BMW 325i 1999-2005 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: BMW Model: 325i Product Type: Workshop Service Manual Repair Codes Chassis Codes: E46 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Target Audience: Enthusiast owners,...

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类型: Car

斯库: 383647

标签: 1999 2000 2001 2002 2003 2004 2005 325i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Product Type:

Workshop Service Manual Repair

Codes

Chassis Codes:

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Coupe

Target Audience:

Enthusiast owners, independent repair shops, DIY mechanics.

Competitive Analysis

Key Competitors:

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

Key Features

Vehicle Strengths:

Sporting handling, refined inline-six engines, premium interior, rear-wheel drive dynamics.

Manual Value Proposition:

Empowers owners to perform complex maintenance and repairs, saving costs and extending vehicle lifespan, by providing official-level technical information.

📋 Manual Details

Coverage Areas

Model Years:

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

Page Count

Estimated Pages:

Over 1500

Manual Type

Type:

Comprehensive Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, diagnosis, timing, seals, gaskets, cooling system, lubrication system, fuel injection (DME), emissions control (EVAP).

Engine Electrical:

Ignition system, starter, alternator, engine control module (DME), sensors (crankshaft, camshaft, knock, O2), wiring diagrams.

Transmission Manual:

Clutch, gearbox overhaul, shift linkage, gears, bearings, seals, fluid specifications.

Transmission Automatic:

Transmission overhaul, valve body, torque converter, electronic controls (GM A5S 325Z), solenoids, fluid specifications, diagnosis.

Drivetrain:

Driveshafts, CV joints, differential, rear axle, wheel bearings.

Suspension:

Front and rear suspension components, struts, shocks, control arms, bushings, springs, anti-roll bars, alignment specifications.

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pads, rotors, calipers, master cylinder, bleeding procedures, parking brake.

Steering:

Power steering system, steering rack, pump, hoses, steering column, alignment.

Electrical System:

Battery, charging system, lighting, fuses, relays, starter, ignition switch, body control module (BCM), comfort electronics.

Climate Control:

HVAC system, blower motor, evaporator, condenser, refrigerant, heater core, climate control module, A/C system diagnosis.

Interior Trim:

Dashboard removal, door panels, seats, headliner, center console.

Exterior Body:

Bumpers, fenders, hood, trunk, doors, glass replacement, body panel alignment, rust repair.

Safety Systems:

Airbags, seatbelt pretensioners, ABS, DSC.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin), spark plug replacement, fluid checks and top-offs, brake inspections.

Troubleshooting:

Diagnostic trouble codes (DTCs), common symptoms and their causes, step-by-step diagnostic flowcharts for various systems.

Component Removal Installation:

Detailed instructions for removing and installing major and minor components across all systems.

Engine Rebuild:

Piston ring replacement, bearing inspection, cylinder head removal and installation, valve stem seals, timing chain service.

Transmission Service:

Fluid and filter changes, torque converter replacement, clutch replacement (manual), solenoid replacement (automatic).

Brake Service:

Brake pad and rotor replacement, caliper overhaul, brake fluid bleeding, ABS/DSC component testing.

Electrical Diagnostics:

Wiring harness repair, sensor testing, module programming (mention of ISTA/DIS compatibility implied), fuse and relay testing.

Suspension Repair:

Strut replacement, control arm bushing replacement, wheel bearing replacement, steering rack replacement.

Air Conditioning Service:

Refrigerant recharge, leak testing, component replacement (compressor, condenser, evaporator), evacuation and charging.

Bodywork Repairs:

Panel replacement, dent repair, door alignment, glass replacement, trim removal/installation.

Technical Depth

Depth:

Comprehensive from basic DIY maintenance to advanced diagnostics and component-level repairs.

Diagnostic Capabilities:

Includes procedures for interpreting diagnostic trouble codes (DTCs) and performing system tests.

Torque Specifications:

Detailed torque values for all critical fasteners across all vehicle systems.

Wiring Diagrams:

Extensive and detailed electrical wiring diagrams for all major systems.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Printable:

Print Quality

Image Resolution:

High-resolution diagrams and images

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Quality:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B30

Engine Type:

3.0L Naturally Aspirated Inline 6-Cylinder (I6)

Displacement:

2979 cc (3.0 Liters)

Bore X Stroke:

84.0 mm x 89.6 mm

Compression Ratio:

10.2:1

Valve Train:

DOHC (Double Overhead Camshaft), 24 Valves, VANOS (Variable Valve Timing)

Fuel System:

Electronic Fuel Injection (EFI) with multi-point injection (MPI)

Ignition System:

Distributorless ignition system (DIS) with individual coil-on-plug ignition

Cooling System:

Pressurized coolant system with electric cooling fan

Performance

Horsepower Hp:

225 hp @ 5900 rpm (approx.)

