BMW 325 325i 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Model Variant: 325 Year: 2002 Codes Chassis Code: E46 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Positioning: The BMW 3 Series...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Variant:

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Coupe

Positioning:

The BMW 3 Series (E46) was renowned for its sporty driving dynamics, premium interior, and sophisticated engineering, positioned as a benchmark in its class.

Competitive Analysis

Key Competitors:

Mercedes-Benz C-Class, Audi A4, Lexus IS300, Infiniti G35.

Key Features

Driving Dynamics:

Balanced chassis, rear-wheel drive architecture, refined suspension setup, communicative steering.

Powertrain:

Smooth and potent inline-six engines known for their performance and refinement.

Interior Quality:

Premium materials, driver-focused cockpit, ergonomic design.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Brakes:

Suspension:

Steering:

Electrical System:

Bodywork And Interior:

Heating And Air Conditioning:

Diagnostic Procedures:

Troubleshooting Guides:

Wiring Diagrams:

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Management:

Detailed diagnostics, component testing, ignition system, fuel injection system (DME - Digital Motor Electronics), emission control systems.

Engine Mechanical:

Engine assembly and disassembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system.

Transmission Manual:

Clutch, gearbox overhaul, shift mechanism, maintenance.

Transmission Automatic:

Steptronic transmission (GM A5S320Z), hydraulic control, torque converter, valve body, removal and installation, fluid specifications.

Drivetrain:

Driveshafts, differential, rear axle assembly.

Brake System:

Front and rear brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid, hydraulic lines, calipers, rotors, pads, bleeding procedures.

Suspension System:

Front and rear suspension components, struts, shocks, control arms, bushings, springs, alignment specifications.

Steering System:

Power steering system, steering rack, steering column, pump, fluid type and capacity.

Electrical System Power:

Battery, alternator, starter motor, charging system.

Electrical System Lighting:

Headlights, taillights, interior lighting, bulb replacement.

Electrical System Accessories:

Power windows, power seats, mirrors, sunroof, central locking, wipers, horn.

Body And Chassis:

Body panel removal and installation, door mechanisms, hood, trunk, bumper repair, rust prevention.

HVAC System:

Air conditioning compressor, evaporator, condenser, refrigerant handling, climate control unit, blower motor, cabin air filter replacement.

Infotainment System:

Radio, CD player, navigation system (if equipped), speaker replacement.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation.

Scheduled Maintenance:

Detailed breakdown of maintenance tasks by mileage or time intervals.

Component Replacement:

Step-by-step instructions for replacing major and minor components across all systems.

Diagnostic Troubleshooting:

Systematic approach to identifying and resolving common and uncommon problems.

Rebuilding Procedures:

Instructions for overhauling engines, transmissions, and other major components.

Electrical Testing:

Testing of sensors, actuators, control modules, and wiring harnesses using multimeters and diagnostic tools.

Special Tool Requirements:

Identification and usage of specialized tools required for specific repairs.

Technical Depth

Depth:

Comprehensive, covering everything from basic owner maintenance to complex internal component overhauls and advanced diagnostics.

Diagnostic Troubleshooting Level:

Includes troubleshooting trees, symptom-based diagnostics, and information on using BMW's diagnostic software (e.g., DIS).

Repair Level:

Detailed step-by-step repair procedures, including torque specifications, clearances, and assembly sequences.

Specification Data:

Provides all necessary technical data, measurements, tolerances, and capacities.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution, suitable for professional printing of individual pages or the entire manual.

Searchable Text:

Yes, the PDF is text-searchable for quick information retrieval.

Binding Type

Binding For Printed:

N/A (Digital Download)

Paper Type

Paper For Printed:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B30

Engine Type:

Naturally Aspirated Inline 6-Cylinder

Displacement:

2979 cc (3.0 Liters)

Bore X Stroke:

84.0 mm x 89.6 mm

Compression Ratio:

10.2:1

Performance

Horsepower Peak:

225 hp @ 5900 rpm

Torque Peak:

214 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI)

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Engine Management

BMW DME MS43

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (Getrag S5D 320Z)

Optional

Type:

5-speed Steptronic Automatic Transmission (GM A5S320Z)

Features

Clutch Type:

Hydraulically Actuated Single Dry Plate (Manual)

Automatic Features:

Sport mode, manual shifting capability (Steptronic).

