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BMW 3 Series 325i 1999-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i Codes Chassis Code: E46 Engine Code: M54B25 👋 Introduction Market Position Market Position: The BMW 3 Series (E46)...
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BMW 3 Series 325i 1999-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Model Variant:
325i
Codes
Chassis Code:
E46
Engine Code:
M54B25
👋 Introduction
Market Position
Market Position:
The BMW 3 Series (E46) represented the compact executive car segment, known for its driving dynamics, premium quality, and performance. The 325i model was a popular mid-range offering within the E46 lineup.
Competitive Analysis
Competitors:
Primary competitors included the Mercedes-Benz C-Class, Audi A4, Lexus IS, and Infiniti G35.
Key Features
Key Features:
Rear-wheel drive bias, balanced chassis, responsive engines, premium interior appointments, and advanced technology for its era.
Chassis Dynamics:
The E46 platform is renowned for its well-engineered multi-link front suspension and independent rear suspension, contributing to its exceptional handling characteristics.
📋 Manual Details
Coverage Areas
Applicable Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Page Count:
1250
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Instant Download)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, engine management (DME), emissions control.
Transmission:
Manual and Automatic transmission systems, clutch, driveline, drive axles.
Brakes:
Brake system (hydraulic, ABS, DSC), brake pad replacement, rotor replacement, caliper service.
Electrical:
Complete electrical system, wiring diagrams, fuses, relays, battery, charging system, starting system, lighting, instrumentation, body electronics (BCM, comfort modules).
Suspension:
Front and rear suspension components, shock absorbers, struts, control arms, bushings, steering system.
Body:
Body structure, body panels, doors, hood, trunk, interior trim, HVAC system, exterior lighting.
Fuel System Detail:
Fuel pump, fuel injectors, fuel pressure regulator, fuel filter, evaporative emissions control system.
Ignition System Detail:
Ignition coils, spark plugs, crankshaft position sensor, camshaft position sensors.
Procedures Included
Maintenance:
Oil change, filter replacement, spark plug replacement, fluid checks and changes, belt inspection and replacement.
Repair:
Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component repair.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, diagnostic connector location.
Exhaust System:
Diagnosis and repair of exhaust system components, catalytic converter replacement, muffler service.
Steering:
Power steering system diagnosis and repair, steering rack replacement, tie rod end replacement.
Climate Control:
HVAC system diagnosis, refrigerant service, blower motor replacement, evaporator core replacement.
Body And Trim:
Interior and exterior trim removal and installation, door panel removal, seat removal, window regulator repair.
Wheel And Tire:
Wheel and tire replacement, torque specifications, alignment procedures.
Chassis And Frame:
Chassis component inspection and repair, rust prevention and repair guidance.
Timing Belt Chain:
While the M54 engine features a timing chain, the manual would cover inspection, tensioner service, and associated component replacement if needed, unlike timing belts.
Technical Depth
Depth:
Comprehensive, covering routine maintenance, diagnostics, repair, and overhaul procedures for all major vehicle systems.
Electrical Diagnostics Detail:
Detailed wiring diagrams for all circuits, fuse and relay box locations, troubleshooting trees for electrical faults.
Engine Performance Tuning:
Information on engine control unit (ECU) parameters and potential adjustments, although primarily focused on stock specifications and repair.
Transmission Rebuild:
Detailed procedures for manual and automatic transmission overhaul, including component identification, torque specifications, and assembly sequences.
Diagnostic Tool Interface:
Information regarding the OBD-II diagnostic port and common diagnostic tools used for BMW vehicles of this era.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire document.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Text Searchable:
Yes
Navigation
Hyperlinked Sections:
Typically Yes for PDF manuals of this caliber, allowing for easy navigation between sections and topics.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-6 Cylinder, Naturally Aspirated
Engine Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
184 hp @ 6000 rpm
Torque:
245 Nm (181 lb-ft) @ 3500 rpm
Engine Code Designation:
M54B25 signifies a 2.5-liter displacement (B25) M54 engine.
