BMW 325xi 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 325xi Year: 2002 Codes Chassis Code: E46 Engine Code Typical: M54B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Wagon Competitors 2002: Audi A4...

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Description

🏷️ Basic Information

Identification

Make:

Model:

325xi

Year:

Codes

Chassis Code:

Engine Code Typical:

M54B25

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Wagon

Competitors 2002:

Audi A4 Quattro, Mercedes-Benz C-Class, Lexus IS300, Acura TL

Competitive Analysis

Key Selling Points:

Performance, handling, build quality, rear-wheel-drive bias (even with AWD), premium interior.

Key Features

Driving Dynamics:

Renowned BMW handling, balanced chassis, responsive steering.

All Wheel Drive:

xDrive all-wheel-drive system providing enhanced traction and stability.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (with specific regional variations noted where applicable)

Trim Levels Covered:

All Trim Levels

Transmission Types Covered:

All Transmission Types (including Automatic and Manual)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, including cylinder head, block, pistons, crankshaft, camshafts, timing.

Engine Management:

EFI (Electronic Fuel Injection), ignition system, sensors, actuators, ECU diagnostics, emissions control.

Transmission Drivetrain:

Automatic and Manual transmission servicing, repair, removal/installation, and final drive/differential.

Suspension:

Front and rear suspension components, steering system, shock absorbers, springs, bushings.

Brakes:

Brake system diagnostics, ABS, DSC (Dynamic Stability Control), disc brakes, pads, rotors, hydraulic system.

Electrical System:

Wiring diagrams, battery, alternator, starter, lighting, power windows, central locking, fuses, relays.

Comfort Systems:

HVAC (Heating, Ventilation, and Air Conditioning), climate control, power seats, sunroof operation.

Bodywork:

Body panel repair, doors, hood, trunk, bumpers, interior trim removal/installation.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plugs, ignition coils.

Troubleshooting:

Diagnostic procedures, fault code interpretation, common problems and solutions.

Repair Procedures:

Step-by-step repair instructions with torque specifications, special tool requirements.

Diagnostics:

OBD-II diagnostics, sensor testing, component testing using diagnostic tools.

Technical Depth

Depth:

Comprehensive from basic maintenance to full engine and transmission rebuilds, including electrical troubleshooting.

📊 Manual Specifications

File Format

Searchable Text:

Printable:

Print Quality

Image Clarity:

High-resolution diagrams and illustrations

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated Inline 6-Cylinder

Engine Displacement:

2.5 Liters (2494 cc)

Engine Code:

M54B25

Performance

Horsepower:

184 hp @ 6000 rpm

Torque:

175 lb-ft (237 Nm) @ 3500 rpm

Fuel System

Fuel Delivery:

Sequential Multi-port Fuel Injection (S<bos>-MFI)

Fuel Type Recommendation:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Engine Components

Valvetrain:

DOHC (Dual Overhead Camshafts), 4 valves per cylinder

Cooling System:

Liquid-cooled, pressurized system with thermostat and fan.

🔧 Transmission

Standard

Transmission Type:

5-speed Manual (Getrag 250)

Optional

Transmission Type:

5-speed Automatic (Steptronic)

Features

Drivetrain:

xDrive All-Wheel Drive (Permanent)

Gear Ratios:

Detailed ratios available in manual for both transmission types.

Fluid Specifications

Automatic Transmission Fluid:

BMW LT-2 or equivalent Dexron III/Mercon approved fluid

Manual Transmission Fluid:

BMW recommends specific gear oil for manual transmissions, typically GL-4 or GL-5, viscosity varies by temperature.

📐 Dimensions

Exterior

Length:

177.4 inches (4506 mm)

Width:

68.7 inches (1745 mm)

Height:

55.7 inches (1415 mm)

Wheelbase:

107.3 inches (2726 mm)

Weights

Curb Weight:

Approx. 3500-3600 lbs (1588-1633 kg), varies by configuration.

Gross Vehicle Weight Rating:

Varies by model, consult vehicle data plate.

Cargo

Trunk Volume:

Approx. 13.6 cu ft (385 Liters)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star (for applicable models/years)

NHTSA Front Impact Passenger:

5-Star (for applicable models/years)

IIHS Frontal Offset:

Good (for applicable models/years)

Active Features

Stability Control:

DSC (Dynamic Stability Control), Traction Control (ASC+T)

Braking Assistance:

ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution)

Passive Features

Airbags:

Frontal airbags, side airbags, available head protection airbags.

Seatbelts:

3-point seatbelts with pretensioners and force limiters.

💡 Technology Features

Infotainment

Head Unit:

BMW Professional CD, available with optional navigation system (MK III/IV).

Audio System:

Standard 6-speaker system, optional Harman Kardon premium audio.

Driver Assistance

Parking Assistance:

Optional rear Park Distance Control (PDC).

Connectivity

Cruise Control:

Standard cruise control.

Keyless Entry:

Standard remote keyless entry and central locking.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or as indicated by the Service Indicator (CBS - Condition Based Service).

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions.

Cabin Air Filter:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or annually.

Spark Plug Replacement:

Every 60,000 - 100,000 miles (96,000 - 160,000 km) depending on spark plug type (e.g., platinum or iridium).

Fluid Specifications

Engine Oil Type:

BMW Longlife-01 (LL-01) synthetic oil, SAE 5W-30 or 0W-30

Engine Oil Capacity:

Approx. 6.5 US quarts (6.2 Liters)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)

Brake Fluid:

DOT 4 Low Viscosity (LV) brake fluid

Known Issues

Cooling System Failures:

Plastic coolant expansion tank, water pump, and thermostat housing are common failure points leading to leaks.

Oil Filter Housing Gasket Leaks:

Degradation of the oil filter housing gasket can lead to oil leaks.

Crankcase Ventilation System:

Clogged PCV (Positive Crankcase Ventilation) valve and hoses can cause rough idle, oil consumption, and vacuum leaks.

Suspension Components:

Wear on control arm bushings and ball joints is common due to age and mileage.

Ignition Coils:

Misfires due to failing ignition coils are a known issue on the M54 engine.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure, performance-oriented luxury vehicles.

Model Evolution

E46 Generation Introduction:

Introduced in 1998 (for model year 1999), the E46 represented a significant evolution in BMW's compact executive segment.

325Xi Introduction:

The 'xi' designation signifies all-wheel drive, introduced to broaden the 3 Series appeal, especially in markets with varied weather conditions.

Production

Manufacturing Locations:

Primarily Germany (e.g., Dingolfing, Munich), and some assembly in South Africa.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The 3 Series (E46 generation) was frequently recognized on Car and Driver's 10Best lists in various configurations.

Consumer Reports:

Generally rated well for reliability and performance, though specific model years and components can have varying ratings.