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BMW 325i 1999 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Year: 1999 Market Segment: Compact Executive Sedan/Coupe/Convertible/Wagon 👋 Introduction Market Position Vehicle Class: Entry-level luxury compact executive vehicle Bmw Positioning: Sporty and driver-focused alternative to traditional luxury sedans Competitive Analysis Key Competitors: Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G20 Key Features Driving Dynamics: Renowned for balanced chassis, rear-wheel drive bias, and engaging handling Engine Smoothness: Inline-six engine known for its refinement and linear power delivery Build Quality: Typical BMW build quality with durable materials and solid construction 📋 Manual Details Coverage Areas Manual Type: Full Service & Repair Manual Language: English Format: Digital (Likely PDF, implied by 'all diagnostic...') Publisher Type: Aftermarket/Independent Page Count Estimated Page Count: 1500+ 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, rebuild, timing, lubrication, cooling, fuel injection (DME), emissions Engine Electrical: Ignition system, starter, alternator, DME troubleshooting, sensor diagnostics Transmission Mechanical: Manual & Automatic transmission overhaul, clutch, torque converter, gear selector Transmission Electrical: Automatic transmission control unit (GM/TCM) diagnostics, solenoid testing Drivetrain: Driveshafts, differential, axles, wheel bearings Suspension: Front and rear struts, springs, control arms, bushings, sway bars Steering: Power steering system, steering rack, tie rods, steering column Brakes: Hydraulic system, ABS, master cylinder, calipers, rotors, brake pads, bleeding procedures Electrical System: Wiring diagrams, fuses, relays, lighting, horn, power windows, mirrors, seats HVAC: Air conditioning, heating, climate control unit, blower motor, refrigerant system Body And Interior: Body panels, doors, hood, trunk, bumpers, upholstery, dashboard removal Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug changes, belt inspection/replacement, fluid checks/flushes Repair Procedures: Component replacement (alternator, starter, water pump, fuel pump), brake pad/rotor replacement, suspension component replacement Rebuild Procedures: Engine, transmission, differential, carburetor (if applicable, though unlikely for '99 325i) overhaul Troubleshooting Diagnostics: Step-by-step diagnostic trees, symptom-based troubleshooting, fault code interpretation (OBD-II) Refurbishment Restoration: Detailed instructions for bringing the vehicle back to original specifications Technical Depth Diagnostic Capability: Advanced, including sensor data analysis and component-level testing Repair Complexity: Covers everything from routine maintenance to complete engine and transmission rebuilds Diagram Quality: Detailed exploded views, wiring diagrams, and system schematics 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Likely text-searchable (standard for quality PDFs) Printability: Printable pages, suitable for individual chapter printing or full manual binding Print Quality Image Resolution: High resolution for clear diagrams and photographs Binding Type Digital Binding: N/A (Digital format) Paper Type Digital Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Code: M52B25 Engine Type: Naturally Aspirated Inline-6 Cylinder Displacement: 2494 cc (2.5 Liters) Bore X Stroke: 84 mm x 75 mm Compression Ratio: 10.2:1 Valvetrain: Dual Overhead Camshafts (DOHC), 24 Valves (4 per cylinder), VANOS (Variable Valve Timing) Performance Horsepower: 170 hp @ 5500 rpm (approx.) Torque: 181 lb-ft (245 Nm) @ 3500 rpm (approx.) Fuel System Fuel Delivery: Multi-Point Fuel Injection (Bosch Motronic M5.2 DME) Fuel Type: Unleaded Premium (91 Octane Recommended) Ignition System: Distributorless Electronic Ignition (DIS) with coil-on-plug (later M52 variants) or coil packs with spark plug wires 🔧 Transmission Standard Transmission Type: 5-speed Manual (Getrag 260/5) Optional Transmission Type: 5-speed Automatic (Steptronic/GM 5L40-E) Features Clutch Type: Hydraulic, single dry plate (Manual) Drivetrain: Rear-Wheel Drive (RWD) Differential: Open differential, optional limited-slip differential (LSD) 📐 Dimensions Exterior Length: 4465-4770 mm (Sedan/Coupe/Convertible/Wagon) Width: 1709-1711 mm Height: 1374-1417 mm Wheelbase: 2700-2710 mm Weights Curb Weight: 1400-1550 kg (approx.) 