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BMW 325xi 1999 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325xi Year: 1999 Generation Chassis Code: E46 Codes Engine Code Primary: M52TU B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Wagon Target Audience: Enthusiast owners, independent repair shops, DIY mechanics Competitive Analysis Key Competitors: Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus IS200/IS300 (XE10), Alfa Romeo 155/156 Key Features Differentiators: Inline-6 engine smoothness, advanced xDrive AWD, sporty handling, premium interior appointments Value Proposition: Empowers owners to maintain and repair their vehicle with confidence, saving on labor costs 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair Page Count Estimated Page Count: 1500+ Manual Type Type: Workshop Manual / Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: M52TU Inline-6, diagnostics, repair, rebuild, cooling, lubrication, fuel delivery, ignition, emissions Transmission: Steptronic Automatic and Manual Transmission systems, diagnostics, repair, fluid service, clutch operation Drivetrain: xDrive All-Wheel Drive system, differentials, driveshafts, CV joints, wheel bearings Suspension: Front struts, rear multi-link, control arms, bushings, springs, shocks, alignment procedures Steering: Hydraulic power steering system, steering rack, tie rods, steering column Brakes: ABS, DSC, brake calipers, rotors, pads, fluid flush and bleed procedures, parking brake Electrical System: Wiring diagrams, component testing, alternator, starter, battery, fuse box, relays, lighting, power windows, locks Body And Interior: Body panel removal/installation, interior trim, seats, doors, hood, trunk, HVAC system, body shell repair Diagnostics And Troubleshooting: OBD-II codes, diagnostic trouble codes (DTCs), symptom-based troubleshooting, diagnostic tools Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and changes Engine Repair: Head gasket replacement, piston ring installation, valve adjustments, timing chain service Transmission Overhaul: Complete gearbox rebuild, torque converter replacement, mechatronic unit service Brake System Service: Brake pad and rotor replacement, caliper overhaul, ABS sensor testing, brake line replacement Electrical Component Replacement: Alternator, starter motor, fuel pump, mass airflow sensor, ignition coils Suspension Component Replacement: Strut replacement, control arm bushings, ball joints, sway bar links Troubleshooting Guides: Step-by-step diagnostic procedures for common and uncommon faults Technical Depth Depth: Comprehensive (from basic fluid changes to full engine/transmission rebuilds) Diagnostic Focus: Detailed diagnostic procedures, including wiring diagrams and sensor data interpretation Rebuild Information: Includes torque specifications, clearances, and rebuild procedures for major components 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable content Print Quality Printability: Printable pages Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: M52TU B25 - DOHC Inline-6 Displacement: 2494 cc (2.5 Liters) Performance Horsepower: 189 hp @ 6000 rpm Torque: 236 Nm (174 lb-ft) @ 3500 rpm Fuel System Fuel Injection: Bosch Motronic ME 7.2 Electronic Fuel Injection (EFI) Fuel Type: Premium Unleaded Gasoline (91+ Octane) Engine Features Variable Valve Timing: VANOS (Double VANOS) Bore X Stroke: 84 mm x 75 mm Compression Ratio: 10.2:1 🔧 Transmission Standard Type: GM A5S 360R 5-speed Manual Transmission Optional Type: Steptronic GA6HP19Z 5-speed Automatic Transmission with Manual Mode Features All Wheel Drive: xDrive Permanent All-Wheel Drive System Transfer Case Ratio: 1.0:1 Fluid Specifications Automatic Transmission Fluid: BMW LT-2, Dexron III (for early models, check specific VIN) Manual Transmission Fluid: BMW MTF LT-2 (or equivalent API GL-4/GL-5) 📐 Dimensions Exterior Wheelbase: 2760 mm (108.7 in) Length: 4471 mm (176.0 in) Width: 1739 mm (68.5 in) Height: 1415 mm (55.7 in) Weights Curb Weight: 1520 kg (3351 lbs) Gross Vehicle Weight Rating: 2000 kg (4409 