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BMW 325I-3 Series (E46) 1999-2005 Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 325i Chassis Code: E46 Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Convertible Target...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Chassis Code:
E46
Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe/Convertible
Target Audience:
Enthusiasts, DIY mechanics, independent repair shops
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS300, Infiniti G35
Key Features
Driver Engagement:
Renowned for its balanced chassis, rear-wheel-drive dynamics, and precise steering.
Engine Lineup:
Offered a range of inline-six engines known for smooth power delivery and durability.
Build Quality:
High levels of interior and exterior build quality, typical of BMW.
📋 Manual Details
Coverage Areas
Manual Type:
Comprehensive Service, Maintenance, and Repair Manual
Language:
English
Format:
Likely Digital (PDF) or Printed Book - specific format not detailed but implies comprehensive document
Page Count
Page Count:
Not explicitly stated, but description implies extensive coverage (often 1000+ pages for such manuals)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, repair, diagnostics, and tuning for M54B25 engine
Engine Electrical:
Ignition system, fuel injection, DME (Digital Motor Electronics) diagnosis, sensor testing, wiring diagrams
Transmission Manual:
Repair, maintenance, and diagnostics of Getrag 5-speed manual transmission (e.g., GS5-39DZ)
Transmission Automatic:
Repair, maintenance, and diagnostics of ZF 5HP19 (or similar) 5-speed automatic transmission
Drivetrain:
Differential, driveshafts, CV joints, clutch system
Suspension:
Front struts, rear multi-link suspension, bushings, control arms, springs, shock absorbers
Steering:
Power steering system, steering rack, tie rods, alignment procedures
Brakes:
Hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pad/rotor replacement, bleeding procedures
Fuel System:
Fuel pump, injectors, fuel filter replacement, EVAP system diagnosis
Cooling System:
Radiator, water pump, thermostat, coolant hoses, fan clutch/electric fan
Exhaust System:
Catalytic converter, mufflers, oxygen sensors, exhaust manifold
Electrical System:
Battery, alternator, starter motor, lighting, power windows, central locking
HVAC:
Air conditioning, heater core, blower motor, climate control module
Body And Chassis:
Body panels, doors, interior trim, frame damage assessment
Diagnostic Troubleshooting:
Extensive troubleshooting charts, fault code interpretation (OBD-II), symptom-based diagnostics
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls
Component Replacement:
Detailed instructions for replacing individual parts like water pump, alternator, starter, sensors, etc.
Troubleshooting Faults:
Step-by-step diagnostic procedures for identifying and rectifying common and uncommon issues
Electrical Diagnostics:
Testing circuits, diagnosing sensor faults, using multimeter and oscilloscopes (implicitly)
Alignment And Balancing:
Wheel alignment specifications and procedures, tire balancing
Bodywork Repair:
Minor dent repair, panel alignment, rust prevention (likely covered to a degree)
Technical Depth
Depth:
Advanced diagnostic procedures, complete rebuild specifications, torque values for all fasteners, detailed wiring diagrams
Diagrams And Illustrations:
Exploded views, schematics, and step-by-step diagrams for visual guidance
📊 Manual Specifications
File Format
File Format:
Likely PDF for digital versions; high-quality print for physical books
Print Quality
Print Quality:
Professional printing with clear text and high-resolution diagrams (typical for reputable manual publishers)
Binding Type
Binding Type:
Likely perfect bound or saddle-stitched for printed versions, allowing lay-flat use in a workshop environment
Paper Type
Paper Type:
Durable, possibly gloss or semi-gloss paper to withstand workshop conditions and protect diagrams
⚙️ Engine Specifications
Primary Engine
Engine Code:
M54B25
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 Hp:
184 hp @ 6000 rpm (approx.)