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 stars (driver/passenger, from contemporary testing) IIHS Side Impact: Good (from contemporary testing) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional ASC+T (Automatic Stability Control + Traction) Passive Features Airbags: Driver and front passenger airbags, optional side airbags Seatbelts: 3-point inertia-reel seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: BMW Business CD or Professional CD stereo, optional navigation system (CCC/MKIV based) Display: Multi-function display (MFD) in instrument cluster for trip computer, diagnostics Driver Assistance Cruise Control: Standard cruise control Parking Sensors: Optional Park Distance Control (PDC) Connectivity Phone Integration: Optional Bluetooth preparation with integrated phone cradle 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500-10,000 miles or 12-18 months (depending on driving conditions and oil used) Spark Plug Replacement: Approximately 60,000 miles (refer to manual for specific plug type and gap) Coolant Flush: Every 2 years or 30,000 miles (BMW recommends BMW blue coolant) Brake Fluid Flush: Every 2 years (regardless of mileage) Fluid Specifications Engine Oil Type: SAE 5W-30 or 5W-40 Synthetic (BMW Longlife-98 specification) Engine Oil Capacity: 6.5 liters (6.9 US quarts) with filter change Coolant Type: BMW Blue Antifreeze/Coolant (Ethylene Glycol based, 50/50 mix with distilled water) Transmission Fluid Manual: MTF LT-1 or LT-2 (or equivalent, consult manual) Transmission Fluid Automatic: ATF Dexron III or equivalent (BMW spec. approved) Power Steering Fluid: Pentosin CHF 11S or equivalent (Green color) Brake Fluid Type: DOT 4 Known Issues Cooling System: Plastic expansion tank prone to...
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BMW 325i 1999 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Year:
1999
Market Segment:
Compact Executive Sedan/Coupe/Convertible/Wagon
👋 Introduction
Market Position
Vehicle Class:
Entry-level luxury compact executive vehicle
Bmw Positioning:
Sporty and driver-focused alternative to traditional luxury sedans
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G20
Key Features
Driving Dynamics:
Renowned for balanced chassis, rear-wheel drive bias, and engaging handling
Engine Smoothness:
Inline-six engine known for its refinement and linear power delivery
Build Quality:
Typical BMW build quality with durable materials and solid construction
📋 Manual Details
Coverage Areas
Manual Type:
Full Service & Repair Manual
Language:
English
Format:
Digital (Likely PDF, implied by 'all diagnostic...')
Publisher Type:
Aftermarket/Independent
Page Count
Estimated Page Count:
1500+
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, rebuild, timing, lubrication, cooling, fuel injection (DME), emissions
Engine Electrical:
Ignition system, starter, alternator, DME troubleshooting, sensor diagnostics
Transmission Mechanical:
Manual & Automatic transmission overhaul, clutch, torque converter, gear selector
Transmission Electrical:
Automatic transmission control unit (GM/TCM) diagnostics, solenoid testing
Drivetrain:
Driveshafts, differential, axles, wheel bearings
Suspension:
Front and rear struts, springs, control arms, bushings, sway bars
Steering:
Power steering system, steering rack, tie rods, steering column
Brakes:
Hydraulic system, ABS, master cylinder, calipers, rotors, brake pads, bleeding procedures
Electrical System:
Wiring diagrams, fuses, relays, lighting, horn, power windows, mirrors, seats
HVAC:
Air conditioning, heating, climate control unit, blower motor, refrigerant system
Body And Interior:
Body panels, doors, hood, trunk, bumpers, upholstery, dashboard removal
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug changes, belt inspection/replacement, fluid checks/flushes
Repair Procedures:
Component replacement (alternator, starter, water pump, fuel pump), brake pad/rotor replacement, suspension component replacement
Rebuild Procedures:
Engine, transmission, differential, carburetor (if applicable, though unlikely for '99 325i) overhaul
Troubleshooting Diagnostics:
Step-by-step diagnostic trees, symptom-based troubleshooting, fault code interpretation (OBD-II)
Refurbishment Restoration:
Detailed instructions for bringing the vehicle back to original specifications
Technical Depth
Diagnostic Capability:
Advanced, including sensor data analysis and component-level testing
Repair Complexity:
Covers everything from routine maintenance to complete engine and transmission rebuilds
Diagram Quality:
Detailed exploded views, wiring diagrams, and system schematics
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable (standard for quality PDFs)
Printability:
Printable pages, suitable for individual chapter printing or full manual binding
Print Quality
Image Resolution:
High resolution for clear diagrams and photographs
Binding Type
Digital Binding:
N/A (Digital format)
Paper Type
Digital Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M52B25
Engine Type:
Naturally Aspirated Inline-6 Cylinder
Displacement:
2494 cc (2.5 Liters)
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
10.2:1
Valvetrain:
Dual Overhead Camshafts (DOHC), 24 Valves (4 per cylinder), VANOS (Variable Valve Timing)
Performance
Horsepower:
170 hp @ 5500 rpm (approx.)
