BMW 323 323i 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 323i Year: 2004 Generation Chassis Code: E46 Production Period: 1998-2006 (E46) 👋 Introduction Market Position Segment: Compact Executive Sedan (Compact Luxury Car) Target...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Generation

Chassis Code:

Production Period:

1998-2006 (E46)

👋 Introduction

Market Position

Segment:

Compact Executive Sedan (Compact Luxury Car)

Target Audience:

Enthusiasts and owners seeking detailed technical information for DIY maintenance and repairs.

Competitive Analysis

Key Competitors:

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

Key Features

Driving Dynamics:

Renowned for sporty handling, balanced chassis, and driver-focused experience, hallmarks of BMW's 'Ultimate Driving Machine' philosophy.

Engine Smoothness:

Inline-six engines known for their refinement and smooth power delivery.

Build Quality:

High standard of German engineering and interior material quality.

📋 Manual Details

Coverage Areas

Primary Coverage:

BMW 323i (2004 Model Year)

Secondary Coverage:

May also include relevant information for closely related E46 variants where applicable, but primarily focused on the 323i.

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete diagnosis, repair, overhaul, and tuning of the M54B25 engine.

Transmission:

Manual (Getrag 420G) and Automatic (GM A5S360R/A5S325Z) transmission service, repair, and troubleshooting.

Drivetrain:

Rear-wheel drive system, differential, driveshafts, CV joints, and hub assemblies.

Suspension:

Front and rear suspension components, alignment procedures, shock absorbers, struts, control arms, bushings, and sway bars.

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pads, rotors, calipers, lines, and fluid service.

Steering:

Power steering system, steering rack, tie rods, and steering column.

Electrical:

Detailed wiring diagrams, fuse box layouts, component testing, starter, alternator, battery, ignition system, lighting, and comfort electronics.

Cooling System:

Radiator, water pump, thermostat, cooling fan, hoses, and coolant specifications.

Fuel System:

Fuel pump, injectors, fuel filter, fuel pressure regulator, evaporative emission control (EVAP) system.

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, and oxygen sensors.

Body And Chassis:

Body panel removal and installation, door mechanisms, glass, interior trim, and chassis components.

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis and repair, including refrigerant handling and component replacement.

Safety Systems:

Airbag system (SRS) diagnosis and repair, seat belt mechanisms.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, fluid checks and changes, brake pad replacement.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, common fault identification, and fault code explanations (OBD-II).

Component Removal Installation:

Step-by-step instructions for replacing virtually every component on the vehicle.

Engine Rebuild:

Detailed instructions for engine disassembly, inspection, repair, and reassembly, including torque specifications.

Transmission Overhaul:

Procedures for rebuilding both manual and automatic transmissions.

Electrical Diagnostics:

Guidance on using multimeters and oscilloscopes, reading wiring diagrams, and tracing electrical faults.

Alignment:

Wheel alignment specifications and procedures.

Special Tools:

Identification and usage of specialized tools required for specific repairs.

Technical Depth

Depth:

Comprehensive from basic maintenance to advanced engine and transmission overhauls, including electrical system diagnostics.

📊 Manual Specifications

File Format

Format Details:

Digital PDF, searchable text, allowing for easy navigation and printing of individual pages or the entire manual.

Print Quality

Quality:

High-resolution, clear diagrams and text, suitable for printing on standard office printers.

Binding Type

Binding For Print:

N/A (Digital download, intended for printing or digital viewing)

Paper Type

Recommended Paper For Print:

N/A (Digital download, for user to print on preferred paper)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B25

Engine Type:

Naturally Aspirated Inline 6-Cylinder

Displacement:

2494 cc (2.5 Liters)

Bore X Stroke:

84 mm x 75 mm

Compression Ratio:

10.2:1

Performance

Horsepower:

184 hp (137 kW) @ 6000 rpm

Torque:

175 lb-ft (237 Nm) @ 3500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Bosch Motronic ME9.2 engine management.

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Engine Management

Ignition System:

Distributorless Ignition System (DIS) with individual coil-on-plug ignition.

Emission Control:

Dual catalytic converters, oxygen sensors (pre and post-catalytic converter), secondary air injection system.

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual (Getrag 420G)

Optional

Transmission Type Optional:

5-Speed Automatic (GM A5S360R/A5S325Z) with Steptronic manual shifting mode.

Features

Manual Clutch:

Hydraulically actuated single-plate dry clutch.

Automatic Features:

Adaptive shift logic, torque converter lock-up.

