BMW 325I 325XI Digital Workshop Repair Manual 1999-2005
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i, 325xi Generation Code: E46 Year: 1999-2005 👋 Introduction Market Position Vehicle Class: Compact Executive Car (Sport Sedan/Coupe) Target Audience: Enthusiasts, DIY mechanics, professional repair shops seeking detailed information for the E46 3 Series Competitive Analysis Key Competitors: Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35 Key Features Powertrain Options: Renowned inline-six engines (M54 series), RWD and AWD (xi) drivetrains Driving Dynamics: Exceptional handling, balanced chassis, engaging driving experience Build Quality: Premium interior materials, solid construction Manual Value Proposition: Comprehensive coverage for maintenance, diagnostics, and repair of complex systems, enabling cost-effective ownership 📋 Manual Details Coverage Areas Manual Type: Digital Workshop Repair Manual Language: English Format: Digital (likely PDF or similar) Page Count: Estimated: 500-1500+ pages (typical for comprehensive workshop manuals) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, block, pistons, connecting rods, crankshaft, lubrication, cooling systems Engine Management: Fuel injection (MS43, MS45), ignition system, emissions control (secondary air injection, EVAP), sensors, actuators, engine control unit (ECU) diagnostics Transmission Manual: Gearbox assembly, disassembly, clutch, shift linkage, maintenance Transmission Automatic: GM 5L40-E gearbox: assembly, disassembly, torque converter, valve body, hydraulic system, electronic controls, maintenance Drivetrain: Driveshafts, constant velocity (CV) joints, differential, axle shafts, wheel bearings (especially for xi models with AWD) Suspension: Front suspension (MacPherson strut, control arms, sway bar), rear suspension (multi-link), shock absorbers, springs, bushings, alignment specifications Steering: Power steering system, steering rack, steering column, steering wheel removal/installation Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid specifications, bleeding procedures, component replacement Electrical System: 12V battery system, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), horn Body And Chassis: Body panels, doors, hood, trunk lid, bumpers, glass, interior trim, chassis structure HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant, blower motor, evaporator, condenser, heater core Infotainment And Comfort: Radio/stereo system, speakers, power windows, power seats, sunroof, central locking, keyless entry Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, fluid checks and top-offs Diagnostic Troubleshooting: Step-by-step diagnostic procedures for common symptoms, using OBD-II codes, electrical troubleshooting guides Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper and rotor replacement, steering rack rebuild/replacement Component Replacement: Detailed instructions for replacing virtually all major and minor components Wiring Diagrams: Comprehensive electrical wiring schematics for all vehicle systems Torque Specifications: Accurate torque values for all critical fasteners Technical Depth Diagnostic Capability: Advanced diagnostic procedures, including interpretation of fault codes and live data streams (requiring compatible scan tools) Rebuild Procedures: Complete rebuild instructions for engines, transmissions, and other major assemblies Special Tools: Identification and usage instructions for specialized BMW tools required for certain repairs Schematic Diagrams: Detailed mechanical and electrical schematics 📊 Manual Specifications File Format File Type: Digital (PDF, HTML, or proprietary format) Searchability: Likely searchable text content for quick information retrieval Print Quality: Printable pages, allowing for physical copies of specific sections or the entire manual Binding Type: Not applicable for digital format (user can choose binding if printed) Paper Type: Not applicable for digital format (user can choose paper type if printed) ⚙️ Engine Specifications Primary Engine Engine Code: M54B30 (3.0L) Engine Type: 3.0L 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 Performance Horsepower: 225 hp @ 5900 rpm Torque: 214 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (Bosch Motronic MS43/MS45) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) 🔧 Transmission Standard Type: 6-Speed Manual (Getrag S6-37) Optional Type: 5-Speed Automatic (GM 5L40-E) Features Drivetrain Options: Rear-Wheel Drive (RWD) or All-Wheel Drive (xDrive / xi) 📐 Dimensions Exterior Wheelbase: Approx. 107.4 inches (2728 mm) Length: Approx. 177.4 inches (4506 mm) Width: Approx. 68.7 inches (1745 mm) Height: Approx. 55.1 inches (1400 mm) Weights Curb Weight: Approx. 3300 - 3550 lbs (1500 - 1610 kg) depending on configuration 🛡️ Safety Features Ratings NHTSA Front Impact: 5 Stars (for driver and front passenger) IIHS Side Impact: Good (for models tested) Active Features Traction Control: Automatic Stability Control (ASC) / Dynamic Traction Control (DTC) Stability Control: Dynamic Stability Control (DSC) ABS: Anti-lock Braking System (ABS) Passive Features Airbags: Front airbags, optional side airbags Seatbelts: Three-point seatbelts with pretensioners 💡 Technology Features Infotainment Head Unit Options: Various factory radio units, including CD players and optional navigation systems (e.g., MkIV navigation). Audio System: Standard 6-speaker system, optional Harman Kardon sound system. Driver Assistance Stability Control Features: DSC and DTC provide active safety interventions for stability and traction. Parking Assistance: Optional rear parking sensors (Park Distance Control - PDC). Connectivity Remote Key: Standard key fob with remote central locking; optional alarm system. 🔧 Maintenance Service Intervals Oil Change Interval:...