Torque:
181 lb-ft (245 Nm) @ 3500 rpm (approx.)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (Bosch Motronic M5.2 DME)
Fuel Type:
Unleaded Premium (91 Octane Recommended)
Ignition System:
Distributorless Electronic Ignition (DIS) with coil-on-plug (later M52 variants) or coil packs with spark plug wires
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (Getrag 260/5)
Optional
Transmission Type:
5-speed Automatic (Steptronic/GM 5L40-E)
Features
Clutch Type:
Hydraulic, single dry plate (Manual)
Drivetrain:
Rear-Wheel Drive (RWD)
Differential:
Open differential, optional limited-slip differential (LSD)
📐 Dimensions
Exterior
Length:
4465-4770 mm (Sedan/Coupe/Convertible/Wagon)
Width:
1709-1711 mm
Height:
1374-1417 mm
Wheelbase:
2700-2710 mm
Weights
Curb Weight:
1400-1550 kg (approx.)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 stars (driver/passenger, from contemporary testing)
IIHS Side Impact:
Good (from contemporary testing)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional ASC+T (Automatic Stability Control + Traction)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System:
BMW Business CD or Professional CD stereo, optional navigation system (CCC/MKIV based)
Display:
Multi-function display (MFD) in instrument cluster for trip computer, diagnostics
Driver Assistance
Cruise Control:
Standard cruise control
Parking Sensors:
Optional Park Distance Control (PDC)
Connectivity
Phone Integration:
Optional Bluetooth preparation with integrated phone cradle
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500-10,000 miles or 12-18 months (depending on driving conditions and oil used)
Spark Plug Replacement:
Approximately 60,000 miles (refer to manual for specific plug type and gap)
Coolant Flush:
Every 2 years or 30,000 miles (BMW recommends BMW blue coolant)
Brake Fluid Flush:
Every 2 years (regardless of mileage)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40 Synthetic (BMW Longlife-98 specification)
Engine Oil Capacity:
6.5 liters (6.9 US quarts) with filter change
Coolant Type:
BMW Blue Antifreeze/Coolant (Ethylene Glycol based, 50/50 mix with distilled water)
Transmission Fluid Manual:
MTF LT-1 or LT-2 (or equivalent, consult manual)
Transmission Fluid Automatic:
ATF Dexron III or equivalent (BMW spec. approved)
Power Steering Fluid:
Pentosin CHF 11S or equivalent (Green color)
Brake Fluid Type:
DOT 4
Known Issues
Cooling System:
Plastic expansion tank prone to cracking, water pump failure (plastic impeller), thermostat housing leaks
Suspension Components:
Front control arm bushings (thrust arm bushings), rear trailing arm bushings, shock mounts
Oil Leaks:
Valve cover gasket, oil pan gasket, oil filter housing gasket
Vanos System:
Solenoid failure leading to rough idle and reduced low-end torque (common on M52TU, less so on earlier M52)
Interior Wear:
Headliner sagging, driver's seat bolster wear, interior trim fitment issues
Electrical Gremlins:
Water intrusion into LCM (Light Control Module), ABS/ASC module failures, window regulator issues
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Long history of producing driver-focused, performance-oriented vehicles
Model Evolution
E46 Generation:
This 325i is part of the E46 generation, which replaced the E36.
E46 Introduction:
The E46 generation was introduced in 1998 for the 1999 model year.
Production
Production Period:
1999-2005 (for the E46 generation)
Manufacturing Locations:
Germany (primarily Dingolfing and Munich)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
E46 generation (including 325i variants) was a frequent recipient of Car and Driver's 10Best lists in the late 1990s and early 2000s.
Motor Trend Car Of The Year:
E46 generation was nominated and highly regarded by various automotive publications.
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