Torque Lb-Ft:
230 Nm (169 lb-ft) @ 3500 rpm (approx.)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (Bosch Motronic ME9 or similar)
Fuel Type:
Premium Unleaded (91+ RON)
Engine Management
Dme Type:
DME MS43 or MS45 (depending on year and specific model variant)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (Getrag GS5-39DZ)
Optional
Transmission Type:
5-Speed Steptronic Automatic (ZF 5HP19)
Features
Clutch Type:
Hydraulic, Single Dry Plate
Gear Ratios Manual Approx
1St Gear:
4.23:1
2Nd Gear:
2.52:1
3Rd Gear:
1.70:1
4Th Gear:
1.23:1
5Th Gear:
1.00:1
Reverse:
3.83:1
Transmission Fluid Manual
Fluid Type:
BMW MTF LT-2 (or equivalent API GL-4 SAE 75W-90)
Transmission Fluid Automatic
Fluid Type:
ZF Lifeguardfluid 5 (or equivalent ATF)
📐 Dimensions
Exterior Sedan Approx
Length:
177.4 inches (4506 mm)
Width:
68.7 inches (1745 mm)
Height:
55.7 inches (1415 mm)
Wheelbase:
107.3 inches (2725 mm)
Weights
Curb Weight Sedan Approx:
3240 lbs (1470 kg)
Gross Vehicle Weight Rating Approx:
4400 lbs (2000 kg)
Cargo
Trunk Capacity Sedan Approx:
11.7 cubic feet (330 liters)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
Good (for compatible model years)
NHTSA Frontal Passenger:
Good (for compatible model years)
IIHS Frontal Offset:
Good (for compatible model years)
Active Features
ABS:
Standard (4-wheel disc brakes)
Traction Control:
ASC (Automatic Stability Control) standard, optional DSC (Dynamic Stability Control)
Brake Assist:
Available on some models/years
Passive Features
Airbags Front:
Driver and front passenger airbags standard
Airbags Side:
Optional front side-impact airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
💡 Technology Features
Infotainment
Head Unit Options:
Various BMW Professional or Business CD radios, some with optional navigation systems (e.g., MKIII or MKIV).
Audio System:
Standard 6-speaker system, optional Harman Kardon premium audio system.
Driver Assistance
Dsc:
Dynamic Stability Control (DSC) available, enhancing vehicle stability under various driving conditions.
Connectivity
Onboard Computer:
Standard OBC providing fuel economy, range, and trip information.
Convenience Features
Cruise Control:
Standard cruise control system.
Power Accessories:
Power windows, power mirrors, remote central locking standard.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Typically every 7,500 to 10,000 miles (12,000 to 15,000 km) or annually, using BMW Longlife-01 approved synthetic oil.
Service Intervals Filters
Oil Filter:
Replace with every oil change. BMW Part Number: 11 42 7 500 188 (or equivalent).
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles. BMW Part Number: 13 72 1 730 945 (or equivalent).
Cabin Air Filter:
Replace annually or every 15,000 miles. BMW Part Number: 64 11 8 363 536 (or equivalent).
Service Intervals Fluids
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 specification), mixed 50/50 with distilled water. BMW Part Number: 83 51 2 352 189 (or equivalent).
Coolant Capacity:
Approximately 7.8 Liters (8.2 US quarts)
Service Intervals Spark Plugs
Spark Plug Type:
NGK BKR6EQUP (or equivalent platinum plugs). Replace every 60,000 miles (96,000 km).
Known Issues
Cooling System Leaks:
Common failures include the plastic expansion tank cracking, water pump bearing failure, and leaky coolant hoses.
Oil Leaks:
Valve cover gasket, oil pan gasket, and oil filter housing gasket can deteriorate and leak.
Subframe Mounts:
Cracking or separation of rear subframe mounting points, requiring reinforcement or replacement.
Window Regulators:
Plastic clips for power window regulators are prone to breaking.
Ccv System:
Crankcase Ventilation (CCV) system can become clogged, leading to oil consumption and rough running.
Alternator Failure:
Alternators can fail prematurely, often due to heat and age.
ABS Wheel Speed Sensors:
These sensors are susceptible to damage and can fail, disabling ABS and DSC.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for producing driver-focused vehicles with excellent engineering and performance.
Model Evolution
E46 Introduction:
The E46 generation was introduced in 1998 (for the 1999 model year), succeeding the E36 3 Series. It represented a significant evolution in design, technology, and chassis dynamics.
E46 Facelift:
The E46 received a facelift (LCI - Life Cycle Impulse) in 2001, which included updated headlights, taillights, bumpers, and interior trim revisions.
Production
Production Locations:
Primarily manufactured in Germany (e.g., Dingolfing plant), with some assembly in other global locations.
Global Sales Impact:
The E46 was a highly successful generation for BMW, significantly boosting sales and solidifying its position in the compact executive segment globally.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E46 generation was frequently named to Car and Driver's '10Best' list, a testament to its driving dynamics and overall excellence.
Auto Motor Und Sport Best Cars:
Consistently ranked highly in various European automotive magazine 'Best Cars' awards.
Certifications
Automotive Engineering Excellence:
Recognized for its advanced chassis engineering, engine technology, and overall build quality.