BMW 325 325i 1999-2005 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 325i Model Designation: E46 Generation Generation Name: E46 Generation Years: 1998-2006 (Global), 1999-2005 (North America) Codes Chassis Code: E46 👋 Introduction Market Position Market Segment: Premium compact executive sedan and coupe. Competitive Analysis Key Competitors: Audi A4, Mercedes-Benz C-Class, Lexus IS, Infiniti G35. Key Features Driving Dynamics: Renowned for its balanced chassis, rear-wheel-drive platform, and engaging driving experience. Build Quality: Characteristic BMW build quality and premium interior materials. Powertrain Refinement: Smooth and powerful inline-six engines. 📋 Manual Details Coverage Areas Covered Model Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Covered Models: BMW 325, BMW 325i Page Count Estimated Page Count: Hundreds of pages (specific number varies based on official factory publication) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable (likely PDF) 📖 Manual Coverage Systems Covered Engine Management: Detailed diagnostics, testing, troubleshooting, and repair procedures for engine control units (ECUs), sensors, actuators, ignition system, fuel injection system, emissions control. Engine Mechanical: Complete overhaul and repair for engine components including cylinder head, pistons, connecting rods, crankshaft, timing system (chain, guides, tensioners), lubrication system, cooling system. Transmission: Service and repair for both manual (Getrag) and automatic (Steptronic) transmissions, including clutch, torque converter, gearshift mechanisms, transmission control module (TCM). Drivetrain And Axles: Repair and maintenance of driveshafts, CV joints, differential, rear axle assembly, wheel bearings. Suspension And Steering: Detailed procedures for front and rear suspension components (struts, shocks, control arms, bushings, sway bars), power steering system (pump, rack, fluid), wheel alignment specifications. Brakes: Service and repair for hydraulic braking system, ABS, DSC (Dynamic Stability Control), brake pad replacement, rotor resurfacing/replacement, brake bleeding, parking brake. Electrical System: Comprehensive wiring diagrams, component location, troubleshooting for starter, alternator, battery, lighting system, power windows, mirrors, locks, central locking, fuse and relay locations. Bodywork And Interior: Repair and adjustment of body panels, doors, hood, trunk, bumpers, interior trim, seat removal, climate control system service (HVAC). Heating Ventilation And Air Conditioning HVAC: Troubleshooting and repair of AC compressor, evaporator, condenser, blower motor, climate control module, cabin air filter replacement. Safety Systems: Airbag system (SRS) diagnostics and replacement, seat belt mechanisms, seat occupant detection. Procedures Included Preventive Maintenance: Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid checks and flushes (coolant, brake, power steering, transmission), belt inspections and replacement. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon faults, fault code interpretation, symptom-based troubleshooting. Component Replacement: Step-by-step instructions for removing and installing major and minor components across all systems. Rebuild Procedures: Detailed instructions for engine and transmission overhauls, including torque specifications and clearances. Diagnostic Tool Usage: Guidance on using BMW-specific diagnostic tools (e.g., DIS, ISTA) and generic OBD-II scanners for fault code reading and live data. Technical Depth Technical Depth: Comprehensive, from basic maintenance to advanced engine and transmission rebuilds, including electrical diagnostics and bodywork. Diagnostic Information: In-depth diagnostic information, including wiring diagrams, component testing procedures, and logic flows for troubleshooting. Specifications Data: Detailed technical specifications, tolerances, clearances, torque values, and fluid capacities for all systems. 📊 Manual Specifications File Format File Format Details: Digital download, likely PDF format. Typically searchable and printable. Print Quality Print Quality: High-resolution scans of original factory documentation, ensuring clarity of text and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M54B30 Engine Type: 3.0L (2979cc) Naturally Aspirated Inline-6 (I6) 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) Engine Control Unit: Bosch Motronic ME7.2 or similar Performance Horsepower Hp: Approximately 225 hp @ 5900 rpm Torque Lb-Ft: Approximately 214 lb-ft @ 3500 rpm Fuel System Fuel Type: Unleaded gasoline (Premium 91 octane or higher recommended) Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission Type: 5-speed Steptronic Automatic Transmission Features Steptronic Functionality: Allows manual selection of gears via shifter or steering wheel buttons (on some models). 📐 Dimensions Exterior Length Sedan: Approximately 177.4 inches (4506 mm) Width Sedan: Approximately 68.7 inches (1745 mm) Height Sedan: Approximately 56.1 inches (1425 mm) Wheelbase Sedan: Approximately 107.4 inches (2729 mm) Weights Curb Weight Manual Sedan: Approximately 3417 lbs (1550 kg) Curb Weight Automatic Sedan: Approximately 3494 lbs (1585 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 5 Stars (Driver and Passenger) IIHS Side Impact Rating: Good (for models with side airbags) Active Features Traction Control: Automatic Stability Control (ASC) or Dynamic Stability Control (DSC) Anti Lock Brakes: Standard ABS (Anti-lock Braking System) Passive Features Airbags: Frontal airbags (driver and passenger), optional side airbags, optional head protection system (HPS). 💡 Technology Features Infotainment Navigation System: Optional professional navigation system with CD-ROM based maps. Audio System: Standard BMW Business CD/RDS or optional BMW Professional CD/RDS...
