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BMW 325xi 1999-2005 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325xi Model Code: E46 Generation Generation Name: Third Generation (E46) Generation Years: 1998-2006 (Global) Codes Chassis Code: E46 👋 Introduction Market Position Segment:...
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BMW 325xi 1999-2005 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325xi
Model Code:
E46
Generation
Generation Name:
Third Generation (E46)
Generation Years:
1998-2006 (Global)
Codes
Chassis Code:
E46
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Wagon
Brand Perception:
Sporty handling, premium build quality, driver-focused experience.
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS300, Acura TL.
Key Features
Performance Orientation:
Emphasis on driving dynamics, rear-wheel drive bias (even with AWD system).
Premium Interior:
High-quality materials, driver-centric cockpit design.
Xdrive AWD:
BMW's intelligent all-wheel-drive system providing enhanced traction and stability.
📋 Manual Details
Coverage Areas
Vehicle Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Model Variant:
325xi (AWD)
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Full Service and Repair Manual
Manual Purpose:
Comprehensive DIY and professional workshop guide
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, engine management (DME), turbocharger (if applicable to variant), timing systems.
Transmission Drivetrain:
Manual transmission (Getrag 420G), Automatic transmission (ZF 5HP19/24), xDrive all-wheel drive system, differentials, driveshafts, CV joints.
Suspension Steering:
Front suspension (MacPherson struts, multi-link), Rear suspension (multi-link Z-axle), power steering system, steering rack, suspension components, alignment specifications.
Brakes ABS:
Front/Rear disc brakes, hydraulic system, ABS (Anti-lock Braking System) components and diagnostics, DSC (Dynamic Stability Control), parking brake.
Electrical Electronics:
12V electrical system, battery, alternator, starter, lighting, body control module (BCM), fuse box diagrams, wiring diagrams, instrument cluster, comfort systems, diagnostics (OBD-II).
Body Chassis:
Body structure, exterior panels, doors, hood, trunk, interior trim, climate control HVAC, seats, glass, convertible top (if applicable).
Procedures Included
Maintenance Procedures:
Oil change, filter replacement, spark plug replacement, fluid checks and top-ups, brake pad/rotor replacement, belt inspection/replacement, coolant flush, air filter replacement.
Repair Procedures:
Engine component repair/replacement (e.g., head gasket, pistons), transmission overhaul, driveline component repair, suspension strut/shock absorber replacement, brake caliper overhaul, starter/alternator replacement.
Diagnostics Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, fault code interpretation (DME, ABS, SRS), wiring harness troubleshooting, component testing.
Special Tools Procedures:
Identification and usage of specialized BMW tools required for specific repairs (e.g., flywheel locking tools, spring compressor sets, diagnostic interfaces).
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds, detailed electrical schematics).
Diagnostic Coverage:
In-depth coverage of diagnostic trouble codes (DTCs) and step-by-step troubleshooting guides.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Image Resolution:
High-resolution diagrams and illustrations.
Document Clarity:
Clear, professional layout and formatting.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Family:
M54
Engine Code:
M54B30
Displacement:
2.979 cc (3.0 Liters)
Configuration:
Inline-6 Cylinder (Straight-six)
Bore X Stroke:
84.0 mm x 89.6 mm
Compression Ratio:
10.2:1
Valvetrain:
DOHC, 24 valves (4 per cylinder), Double VANOS (Variable Valve Timing)
Performance
Horsepower Hp:
225 hp @ 5,900 rpm
Torque Lb-Ft:
214 lb-ft @ 3,500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (MFI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane Recommended)
Engine Management:
Bosch Motronic ME7.2 Digital Motor Electronics
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission (Getrag 420G)
Optional
Transmission Type:
5-Speed Steptronic Automatic Transmission (ZF 5HP19/24)
Features
Drivetrain:
xDrive All-Wheel Drive System (Permanent)
AWD Power Distribution:
Typically 38% front, 62% rear bias, variable based on traction.
📐 Dimensions
Exterior
Length:
4,471 mm (176.0 in)
Width:
1,739 mm (68.5 in)
Height:
1,415 mm (55.7 in)
Wheelbase:
2,725 mm (107.3 in)
Front Track:
1,471 mm (57.9 in)
Rear Track:
1,494 mm (58.8 in)
Cargo
Trunk Volume:
430 Liters (15.2 cu ft)
Weights
Curb Weight Manual:
Approx. 1,540 kg (3,395 lbs)
Curb Weight Automatic:
Approx. 1,565 kg (3,450 lbs)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
5-Star
NHTSA Frontal Passenger:
5-Star
IIHS Side Impact:
Good (for models equipped with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System
Dsc:
Standard Dynamic Stability Control (DSC)
Traction Control:
Standard Automatic Stability Control (ASC+T)
Passive Features
Airbags:
Front dual-stage airbags, optional front side-impact airbags, optional front and rear head protection system (HPS).
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters.
Body Structure:
Reinforced safety cage, crumple zones.
💡 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
Parking Assistance:
Optional rear parking sensors (Park Distance Control - PDC).
Cruise Control:
Standard cruise control.
Connectivity
Phone Integration:
Optional Bluetooth interface or older cellular phone cradles.
Diagnostics Interface:
OBD-II port, typically requires BMW-specific diagnostic software (e.g., INPA, ISTA/D) for full access.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually.
Spark Plug Replacement:
Typically every 60,000 - 100,000 miles depending on plug type (e.g., Long Life Iridium).
Coolant Flush:
Every 2-4 years or 30,000-50,000 miles.
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or LL-04 approved synthetic oil, viscosity 5W-30 or 5W-40.
Engine Oil Capacity:
6.5 Liters (approx. 6.9 US quarts)
Coolant Type:
BMW Blue/Green Antifreeze/Coolant, mixed 50/50 with distilled water.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, specific viscosity depending on BMW recommendation (e.g., 75W-90).
Transmission Fluid Automatic:
ZF Lifeguardfluid 5 (or equivalent like Esso JWS 3309/Texaco ETL-7045E), requires filter kit and gasket.
Brake Fluid Type:
DOT 4 (preferably DOT 4 LV for improved low-temperature performance).
Known Issues
Cooling System:
Plastic coolant expansion tank prone to cracking, water pump failure (often plastic impeller), radiator leaks, VANOS O-ring degradation.
Engine:
Oil leaks from valve cover gasket and oil pan gasket, CCV (Crankcase Ventilation) system clogging leading to rough idle and oil consumption, VANOS solenoid failure causing rattling or performance issues.
Suspension:
Front control arm bushings wear, rear shock mounts fail, subframe mounting points can crack.
Electrical:
LCM (Light Module Control) failure, window regulator failures, dead pixels on instrument cluster, ABS/DSC sensor failures.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Founded in 1916, renowned for performance, engineering, and luxury.
Model Evolution
E46 Introduction:
Launched in 1998 as a successor to the E36, marked a significant design and engineering update.
325Xi Positioning:
Introduced as part of the E46 lineup to offer all-wheel-drive capability in the 3-series, enhancing all-weather performance.
Production
Manufacturing Locations:
Primarily Dingolfing, Germany; also assembled in other BMW plants globally.
E46 Production Years:
1998-2006
🏆 Awards & Recognition
Recognitions
Car And Driver:
Car and Driver's 10Best list multiple times during the E46 generation for various models.
Ratings
Consumer Reports:
Generally good reliability ratings for the E46 generation, though some model years and specific components received average or below-average ratings.
Certifications
Emission Standards:
Meets EPA and CARB emission standards for its model years.
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