Torque Lb Ft:

214 lb-ft @ 3500 rpm (approx.)

Redline:

6500 rpm (approx.)

🔧 Transmission

Standard

Type:

5-Speed Manual (Getrag 420G)

Optional

Type:

5-Speed Automatic (GM A5S 325Z)

Features

Clutch Type:

Hydraulically actuated single-plate dry clutch

Differential:

Open differential (standard), optional limited-slip differential (LSD)

📐 Dimensions

Exterior

Length:

177.4 inches (4505 mm)

Width:

68.5 inches (1740 mm)

Height:

55.7 inches (1415 mm)

Wheelbase:

107.4 inches (2729 mm)

Weights

Curb Weight Lbs:

3461 lbs (approx. for manual sedan)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test:

4 Stars (Driver and Passenger - for sedan models of similar era)

Active Features

Standard Anti-lock Braking System

Optional Dynamic Stability Control

Passive Features

Airbags:

Frontal airbags for driver and passenger, optional side airbags.

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD/Professional CD, optional navigation system (MKIII/MKIV).

Audio System:

Standard 6-speaker system, optional Harman Kardon premium audio.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Sensors:

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

Connectivity

Phone Integration:

Optional Bluetooth phone preparation (often requiring an adapter).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 - 15,000 miles or annually, depending on driving conditions and oil type (refer to Condition Based Service - CBS system or manual recommendations).

Transmission Fluid Change:

Manual: Inspect periodically, change fluid based on mileage/usage (e.g., 60,000-100,000 miles). Automatic: Typically recommended around 60,000-100,000 miles or sooner under severe use.

Coolant Flush:

Every 2-4 years or 30,000-60,000 miles.

Brake Fluid Flush:

Every 2 years regardless of mileage.

Fluid Specifications

Engine Oil:

SAE 0W-30 or 5W-30, BMW LL-01 approved synthetic oil (e.g., Castrol Edge Professional OE 0W-30).

Coolant:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) mixed 50/50 with distilled water.

Transmission Fluid Manual:

SAE 75W-90 synthetic gear oil, meeting BMW specifications (e.g., Castrol Syntrans FE 75W-90).

Transmission Fluid Automatic:

ATF LT 71141 (Dexron III may be used as a substitute in some cases, but LT 71141 is preferred, e.g., Pentosin ATF 1).

Brake Fluid:

DOT 4 low-viscosity brake fluid (BMW recommends DOT 4 HP).

Power Steering Fluid:

Pentosin CHF 11S or CHF 202 (Green colored fluid).

Known Issues

Cooling System Failures:

Cracked plastic expansion tanks, failing water pumps (plastic impellers), thermostat housing leaks, burst coolant hoses.

Oil Leaks:

Valve cover gasket leaks, oil pan gasket leaks, oil filter housing gasket leaks (common on M54 engines).

Suspension Wear:

Control arm bushings (FCABs), sway bar links/bushings, ball joints, tie rod ends, rear shock mounts.

Ccv System:

Crankcase Ventilation (CCV) system failure leading to oil consumption and vacuum leaks.

ABS Wheel Speed Sensors:

Failure of ABS wheel speed sensors can cause ABS and traction control warnings.

Interior Electronics:

Pixelation on the instrument cluster display, HVAC control unit issues, central locking problems.

Pre Catalytic Converters:

Cracking or failure of pre-catalytic converters (especially on early M54 engines) leading to exhaust leaks and rough running.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW's reputation for building driver-focused, sporty luxury vehicles.

Model Evolution

E46 Generation:

The E46 generation (1998-2006) represented a significant evolution in BMW's 3 Series, known for its improved chassis dynamics and refined powertrains compared to the E36.

Production

Production Years:

1999-2006 (for E46 325i)

Manufacturing Locations:

Germany (primarily Dingolfing and Regensburg)

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E46 3 Series frequently appeared on Car and Driver's '10Best' lists during its production run, highlighting its driving dynamics and overall quality.