BMW 325xi 2003 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 325xi Year: 2003 Codes Chassis Code: E46 Engine Code Prefix: M54 👋 Introduction Market Position Segment: Compact Executive Sedan/Wagon Usp: Sporty handling, luxury...

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标签: 2003 325xi BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

325xi

Year:

Codes

Chassis Code:

Engine Code Prefix:

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Wagon

Sporty handling, luxury features, rear-wheel-drive bias (with xDrive all-wheel-drive variant)

Competitive Analysis

Key Competitors:

Audi A4, Mercedes-Benz C-Class, Lexus IS, Infiniti G35

Key Features

Powertrain:

Renowned BMW inline-six engines, optional xDrive all-wheel-drive system

Driving Dynamics:

Balanced chassis, precise steering, engaging driving experience

Interior Appointments:

Driver-focused cockpit, premium materials, ergonomic design

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Full service and repair instructions

Page Count

Estimated Page Count:

Approx. 1500-2500 pages (typical for comprehensive BMW workshop manuals of this era)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Likely PDF (digital format) or Printed Book

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system

Engine Management:

Fuel injection, ignition system, emission control systems, engine control unit (ECU) diagnosis

Transmission:

Manual transmission (SMG optional), automatic transmission (Steptronic), clutch, torque converter, transmission control

Drivetrain:

All-wheel drive (xDrive) system, front and rear differentials, drive shafts, CV joints

Suspension:

Front suspension (MacPherson strut, multi-link), rear suspension (multi-link), shock absorbers, springs, control arms, subframes

Brakes:

Hydraulic brake system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake discs, pads, calipers, brake lines, parking brake

Steering:

Power steering system, steering rack, steering column, wheel alignment

Electrical System:

Battery, charging system (alternator), starter motor, lighting system, power windows, locks, mirrors, wipers, horn

Body And Interior:

Body panels, doors, hoods, trunk, bumpers, interior trim, seats, airbags, climate control system (HVAC)

Body Electronics:

Central body electronics module (ZKE), remote control, alarm system, immobilizer

Infotainment:

Radio, CD player, navigation system (optional), speaker system

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, brake inspections

Troubleshooting:

Diagnostic procedures for common and complex issues, symptom-based troubleshooting guides

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation

Diagnostic Trouble Codes:

Explanation and interpretation of OBD-II diagnostic trouble codes (DTCs)

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems

Specifications And Tolerances:

Torque specifications, clearances, fluid capacities, and other critical measurements

Technical Depth

Depth Of Information:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds

Diagnostic Capabilities:

Advanced diagnostic procedures, including the use of BMW-specific diagnostic tools (e.g., DIS, ISTA/E)

Repair Complexity:

Suitable for both DIY enthusiasts and professional mechanics

📊 Manual Specifications

File Format

Digital Format Details:

Searchable text, hyperlinked chapters, bookmark functionality (typical for high-quality PDFs)

Print Quality

Print Quality Description:

High-resolution diagrams and clear text, suitable for printing

Binding Type

Binding Description:

Professional binding (e.g., perfect bound, spiral bound) for durability if printed

Paper Type

Paper Type Description:

Durable, high-quality paper stock resistant to workshop conditions if printed

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B30

Engine Type:

Naturally Aspirated Inline 6-Cylinder

Displacement:

2979 cc (3.0 Liters)

Bore X Stroke:

84.0 mm x 89.6 mm

Compression Ratio:

10.2:1

Valve Train:

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

Performance

Horsepower:

225 hp @ 6000 rpm

Torque:

214 lb-ft (290 Nm) @ 3500 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Ignition System:

Distributorless Electronic Ignition (DIS) with Coil-on-Plug (COP) ignition coils

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission (Getrag Type G)

Optional

Type:

5-Speed Steptronic Automatic Transmission (GM 5L40-E)

Type Sport:

5-Speed SMG (Sequential Manual Gearbox) - less common for 325xi

Features

All Wheel Drive:

xDrive permanent all-wheel-drive system with viscous coupling and planetary gear center differential

Automatic Features:

Steptronic manual shifting mode

📐 Dimensions

Exterior

Length:

177.4 inches (4506 mm)

Width:

68.7 inches (1745 mm)

Height:

55.5 inches (1410 mm)

