BMW 330 330i 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 330i Model Designation: E46 Year: 2002 Generation Generation Code: E46 Generation Years: 1999-2006 Codes Chassis Code: E46 👋 Introduction Market Position Market Position:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Designation:

Year:

Generation

Generation Code:

Generation Years:

1999-2006

Codes

Chassis Code:

👋 Introduction

Market Position

Market Position:

The BMW 3 Series (E46) in 2002 represented the premium compact executive sedan segment, known for its sporty driving dynamics, refined interior, and advanced engineering. The 330i was positioned as a higher-performance variant within the popular E46 lineup.

Competitive Analysis

Competitive Analysis:

Competed directly with established rivals like the Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS (XE10), and Infiniti G20. The E46 3 Series was widely praised for its handling, driver engagement, and build quality.

Key Features

Key Features:

• Rear-wheel drive bias with optional xDrive (AWD) in some variants

• Inline-6 engine providing smooth power delivery

• Near 50/50 weight distribution for balanced handling

• Advanced suspension geometry for superior ride and handling

• Available in Sedan, Coupe, Convertible, and Wagon body styles (though this manual focuses on Sedan/Saloon variants for 330i)

📋 Manual Details

Coverage Areas

Coverage Areas:

• Engine Mechanical

• Engine Fuel & Emissions

• Engine Electrical

• Transmission (Manual & Automatic)

• Drivetrain & Axles

• Suspension

• Steering

• Brakes

• Body & Chassis

• Heating, Ventilation & Air Conditioning (HVAC)

• Electrical System & Components

• Diagnostic Procedures

• Troubleshooting

• Maintenance Procedures

Page Count

Page Count:

Hundreds of pages (specific count not provided but implies comprehensive)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Systems Covered:

• M54B30 Engine (3.0L Inline-6)

• ZF 5HP19 Automatic Transmission

• Getrag 420G Manual Transmission

• Servotronic Steering System

• ABS/DSC (Dynamic Stability Control)

• EHC (Electronic Height Control - if applicable to specific trims)

• BC (On-Board Computer) Systems

• Immobilizer System

• Airbag System

• HVAC System with Automatic Climate Control

• Halogen and Xenon Headlight Systems

• Body Control Module (BCM)

• Instrument Cluster and Gauges

• Audio Systems and Speaker Installation

• Central Locking System

• Power Window and Mirror Systems

• Lighting Systems (Interior & Exterior)

• Wiper and Washer Systems

Procedures Included

Procedures Included:

• Scheduled Maintenance (Oil changes, filter replacements, spark plugs, etc.)

• Engine Overhaul and Rebuilding

• Transmission Removal, Installation, and Rebuilding

• Brake System Service (Pads, rotors, fluid flush, caliper repair)

• Suspension Component Replacement (shocks, struts, control arms, bushings)

• Steering System Diagnosis and Repair

• Electrical Troubleshooting using wiring diagrams

• Component Diagnosis and Replacement (e.g., alternator, starter, fuel pump)

• Body Panel Repair and Alignment

• HVAC System Repair (compressor, evaporator, blower motor)

• Diagnostic Trouble Code (DTC) interpretation and resolution

• Fuel System Diagnosis and Service (injectors, fuel pump, filter)

• Exhaust System Repair and Replacement

• Cooling System Service and Repair

• Tire and Wheel Service

• Airbag System Inspection and Replacement Procedures

• Comfort System Adjustments and Repairs

Technical Depth

Technical Depth:

Comprehensive factory-level detail, covering basic maintenance to complete engine and transmission overhauls. Includes detailed diagnostic procedures, wiring diagrams, exploded views, and torque specifications. Suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, enabling clear printing of diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Displacement:

M54B30 / 3.0 Liter (2979 cc)

Engine Configuration:

Naturally Aspirated Inline 6-Cylinder (DOHC, 24 valves)

Performance

Horsepower:

225 hp @ 5900 rpm

Torque:

214 lb-ft (290 Nm) @ 3500 rpm

Redline:

6500 rpm

Fuel System

Fuel Induction:

Sequential Electronic Fuel Injection (Bosch Motronic ME7.2)

Fuel Type:

Premium Unleaded (91 Octane or higher recommended)

Emissions Control:

Dual Catalytic Converters, Secondary Air Injection System (SAI)

Cooling System

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based, 50/50 mix with distilled water)

Oil System

Oil Type Specification:

SAE 5W-30 Synthetic, API SN, ACEA A3/B4

Oil Capacity With Filter:

6.5 US quarts (6.2 Liters)

🔧 Transmission

Standard

Transmission Type Standard:

ZF 5HP19 5-speed Automatic

Optional

Transmission Type Optional:

Getrag 420G 6-speed Manual

Features

Automatic Transmission Features:

Steptronic (manual shifting mode), electronically controlled.

