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BMW 325i 1999-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Generation: E46 Codes Chassis Code: E46 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Prestige: Premium, performance-oriented luxury vehicle Competitive Analysis Key...
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BMW 325i 1999-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Generation:
E46
Codes
Chassis Code:
E46
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Prestige:
Premium, performance-oriented luxury vehicle
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 driver engagement
Powertrain Emphasis:
Inline-six engines known for smooth power delivery and characteristic BMW sound
Build Quality:
High level of fit and finish, robust construction characteristic of BMW engineering
📋 Manual Details
Coverage Areas
Applicable Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Covered Models:
BMW 325i
Page Count
Estimated Pages:
Extensive (typical for comprehensive BMW workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Drivetrain, Fuel System, Exhaust System
Chassis:
Suspension, Steering, Brakes, Wheels, Tires
Electrical:
Wiring Diagrams, Lighting, Ignition, Starting System, Charging System, Instrumentation, Body Electronics (ECU, modules)
Body:
Bodywork, Exterior Trim, Interior Trim, HVAC System, Safety Restraints (Airbags)
Procedures Included
Maintenance:
Routine service, fluid changes, filter replacements, inspections
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-II)
Repair:
Component removal and installation, disassembly and reassembly, component testing and adjustment
Technical Specifications:
Torque specifications, clearances, alignment data, diagnostic parameters
Technical Depth
Depth:
Comprehensive: From basic maintenance to complex engine and transmission rebuilds, electrical system diagnostics and repair.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (typical for professional PDFs)
Printable:
Yes (typically)
Print Quality
Quality:
High-resolution diagrams and text (expected for digital workshop manuals)
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M54B30 (primarily for 330i, but common engine family)
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
Valve Train:
Double Overhead Camshafts (DOHC), 4 valves per cylinder, VANOS (Variable Valve Timing)
Performance
Horsepower:
184 hp @ 6000 rpm (approximate, depending on specific market and tuning)
Torque:
235 Nm (173 lb-ft) @ 3500 rpm (approximate)
Fuel System
Injection Type:
Multi-Point Fuel Injection (Bosch Motronic ME 7.2 or similar)
Fuel Type:
Premium Unleaded Gasoline (91 AKI or higher recommended)
Engine Management
ECU:
Engine Control Unit (ECU) with diagnostic capabilities
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (Getrag 250 or similar)
Optional
Transmission Type:
5-Speed Automatic (ZF 5HP19 or similar)
Features
Drivetrain:
Rear-Wheel Drive (RWD)
Differential:
Open Differential (optional limited-slip differential may have been available)
📐 Dimensions
Exterior
Length:
Approx. 4471 mm (176.0 in) for Sedan
Width:
Approx. 1739 mm (68.5 in)
Height:
Approx. 1415 mm (55.7 in) for Sedan
Wheelbase:
Approx. 2760 mm (108.7 in)
Weights
Curb Weight:
Approx. 1500-1550 kg (3300-3400 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-Star (Driver), 4-Star (Passenger) - for comparable E46 sedans of that era
IIHS Side Impact:
Good (for comparable E46 sedans of that era)
Active Features
Stability Control:
Dynamic Stability Control (DSC) standard on most models/years
Traction Control:
Automatic Stability Control and Traction (ASC+T)
Braking System:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)
Passive Features
Airbags:
Frontal airbags, Side-impact airbags (optional or standard depending on market/year)
Seat Belts:
3-point inertia-reel seat belts with pretensioners
Body Structure:
Reinforced passenger cell, crumple zones
💡 Technology Features
Infotainment
Audio System:
BMW Business CD or Professional CD/Radio. Optional navigation system (MK III or MK IV).
Speakers:
Standard 6-speaker system, optional Harman Kardon premium sound system.
Driver Assistance
Cruise Control:
Standard cruise control
Parking Sensors:
Optional Park Distance Control (PDC)
Connectivity
Bluetooth:
Not typically factory-equipped for this era. Aftermarket solutions available.
Usb Aux:
Not factory-equipped. Aftermarket CD changers or aux inputs may have been optioned.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually, whichever comes first.
Filter Replacement:
Air filter: ~30,000 miles; Cabin filter: ~15,000 miles or annually; Fuel filter: High-quality, long-life, often not on a fixed schedule but checked.
Spark Plugs:
Approx. 100,000 miles (e.g., Bosch FGR7DQP+ or equivalent NGK equivalent like BKR6EQUP)
Fluid Specifications
Engine Oil:
SAE 5W-30 or 5W-40 synthetic oil meeting BMW LL-01 or LL-98 specifications. Capacity: Approx. 6.5 liters (6.9 US quarts).
Coolant:
BMW Blue Antifreeze/Coolant (G48 type), mixed 50/50 with distilled water. Capacity: Approx. 8.0 liters (8.5 US quarts).
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 synthetic gear oil. Capacity: Approx. 1.5 liters (1.6 US quarts).
Transmission Fluid Automatic:
ZF LifeguardFluid 5 (or equivalent ATF). Capacity: Approx. 7.0 liters (7.4 US quarts) for a dry fill.
Brake Fluid:
DOT 4 Low Viscosity (LV) or DOT 4 Plus. Changed every 2 years.
Known Issues
Cooling System:
Plastic expansion tank cracks, water pump failure (often plastic impeller), thermostat housing leaks.
Oil Leaks:
Valve cover gasket, oil pan gasket, oil filter housing gasket, CCV system leaks.
Suspension:
Worn control arm bushings (vibrations, steering wander), sway bar links, strut mounts.
Electrical:
Heater core O-rings, ABS/DSC sensor failures, VANOS solenoids, window regulator failures.
Engine Performance:
CCV (Crankcase Ventilation) system blockage leading to oil consumption and pressure issues.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Long history of producing performance-oriented, driver-focused luxury vehicles
Model Evolution
E46 Introduction:
The E46 generation replaced the E36 generation and was produced from 1998 to 2006 (model years vary by market).
325I Positioning:
Positioned as a mid-range model within the E46 lineup, offering a balance of performance and luxury, sitting above the 323i and below the 330i.
Production
Manufacturing Locations:
Primarily Dingolfing, Germany, with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E46 3-series (including variants close to the 325i) was a frequent recipient of Car and Driver's '10Best' list during its production run, highlighting its exceptional driving dynamics and overall value proposition.
Popular Mechanics Car Of The Year:
While specific awards for the 325i are numerous, the E46 generation as a whole was widely praised by automotive journalists for its blend of performance, luxury, and build quality.
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