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2003 BMW 325XI Service & Repair Manual Software

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๐Ÿท๏ธ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325xi Year: 2003 Generation Chassis Code: E46 Generation Name: Fifth Generation E46 Codes Engine Code: M54B25 ๐Ÿ‘‹ Introduction Market Position Market Position: Premium compact executive sedan/wagon offering sporty handling, advanced technology, and all-wheel drive capability Competitive Analysis Competitive Analysis: Competed directly with the Audi A4 Quattro, Mercedes-Benz C-Class 4MATIC, and Lexus IS series Key Features Key Features: xDrive all-wheel drive system, refined inline-six engine, engaging driving dynamics, premium interior appointments, advanced safety features ๐Ÿ“‹ Manual Details Coverage Areas Coverage Areas: Engine, Drivetrain, Suspension, Steering, Brakes, Electrical Systems, HVAC, Bodywork, Diagnostics, Maintenance, Repair Procedures Page Count Page Count: Extensive (Software-based, dynamically displayed) Manual Type Manual Type: Service and Repair Manual Software Language Language: English Format Format: Digital Software (Downloadable) ๐Ÿ“– Manual Coverage Systems Covered Engine Systems: M54B25 inline-six: Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, exhaust system Drivetrain Systems: xDrive All-Wheel Drive System: Transfer case, front and rear driveshafts, differentials, axle shafts, AWD control module Transmission Systems: GM 5L475-E (5-speed automatic): Gearbox operation, torque converter, valve body, electronic control module, fluid specifications, service Suspension Steering: Front and Rear Suspension: MacPherson struts, multi-link rear, control arms, bushings, shock absorbers, steering rack, power steering system Brake Systems: Front and Rear Disc Brakes: ABS, DSC (Dynamic Stability Control), EBD (Electronic Brakeforce Distribution), brake pad replacement, rotor resurfacing/replacement, hydraulic system Electrical Systems: 12V Electrical System: Battery, alternator, starter, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, diagnostic trouble codes (DTCs) HVAC Systems: Climate Control System: Air conditioning, heating, ventilation, blower motor, refrigerant handling, cabin air filter replacement Bodywork Interior: Body Panels, Doors, Windows, Seats, Trim, Convertible Top Mechanism (if applicable), Convertible Top Frame Procedures Included Engine Procedures: Engine oil and filter change, spark plug replacement, coolant flush and fill, drive belt replacement, complete engine removal and installation, cylinder head overhaul Drivetrain Procedures: Transfer case fluid change, differential fluid change, driveshaft and CV joint inspection and replacement, AWD system diagnostics Transmission Procedures: Automatic transmission fluid and filter change, transmission removal and installation, torque converter replacement, troubleshooting transmission shift issues Suspension Steering Procedures: Strut and shock absorber replacement, control arm and bushing replacement, wheel bearing replacement, power steering fluid flush, steering rack repair Brake Procedures: Brake pad and rotor replacement, brake fluid flush and bleed, ABS/DSC component testing and replacement, parking brake adjustment Electrical Procedures: Battery testing and replacement, alternator testing and replacement, starter replacement, headlight/taillight bulb replacement, fuse and relay diagnosis, wiring harness repair HVAC Procedures: AC system recharge, cabin filter replacement, heater core replacement, blower motor replacement, diagnosis of climate control system faults Bodywork Procedures: Door lock and window regulator repair, mirror replacement, bumper cover repair, interior trim panel removal and installation Diagnostic Procedures: OBD-II scanning, Diagnostic Trouble Code (DTC) interpretation, component testing, troubleshooting common drivability issues Technical Depth Technical Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams ๐Ÿ“Š Manual Specifications File Format File Format: Digital Software (likely PDF or proprietary executable) Print Quality Print Quality: N/A (Digital - excellent clarity and detail) Binding Type Binding Type: N/A (Digital) Paper Type Paper Type: N/A (Digital) โš™๏ธ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline 6-Cylinder Engine Code: M54B25 Displacement: 2494 cc (2.5 Liters) Bore X Stroke: 84.0 mm x 90.0 mm Compression Ratio: 10.2:1 Valve Train: Double Overhead Camshafts (DOHC), 4 valves per cylinder, VANOS (Variable Valve Timing) Performance Horsepower: 184 hp @ 6000 rpm Torque: 230 Nm (169 lb-ft) @ 3500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Fuel Tank Capacity: 66 Liters (17.4 US Gallons) ๐Ÿ”ง Transmission Standard Transmission Type: 5-Speed Automatic (GM 5L475-E) Optional Optional Transmission: 5-Speed Manual (S5-42/3Z) Features Drivetrain Type: xDrive All-Wheel Drive Transfer Case: Electronically controlled multi-plate clutch system with planetary gearset Automatic Transmission Fluid: Dexron III/VI or equivalent (refer to manual for specific BMW P/N) Manual Transmission Fluid: SAE 75W-90 Synthetic Gear Oil (refer to manual for specific BMW P/N) ๐Ÿ“ Dimensions Exterior Wheelbase: 2760 mm (108.7 inches) Length: 4471 mm (176.0 inches) Width: 1739 mm (68.5 inches) Height: 1415 mm (55.7 inches) Ground Clearance: Approximately 140 mm (5.5 inches) Weights Curb Weight: 1550 kg (3417 lbs) approx. Gross Vehicle Weight Rating: 2000 kg (4409 lbs) approx. ๐Ÿ›ก๏ธ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars NHTSA Front Impact Passenger: 5 Stars NHTSA Side Impact Front Driver: 5 Stars NHTSA Side Impact Front Passenger: 5 Stars NHTSA Side Impact Rear Driver: 4 Stars NHTSA Side Impact Rear Passenger: 4 Stars IIHS Moderate Overlap Front: Good IIHS Side Impact: Good Active Features Active Safety Features: Anti-lock Braking System (ABS), Dynamic Stability Control (DSC), Traction Control System (TCS), Electronic Brakeforce Distribution (EBD), All-Season Traction (from xDrive) Passive Features Passive Safety Features: Front airbags,...
