BMW 3-series (E46) 2002 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3-Series Chassis Code: E46 Year: 2002 Generation Generation Code: E46 (Third Generation) Generation Years: 1998-2006 (Global Production) Codes Product Name: BMW 3-series (E46) 2002 Service and Repair Manual 👋 Introduction Market Position Brand Heritage: BMW's reputation for performance, luxury, and engineering excellence Model Significance: The E46 3-Series is widely considered a benchmark in the compact executive sedan segment, known for its driving dynamics. Competitive Analysis Key Competitors: Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS (XE10), Alfa Romeo 156 Key Features Driving Dynamics: Renowned for balanced chassis, precise steering, and engaging ride Build Quality: High standard of interior and exterior build quality typical of BMW Powertrain Options: Wide range of inline-4 and inline-6 gasoline engines, along with efficient diesel options 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive A-Z repairs for all E46 models Engine Coverage: All gasoline and diesel engine variants for 2002 model year Drivetrain Coverage: Manual and automatic transmissions, rear-wheel drive, xDrive (all-wheel drive) systems Chassis Coverage: Suspension, steering, braking systems, chassis components Electrical Coverage: Complete electrical systems, wiring diagrams, modules, troubleshooting Body Coverage: Bodywork, interior trim, HVAC, safety systems (airbags, seatbelts) Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Purpose: Maintenance, diagnosis, repair, overhaul Language Language: English Format Format: Digital (likely PDF) Searchability: Searchable text 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, crankshaft, pistons, connecting rods, valve train Engine Management: Fuel injection, ignition, emissions control, ECU diagnostics Cooling System: Radiator, thermostat, water pump, coolant specifications Lubrication System: Oil pump, oil filter, oil specifications, lubrication points Transmission Manual: Clutch, gearbox components, shift mechanism, fluid types Transmission Automatic: Torque converter, valve body, planetary gears, transmission fluid, control modules Drive Axles: CV joints, drive shafts, differential, wheel bearings Suspension Front: MacPherson struts, control arms, anti-roll bar, bushings Suspension Rear: Multi-link independent suspension, shock absorbers, springs, bushings Steering System: Power steering pump, rack and pinion, steering column, alignment specifications Brake System: Disc brakes (front and rear), ABS, DSC, brake fluid specifications, bleeding procedures Electrical System General: Battery, charging system, starter motor, lighting Body Control Module: BCM diagnostics and repair Infotainment System: Radio, navigation (if equipped), speaker systems HVAC System: Air conditioning, heating, climate control, blower motor, refrigerant Safety Systems: Airbag system, seatbelt pre-tensioners, SRS module diagnostics Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs Major Servicing: Spark plug replacement, ignition coil service, serpentine belt replacement Engine Repair: Timing chain/belt service, head gasket replacement, piston ring installation, complete engine rebuild Transmission Repair: Clutch replacement, transmission overhaul, seal replacements Brake Service: Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS bleeding Suspension Repair: Shock/strut replacement, control arm bushing replacement, ball joint replacement Steering Repair: Power steering pump replacement, steering rack replacement Electrical Troubleshooting: Diagnostic procedures for electrical faults, wiring harness repair Diagnostics: Fault code retrieval and interpretation, diagnostic scan tool procedures Bodywork: Panel replacement, door repair, bumper repair Component Replacement: Detailed instructions for replacing virtually every component Technical Depth Depth Level: Factory-level technical expertise and detail Diagnostic Tools: Information on required diagnostic tools and software (e.g., DIS, ISTA) Technical Data: Torque specifications, clearances, measurements, test values Troubleshooting Charts: Systematic troubleshooting guides and flowcharts Wiring Diagrams: Comprehensive, color-coded wiring schematics Exploded Views: Detailed diagrams showing component assembly 📊 Manual Specifications File Format Digital Format: PDF Print Quality Image Resolution: High resolution, suitable for screen viewing and printing Binding Type Binding Digital: N/A (Digital Format) Paper Type Paper Digital: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Variants 2002: 320i, 323i, 325i, 330i, 318d, 320d, 330d (depending on market) Typical Engine Lineup: Inline-4 (M43/N42/N46), Inline-6 (M54) Performance M54B25 Power: 184 hp @ 6000 rpm M54B25 Torque: 175 lb-ft @ 3500 rpm M54B30 Power: 225 hp @ 5900 rpm M54B30 Torque: 214 lb-ft @ 3500 rpm Fuel System Fuel Injection: Bosch Motronic electronic fuel injection (EFI) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Engine Codes Engine Code M54: M54B22, M54B25, M54B30 🔧 Transmission Standard Standard Transmission: 5-speed Manual (Getrag 260/5 or ZF S5D 320Z depending on engine) Optional Optional Transmission: 5-speed Automatic (GM A5S360R/A5S390R) Features Drivetrain Layout: Rear-Wheel Drive (RWD) standard, xDrive (AWD) optional on some models Manual Clutch Type: Hydraulically actuated single-plate dry clutch 📐 Dimensions Exterior Body Styles: Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon, 5-door) Wheelbase Sedan Coupe: 107.4 inches (2728 mm) Wheelbase Touring: 108.5 inches (2756 mm) Weights Curb Weight Range: Approx. 3100 - 3600 lbs (1400 - 1630 kg), varies by model and options Gross Vehicle Weight Rating: Model dependent, typically around 4200 - 4600 lbs 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 stars (Driver/Passenger) IIHS Side Impact: Good (for models equipped with side airbags) Active Features Standard Safety: ABS, Traction Control (ASC+T), Dynamic Stability Control (DSC) optional/standard on higher trims...

