BMW 325xi 1999 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325xi Year: 1999 Generation Chassis Code: E46 Codes Engine Code Primary: M52TU B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Wagon Target Audience:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

325xi

Year:

Generation

Chassis Code:

Codes

Engine Code Primary:

M52TU B25

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Wagon

Target Audience:

Enthusiast owners, independent repair shops, DIY mechanics

Competitive Analysis

Key Competitors:

Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus IS200/IS300 (XE10), Alfa Romeo 155/156

Key Features

Differentiators:

Inline-6 engine smoothness, advanced xDrive AWD, sporty handling, premium interior appointments

Value Proposition:

Empowers owners to maintain and repair their vehicle with confidence, saving on labor costs

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service Repair

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Workshop Manual / Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

M52TU Inline-6, diagnostics, repair, rebuild, cooling, lubrication, fuel delivery, ignition, emissions

Transmission:

Steptronic Automatic and Manual Transmission systems, diagnostics, repair, fluid service, clutch operation

Drivetrain:

xDrive All-Wheel Drive system, differentials, driveshafts, CV joints, wheel bearings

Suspension:

Front struts, rear multi-link, control arms, bushings, springs, shocks, alignment procedures

Steering:

Hydraulic power steering system, steering rack, tie rods, steering column

Brakes:

ABS, DSC, brake calipers, rotors, pads, fluid flush and bleed procedures, parking brake

Electrical System:

Wiring diagrams, component testing, alternator, starter, battery, fuse box, relays, lighting, power windows, locks

Body And Interior:

Body panel removal/installation, interior trim, seats, doors, hood, trunk, HVAC system, body shell repair

Diagnostics And Troubleshooting:

OBD-II codes, diagnostic trouble codes (DTCs), symptom-based troubleshooting, diagnostic tools

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and changes

Engine Repair:

Head gasket replacement, piston ring installation, valve adjustments, timing chain service

Transmission Overhaul:

Complete gearbox rebuild, torque converter replacement, mechatronic unit service

Brake System Service:

Brake pad and rotor replacement, caliper overhaul, ABS sensor testing, brake line replacement

Electrical Component Replacement:

Alternator, starter motor, fuel pump, mass airflow sensor, ignition coils

Suspension Component Replacement:

Strut replacement, control arm bushings, ball joints, sway bar links

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and uncommon faults

Technical Depth

Depth:

Comprehensive (from basic fluid changes to full engine/transmission rebuilds)

Diagnostic Focus:

Detailed diagnostic procedures, including wiring diagrams and sensor data interpretation

Rebuild Information:

Includes torque specifications, clearances, and rebuild procedures for major components

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable content

Print Quality

Printability:

Printable pages

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

M52TU B25 - DOHC Inline-6

Displacement:

2494 cc (2.5 Liters)

Performance

Horsepower:

189 hp @ 6000 rpm

Torque:

236 Nm (174 lb-ft) @ 3500 rpm

Fuel System

Fuel Injection:

Bosch Motronic ME 7.2 Electronic Fuel Injection (EFI)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

Engine Features

Variable Valve Timing:

VANOS (Double VANOS)

Bore X Stroke:

84 mm x 75 mm

Compression Ratio:

10.2:1

🔧 Transmission

Standard

Type:

GM A5S 360R 5-speed Manual Transmission

Optional

Type:

Steptronic GA6HP19Z 5-speed Automatic Transmission with Manual Mode

Features

All Wheel Drive:

xDrive Permanent All-Wheel Drive System

Transfer Case Ratio:

1.0:1

Fluid Specifications

Automatic Transmission Fluid:

BMW LT-2, Dexron III (for early models, check specific VIN)

Manual Transmission Fluid:

BMW MTF LT-2 (or equivalent API GL-4/GL-5)

📐 Dimensions

Exterior

Wheelbase:

2760 mm (108.7 in)

Length:

4471 mm (176.0 in)

Width:

1739 mm (68.5 in)

Height:

1415 mm (55.7 in)

Weights

Curb Weight:

1520 kg (3351 lbs)

Gross Vehicle Weight Rating:

2000 kg (4409 lbs)

Cargo

Trunk Volume:

440 Liters (15.5 cu ft)

Wheels And Tires

Wheelbase:

2760 mm (108.7 in)

Wheel Bolt Pattern:

5x120

Tire Size Standard:

205/55 R16

Wheel Size Standard:

16 x 7.0

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4/5 Stars

NHTSA Side Impact:

4/5 Stars

Active Features

Traction Control:

Automatic Stability Control (ASC) / Dynamic Stability Control (DSC)

Anti Lock Brakes:

Standard Anti-lock Braking System (ABS)

Passive Features

Airbags:

Front driver and passenger airbags, optional side-impact airbags

Seatbelts:

Three-point seat belts with pretensioners

💡 Technology Features

Infotainment

Audio System:

BMW Professional Radio, optional CD changer, Harman Kardon audio upgrade

Navigation:

Optional BMW Business or Professional Navigation System

Driver Assistance

Cruise Control:

Standard Cruise Control

Connectivity

Phone Integration:

Optional Bluetooth preparation and cradle

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable, typically 7,500-15,000 miles or as indicated by Condition Based Service (CBS) system

Spark Plug Replacement:

Approximately 60,000 miles

Coolant Flush:

Every 2-4 years or 30,000-60,000 miles

Fluid Specifications

Engine Oil:

BMW Longlife-01 (LL-01) or LL-04 approved 5W-30 or 0W-30 Synthetic Oil

Coolant:

BMW Blue Antifreeze/Coolant (G48/G40) or equivalent silicate-free ethylene glycol based coolant

Brake Fluid:

DOT 4 BMW Brake Fluid (or equivalent DOT 4 LV)

Known Issues

Cooling System:

Plastic coolant expansion tanks are prone to cracking, water pump failure, thermostat issues

Oil Leaks:

Valve cover gasket, oil pan gasket, front and rear main seals common

Suspension:

Control arm bushings, rear shock mounts, tie rod ends wear out

Electrical:

ABS/DSC module failures, CCV system (crankcase ventilation) issues

Vanos:

Vanos solenoids and seals can degrade, leading to rough idle and power loss

📚 Vehicle History

Brand Heritage

Bmw Legacy:

Renowned for sporting sedans and performance engineering

Model Evolution

E46 Introduction:

Launched in 1998 as the successor to the E36 generation

E46 Highlights:

Introduced significantly revised chassis dynamics, improved interior quality, and advanced technology

Production

E46 Production Years:

1998-2006 (Sedan/Touring 1998-2005)

Manufacturing Location:

Germany (Dingolfing, Munich)

🏆 Awards & Recognition

Recognitions

Car And Driver:

Car and Driver 10Best list multiple times (for E46 generation in general)

Ward S Auto:

Ward's 10 Best Engines award for the M52/M54 engine family