Manual Transmission Features

Manual Transmission Features:

Dual-mass flywheel, hydraulic clutch actuation.

Fluid Specifications

Automatic Transmission Fluid:

BMW ATF LT-71141 or equivalent (e.g., Pentosin ATF1)

Manual Transmission Fluid:

SAE 75W-90 Synthetic, API GL-4/GL-5

📐 Dimensions

Exterior

Wheelbase:

107.3 inches (2725 mm)

Length:

177.4 inches (4506 mm)

Width:

68.9 inches (1750 mm)

Height:

56.1 inches (1425 mm)

Weights

Curb Weight Approx:

3300 - 3500 lbs (1497 - 1588 kg) depending on transmission and options

Gross Vehicle Weight Rating Gvwr:

Approx. 4500 lbs (2041 kg)

Cargo

Trunk Volume:

13.6 cubic feet (385 liters)

Wheels Tires

Standard Wheel Size:

17 x 8.0 inch alloy

Standard Tire Size:

225/45R17

Wheel Bolt Pattern:

5x120mm

Center Bore:

72.5 mm

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

4/5 Stars (Driver & Passenger)

IIHS Front Offset Crash Test:

Active Features

Active Safety Features:

• Anti-lock Braking System (ABS)

• Dynamic Stability Control (DSC) / Traction Control

• Electronic Brakeforce Distribution (EBD)

• Brake Assist

Passive Features

Passive Safety Features:

• Frontal Airbags (Driver and Passenger)

• Side Airbags (Integrated into seat backs)

• Optional Head Protection System (HPS) airbags

• Pretensioner seatbelts

• Reinforced chassis construction

💡 Technology Features

Infotainment

Infotainment System:

BMW Professional Radio/Cassette or CD player, optional navigation system (CCC-Business or CCC-Professional) with integrated CD-ROM map data. Optional Harman Kardon audio system.

Driver Assistance

Driver Assistance Features:

Park Distance Control (PDC) available as an option.

Connectivity

Connectivity Features:

Optional Bluetooth integration for mobile phones (may require specific cradle/adapter depending on build date).

Comfort Features

Comfort Features:

• Automatic Climate Control

• Cruise Control

• Power adjustable front seats with memory for driver

• Rain-sensing wipers

• Auto-dimming rearview mirror

🔧 Maintenance

Service Intervals

Oil Change Interval:

Condition Based Service (CBS) system, typically every 10,000-15,000 miles (16,000-24,000 km) or annually. Refer to CBS display for exact intervals.

Spark Plug Replacement Interval:

Approx. 60,000 miles (96,000 km) for iridium plugs.

Coolant Flush Interval:

Every 2-3 years or 30,000-40,000 miles (48,000-64,000 km).

Brake Fluid Flush Interval:

Every 2 years, regardless of mileage.

Fluid Specifications

Power Steering Fluid:

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

Windshield Washer Fluid:

Water with BMW approved washer fluid concentrate.

Known Issues

Known Issues Common Problems:

• Cracked PCV (Positive Crankcase Ventilation) valve and hoses

• Cooling system leaks (water pump, thermostat housing, expansion tank)

• Oil separator system (CCV) issues leading to oil consumption and leaks

• VANOS (Variable Valve Timing) solenoid seals and unit issues

• Power steering hose leaks

• Subframe mounting points and chassis cracks (rear)

• ABS/DSC sensor failures

• Window regulator failures

• Ignition coil failures

• Worn shock mounts and bushings

Maintenance Parts Notes:

Importance of using OEM or high-quality aftermarket parts for reliability, especially for cooling system components and PCV system.

📚 Vehicle History

Brand Heritage

Brand Heritage:

BMW (Bayerische Motoren Werke AG) has a long and storied history dating back to 1916, renowned for producing performance-oriented luxury vehicles with a focus on driving dynamics and engineering excellence.

Model Evolution

Model Evolution E46:

The E46 generation, launched in 1999, was a significant evolution from the E36. It refined the driving experience, improved interior quality, and introduced more advanced technology and safety features. The 330i replaced the 328i as the top non-M performance model.

Production

Production Period:

The E46 generation was produced from 1999 to 2006. The 330i model was introduced in late 2000 for the 2001 model year, with the 2002 model falling within this primary production span.

Manufacturing Locations:

Primarily Dingolfing and Regensburg, Germany, with some assembly also occurring in other BMW facilities globally.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E46 3 Series, including variants like the 330i, was a frequent recipient of Car and Driver's '10Best' list during its production run, underscoring its benchmark status in the segment.

Industry Reputation:

Widely regarded by automotive journalists and enthusiasts as one of the best-driving sedans of its era, setting a high standard for handling, steering feel, and overall driver engagement.