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Description

🏷️ Basic Information

Identification

Make:

Model:

3-Series

Chassis Code:

Year:

Generation

Generation Code:

E46 (Third Generation)

Generation Years:

1998-2006 (Global Production)

Codes

Product Name:

BMW 3-series (E46) 2002 Service and Repair Manual

👋 Introduction

Market Position

Brand Heritage:

BMW's reputation for performance, luxury, and engineering excellence

Model Significance:

The E46 3-Series is widely considered a benchmark in the compact executive sedan segment, known for its driving dynamics.

Competitive Analysis

Key Competitors:

Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS (XE10), Alfa Romeo 156

Key Features

Driving Dynamics:

Renowned for balanced chassis, precise steering, and engaging ride

Build Quality:

High standard of interior and exterior build quality typical of BMW

Powertrain Options:

Wide range of inline-4 and inline-6 gasoline engines, along with efficient diesel options

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive A-Z repairs for all E46 models

Engine Coverage:

All gasoline and diesel engine variants for 2002 model year

Drivetrain Coverage:

Manual and automatic transmissions, rear-wheel drive, xDrive (all-wheel drive) systems

Chassis Coverage:

Suspension, steering, braking systems, chassis components

Electrical Coverage:

Complete electrical systems, wiring diagrams, modules, troubleshooting

Body Coverage:

Bodywork, interior trim, HVAC, safety systems (airbags, seatbelts)

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual

Purpose:

Maintenance, diagnosis, repair, overhaul

Language

Language:

English

Format

Format:

Digital (likely PDF)

Searchability:

Searchable text

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, crankshaft, pistons, connecting rods, valve train

Engine Management:

Fuel injection, ignition, emissions control, ECU diagnostics

Cooling System:

Radiator, thermostat, water pump, coolant specifications

Lubrication System:

Oil pump, oil filter, oil specifications, lubrication points

Transmission Manual:

Clutch, gearbox components, shift mechanism, fluid types

Transmission Automatic:

Torque converter, valve body, planetary gears, transmission fluid, control modules

Drive Axles:

CV joints, drive shafts, differential, wheel bearings

Suspension Front:

MacPherson struts, control arms, anti-roll bar, bushings

Suspension Rear:

Multi-link independent suspension, shock absorbers, springs, bushings

Steering System:

Power steering pump, rack and pinion, steering column, alignment specifications

Brake System:

Disc brakes (front and rear), ABS, DSC, brake fluid specifications, bleeding procedures

Electrical System General:

Battery, charging system, starter motor, lighting

Body Control Module:

BCM diagnostics and repair

Infotainment System:

Radio, navigation (if equipped), speaker systems

HVAC System:

Air conditioning, heating, climate control, blower motor, refrigerant

Safety Systems:

Airbag system, seatbelt pre-tensioners, SRS module diagnostics

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs

Major Servicing:

Spark plug replacement, ignition coil service, serpentine belt replacement

Engine Repair:

Timing chain/belt service, head gasket replacement, piston ring installation, complete engine rebuild

Transmission Repair:

Clutch replacement, transmission overhaul, seal replacements

Brake Service:

Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS bleeding

Suspension Repair:

Shock/strut replacement, control arm bushing replacement, ball joint replacement

Steering Repair:

Power steering pump replacement, steering rack replacement

Electrical Troubleshooting:

Diagnostic procedures for electrical faults, wiring harness repair

Diagnostics:

Fault code retrieval and interpretation, diagnostic scan tool procedures

Bodywork:

Panel replacement, door repair, bumper repair

Component Replacement:

Detailed instructions for replacing virtually every component

Technical Depth

Depth Level:

Factory-level technical expertise and detail

Diagnostic Tools:

Information on required diagnostic tools and software (e.g., DIS, ISTA)

Technical Data:

Torque specifications, clearances, measurements, test values

Troubleshooting Charts:

Systematic troubleshooting guides and flowcharts

Wiring Diagrams:

