BMW Sport Wagon 1999-2005 Workshop Service Manual Repair
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Sport Wagon Model Code: E46 Touring Applicable Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Codes Platform Code: E46 👋 Introduction Market Position Segment: Premium Compact Executive Sport Wagon Target Audience: Enthusiasts, DIY mechanics, professional repair shops Competitive Analysis Key Competitors: Audi A4 Avant, Mercedes-Benz C-Class Estate, Volvo V40/V50 (early years) Key Features Vehicle Selling Points: Rear-wheel drive dynamics (or xDrive AWD), premium interior, sporty handling, versatile cargo space Manual Value Proposition: Empowers owners to perform comprehensive maintenance and repairs, saving on labor costs and ensuring optimal vehicle performance. 📋 Manual Details Coverage Areas Primary Coverage: Complete Workshop Service and Repair Engine Coverage: All gasoline and diesel engines for the E46 Touring platform Transmission Coverage: Manual and Automatic Transmissions Chassis Coverage: Suspension, Steering, Brakes, Wheels, Tires Electrical Coverage: Engine Management, Body Electronics, Lighting, Infotainment, Diagnostics Body Coverage: Exterior, Interior, Safety Systems, Climate Control Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel injection, ignition, exhaust, cooling, lubrication, drivetrain (driveshafts, differentials) Chassis Suspension Steering: Front/rear suspension, shock absorbers, springs, control arms, sway bars, power steering system, steering rack Brakes Wheels Tires: Hydraulic system, ABS, EBD, brake discs, pads, calipers, parking brake, wheel bearing replacement, tire pressure monitoring (if applicable) Electrical Electronics: Starter, alternator, battery, wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior), power windows, mirrors, central locking, instrument cluster Body Interior: Body panels, doors, hood, tailgate, bumpers, interior trim, seats, airbags, climate control (HVAC), infotainment system Diagnostics: OBD-II troubleshooting, diagnostic trouble codes (DTCs), sensor testing, ECU functions Procedures Included Maintenance: Oil changes, filter replacements, fluid flushes (coolant, brake, power steering), spark plug replacement, belt inspection/replacement, air filter replacement Repair Overhaul: Engine overhaul, transmission rebuild, suspension component replacement, brake system repair, electrical component diagnosis and replacement, body panel repair Troubleshooting: Step-by-step diagnostic guides for common and uncommon issues, symptom-based troubleshooting trees Specifications Data: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters Technical Depth Depth: Comprehensive; covers everything from basic routine maintenance to complex system overhauls and diagnostics Detail Level: Detailed step-by-step instructions with illustrations and diagrams Special Tools: Lists and descriptions of specialized tools required for specific procedures 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable text for quick information retrieval Print Quality: High-resolution, suitable for printing individual pages or sections Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Completeness Scope: Factory-level comprehensive service information ⚙️ Engine Specifications Primary Engine Common Engines: 2.5L Inline-6 (M54B25), 3.0L Inline-6 (M54B30), 2.0L Inline-4 (M43/N42 variants), 2.0L/2.5L/3.0L Diesel (M47, M57 variants) Performance Horsepower Range: Approx. 163 hp to 231 hp (gasoline), 136 hp to 184 hp (diesel) Torque Range: Approx. 220 Nm to 300 Nm (gasoline), 280 Nm to 410 Nm (diesel) Fuel System Injection Type: Sequential Multi-Point Fuel Injection (MPI), Common Rail Direct Injection (CRDi) for diesel Fuel Type: Unleaded gasoline (RON 91+), Diesel fuel Engine Management ECU Type: Siemens MS43/MS45, Bosch Motronic, EDC15/EDC16 (diesel) Cooling System Coolant Type: BMW Blue or Pentosin NF (Ethylene Glycol based) Lubrication Oil Type Gasoline: SAE 5W-30 or 5W-40, BMW LL-01 Approved (e.g., Castrol Syntec) Oil Type Diesel: SAE 5W-30 or 0W-30, BMW LL-04 Approved 🔧 Transmission Standard Manual Transmission: 5-speed Getrag GS53Z (e.g., for 325i), 6-speed ZF S6-37/S6-45 (e.g., for 330i) Optional Automatic Transmission: 5-speed ZF 5HP19FL/ZFL (e.g., for 325i), 5-speed ZF 5HP24Z (e.g., for 330i) Features All Wheel Drive: Optional xDrive (model dependent, primarily later years) Fluid Specifications Manual Transmission Fluid: GL-4 or GL-5 rated gear oil, specific viscosity per model (e.g., SAE 75W-90) Automatic Transmission Fluid: ZF LifeguardFluid 5 or equivalent (e.g., Pentosin ATF1) 📐 Dimensions Exterior Length: Approx. 4471 mm (176.0 inches) Width: Approx. 1739 mm (68.5 inches) Height: Approx. 1407 mm (55.4 inches) Wheelbase: Approx. 2725 mm (107.3 inches) Cargo Cargo Volume: Approx. 435-1450 liters (15.4-51.2 cubic feet) with rear seats folded Weights Curb Weight Range: Approx. 1450 kg to 1650 kg (3200 lbs to 3640 lbs) Towing Capacity: Typically not specified or limited for this model in many markets 🛡️ Safety Features Ratings NHTSA Front Impact: Likely 4-star (based on sedan counterpart, specific wagon ratings may vary) IIHS Side Impact: Likely Good (based on sedan counterpart, specific wagon ratings may vary) Active Features ABS: Standard Anti-lock Braking System Traction Control: Standard Dynamic Stability Control (DSC) or Traction Control System (TCS) Brake Assist: Optional or standard on later models Passive Features Airbags: Front dual-stage airbags, front side-impact airbags, optional head protection airbags Seatbelts: 3-point inertia-reel seatbelts with pretensioners and force limiters Child Seat Anchors: ISOFIX/LATCH system (standard on rear seats) 💡 Technology Features Infotainment Head Unit: BMW Business CD, BMW Professional CD, optional Navigation System (MKIII/MKIV) Audio System: Standard 6-speaker system,...