Audi A4, Mercedes-Benz C-Class, Lexus IS, Infiniti G35.
Key Features
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel-drive platform, and engaging driving experience.
Build Quality:
Characteristic BMW build quality and premium interior materials.
Powertrain Refinement:
Smooth and powerful inline-six engines.
📋 Manual Details
Coverage Areas
Covered Model Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Covered Models:
BMW 325, BMW 325i
Page Count
Estimated Page Count:
Hundreds of pages (specific number varies based on official factory publication)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Management:
Detailed diagnostics, testing, troubleshooting, and repair procedures for engine control units (ECUs), sensors, actuators, ignition system, fuel injection system, emissions control.
Engine Mechanical:
Complete overhaul and repair for engine components including cylinder head, pistons, connecting rods, crankshaft, timing system (chain, guides, tensioners), lubrication system, cooling system.
Transmission:
Service and repair for both manual (Getrag) and automatic (Steptronic) transmissions, including clutch, torque converter, gearshift mechanisms, transmission control module (TCM).
Drivetrain And Axles:
Repair and maintenance of driveshafts, CV joints, differential, rear axle assembly, wheel bearings.
Suspension And Steering:
Detailed procedures for front and rear suspension components (struts, shocks, control arms, bushings, sway bars), power steering system (pump, rack, fluid), wheel alignment specifications.
Brakes:
Service and repair for hydraulic braking system, ABS, DSC (Dynamic Stability Control), brake pad replacement, rotor resurfacing/replacement, brake bleeding, parking brake.
Electrical System:
Comprehensive wiring diagrams, component location, troubleshooting for starter, alternator, battery, lighting system, power windows, mirrors, locks, central locking, fuse and relay locations.
Bodywork And Interior:
Repair and adjustment of body panels, doors, hood, trunk, bumpers, interior trim, seat removal, climate control system service (HVAC).
Heating Ventilation And Air Conditioning HVAC:
Troubleshooting and repair of AC compressor, evaporator, condenser, blower motor, climate control module, cabin air filter replacement.
Safety Systems:
Airbag system (SRS) diagnostics and replacement, seat belt mechanisms, seat occupant detection.
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid checks and flushes (coolant, brake, power steering, transmission), belt inspections and replacement.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon faults, fault code interpretation, symptom-based troubleshooting.
Component Replacement:
Step-by-step instructions for removing and installing major and minor components across all systems.
Rebuild Procedures:
Detailed instructions for engine and transmission overhauls, including torque specifications and clearances.
Diagnostic Tool Usage:
Guidance on using BMW-specific diagnostic tools (e.g., DIS, ISTA) and generic OBD-II scanners for fault code reading and live data.
Technical Depth
Technical Depth:
Comprehensive, from basic maintenance to advanced engine and transmission rebuilds, including electrical diagnostics and bodywork.
Diagnostic Information:
In-depth diagnostic information, including wiring diagrams, component testing procedures, and logic flows for troubleshooting.
