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BMW 325 325i 1999-2005 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: BMW Model: 325i Model Variant: 325 Codes Chassis Code: E46 Engine Code: M54B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Competitive Analysis Key Competitors:...
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BMW 325 325i 1999-2005 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Model Variant:
325
Codes
Chassis Code:
E46
Engine Code:
M54B25
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS300, Acura TL
Key Features
Driving Dynamics:
Renowned for balanced chassis, rear-wheel drive dynamics, and engaging driving experience.
Engine Type:
Inline-six cylinder engine, a hallmark of BMW's engineering.
Build Quality:
High-quality materials and robust construction characteristic of BMW vehicles.
📋 Manual Details
Coverage Areas
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Page Count:
1258
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full disassembly, inspection, repair, and reassembly procedures for the M54B25 inline-six engine.
Engine Management:
Diagnosis and repair of DME (Digital Motor Electronics), fuel injection, ignition system, emissions control systems (SAE J1850 PWM, ISO 9141-2).
Transmission Manual:
Repair and overhaul of manual gearboxes (e.g., Getrag S5D 250G).
Transmission Automatic:
Repair and overhaul of automatic transmissions (e.g., GM 5L40-E).
Drivetrain:
Front suspension, rear axle, driveshafts, CV joints, differentials, wheel bearings.
Braking System:
Front and rear disc brakes, ABS (Anti-lock Braking System) diagnosis and repair, brake fluid specifications.
Steering System:
Power steering system diagnosis, repair, and fluid specifications; steering rack and linkage.
Suspension System:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.
Electrical System:
Wiring diagrams, starter motor, alternator, battery, fuses, relays, lighting systems, body control module (BCM).
Climate Control:
HVAC system diagnosis, refrigerant, compressor, blower motor, control panel repair.
Body And Chassis:
Body panel repair, doors, windows, locks, exterior trim, chassis component tightening torque specifications.
Interior Systems:
Seats, airbags, dashboard, instrument cluster, interior trim removal and installation.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, coolant flushes, brake pad/rotor service.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for common issues.
Repair Procedures:
Step-by-step guides for component removal, installation, and adjustment for all major systems.
Overhaul Procedures:
Detailed instructions for complete engine and transmission rebuilds.
Electrical Diagnostics:
Component testing, circuit continuity checks, ECU troubleshooting.
Bodywork Repair:
Panel alignment, dent removal, rust repair, glass replacement.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls, including advanced diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Print Readability:
High-resolution scans suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M54B25
Engine Type:
Naturally Aspirated Inline-6
Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
189 hp @ 6000 rpm
Torque:
245 Nm (181 lb-ft) @ 3500 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Features
Valve Train:
Double Overhead Camshafts (DOHC), 24 Valves, VANOS (Variable Valve Timing)
🔧 Transmission
Standard
Transmission Type Std:
5-Speed Manual (e.g., Getrag S5D 250G)
Optional
Transmission Type Opt:
5-Speed Automatic (e.g., GM 5L40-E)
Features
Transmission Fluid Manual:
BMW MTF LT-2 or equivalent
Transmission Fluid Automatic:
Dexron III or equivalent (check specific model)
📐 Dimensions
Exterior
Length:
4471 mm (176.0 in) for Sedan
Width:
1739 mm (68.5 in)
Height:
1415 mm (55.7 in) for Sedan
Wheelbase:
2760 mm (108.7 in)
Weights
Curb Weight:
Approx. 1500 kg (3307 lbs)
Wheel Bolt Pattern:
5x120 mm
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for applicable models/years)
IIHS Side Impact:
Good (for applicable models/years)
Active Features
ABS:
Standard Anti-lock Braking System
Asc:
Optional Automatic Stability Control (ASC)
Dsc:
Optional Dynamic Stability Control (DSC)
Passive Features
Airbags:
Frontal airbags, optional side airbags
Seatbelts:
Three-point inertia-reel seatbelts with front pre-tensioners
💡 Technology Features
Infotainment
Radio Options:
Standard BMW Business CD radio, optional BMW Professional CD/DSP (Digital Signal Processor) system.
Navigation:
Optional factory navigation system (MKIII or MKIV based).
Driver Assistance
Parking Sensors:
Optional Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional Bluetooth preparation or BMW Assist telematics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-15,000 miles or as indicated by the Condition Based Service (CBS) system.
Major Service:
Around 60,000 miles, including spark plugs, coolant, and comprehensive inspection.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) synthetic oil, 5W-30 or 0W-30 recommended.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) or equivalent.
Brake Fluid Type:
DOT 4 (BMW Premium Brake Fluid recommended)
Known Issues
Cooling System:
Plastic expansion tank failures, coolant hose leaks, water pump issues.
Oil Leaks:
VPC (Valve Cover Gasket) leaks, oil pan gasket leaks, O-ring seals on VANOS and oil filter housing.
Suspension:
Front control arm bushings ('bushings'), sway bar links, rear subframe bushings.
Electrical:
ABS/ASC sensor failures, VANOS solenoid issues, CCV (Crankcase Ventilation) system failure leading to oil consumption.
Interior:
Pixelation on instrument cluster displays, sagging headliner.
📚 Vehicle History
Brand Heritage
Brand Focus:
Performance, luxury, and engineering innovation.
Model Evolution
E46 Generation:
Fourth generation of the BMW 3 Series, produced from 1997 (2000 model year in North America) to 2006.
325I Positioning:
Positioned as a mid-range model within the E46 lineup, offering a blend of performance and refinement.
Production
Production Period:
1999-2005
🏆 Awards & Recognition
Recognitions
Ward Auto:
WardsAuto recognized the M54 engine for its '10 Best Engines' multiple times.
Car And Driver:
Car and Driver 10Best list inclusion for various E46 models.
Ratings
Reliability Perception:
Generally good reliability when properly maintained, though some specific components are known to require attention.
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