SAE 5W-30 or 5W-40, BMW LL-01 Approved (e.g., Castrol Syntec)
Oil Type Diesel:
SAE 5W-30 or 0W-30, BMW LL-04 Approved
🔧 Transmission
Standard
Manual Transmission:
5-speed Getrag GS53Z (e.g., for 325i), 6-speed ZF S6-37/S6-45 (e.g., for 330i)
Optional
Automatic Transmission:
5-speed ZF 5HP19FL/ZFL (e.g., for 325i), 5-speed ZF 5HP24Z (e.g., for 330i)
Features
All Wheel Drive:
Optional xDrive (model dependent, primarily later years)
Fluid Specifications
Manual Transmission Fluid:
GL-4 or GL-5 rated gear oil, specific viscosity per model (e.g., SAE 75W-90)
Automatic Transmission Fluid:
ZF LifeguardFluid 5 or equivalent (e.g., Pentosin ATF1)
📐 Dimensions
Exterior
Length:
Approx. 4471 mm (176.0 inches)
Width:
Approx. 1739 mm (68.5 inches)
Height:
Approx. 1407 mm (55.4 inches)
Wheelbase:
Approx. 2725 mm (107.3 inches)
Cargo
Cargo Volume:
Approx. 435-1450 liters (15.4-51.2 cubic feet) with rear seats folded
Weights
Curb Weight Range:
Approx. 1450 kg to 1650 kg (3200 lbs to 3640 lbs)
Towing Capacity:
Typically not specified or limited for this model in many markets
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Likely 4-star (based on sedan counterpart, specific wagon ratings may vary)
IIHS Side Impact:
Likely Good (based on sedan counterpart, specific wagon ratings may vary)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard Dynamic Stability Control (DSC) or Traction Control System (TCS)
Brake Assist:
Optional or standard on later models
Passive Features
Airbags:
Front dual-stage airbags, front side-impact airbags, optional head protection airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters
Child Seat Anchors:
ISOFIX/LATCH system (standard on rear seats)
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD, BMW Professional CD, optional Navigation System (MKIII/MKIV)
Audio System:
Standard 6-speaker system, optional Harman Kardon premium sound system.
Driver Assistance
Parking Sensors:
Optional rear Park Distance Control (PDC).
Cruise Control:
Standard cruise control system.
Connectivity
Auxiliary Input:
Not typically standard; aftermarket solutions or CD changer inputs are common.
Bluetooth:
Optional Bluetooth hands-free preparation (requires separate phone cradle/module).
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system; typically 10,000-15,000 miles or annually, whichever comes first. Manual specifies inspection and replacement based on driving conditions.
Air Filter Replacement:
Every 30,000-45,000 miles or as indicated by CBS.
Spark Plug Replacement:
Approx. 60,000 miles for iridium plugs (M54 engines).
The manual provides detailed diagnostic procedures for these common issues, including fault code interpretation and component testing.
📚 Vehicle History
Brand Heritage
Bmw Heritage:
Known for performance, luxury, and driving dynamics since its inception.
Model Evolution
E46 Generation:
The E46 generation (1998-2006) was a highly acclaimed platform known for its balanced chassis and driver engagement. The Touring (wagon) variant offered practicality without compromising the core BMW driving experience.
Production
Production Period:
1999-2005 for the E46 Touring body style.
Manufacturing Locations:
Primarily Germany (Dingolfing Plant), with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
The E46 3 Series sedan and coupe variants were frequent recipients of Car and Driver's '10Best' list, indicating the platform's overall excellence.
Ratings
Consumer Reports:
Generally rated well for performance and handling, with some noted concerns regarding reliability in specific areas, which this manual helps address.
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