Specifications Data:
Detailed technical specifications, tolerances, clearances, torque values, and fluid capacities for all systems.
📊 Manual Specifications
File Format
File Format Details:
Digital download, likely PDF format. Typically searchable and printable.
Print Quality
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.
Unleaded gasoline (Premium 91 octane or higher recommended)
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission Type:
5-speed Steptronic Automatic Transmission
Features
Steptronic Functionality:
Allows manual selection of gears via shifter or steering wheel buttons (on some models).
📐 Dimensions
Exterior
Length Sedan:
Approximately 177.4 inches (4506 mm)
Width Sedan:
Approximately 68.7 inches (1745 mm)
Height Sedan:
Approximately 56.1 inches (1425 mm)
Wheelbase Sedan:
Approximately 107.4 inches (2729 mm)
Weights
Curb Weight Manual Sedan:
Approximately 3417 lbs (1550 kg)
Curb Weight Automatic Sedan:
Approximately 3494 lbs (1585 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
5 Stars (Driver and Passenger)
IIHS Side Impact Rating:
Good (for models with side airbags)
Active Features
Traction Control:
Automatic Stability Control (ASC) or Dynamic Stability Control (DSC)
Anti Lock Brakes:
Standard ABS (Anti-lock Braking System)
Passive Features
Airbags:
Frontal airbags (driver and passenger), optional side airbags, optional head protection system (HPS).
💡 Technology Features
Infotainment
Navigation System:
Optional professional navigation system with CD-ROM based maps.
Audio System:
Standard BMW Business CD/RDS or optional BMW Professional CD/RDS stereo. Harman Kardon premium audio available.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Assistance:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Cellular Integration:
Optional Bluetooth integration for mobile phones (via TCU - Telematics Control Unit).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles or as indicated by the vehicle's Condition Based Service (CBS) system, or annually.
Engine Oil Type Capacity:
SAE 5W-30 Synthetic (BMW LL-01 approved) - approximately 6.5 liters (6.9 US quarts).
Coolant Type Capacity:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) - approximately 9.5 liters (10 US quarts) with heater.
Spark Plug Replacement:
Typically around 100,000 miles for iridium spark plugs (e.g., NGK BKR6EQUP).
Transmission Fluid Change:
Manual: Often considered 'lifetime' but an interval of 60,000-100,000 miles is recommended for longevity. Automatic: BMW typically listed as 'lifetime', but 50,000-80,000 miles is prudent for fluid and filter replacement.
Fluid Specifications
Brake Fluid Type:
DOT 4 (or DOT 4 LV for vehicles with DSC/ABS).
Power Steering Fluid Type:
Pentosin CHF 11S or equivalent (check specific vehicle label).
Known Issues
Crankshaft Seal Leaks:
Rear main crankshaft seal and oil pan gasket common leak points.
Cooling System Failures:
Plastic coolant expansion tank, water pump, and thermostat housing are prone to cracking/failure.
Oil Separator Failures:
PCV (Positive Crankcase Ventilation) system can clog or fail, leading to rough idle, oil leaks, and increased oil consumption.
Valve Cover Gasket Leaks:
Common leak point on the M54 engine, often accompanied by PCV issues.
Suspension Wear:
Front control arm bushings, ball joints, and rear trailing arm bushings are common wear items.
ABS/Dsc Sensor Failures:
Wheel speed sensors for ABS and DSC are known to fail.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
The 'Ultimate Driving Machine' – emphasis on performance, engineering, and driver engagement.
Model Evolution
E46 Introduction:
The E46 generation replaced the E36 3 Series and introduced significant advancements in chassis design, technology, and refinement.
325I Positioning:
Positioned as a balance of performance and luxury, above the 320i and 325xi, and below the 330i. Featured the M54 engine family.
Production
Production Years North America:
1999-2005
Manufacturing Plants:
Primary assembly in Dingolfing, Germany, with some production for specific markets potentially elsewhere.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E46 3 Series platform, including the 325i variants, was frequently recognized on Car and Driver's 10Best lists during its production run.
Ratings
Consumer Reports Reliability:
Mixed to average reliability ratings historically, with certain common issues noted in owner surveys.