Fluid Specifications

Manual Transmission Fluid:

BMW recommends MTF LT-2 or equivalent (e.g., Pentosin MTF2).

Automatic Transmission Fluid:

BMW recommends ATF LT-1 (Dexron III compatible) or ATF LT-2 for later models.

📐 Dimensions

Exterior

Length:

177.4 inches (4506 mm)

Width:

68.8 inches (1748 mm)

Height:

55.7 inches (1415 mm)

Wheelbase:

107.4 inches (2728 mm)

Weights

Curb Weight:

Approximately 3350-3450 lbs (1520-1565 kg) depending on configuration.

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

4-star driver, 4-star passenger (for sedan models)

IIHS Side Impact:

Good (for sedan models)

Active Features

Standard Anti-lock Braking System

Standard Dynamic Stability Control

Traction Control:

Standard Automatic Stability Control (ASC+T)

Passive Features

Airbags:

Frontal airbags, front side-impact airbags. Optional head protection airbags.

Seatbelts:

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

Chassis:

Reinforced safety cell, crumple zones.

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD or Professional RDS CD player, with optional Navigation system.

Audio System:

Standard 6-speaker system, optional Hi-Fi system with amplifier and more speakers.

Driver Assistance

Park Distance Control:

Optional rear Park Distance Control (PDC).

Cruise Control:

Standard cruise control system.

Connectivity

Auxiliary Input:

Not standard; often an aftermarket addition.

Bluetooth:

Optional BMW Assist with Bluetooth for hands-free calling.

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) system recommends oil changes based on driving conditions, typically around 10,000-15,000 miles (16,000-24,000 km) or annually.

Air Filter Replacement:

Typically every 30,000-50,000 miles (48,000-80,000 km), or as indicated by CBS.

Cabin Filter Replacement:

Annually or every 15,000 miles (24,000 km).

Spark Plug Replacement:

Recommended every 60,000 miles (96,000 km) for iridium spark plugs.

Coolant Flush:

Recommended every 2-4 years or 30,000-50,000 miles (48,000-80,000 km).

Fluid Specifications

Engine Oil Capacity:

6.5 U.S. quarts (6.2 Liters) with filter change.

Engine Oil Viscosity:

BMW Longlife-01 approved synthetic oil, typically 0W-30 or 5W-30.

Coolant Type:

BMW Blue (G48) Antifreeze/Coolant, mixed 50/50 with distilled water.

Known Issues

Cooling System:

Plastic expansion tank prone to cracking, water pump failures (especially the plastic impeller type).

Valve Cover Gasket:

Commonly leaks oil due to age and heat cycles.

Oil Pan Gasket:

Can also leak oil, often addressed during other major engine work.

Ccv System:

Crankcase Ventilation system can become clogged, leading to oil leaks and rough idle.

ABS Wheel Speed Sensors:

Prone to failure, causing ABS and traction control warning lights.

Front Control Arm Bushings:

Wear out over time, leading to steering looseness and clunking noises.

Rear Subframe Mounts:

Can crack or detach, causing suspension noises and alignment issues.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's long-standing reputation for building driver-focused, performance-oriented luxury vehicles.

Model Evolution

E46 Generation:

The E46 generation (1998-2006) represented a significant evolution from the E36, offering improved styling, technology, and driving dynamics.

325I Positioning:

The 325i served as the mid-range gasoline model in the E46 lineup, slotting above the 320i/325xi and below the 330i/330xi.

Production

Production Years E46:

1998-2006 (globally); 1999-2006 (North America)

Manufacturing Locations:

Germany (Main), Austria, South Africa, Thailand, Russia, Egypt, China, India, Brazil, Mexico.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E46 3 Series was a multiple recipient of Car and Driver's 10Best awards during its production run, including for the 2002 model year.

Ratings

Driving Dynamics Awards:

Consistently praised by automotive critics for its superior handling and driving feel.

Certifications

Build Quality:

Generally regarded as having excellent build quality and durability for its era.