Wheelbase:

107.0 inches (2718 mm)

Front Track:

58.7 inches (1491 mm)

Rear Track:

59.2 inches (1504 mm)

Cargo

Trunk Volume Sedan:

11.7 cubic feet (331 Liters)

Weights

Curb Weight Manual:

3516 lbs (1595 kg)

Curb Weight Automatic:

3571 lbs (1620 kg)

Gross Vehicle Weight Rating:

4519 lbs (2050 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test:

5-Star (Driver), 4-Star (Passenger)

IIHS Frontal Offset:

Active Features

Traction Control:

ASC+T (Automatic Stability Control + Traction) standard

Stability Control:

DSC (Dynamic Stability Control) standard

Antilock Brakes:

ABS (Anti-lock Braking System) standard

All Wheel Drive Benefit:

Enhanced traction and stability, especially in adverse weather conditions

Passive Features

Airbags:

Frontal airbags (driver and passenger), front side-impact airbags, front and rear head protection system (optional/standard based on market)

Seatbelts:

Pretensioning front seatbelts with force limiters

Chassis Design:

High-strength steel passenger cell, crumple zones

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD/RDS or Professional CD/RDS radio/cassette, optional CD changer

Navigation:

Optional MKIV (Mk4) navigation system with DVD-ROM maps

Driver Assistance

Cruise Control:

Standard cruise control system

Connectivity

Audio Inputs:

Typically auxiliary inputs are not standard on this model year, though aftermarket solutions exist.

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) system typically recommends intervals of 10,000-15,000 miles or based on driving conditions. Manual will provide specific guidance.

Spark Plug Replacement:

Typically around 60,000-100,000 miles depending on plug type and condition. Manual will specify.

Coolant Flush:

BMW recommends every 2-4 years or 30,000-60,000 miles. Manual will detail exact procedure and fluid.

Fluid Specifications

Engine Oil:

BMW Longlife-01 (LL-01) approved 5W-30 or 0W-30 synthetic oil. Manual will list exact capacity.

Coolant:

BMW Blue Antifreeze/Coolant, typically a 50/50 mix with distilled water. Manual will specify type and capacity.

Brake Fluid:

DOT 4 Low Viscosity (LV) brake fluid. Manual will specify replacement interval and procedure.

Transmission Fluid Automatic:

BMW ATF LT 71141 or equivalent synthetic ATF. Manual will specify replacement interval and capacity.

Transmission Fluid Manual:

BMW MTF LT-2 or equivalent synthetic manual transmission fluid. Manual will specify capacity.

Differential Fluid:

BMW SAF-XJ or equivalent synthetic rear differential fluid. Manual will specify capacity.

Known Issues

Ccv System:

Crankcase Ventilation (CCV) system failure leading to oil consumption, vacuum leaks, and poor running. Manual will detail inspection and replacement.

Cooling System:

Plastic coolant expansion tanks and water pumps prone to cracking or failure. Thermostat housing leaks. Manual will cover replacement procedures.

Oil Pan Gasket:

Oil pan gasket and rear main crankshaft seal leaks are common with age. Manual will detail R&R procedures.

E46 Subframe:

Cracking or separation of the rear subframe mounting points due to chassis flex, especially in sedans. Manual will show reinforcement options.

Window Regulators:

Plastic components in window regulators can break. Manual will cover repair or replacement.

📚 Vehicle History

Brand Heritage

Brand Philosophy:

Sheer Driving Pleasure, engineering excellence, performance focus

Model Evolution

E46 Generation:

Fourth generation 3 Series, introduced in 1998 for the 1999 model year, received a facelift for 2002 models.

325Xi Introduction:

The xDrive all-wheel-drive system was introduced to the E46 sedan and wagon lineup for the 2001 model year, with the 325xi becoming a popular choice.

Production

Production Era:

E46 generation: 1998-2006 (Sedan/Wagon), 1999-2006 (Coupe/Convertible)

Manufacturing Locations:

Primarily Germany (Dingolfing, Munich), with some assembly in other international locations.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E46 3 Series platform was a frequent recipient of Car and Driver's '10Best' awards during its production run.

Ratings

Consumer Reports:

Generally received good ratings for performance and driving dynamics, though some reliability concerns emerged with age, particularly related to cooling and electrical systems.