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BMW 325xi-3 Series (E46) 1999-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E46 Variant: 325xi Codes Engine Code Typical: M54B25 Chassis Code Full: E46 (all-wheel drive variant) 👋 Introduction Market Position...
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BMW 325xi-3 Series (E46) 1999-2005 Workshop Service Repair ManualBMW 325xi-3 Series (E46) 1999-2005 Workshop Service Repair ManualBMW 325xi-3 Series (E46) 1999-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Variant:
325xi
Codes
Engine Code Typical:
M54B25
Chassis Code Full:
E46 (all-wheel drive variant)
👋 Introduction
Market Position
Vehicle Class:
Compact Executive Sedan/Wagon (3 Series E46)
Target Audience:
Discerning drivers valuing performance, luxury, and a sporting feel.
Competitive Analysis
Key Competitors:
Audi A4 Quattro, Mercedes-Benz C-Class 4MATIC, Lexus IS300 AWD.
Key Features
Drivetrain:
xDrive all-wheel drive system providing enhanced traction and stability.
Engine Smoothness:
Renowned inline-six smoothness and power delivery.
Handling:
Excellent chassis dynamics and balanced handling characteristic of BMW.
Manual Purpose
Value Proposition:
Enables owners and independent mechanics to perform maintenance and repairs accurately, saving on dealership costs and ensuring proper vehicle upkeep.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Manual Origin:
Official Full Factory Service Manual
Language:
English
Format Description:
Printable hundreds of pages, allowing for full printout or selective page printing.
Page Count
Estimated Pages:
Hundreds (exact count not specified but implies substantial detail)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (M54B25), Transmission (e.g., GM A5S325Z automatic, Getrag S5D 250G manual), Drivetrain (xDrive all-wheel drive system)
Chassis:
Suspension (front MacPherson strut, rear multi-link), Steering (rack and pinion with hydraulic assist), Brakes (front ventilated discs, rear solid discs with ABS, DSC)
Electrical:
12V system, charging system, starting system, lighting, instrumentation, body electronics, DME (Digital Motor Electronics), EWS (Electronic Immobilizer System), various control modules
Bodywork:
Body panel removal/installation, interior trim, exterior trim, doors, windows, sunroof, bumpers, chassis repair
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug service, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), brake pad/rotor replacement, belt inspection/replacement
Diagnostics:
Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs) interpretation, component testing procedures, wiring diagrams
Repair:
Engine component replacement (e.g., valve cover gasket, oil pan gasket, cooling system components, fuel injectors), transmission service and repair, suspension and steering component replacement, brake system overhaul, electrical component diagnosis and replacement, exhaust system repair
Special Procedures:
Component removal and installation with torque specifications, specialized tool requirements, alignment procedures, clutch replacement (manual transmission), radiator/water pump replacement, VANOS (Variable Valve Timing) system diagnosis and repair
Technical Depth
Depth:
Comprehensive, covering everything from routine maintenance to major component overhauls and troubleshooting.
Diagnostic Focus:
Detailed electrical schematics, pinpoint tests for electrical faults, sensor data interpretation.
Rebuild Information:
Likely includes specifications for engine and transmission rebuilding, though major component rebuilds might be more conceptual or refer to specialized rebuilders.
📊 Manual Specifications
File Format
Digital Format:
PDF (implied by 'hundreds of pages allow you to print it out')
Searchability:
Likely searchable if it's a well-produced PDF, enhancing usability.
Print Quality
Page Quality:
High-quality, factory-level detail suitable for printing.
Binding Type
Physical Binding:
Not specified (as it's a printable file), but a professional print shop would recommend a durable binding like spiral or comb binding.