Comprehensive, color-coded wiring schematics

Exploded Views:

Detailed diagrams showing component assembly

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Image Resolution:

High resolution, suitable for screen viewing and printing

Binding Type

Binding Digital:

N/A (Digital Format)

Paper Type

Paper Digital:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Variants 2002:

320i, 323i, 325i, 330i, 318d, 320d, 330d (depending on market)

Typical Engine Lineup:

Inline-4 (M43/N42/N46), Inline-6 (M54)

Performance

M54B25 Power:

184 hp @ 6000 rpm

M54B25 Torque:

175 lb-ft @ 3500 rpm

M54B30 Power:

225 hp @ 5900 rpm

M54B30 Torque:

214 lb-ft @ 3500 rpm

Fuel System

Fuel Injection:

Bosch Motronic electronic fuel injection (EFI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Engine Codes

Engine Code M54:

M54B22, M54B25, M54B30

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual (Getrag 260/5 or ZF S5D 320Z depending on engine)

Optional

Optional Transmission:

5-speed Automatic (GM A5S360R/A5S390R)

Features

Drivetrain Layout:

Rear-Wheel Drive (RWD) standard, xDrive (AWD) optional on some models

Manual Clutch Type:

Hydraulically actuated single-plate dry clutch

📐 Dimensions

Exterior

Body Styles:

Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon, 5-door)

Wheelbase Sedan Coupe:

107.4 inches (2728 mm)

Wheelbase Touring:

108.5 inches (2756 mm)

Weights

Curb Weight Range:

Approx. 3100 - 3600 lbs (1400 - 1630 kg), varies by model and options

Gross Vehicle Weight Rating:

Model dependent, typically around 4200 - 4600 lbs

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4/5 stars (Driver/Passenger)

IIHS Side Impact:

Good (for models equipped with side airbags)

Active Features

Standard Safety:

ABS, Traction Control (ASC+T), Dynamic Stability Control (DSC) optional/standard on higher trims

Lighting Features:

Halogen headlights, optional Xenon Adaptive Headlights

Passive Features

Airbags:

Front driver and passenger airbags, optional front side airbags, optional head protection system (HPS)

Seatbelts:

3-point inertia-reel seatbelts with pre-tensioners and force limiters

💡 Technology Features

Infotainment

Infotainment Options:

BMW Professional Radio, optional CD player, optional navigation system (CCC, MKIV based).

Audio System:

Standard 6-speaker system, optional Harman Kardon premium audio.

Driver Assistance

Driver Assistance Features:

Park Distance Control (PDC) optional, Cruise Control standard on most models.

Connectivity

Connectivity Features:

Optional Bluetooth hands-free system (integration varied by year and head unit).

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) typically suggests oil changes every 10,000-15,000 miles or annually, depending on driving conditions.

Brake Fluid Flush:

Recommended every 2 years

Coolant Change:

BMW recommends coolant replacement typically around 60,000 miles or 4 years, but manual should be consulted for specific intervals.

Fluid Specifications

Engine Oil Specification:

BMW Longlife-01 (LL-01) or Longlife-98 (LL-98) synthetic oil, viscosity typically 0W-40 or 5W-40, depending on climate.

Coolant Specification:

BMW Blue Antifreeze/Coolant (G48 based)

Brake Fluid Specification:

DOT 4

Transmission Fluid Manual:

SAE 75W-90 GL-4 or GL-5 synthetic gear oil (specific BMW P/N recommended)

Transmission Fluid Automatic:

BMW ATF LT-2 or LT-3 (specific BMW P/N recommended), often requires filter replacement at service.

Known Issues

Common E46 Issues:

Vanos seals degradation, oil leaks (valve cover gasket, oil pan gasket), cooling system components (water pump, thermostat, expansion tank), subframe cracking (particularly on early models), window regulator failures, CCV system issues (crankcase ventilation).

Vanos Repair:

Degraded Vanos seals can lead to rough idle and loss of low-end torque; rebuild kits are available.

Cooling System Maintenance:

Plastic components in the cooling system are prone to becoming brittle and failing; proactive replacement is advised.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure - emphasis on performance, handling, and driver engagement

Model Evolution

E46 Introduction:

Introduced in late 1997 (for model year 1998) as the successor to the E36 3-Series.

E46 Facelift:

Received a significant facelift (LCI) for the 2002 model year, including updated front and rear styling, engine enhancements, and interior refinements.

Production

Production Period:

1998-2006

Manufacturing Locations:

Primary manufacturing in Dingolfing, Germany; also produced in South Africa, Thailand, Mexico, Egypt, and Russia.

🏆 Awards & Recognition

Recognitions

Car And Driver Awards:

Car and Driver's 10Best list multiple times during its production run.

Reputation:

Consistently praised by automotive journalists for its driving dynamics and overall refinement.