fluid Specifications
Manual Transmission Fluid: SAE 75W-90 Synthetic Gear Oil (BMW recommends specific types, e.g., ATF Dextron III for some earlier models, but typically GL-4 or GL-5 for the manual gearbox)
Automatic Transmission Fluid: BMW ATF LT-3 (for 5HP19Z automatic)
Dimensions
Exterior
Length: 4471 mm (176.0 in)
Width: 1739 mm (68.5 in)
Height: 1412 mm (55.6 in)
Wheelbase: 2760 mm (108.7 in)
Front Track: 1471 mm (57.9 in)
Rear Track: 1477 mm (58.1 in)
Weights
Curb Weight: Approximately 1450-1550 kg (3197-3417 lbs)
Gross Vehicle Weight: Approximately 1950 kg (4299 lbs)
Cargo
Trunk Volume: 440 Liters (15.5 cu ft)
Wheels Tires
Wheel Bolt Pattern: 5x120
Standard Wheel Size: 16x7.0 inches
Standard Tire Size: 205/55R16
Optional Wheel Size: 17x7.5 inches front, 17x8.0 inches rear
Optional Tire Size: 225/45R17 front, 245/40R17 rear
Safety Features
Ratings
NHTSA Front Impact: 4/5 Stars (for Sedan models, varying slightly by year/specific test)
IIHS Side Impact: Good (for Sedan models, varying slightly by year/specific test)
Active Features
ABS: Standard Anti-lock Braking System
Dsc: Standard Dynamic Stability Control (DSC)
Traction Control: Standard Traction Control System (ASC+T or DTC depending on year/options)
Passive Features
Airbags: Frontal airbags, optional side-impact airbags, optional head protection airbags
Seatbelts: Three-point inertia-reel seatbelts with pretensioners and force limiters
Body Structure: Reinforced safety cage, crumple zones
Technology Features
Infotainment
Infotainment System: Optional Professional Navigation System with CD player, Radio, and integrated climate controls. Base models feature a standard radio and CD player.
Speaker System: Standard 10-speaker Hi-Fi system, optional Harman Kardon audio system.
Driver Assistance
Parking Assist: Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Phone Integration: Optional Bluetooth mobile phone preparation with hands-free system.
Convenience
Cruise Control: Standard or optional cruise control system.
Maintenance
Service Intervals
Oil Change Interval: Variable via Condition Based Service (CBS) system, typically around 15,000 miles or 12-24 months, but dependent on driving conditions. Manual recommends checks at shorter intervals.
Air Filter Replacement: Every 30,000-50,000 miles, or as indicated by CBS.
Cabin Filter Replacement: Every 15,000-30,000 miles or annually.
Spark Plug Replacement: Approximately 60,000 miles for standard spark plugs (e.g., Bosch FGR7DQP+).
Brake Fluid Flush: Every 2 years, regardless of mileage.
Coolant Flush: Every 3-4 years or approximately 50,000-60,000 miles.
Known Issues
Cooling System: Plastic expansion tank, water pump, and radiator can become brittle and prone to leaks over time. Thermostat housing also a common failure point.
Suspension: Front control arm bushings, rear subframe bushings, and rear trailing arm bushings are common wear items, leading to clunking noises or poor handling.
Oil Leaks: Valve cover gasket, oil pan gasket, and oil filter housing gasket are frequent sources of oil leaks.
Electrical: ABS wheel speed sensors, VANOS solenoids, and CCV (Crankcase Ventilation) system can fail, causing various performance and warning light issues.
Interior: Headliner sagging, pixelated instrument cluster displays, and worn seat bolsters are common interior wear points.
Vibration Issues: Driveshaft flex disc, center bearing, and wheel balancing can contribute to vibrations.
Vehicle History
Brand Heritage
Bmw Heritage: BMW, a German manufacturer, has a long-standing reputation for producing sporty, premium automobiles with a focus on driving pleasure and engineering excellence.
Model Evolution
E46 Introduction: The E46 generation of the 3 Series was introduced in 1998 (as a 1999 model year) succeeding the E36. It was available in sedan, coupe, convertible, and wagon body styles.
E46 Facelift: Received a significant facelift (LCI - Life Cycle Impulse) in late 2001 for the 2002 model year, with updated styling, improved interior, and powertrain refinements.
Production
Manufacturing Locations: Primarily produced at BMW's Dingolfing plant in Germany, with some assembly in other locations worldwide.
Sales Figures: The E46 was a highly successful generation for BMW, with over 1.5 million units sold globally.
Awards & Recognition
Recognitions
Car And Driver 10Best: The BMW 3 Series (E46) was a frequent recipient of Car and Driver's 10Best list during its production run, a testament to its exceptional driving dynamics and overall quality.
Automotive Journalism Praise: Consistently praised by automotive journalists for its handling, ride quality, engine performance, and build quality.
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