Paper Type
Suggested Paper:
Standard printer paper (8.5x11 inches) or A4 for optimal printing. Glossy paper not recommended for technical diagrams.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Engine Displacement:
2.5 Liters (2494 cc)
Engine Code:
M54B25
Bore X Stroke:
84.0 mm x 75.0 mm
Compression Ratio:
10.2:1
Valve Train:
Dual Overhead Camshafts (DOHC), 24 Valves, Double VANOS
Performance
Horsepower Est:
184 hp @ 6000 rpm
Torque Est:
235 Nm (173 lb-ft) @ 3500 rpm
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (Bosch Motronic DME)
Recommended Fuel:
Premium Unleaded (91 Octane or higher)
Cooling System
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 or equivalent)
Coolant Capacity Est:
8.5 Liters (8.9 Quarts)
🔧 Transmission
Standard
Type Automatic:
5-speed GM A5S325Z (Steptronic optional)
Optional
Type Manual:
5-speed Getrag S5D 250G
Features
Drivetrain:
xDrive All-Wheel Drive System with variable torque distribution
Fluid Specs
Automatic Transmission Fluid:
Dexron III or Dexron VI (specific BMW P/N often recommended, e.g., 83229407807 for Dexron III)
Manual Transmission Fluid:
BMW MTF LT-2 (or equivalent SAE 75W-90 GL-4/GL-5 synthetic)
📐 Dimensions
Exterior
Length Est:
4471 mm (176.0 inches)
Width Est:
1739 mm (68.5 inches)
Height Est:
1415 mm (55.7 inches)
Wheelbase Est:
2760 mm (108.7 inches)
Weights
Curb Weight Est:
1550 - 1600 kg (3417 - 3527 lbs)
Gross Vehicle Weight Rating Est:
2000 kg (4409 lbs)
Wheels Tires
Wheel Bolt Pattern:
5x120
Center Bore:
72.5 mm
Typical Tire Size Front:
225/45R17
Typical Tire Size Rear:
225/45R17
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (for E46 Sedan)
IIHS Side Impact:
Good (for E46 Sedan)
Active Features
Traction Control:
Dynamic Traction Control (DTC)
Stability Control:
Dynamic Stability Control (DSC)
Braking System:
Anti-lock Braking System (ABS)
Passive Features
Airbags:
Frontal airbags, side-impact airbags (front), optional rear side airbags.
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters.
Chassis Design:
Reinforced safety cell, crumple zones.
💡 Technology Features
Infotainment
Head Unit Options:
Various BMW Business and Professional CD/Radio units, often with optional navigation system (MKIV).
Audio System:
Standard 6-speaker system, optional Hi-Fi system with amplifier, optional Harman Kardon system.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Assistance:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Phone Integration:
Optional Bluetooth preparation with cradle and hands-free system.
Lighting
Headlights:
Standard reflector headlights, optional Xenon (HID) headlights with auto-leveling and headlight washers.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically every 10,000-15,000 miles or annually, whichever comes first.
Air Filter Replacement:
Check every 15,000 miles, replace as needed or approximately every 30,000 miles.
Spark Plug Replacement:
NGK BKR6EQUP (or equivalent), replace approximately every 60,000 miles.
Coolant Flush:
Every 2-4 years or as indicated by CBS.
Brake Fluid Flush:
Every 2 years (DOT 4 specification).
Fluid Specifications
Engine Oil Capacity:
6.5 Liters (6.9 Quarts) with filter change.
Recommended Engine Oil:
BMW Longlife-01 (LL-01) or LL-04 synthetic oil, 5W-30 or 5W-40 viscosity grade.
Power Steering Fluid:
Pentosin CHF 11S or equivalent.
Known Issues
Cooling System:
Plastic coolant expansion tank (prone to cracking), water pump failure (often plastic impeller), thermostat housing leaks.
Engine Performance:
VANOS (Variable Valve Timing) solenoids and seals can degrade, leading to rough idle and power loss. Oil leaks from valve cover gasket, oil filter housing gasket, and oil pan gasket.
Suspension:
Front control arm bushings (vibration and steering wheel shimmy), rear trailing arm bushings, strut mounts.
Electrical:
ABS/DSC module failure (common), rear light module corrosion, power window regulators.
Drivetrain X Drive:
Transfer case actuator or motor issues, front differential seals.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Sheer Driving Pleasure - emphasis on driver engagement and engineering excellence.
Model Evolution
E46 Generation Introduction:
Launched in 1998 (as a 1999 model year), replacing the E36 generation. The 325xi variant was introduced later in the E46 lifecycle.
E46 Facelift:
Significant facelift ('LCI') introduced for the 2002 model year, with updated styling, interior refinements, and powertrain improvements.
325Xi Placement:
Positioned as a capable all-season performance variant within the 3 Series lineup.
Production
Production Years:
1999-2006 (for E46 generation, 325xi production likely within this range, specifically covering 1999-2005 as per manual title)
Manufacturing Locations:
Germany (Dingolfing, Munich), Austria (Graz - Magna Steyr), South Africa, Thailand, Egypt, Russia, China, Brazil, India, Mexico.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
E46 3 Series was a consistent recipient of Car and Driver's 10Best award during its production run, highlighting its excellent driving dynamics.
Top Gear Magazine:
Frequently praised by automotive journalists for its balance of performance, comfort, and practicality.
Certifications
Safety Certifications:
Achieved strong safety ratings in contemporary crash tests (e.g., IIHS, Euro NCAP).
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