lbs) Cargo Trunk Volume: 440 Liters (15.5 cu ft) Wheels And Tires Wheelbase: 2760 mm (108.7 in) Wheel Bolt Pattern: 5x120 Tire Size Standard: 205/55 R16 Wheel Size Standard: 16 x 7.0 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars NHTSA Side Impact: 4/5 Stars Active Features Traction Control: Automatic Stability Control (ASC) / Dynamic Stability Control (DSC) Anti Lock Brakes: Standard Anti-lock Braking System (ABS) Passive Features Airbags: Front driver and passenger airbags, optional side-impact airbags Seatbelts: Three-point seat belts with pretensioners 💡 Technology Features Infotainment Audio System: BMW Professional Radio, optional CD changer, Harman Kardon audio upgrade Navigation: Optional BMW Business or Professional Navigation System Driver Assistance Cruise Control: Standard Cruise Control Connectivity Phone Integration: Optional Bluetooth preparation and cradle 🔧 Maintenance Service Intervals Oil Change Interval: Variable, typically 7,500-15,000 miles or as indicated by Condition Based Service (CBS) system Spark Plug Replacement: Approximately 60,000 miles Coolant Flush: Every 2-4 years or 30,000-60,000 miles Fluid Specifications Engine Oil: BMW Longlife-01 (LL-01) or LL-04 approved 5W-30 or 0W-30 Synthetic Oil Coolant: BMW Blue Antifreeze/Coolant (G48/G40) or equivalent silicate-free ethylene glycol based coolant Brake Fluid: DOT 4 BMW Brake Fluid (or equivalent DOT 4 LV) Known Issues Cooling System: Plastic coolant expansion tanks are prone to cracking, water pump failure, thermostat issues Oil Leaks: Valve cover gasket, oil pan gasket, front and rear main seals common Suspension: Control arm bushings, rear shock mounts, tie rod ends wear out...
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BMW 325xi 1999 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325xi
Year:
1999
Generation
Chassis Code:
E46
Codes
Engine Code Primary:
M52TU B25
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Wagon
Target Audience:
Enthusiast owners, independent repair shops, DIY mechanics
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus IS200/IS300 (XE10), Alfa Romeo 155/156
Key Features
Differentiators:
Inline-6 engine smoothness, advanced xDrive AWD, sporty handling, premium interior appointments
Value Proposition:
Empowers owners to maintain and repair their vehicle with confidence, saving on labor costs
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Workshop Manual / Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
M52TU Inline-6, diagnostics, repair, rebuild, cooling, lubrication, fuel delivery, ignition, emissions
Transmission:
Steptronic Automatic and Manual Transmission systems, diagnostics, repair, fluid service, clutch operation
Drivetrain:
xDrive All-Wheel Drive system, differentials, driveshafts, CV joints, wheel bearings
Suspension:
Front struts, rear multi-link, control arms, bushings, springs, shocks, alignment procedures
Steering:
Hydraulic power steering system, steering rack, tie rods, steering column
Brakes:
ABS, DSC, brake calipers, rotors, pads, fluid flush and bleed procedures, parking brake
Electrical System:
Wiring diagrams, component testing, alternator, starter, battery, fuse box, relays, lighting, power windows, locks
Body And Interior:
Body panel removal/installation, interior trim, seats, doors, hood, trunk, HVAC system, body shell repair
Diagnostics And Troubleshooting:
OBD-II codes, diagnostic trouble codes (DTCs), symptom-based troubleshooting, diagnostic tools
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and changes
Engine Repair:
Head gasket replacement, piston ring installation, valve adjustments, timing chain service
Transmission Overhaul:
Complete gearbox rebuild, torque converter replacement, mechatronic unit service
Brake System Service:
Brake pad and rotor replacement, caliper overhaul, ABS sensor testing, brake line replacement
Electrical Component Replacement:
Alternator, starter motor, fuel pump, mass airflow sensor, ignition coils
Suspension Component Replacement:
Strut replacement, control arm bushings, ball joints, sway bar links