Fuel injection (MS43, MS45), ignition system, emissions control (secondary air injection, EVAP), sensors, actuators, engine control unit (ECU) diagnostics
Premium Unleaded Gasoline (91 octane or higher recommended)
🔧 Transmission
Standard
Type:
6-Speed Manual (Getrag S6-37)
Optional
Type:
5-Speed Automatic (GM 5L40-E)
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) or All-Wheel Drive (xDrive / xi)
📐 Dimensions
Exterior
Wheelbase:
Approx. 107.4 inches (2728 mm)
Length:
Approx. 177.4 inches (4506 mm)
Width:
Approx. 68.7 inches (1745 mm)
Height:
Approx. 55.1 inches (1400 mm)
Weights
Curb Weight:
Approx. 3300 - 3550 lbs (1500 - 1610 kg) depending on configuration
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5 Stars (for driver and front passenger)
IIHS Side Impact:
Good (for models tested)
Active Features
Traction Control:
Automatic Stability Control (ASC) / Dynamic Traction Control (DTC)
Stability Control:
Dynamic Stability Control (DSC)
ABS:
Anti-lock Braking System (ABS)
Passive Features
Airbags:
Front airbags, optional side airbags
Seatbelts:
Three-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Head Unit Options:
Various factory radio units, including CD players and optional navigation systems (e.g., MkIV navigation).
Audio System:
Standard 6-speaker system, optional Harman Kardon sound system.
Driver Assistance
Stability Control Features:
DSC and DTC provide active safety interventions for stability and traction.
Parking Assistance:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Remote Key:
Standard key fob with remote central locking; optional alarm system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable Oil Service (Condition Based Service - CBS) typically 10,000-15,000 miles or annually, whichever comes first. Consult manual for specific interval.
Spark Plug Replacement:
Approximately 60,000 miles (100,000 km) for iridium plugs.
Coolant Flush:
Recommended every 2-3 years or 30,000-50,000 miles.
Brake Fluid Flush:
Recommended every 2 years.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) approved synthetic oil, typically 5W-30 or 5W-40.
Engine Oil Capacity:
6.5 quarts (6.2 Liters) with filter for M54B30.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 formulation) or equivalent silicate-free antifreeze.
Transmission Fluid Manual:
SAE 75W-90 synthetic gear oil (BMW recommends their own fluid or equivalent).
Transmission Fluid Automatic:
GM Dexron III or Dexron VI (consult manual for specific sub-model requirement) for 5L40-E.
Brake Fluid Type:
DOT 4 Low Viscosity (LV) brake fluid.
Known Issues
Cooling System:
Plastic expansion tank failures, water pump bearing failure, radiator leaks, thermostat housing leaks.
Oil Leaks:
Valve cover gasket, oil pan gasket, oil filter housing gasket, OFHG (Oil Filter Housing Gasket) are common failure points.
Ccv System:
Crankcase Ventilation (CCV) system failure can lead to oil consumption and vacuum leaks.
Suspension Wear:
Front control arm bushings, rear subframe bushings, and ball joints are common wear items.
Window Regulators:
Plastic components in power window regulators often fail.
ABS Wheel Speed Sensors:
Front ABS sensors are prone to failure, affecting ABS and DSC functionality.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Sheer Driving Pleasure - focus on performance, handling, and driver engagement
Model Evolution
E46 Introduction:
Introduced in 1998 (for model year 1999), succeeding the E36 generation
E46 Facelift:
Significant facelift (LCI) in 2001/2002 with updated styling and some mechanical improvements
E46 Variants:
Offered as Sedan, Coupe, Convertible, and Wagon (Touring) body styles. 325i and 325xi are specific sedan/wagon variants.