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BMW 323 323i 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 323i Year: 2002 Codes Chassis Code: E46 👋 Introduction Market Position Market Segment: Compact Executive Sedan/Coupe/Convertible Competitive Analysis Key Competitors: Mercedes-Benz C-Class, Audi...
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BMW 323 323i 2002 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
323i
Year:
2002
Codes
Chassis Code:
E46
👋 Introduction
Market Position
Market Segment:
Compact Executive Sedan/Coupe/Convertible
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS300, Infiniti G35
Key Features
Model Strengths:
Balanced chassis, engaging driving dynamics, refined inline-6 engine, premium interior appointments
Manual Value Proposition:
Empowers owners and independent workshops with professional-grade diagnostic and repair data for cost-effective maintenance and longevity.
📋 Manual Details
Coverage Areas
Engine Options Covered:
2.5L M52TU inline-6
Transmission Options Covered:
5-speed manual (S5D 250G), 5-speed automatic (GM A5S 325Z)
Trim Levels Covered:
All E46 323i Sedan, Coupe, Convertible, and Sport Wagon variants
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, component testing, timing, cooling, lubrication, emissions control
Engine Electrical:
Ignition system, fuel injection (DME), starter, alternator, sensors, wiring diagrams
Transmission:
Manual and automatic gearbox repair, clutch, driveline, differentials
Chassis And Suspension:
Front and rear suspension components, steering system, wheel bearings, alignments
Brakes:
Hydraulic system, ABS, DSC, brake pad/rotor replacement, caliper service
Body And Interior:
Body panels, doors, windows, locks, seats, trim, HVAC
Electrical And Electronics:
Lighting, power accessories, instrument cluster, body control modules (BCM), DME, EWS, radio
HVAC:
Air conditioning, heating, climate control system diagnostics and repair
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plugs, coolant flushes, brake fluid changes
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for common and intermittent faults
Repair Procedures:
Step-by-step instructions with torque specifications, special tool requirements, and critical procedures
Diagnostics:
OBD-II codes, DME diagnostic procedures, EWS (Immobilizer) system troubleshooting
Technical Depth
Depth Of Coverage:
Comprehensive, from basic fluid checks to full engine and transmission rebuilds, including electrical schematics and component testing
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Print Quality:
High-resolution, printable pages
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M52TU B25
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84.0 mm x 75.0 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
189 hp @ 5900 rpm
Torque:
245 Nm (181 lb-ft) @ 3500 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (Bosch Motronic ME7.2)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual (Getrag S5D 250G)
Optional
Optional Transmission:
5-Speed Steptronic Automatic (GM A5S 325Z)
Features
Manual Clutch:
Hydraulic actuation, single dry plate
Automatic Features:
Tiptronic style manual shifting mode
📐 Dimensions
Exterior
Length:
4520 mm (Sedan)
Width:
1751 mm
Height:
1412 mm (Sedan)
Wheelbase:
2760 mm
Weights
Curb Weight:
1500 kg (approx. Manual Sedan)
Gross Vehicle Weight:
2000 kg (approx.)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test:
4-star driver, 5-star passenger (for E46 sedan)
Active Features
Stability Control:
Dynamic Stability Control (DSC)
Traction Control:
Automatic Stability Control and Traction (ASC+T)
Passive Features
Airbags:
Frontal airbags, optional side airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Body Structure:
Reinforced safety cage, crumple zones
💡 Technology Features
Infotainment
Infotainment System:
Optional BMW Business CD or Professional CD radios, optional navigation system (MKIV)
Driver Assistance
Parking Assistance:
Optional Rear Park Distance Control (PDC)
Connectivity
Connectivity Features:
Optional Bluetooth integration (via specific phone modules)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable Oil Service Indicator (VOSI), typically 10,000-15,000 miles or annually
Spark Plug Replacement:
Every 60,000 miles (depending on plug type)
Coolant Flush:
Every 30,000 miles or 2 years
Fluid Specifications
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-04 approved synthetic, SAE 0W-40 or 5W-40
Engine Oil Capacity:
6.5 Liters (6.9 US Quarts)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 or equivalent)
Brake Fluid Specification:
DOT 4 (preferably low viscosity, e.g., DOT 4 LV)
Automatic Transmission Fluid:
BMW ATF LT71141 (for GM 5L40-E, often branded as Esso LT 71141)
Known Issues
Common Wear Items:
Coolant expansion tank leaks, VANOS solenoid/seal issues, oil pan gasket leaks, rear main seal leaks, front control arm bushings, valve cover gasket leaks, CCV system failure.
Electrical Faults:
ABS/DSC sensor failures, instrument cluster pixelation, ignition coil failures, alternator issues.
📚 Vehicle History
Brand Heritage
Bmw Heritage:
Known for performance, luxury, and driving enjoyment since 1916.
Model Evolution
E46 Generation Introduction:
Introduced in 1998 for the 1999 model year, replacing the E36.
323I Positioning:
Positioned as a more accessible, yet still potent, entry into BMW's 3 Series lineup, bridging the gap between the 320i and 328i/330i.
Production
Production Years For 323I E46:
1998-2001 (Europe), 1999-2000 (North America)
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
E46 platform (various models) frequently cited on Car and Driver's 10 Best lists during its production run.
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