Troubleshooting Guides:
Step-by-step diagnostic procedures for common and uncommon faults
Technical Depth
Depth:
Comprehensive (from basic fluid changes to full engine/transmission rebuilds)
Diagnostic Focus:
Detailed diagnostic procedures, including wiring diagrams and sensor data interpretation
Rebuild Information:
Includes torque specifications, clearances, and rebuild procedures for major components
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable content
Print Quality
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
M52TU B25 - DOHC Inline-6
Displacement:
2494 cc (2.5 Liters)
Performance
Horsepower:
189 hp @ 6000 rpm
Torque:
236 Nm (174 lb-ft) @ 3500 rpm
Fuel System
Fuel Injection:
Bosch Motronic ME 7.2 Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Engine Features
Variable Valve Timing:
VANOS (Double VANOS)
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
10.2:1
🔧 Transmission
Standard
Type:
GM A5S 360R 5-speed Manual Transmission
Optional
Type:
Steptronic GA6HP19Z 5-speed Automatic Transmission with Manual Mode
Features
All Wheel Drive:
xDrive Permanent All-Wheel Drive System
Transfer Case Ratio:
1.0:1
Fluid Specifications
Automatic Transmission Fluid:
BMW LT-2, Dexron III (for early models, check specific VIN)
Manual Transmission Fluid:
BMW MTF LT-2 (or equivalent API GL-4/GL-5)
📐 Dimensions
Exterior
Wheelbase:
2760 mm (108.7 in)
Length:
4471 mm (176.0 in)
Width:
1739 mm (68.5 in)
Height:
1415 mm (55.7 in)
Weights
Curb Weight:
1520 kg (3351 lbs)
Gross Vehicle Weight Rating:
2000 kg (4409 lbs)
Cargo
Trunk Volume:
440 Liters (15.5 cu ft)
Wheels And Tires
Wheelbase:
2760 mm (108.7 in)
Wheel Bolt Pattern:
5x120
Tire Size Standard:
205/55 R16
Wheel Size Standard:
16 x 7.0
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars
NHTSA Side Impact:
4/5 Stars
Active Features
Traction Control:
Automatic Stability Control (ASC) / Dynamic Stability Control (DSC)
Anti Lock Brakes:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags:
Front driver and passenger airbags, optional side-impact airbags
Seatbelts:
Three-point seat belts with pretensioners
💡 Technology Features
Infotainment
Audio System:
BMW Professional Radio, optional CD changer, Harman Kardon audio upgrade
Navigation:
Optional BMW Business or Professional Navigation System
Driver Assistance
Cruise Control:
Standard Cruise Control
Connectivity
Phone Integration:
Optional Bluetooth preparation and cradle
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable, typically 7,500-15,000 miles or as indicated by Condition Based Service (CBS) system
Spark Plug Replacement:
Approximately 60,000 miles
Coolant Flush:
Every 2-4 years or 30,000-60,000 miles
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) or LL-04 approved 5W-30 or 0W-30 Synthetic Oil
Coolant:
BMW Blue Antifreeze/Coolant (G48/G40) or equivalent silicate-free ethylene glycol based coolant
Brake Fluid:
DOT 4 BMW Brake Fluid (or equivalent DOT 4 LV)
Known Issues
Cooling System:
Plastic coolant expansion tanks are prone to cracking, water pump failure, thermostat issues
Oil Leaks:
Valve cover gasket, oil pan gasket, front and rear main seals common
Suspension:
Control arm bushings, rear shock mounts, tie rod ends wear out
Electrical:
ABS/DSC module failures, CCV system (crankcase ventilation) issues
Vanos:
Vanos solenoids and seals can degrade, leading to rough idle and power loss
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Renowned for sporting sedans and performance engineering
Model Evolution
E46 Introduction:
Launched in 1998 as the successor to the E36 generation
E46 Highlights:
Introduced significantly revised chassis dynamics, improved interior quality, and advanced technology
Production
E46 Production Years:
1998-2006 (Sedan/Touring 1998-2005)
Manufacturing Location:
Germany (Dingolfing, Munich)
🏆 Awards & Recognition
Recognitions
Car And Driver:
Car and Driver 10Best list multiple times (for E46 generation in general)
Ward S Auto:
Ward's 10 Best Engines award for the M52/M54 engine family
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