Fuel System
Fuel System Type:
Multi-point Fuel Injection (Bosch Motronic ME 7.2)
Recommended Fuel:
Premium Unleaded Gasoline (91 Octane or higher)
Engine Management
Dme Model:
Bosch Motronic ME 7.2
Engine Internals
Bore X Stroke:
84.0 mm x 90.0 mm
Compression Ratio:
10.2:1
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual
Optional
Transmission Type Optional:
5-Speed Automatic (Steptronic)
Features
Drivetrain:
Rear-Wheel Drive (RWD)
📐 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 Overhang:
825 mm (32.5 in)
Rear Overhang:
885 mm (34.8 in)
Weights
Curb Weight:
1480 kg (3263 lbs) - Manual Transmission
Gross Vehicle Weight Rating Gvwr:
Varies by model and configuration, but typically around 1950 kg (4300 lbs). Consult manual for precise rating.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star
NHTSA Front Impact Passenger:
5-Star
IIHS Moderate Overlap Frontal Offset:
Good
Passive Features
Airbags:
Front dual-stage airbags, front side airbags.
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Dynamic Stability Control (DSC) or Traction Control System (ASC+T) depending on model year and options.
💡 Technology Features
Infotainment
Infotainment System:
Optional BMW Business or Professional CD radios, optional navigation system. Basic audio controls and display. Later models may feature more advanced displays.
Driver Assistance
Driver Assistance Features:
Cruise control, optional parking sensors (Park Distance Control - PDC).
Connectivity
Connectivity Features:
Limited connectivity by modern standards. CD player, optional cassette player, potential for aftermarket Bluetooth integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system or approximately every 7,500-15,000 miles (12,000-24,000 km) depending on driving conditions and oil type.
Spark Plug Replacement:
Typically around 100,000 miles (160,000 km) for iridium spark plugs (check specific recommendation for original equipment).
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) approved synthetic oil, typically SAE 0W-30 or 5W-30. Consult manual for precise specification.
Coolant Type:
BMW Blue Antifreeze (G48 ethylene glycol based). Mix 50/50 with distilled water.
Brake Fluid Type:
DOT 4 High Performance brake fluid.
Automatic Transmission Fluid Type:
BMW ATF LT-71141 (for earlier models) or Esso LT 71141 / Shell LA2634 (for later models). Refer to manual for specific transmission type.
Known Issues
Cooling System:
Plastic expansion tank prone to cracking, water pump failure, thermostat housing leaks.
Suspension:
Worn control arm bushings (specifically the front lower control arm bushings, often referred to as 'RTABs' for rear trailing arm bushings as well), worn sway bar links.
Engine Oil Leaks:
Valve cover gasket, oil filter housing gasket (o-ring), oil pan gasket.
Electrical:
CCV (Crankcase Ventilation) system issues leading to oil consumption and seal failures, VANOS (Variable Valve Timing) solenoid issues, oxygen sensor failures.
Fluid Capacities
Engine Oil Capacity:
Approx. 6.5 Liters (6.9 US Quarts) with filter change. Consult manual for exact capacity.
Coolant Capacity:
Approx. 8.0 Liters (8.5 US Quarts). Consult manual for exact capacity.
Automatic Transmission Fluid Capacity:
Approx. 5.5-6.5 Liters (5.8-6.9 US Quarts) for a pan drop and fill. Full refill capacity will be higher. Consult manual.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Bayerische Motoren Werke AG (BMW) has a long-standing reputation for producing sporty, luxurious, and technologically advanced vehicles, particularly known for its focus on driving pleasure ('The Ultimate Driving Machine').
Model Evolution
Model Evolution:
The E46 generation, produced from 1998 to 2006, succeeded the E36 3 Series. It was praised for its refined chassis, improved interior quality, and advanced engineering over its predecessor. The 325i model replaced the 328i from the previous generation, offering a balance of performance and efficiency.
Body Styles Available E46:
Sedan, Coupe, Convertible, Sports Wagon (Touring), M3 performance variant.
Production
Production Years E46:
1998-2006
Production Locations:
Primarily produced at BMW's manufacturing plants in Germany (e.g., Munich, Regensburg, Dingolfing) and also in other global locations for specific markets.
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