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

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🏷️ Basic Information Identification Make: BMW Model: 325 Sub Model: 325xi Codes Chassis Code: E46 Engine Code Family: M54 👋 Introduction Market Position Segment: Compact Executive Sedan/Wagon Reputation: Known for...
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BMW 325 325xi 1999-2005 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
BMW
Model:
325
Sub Model:
325xi
Codes
Chassis Code:
E46
Engine Code Family:
M54
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Wagon
Reputation:
Known for sporty handling, premium interior, and engaging driving experience.
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS.
Key Features
Driving Dynamics:
Balanced chassis, rear-wheel-drive bias (even in xi models), responsive steering.
Premium Appointments:
High-quality interior materials, ergonomic design, driver-focused cockpit.
Manual Value Proposition
Benefit:
Empowers owners and technicians with detailed, authoritative repair and maintenance information for the BMW 325xi E46 generation.
📋 Manual Details
Coverage Areas
Covered Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Page Count:
1258
Manual Type
Manual Type:
Workshop Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, engine electrical, powertrain control module (PCM).
Drivetrain:
All-Wheel Drive (xDrive) system, differentials (front, center, rear), driveshafts, transfer case, hub assemblies.
Chassis:
Suspension (front and rear), steering system, braking system (ABS, DSC), wheel alignment.
Electrical:
Body electrical systems, lighting, instruments, gauges, power windows, central locking, climate control, SRS airbags, diagnostic connectors (OBD-II).
Bodywork:
Body and frame construction, exterior trim, interior trim, doors, hood, trunk, bumpers, glass, seals.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.
Repair:
Engine repair (head gasket, timing chain, valve seals), transmission service and repair, brake component replacement, suspension and steering component replacement, electrical diagnostics and component replacement.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, component testing procedures.
Overhaul:
Engine overhaul procedures, transmission overhaul, differential rebuilds.
Technical Depth
Depth:
Comprehensive (from basic maintenance to advanced diagnostics and full rebuild procedures).
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Quality:
High-resolution, searchable text, printable pages.
Binding Type
Binding:
Not Applicable (Digital PDF)
Paper Type
Paper Type:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Name:
BMW M54B30
Engine Type:
Inline-6, Naturally Aspirated
Displacement:
2.979 cc (3.0 Liters)
Bore X Stroke:
84.0 mm x 89.6 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
225 hp @ 6000 rpm
Torque:
214 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Point Fuel Injection (Bosch Motronic ME7.2)
Fuel Type:
Premium Unleaded Gasoline (91 Octane Recommended)
Other Engine Details
Valvetrain:
Dual Overhead Camshafts (DOHC), 4 valves per cylinder, VANOS (Variable Valve Timing).
Engine Management:
BMW Electronic Engine Management (MS43/MS45 depending on model year variations).
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (Getrag GS5-39DZ)
Optional
Transmission Type:
5-Speed Automatic (GM Steptronic A5S 325Z)
Features
Drivetrain Configuration:
xDrive All-Wheel Drive
Transfer Case:
Gerodisc multi-plate clutch system for variable torque distribution.
Fluid Specifications
Manual Transmission Fluid:
BMW MTF-LT-2 (or equivalent, e.g., Red Line D4 ATF, Pentosin MTF-2)
Automatic Transmission Fluid:
BMW ETL-7045E (or equivalent, e.g., Dexron III)
Transfer Case Fluid:
BMW Fluid G2 / G3 (or equivalent, e.g., Pentosin FFL-3)
📐 Dimensions
Exterior
Wheelbase:
107.4 inches (2728 mm)
Length:
177.4 inches (4506 mm)
Width:
68.7 inches (1745 mm)
Height:
55.6 inches (1412 mm)
Weights
Curb Weight:
Approx. 3450 lbs (1565 kg)
Gross Vehicle Weight Rating:
Approx. 4542 lbs (2060 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5 Stars
NHTSA Side Impact:
4 Stars
Active Features
Stability Control:
Dynamic Stability Control (DSC) standard.
Traction Control:
Automatic Stability Control and Traction (ASC+T).
Braking:
Anti-lock Braking System (ABS), ventilated front and solid rear disc brakes.
Passive Features
Airbags:
Frontal airbags for driver and passenger, optional side-impact airbags.
Body Structure:
Reinforced safety cell, crumple zones.
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD or Professional CD/RDS radio, optional Professional Navigation system.
Audio System:
Standard 6-speaker system, optional Harman Kardon premium audio.
Driver Assistance
Stability Control:
DSC (Dynamic Stability Control) system with integration to ABS and traction control.
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions often available.
Convenience Features
Climate Control:
Manual or optional automatic climate control (ACC).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles or as indicated by the Condition Based Service (CBS) system.
Spark Plug Replacement:
100,000 miles (Long-Life Platinum or Iridium plugs).
Coolant Flush:
Every 2-4 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil Specification:
BMW Longlife-01 (LL-01) approved synthetic oil, SAE 5W-30 or 5W-40.
Engine Oil Capacity:
6.5 U.S. quarts (6.2 liters) with filter.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48).
Known Issues
Common Faults:
Oil filter housing gasket leaks, CCV (Crankcase Ventilation) system failure leading to oil consumption/sealing issues, radiator end-tank cracks, water pump failure, VANOS solenoid issues, power steering leaks, cooling fan clutch failure (mechanical fan), subframe mounting fatigue.
Diagnostic Tips:
The manual provides detailed troubleshooting for common issues like rough idle (CCV/vacuum leaks), misfires (ignition coils, spark plugs), and cooling system faults.
📚 Vehicle History
Brand Heritage
Brand Legacy:
BMW, Bayerische Motoren Werke AG, a long-standing German manufacturer renowned for luxury vehicles and driving dynamics.
Model Evolution
E46 Generation:
The E46 generation (1998-2006) represented a significant evolution for the 3 Series, balancing comfort and sportiness. The 325xi was introduced later in this generation, offering all-wheel drive for enhanced traction.
Production
Production Years:
1999-2005 for the 325/325xi model line.
Manufacturing Locations:
Primarily Dingolfing and Regensburg, Germany.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E46 3 Series, including variants like the 325i/xi, was frequently recognized on Car and Driver's 10Best lists during its production run for its exceptional driving dynamics.
Ratings
Consumer Reports:
Generally rated well for performance and luxury, though specific model years and common issues were noted in reliability ratings.
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