BMW 323 323i 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 323i Model Variant: 323 Year: 2004 Codes Chassis Code: E46 Engine Code Suffix: B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Competitors:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Variant:

Year:

Codes

Chassis Code:

Engine Code Suffix:

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Coupe

Competitors:

Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35

Key Features

Driving Dynamics:

Renowned for BMW's signature 'Ultimate Driving Machine' handling and balance

Powertrain:

Smooth and responsive inline-six engine

Build Quality:

High-quality interior materials and solid construction

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service, repair, and diagnostic procedures

Included Sections:

Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Exterior, Interior

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Service and Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing systems (VANOS), lubrication, cooling

Engine Electrical:

Ignition system, fuel injection system (DME - Digital Motor Electronics), sensors, actuators, ECU diagnostics

Transmission:

Manual and Automatic Transmission (GM 5L40-E) service, repair, overhaul, fluid specifications, control modules

Drivetrain:

Clutch, driveshafts, differential, axles, wheel bearings

Suspension:

Front and rear suspension components (struts, shock absorbers, control arms, ball joints, bushings), alignment specifications

Steering:

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

Brakes:

Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), hydraulic system, bleeding procedures

Electrical System:

Wiring diagrams, fuse box locations, lighting, power windows, mirrors, central locking, battery, starter, alternator

HVAC:

Air conditioning system, heater core, blower motor, climate control module, refrigerant handling

Body Exterior:

Body panels, doors, hood, trunk, bumpers, glass, seals, rust prevention

Body Interior:

Seats, dashboard, trim panels, airbags, seatbelts, interior lighting

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting for common issues

Repair:

Detailed step-by-step repair instructions for all major components and systems

Diagnostics:

OBD-II (On-Board Diagnostics II) procedures, fault code interpretation, sensor testing, diagnostic tool usage

Disassembly Reassembly:

Complete procedures for removing, inspecting, repairing, and reinstalling components

Technical Depth

Depth:

Expert-level, suitable for professional mechanics and advanced DIY enthusiasts

Diagnostic Tools:

Information on using BMW-specific diagnostic tools (e.g., DIS, ISTA) and general OBD-II scanners

Wiring Diagrams:

Detailed, system-specific wiring schematics

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable

Printability:

Printable

Print Quality

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B25

Engine Type:

Naturally Aspirated Inline-6 Cylinder

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

82.0 mm x 79.5 mm

Compression Ratio:

10.2:1

Performance

Horsepower:

184 hp @ 6000 rpm

Torque:

237 Nm (175 lb-ft) @ 3500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (Bosch Motronic ME7.2)

Fuel Type:

Premium Unleaded (91 octane or higher recommended)

Emission Control:

Secondary Air Injection System, Catalytic Converters

Engine Features

Valvetrain:

Double Overhead Camshafts (DOHC), 24 Valves, Double VANOS (Variable Valve Timing)

Cooling System:

Pressurized liquid cooling system with electric fan

Lubrication System:

Wet sump lubrication, oil filter, oil cooler (if equipped)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual (Getrag S5D 320Z)

Optional

Transmission Type:

5-speed Automatic (GM 5L40-E)

Features

Clutch Type:

Hydraulically operated single dry plate clutch (Manual)

Automatic Control:

Electronic control, Steptronic (manual shifting mode)

📐 Dimensions

Exterior

Length:

4471 mm (176.0 inches)

Width:

1739 mm (68.5 inches)

Height:

1414 mm (55.7 inches)

Wheelbase:

2760 mm (108.7 inches)

Weights

Curb Weight Manual:

1450 kg (3197 lbs)

Curb Weight Automatic:

1490 kg (3285 lbs)

Gross Vehicle Weight Rating:

1900 kg (4189 lbs)

Wheel Bolt Pattern:

5 x 120 mm

Wheel Size:

16-inch or 17-inch alloy wheels

Tire Size Standard:

205/55 R16 (Front), 225/50 R16 (Rear)

Cargo

Trunk Volume:

440 Liters (15.5 cubic feet)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star

NHTSA Front Impact Passenger:

5-Star

IIHS Side Impact:

Good (for vehicles equipped with side airbags)

Active Features

Standard Anti-lock Braking System

Standard Dynamic Stability Control

Traction Control:

Standard Automatic Stability Control + Traction (ASC+T)

Passive Features

Airbags:

Frontal airbags, optional front side-impact airbags

Seatbelts:

3-point inertia-reel seatbelts with pretensioners

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system (where applicable)

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD or Professional CD/Cassette radio, optional CD changer

Navigation:

Optional BMW Professional Navigation System (MK4 unit)

Driver Assistance

Parking Sensors:

Optional Rear Park Distance Control (PDC)

Cruise Control:

Standard Cruise Control

Connectivity

Bluetooth:

Optional Bluetooth mobile phone integration (often requiring a separate cradle)

Comfort Features

Climate Control:

Optional Automatic Climate Control with digital display

🔧 Maintenance

Service Intervals

Oil Change Interval:

Approximately every 7,500-15,000 miles or as indicated by the Condition Based Service (CBS) system

Brake Fluid Change:

Every 2 years (regardless of mileage)

Coolant Change:

Every 3-4 years or as recommended by BMW (BMW Blue Coolant)

Spark Plug Replacement:

Around 60,000 - 100,000 miles, depending on spark plug type

Fluid Specifications

Engine Oil Type:

SAE 5W-30 Synthetic (BMW LL-01 approved)

Engine Oil Capacity:

6.5 Liters (6.9 US Quarts)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)

Brake Fluid Type:

DOT 4 (BMW Heavy Duty Brake Fluid)

Transmission Fluid Manual:

BMW MTF LT-2 (Manual Transmission Fluid) or equivalent

Transmission Fluid Automatic:

Esso LT 71141 (or Pentosin ATF 1)

Known Issues

Oil Leaks:

Valve cover gasket, oil filter housing gasket, oil pan gasket, CCV (Crankcase Ventilation) system leaks

Cooling System:

Water pump failure (plastic impeller), thermostat housing leaks, expansion tank leaks, radiator leaks

Suspension:

Control arm bushings (mentally crack), rear subframe bushings, thrust arm bushings

Electrical:

Heated oxygen sensor (O2 sensor) failures, VANOS solenoid issues, ABS/DSC wheel speed sensor failures

Interior:

Pixelated instrument cluster displays, dead pixels in infotainment screens

Common Repairs

Ccv System:

Regular replacement or modification of the CCV system is recommended to prevent oil leaks and rough idling

Vanos System:

VANOS solenoids and seals can fail, leading to rough idle, poor performance, and increased fuel consumption

📚 Vehicle History

Brand Heritage

Heritage:

BMW's legacy of engineering excellence and sporty driving experience

Model Evolution

E46 Generation:

Fourth generation of the BMW 3 Series, known for refined styling and improved dynamics

323I Positioning:

Positioned below the 325i and 330i, offering a balance of performance and value

Production

Production Years:

1999-2006 (E46 generation)

Manufacturing Location:

Germany, South Africa, Thailand, Brazil, Russia, China

🏆 Awards & Recognition

Recognitions

Model Awards:

Car and Driver's 10Best (1999, 2000, 2001 - for the E46 generation)

Bmw Brand Reputation:

Consistently recognized for engineering, performance, and luxury

Ratings

Consumer Reports Reliability:

Varied, with common issues requiring proactive maintenance