🏷️ Basic Information

Make:

BMW

Model:

325 / 325xi

Model Code:

E46

Production Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005

Engine Codes:

M54B30 (commonly found in 330i, often mistaken or cross-referenced with 325 in this generation depending on market/year - the manual likely covers the applicable M54 variant for the 325 badge)

👋 Introduction

Segment:

Compact Executive Sedan/Wagon (E-segment), known for its sporty handling and premium feel.

Competitors:

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

Driving Dynamics:

Renowned for its balanced chassis, responsive steering, and driver-focused ergonomics, typical of the BMW brand.

Powertrain Options:

The M54 engine provided a strong balance of performance and refinement, with the option of xDrive for enhanced all-weather traction.

Target Audience:

Professional mechanics, DIY enthusiasts, and technicians seeking in-depth repair and maintenance information for the BMW 325/325xi E46 chassis.

📋 Manual Details

Markets:

Primarily North America, potentially global variants covered within the scope of the M54 engine.

Page Count:

1258

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Detailed diagnosis, repair, and overhaul of the M54 engine (including M54B25 variations), cooling system, lubrication system, fuel delivery, ignition system, emissions control, engine management (DME) diagnostics and calibration.

Transmission:

Coverage for both manual (Getrag 6-speed) and automatic (Steptronic ZF 5HP19) transmissions, including removal, installation, repair, fluid service, and shift control diagnostics.

Drivetrain:

Front and rear differentials, drive shafts, CV joints, xDrive (all-wheel drive) system operation, diagnosis, and repair.

Suspension:

Front and rear suspension systems (MacPherson struts, multi-link rear), springs, shock absorbers, control arms, bushings, steering rack, power steering system, alignment specifications.

Brakes:

Hydraulic brake system (ABS, DSC), brake fluid specifications, rotor/pad replacement, caliper service, parking brake, hydraulic component testing.

Electrical:

Comprehensive electrical schematics, wiring diagrams, component testing, fuse/relay identification, power distribution, lighting systems, starter, alternator, battery service, ground points.

Body And Chassis:

Body panel repair, door mechanisms, glass replacement, sealing, underbody protection, structural components, chassis diagnostics.

Climate Control:

HVAC system, A/C system service, blower motor, climate control unit diagnostics, refrigerant handling, heater core service.

Interior:

Seat removal and repair, dashboard disassembly, trim panel replacement, SRS (airbag) system safety precautions and service.

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), BMW specific diagnostic tools (e.g., DIS, ISTA/P), sensor testing, module programming basics.

Maintenance:

Oil and filter change, air filter replacement, cabin air filter replacement, spark plug replacement, fluid level checks and top-ups, brake fluid flush, coolant flush, drive belt inspection/replacement.

Troubleshooting:

Systematic diagnostic flowcharts for common issues (e.g., engine performance, starting problems, electrical faults, HVAC malfunctions), symptom-based troubleshooting.

Repair:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for virtually all systems.

Specifications:

Torque specifications for all fasteners, critical clearances, component tolerances, wiring diagram interpretations, diagnostic parameter values.

Depth:

Comprehensive, covering from basic preventative maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork procedures.

📊 Manual Specifications

File Format:

PDF

Scalability:

Scalable vector graphics and high-resolution raster images for clear viewing of diagrams and illustrations.

Searchability:

Likely text-searchable PDF, allowing quick access to specific topics and procedures.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Family:

M54

Displacement:

2.5 Liters (2494 cc) for the 325i/xi models during this period, though the M54 family also includes 2.2L and 3.0L variants.

Horsepower:

Approximately 184-190 hp (depending on specific year and market tuning).

Torque:

Approximately 175-180 lb-ft (237-245 Nm).

Injection:

Sequential multi-port fuel injection (Bosch Motronic ME7.2).

Fuel Type:

Premium Unleaded (91 RON or higher recommended).

Type:

Distributorless ignition system with coil-on-plug ignition coils.