📐 Dimensions

Exterior

Length:

4471 mm (176.0 inches)

Width:

1739 mm (68.5 inches)

Height:

1413 mm (55.6 inches)

Wheelbase:

2760 mm (108.7 inches)

Front Track:

1471 mm (57.9 inches)

Rear Track:

1484 mm (58.4 inches)

Weights

Curb Weight Manual:

Approx. 1470 kg (3240 lbs)

Curb Weight Automatic:

Approx. 1495 kg (3295 lbs)

Gross Vehicle Weight Rating:

Approx. 1950 kg (4300 lbs)

Cargo

Trunk Capacity:

410 Liters (14.5 cu ft)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5 Stars (Driver and Passenger)

NHTSA Side Impact:

4 Stars (Front and Rear Passengers)

Active Features

Stability Control:

Dynamic Stability Control (DSC) standard.

Traction Control:

Automatic Stability Control and Traction (ASC+T).

Brakes:

Anti-lock Braking System (ABS) standard on all wheels, Electronic Brake Force Distribution (EBD).

Passive Features

Airbags:

Frontal airbags (driver and passenger), front side-impact airbags, optional head protection system (HPS).

Seatbelts:

3-point inertia-reel seat belts with pretensioners and force limiters.

Body Structure:

Reinforced safety cell with crumple zones.

💡 Technology Features

Infotainment

Head Unit:

Standard BMW Business CD radio with cassette player and CD slot. Optional BMW Professional CD/Navigation system.

Speaker System:

Typically 6-10 speakers, with optional Harman Kardon premium sound system.

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Cruise Control:

Standard cruise control.

Connectivity

Bluetooth:

Optional Bluetooth hands-free interface (may require specific phone compatibility).

Aux Input:

Rarely standard; often added via aftermarket solutions.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable Oil Service Interval (Condition Based Service - CBS) typically around 15,000 miles or annually, whichever comes first. Refer to manual for exact CBS conditions.

Brake Fluid Flush:

Every 2 years (regardless of mileage).

Coolant Flush:

BMW Blue coolant, typically recommended at 4 years or 60,000 miles, then every 2 years thereafter.

Spark Plugs:

NGK BKR6EQUP or equivalent. Replacement typically every 60,000 miles.

Fluid Specifications

Engine Oil:

SAE 5W-30 Synthetic (BMW Longlife-01 or Longlife-04 approved). Capacity: Approx. 6.5 liters (6.9 US quarts).

Transmission Fluid Manual:

MTF LT-2 (BMW 83 22 0 309 031) or equivalent. Capacity: Approx. 1.7 liters (1.8 US quarts).

Transmission Fluid Automatic:

BMW ATF LT-71141 (BMW 83 22 9 407 858) or equivalent. Capacity: Approx. 8.0 liters (8.5 US quarts) for a full drain and fill, torque converter may retain more.

Coolant:

BMW Blue Antifreeze/Coolant (G48 specification), mixed 50/50 with distilled water. Capacity: Approx. 9.5 liters (10.0 US quarts).

Brake Fluid:

DOT 4 (BMW High Performance DOT 4).

Known Issues

Oil Leaks:

Common oil leaks from valve cover gasket, oil pan gasket, CCV system (Positive Crankcase Ventilation), and oil filter housing O-rings.

Cooling System Failures:

Cracking of plastic coolant expansion tanks, failure of water pumps (plastic impeller), and thermostat housing leaks.

Ccv System Clogging:

The CCV system can become clogged, leading to increased crankcase pressure, oil leaks, and potential engine damage. Replacement of the CCV valve and associated hoses is a common maintenance item.

Suspension Wear:

Wear in control arm bushings, ball joints, and sway bar links can lead to noise and poor handling.

Window Regulator Failure:

Power window regulators are a known weak point, often failing due to plastic wear or motor issues.

ABS Wheel Speed Sensor Failure:

ABS and DSC warning lights can illuminate due to faulty wheel speed sensors.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW, a German manufacturer with a long history of producing high-performance and luxurious vehicles, particularly known for its focus on driving dynamics.

Model Evolution

E46 Lineage:

The E46 generation BMW 3 Series replaced the E36 and was produced from 1998 to 2006. The 323i was part of the initial E46 lineup, offering a balance of performance and efficiency.

Engine Progression:

The M54 engine series (M54B22, M54B25, M54B30) was a significant advancement over its M52 predecessor, featuring dual VANOS, aluminum block construction, and improved emissions control.

Production

Manufacturing Locations:

Primarily manufactured at BMW's Dingolfing plant in Germany, with some assembly in other global locations.

🏆 Awards & Recognition

Recognitions

Popular Mechanics Editors Choice:

The E46 generation was generally well-regarded and received numerous accolades for its design and driving dynamics during its production run.