🔧 Transmission

Transmission Type:

5-speed Manual (Getrag Type G) or 5-speed Automatic (ZF 5HP19 'Steptronic'). The 325 models primarily received the 2.5L M54B25 which was often paired with the 5-speed manual or 5-speed auto.

Optional Transmission Type:

All-Wheel Drive (xDrive) system was optional on sedan and wagon models, typically paired with the automatic transmission.

Steptronic:

Yes, the automatic transmission offered a manual shift mode ('Steptronic').

📐 Dimensions

Sedan Length:

Approx. 177.4 inches (4506 mm).

Sedan Width:

Approx. 68.5 inches (1740 mm).

Sedan Height:

Approx. 56.2 inches (1428 mm).

Wheelbase:

Approx. 107.4 inches (2728 mm).

Curb Weight:

Approx. 3300-3500 lbs (1497-1588 kg) depending on configuration (sedan/wagon, manual/auto, RWD/xDrive).

🛡️ Safety Features

NHTSA Front Impact:

5 Stars (for 2000-2005 models, tested by NHTSA in sedan configuration).

Traction Control:

Available ASC+T (Automatic Stability Control + Traction) or DSC (Dynamic Stability Control) depending on year and options.

ABS:

Standard Anti-lock Braking System (ABS).

Airbags:

Frontal airbags for driver and passenger, optional side-impact airbags.

Body Structure:

Reinforced passenger cell, crumple zones designed for energy absorption.

💡 Technology Features

Head Unit:

BMW Professional CD radio, optional navigation system (MKIV), Harman Kardon audio system availability.

Parking Sensors:

Optional rear parking sensors (Park Distance Control - PDC).

Bluetooth:

Optional Bluetooth hands-free interface available on later models or as an accessory.

Cruise Control:

Standard cruise control.

Rain Sensing Wipers:

Optional automatic rain-sensing wipers.

🔧 Maintenance

Oil Change:

Typically every 10,000-15,000 miles (16,000-24,000 km) or as indicated by the Condition Based Service (CBS) system or vehicle's oil service light. Manual will specify exact intervals and conditions.

Spark Plugs:

Recommended replacement around 60,000-100,000 miles (96,000-160,000 km) depending on plug type (e.g., long-life iridium).

Coolant Flush:

Often recommended every 2-4 years or 30,000-60,000 miles.

Engine Oil:

BMW Longlife-01 (LL-01) approved synthetic oil, typically 5W-30 or 5W-40.

Coolant:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based), typically a 50/50 mix with distilled water.

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90 synthetic gear oil.

Transmission Fluid Automatic:

ZF TE-ML 11B or LT71141 specification ATF (Automatic Transmission Fluid). Specific BMW part numbers will be detailed in the manual.

Brake Fluid:

DOT 4 Low Viscosity (LV) or higher (e.g., DOT 4+).

Engine Common:

CCV (Crankcase Ventilation) system failures leading to oil consumption and vacuum leaks, VANOS (Variable Valve Timing) solenoid issues, cooling system component failures (plastic expansion tank, water pump, thermostat), oil separator hose cracks.

Suspension Common:

Front control arm bushings (often called 'bushings'), rear subframe bushings, ball joints, tie rod ends, sway bar links.

Electrical Common:

ABS/DSC wheel speed sensor failures, alternator failure, headlight washer system issues, door lock actuator problems, window regulator failures.

📚 Vehicle History

Brand Philosophy:

BMW's 'Ultimate Driving Machine' ethos emphasizing performance, engineering, and driver engagement.

Chassis Code:

E46 generation, succeeding the E36 and preceding the E90. Known for its refined styling and improved dynamics over its predecessor.

Production Period:

1999-2005 model years for this specific manual's coverage.

Manufacturing Locations:

Primary assembly in Germany (e.g., Dingolfing), with potential for assembly in other BMW plants globally.

🏆 Awards & Recognition

Ward Awards:

The E46 generation, including models like the 325i, was frequently recognized for its engineering and driving dynamics by automotive publications.

Consumer Reports:

Generally received good ratings for performance and reliability in its class, though specific model years and common issues would be detailed in owner reviews and reports.