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2003 BMW 325XI Service & Repair Manual Software
๐Ÿท๏ธ Basic Information
Identification
Make:
BMW
Model:
3 Series
Model Variant:
325xi
Year:
2003
Generation
Chassis Code:
E46
Generation Name:
Fifth Generation E46
Codes
Engine Code:
M54B25
๐Ÿ‘‹ Introduction
Market Position
Market Position:
Premium compact executive sedan/wagon offering sporty handling, advanced technology, and all-wheel drive capability
Competitive Analysis
Competitive Analysis:
Competed directly with the Audi A4 Quattro, Mercedes-Benz C-Class 4MATIC, and Lexus IS series
Key Features
Key Features:
xDrive all-wheel drive system, refined inline-six engine, engaging driving dynamics, premium interior appointments, advanced safety features
๐Ÿ“‹ Manual Details
Coverage Areas
Coverage Areas:
Engine, Drivetrain, Suspension, Steering, Brakes, Electrical Systems, HVAC, Bodywork, Diagnostics, Maintenance, Repair Procedures
Page Count
Page Count:
Extensive (Software-based, dynamically displayed)
Manual Type
Manual Type:
Service and Repair Manual Software
Language
Language:
English
Format
Format:
Digital Software (Downloadable)
๐Ÿ“– Manual Coverage
Systems Covered
Engine Systems:
M54B25 inline-six: Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, exhaust system
Drivetrain Systems:
xDrive All-Wheel Drive System: Transfer case, front and rear driveshafts, differentials, axle shafts, AWD control module
Transmission Systems:
GM 5L475-E (5-speed automatic): Gearbox operation, torque converter, valve body, electronic control module, fluid specifications, service
Suspension Steering:
Front and Rear Suspension: MacPherson struts, multi-link rear, control arms, bushings, shock absorbers, steering rack, power steering system
Brake Systems:
Front and Rear Disc Brakes: ABS, DSC (Dynamic Stability Control), EBD (Electronic Brakeforce Distribution), brake pad replacement, rotor resurfacing/replacement, hydraulic system
Electrical Systems:
12V Electrical System: Battery, alternator, starter, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, diagnostic trouble codes (DTCs)
HVAC Systems:
Climate Control System: Air conditioning, heating, ventilation, blower motor, refrigerant handling, cabin air filter replacement
Bodywork Interior:
Body Panels, Doors, Windows, Seats, Trim, Convertible Top Mechanism (if applicable), Convertible Top Frame
Procedures Included
Engine Procedures:
Engine oil and filter change, spark plug replacement, coolant flush and fill, drive belt replacement, complete engine removal and installation, cylinder head overhaul
Drivetrain Procedures:
Transfer case fluid change, differential fluid change, driveshaft and CV joint inspection and replacement, AWD system diagnostics
Transmission Procedures:
Automatic transmission fluid and filter change, transmission removal and installation, torque converter replacement, troubleshooting transmission shift issues
Suspension Steering Procedures:
Strut and shock absorber replacement, control arm and bushing replacement, wheel bearing replacement, power steering fluid flush, steering rack repair
Brake Procedures:
Brake pad and rotor replacement, brake fluid flush and bleed, ABS/DSC component testing and replacement, parking brake adjustment
Electrical Procedures:
Battery testing and replacement, alternator testing and replacement, starter replacement, headlight/taillight bulb replacement, fuse and relay diagnosis, wiring harness repair
HVAC Procedures:
AC system recharge, cabin filter replacement, heater core replacement, blower motor replacement, diagnosis of climate control system faults
Bodywork Procedures:
Door lock and window regulator repair, mirror replacement, bumper cover repair, interior trim panel removal and installation
Diagnostic Procedures:
OBD-II scanning, Diagnostic Trouble Code (DTC) interpretation, component testing, troubleshooting common drivability issues
Technical Depth
Technical Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams
๐Ÿ“Š Manual Specifications
File Format
File Format:
Digital Software (likely PDF or proprietary executable)
Print Quality
Print Quality:
N/A (Digital - excellent clarity and detail)
Binding Type
Binding Type:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
โš™๏ธ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Engine Code:
M54B25
Displacement:
2494 cc (2.5 Liters)
Bore X Stroke:
84.0 mm x 90.0 mm
Compression Ratio:
10.2:1
Valve Train:
Double Overhead Camshafts (DOHC), 4 valves per cylinder, VANOS (Variable Valve Timing)
Performance
Horsepower:
184 hp @ 6000 rpm
Torque:
230 Nm (169 lb-ft) @ 3500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Fuel Tank Capacity:
66 Liters (17.4 US Gallons)
๐Ÿ”ง Transmission
Standard
Transmission Type:
5-Speed Automatic (GM 5L475-E)
Optional
Optional Transmission:
5-Speed Manual (S5-42/3Z)
Features
Drivetrain Type:
xDrive All-Wheel Drive
Transfer Case:
Electronically controlled multi-plate clutch system with planetary gearset
Automatic Transmission Fluid:
Dexron III/VI or equivalent (refer to manual for specific BMW P/N)
Manual Transmission Fluid:
SAE 75W-90 Synthetic Gear Oil (refer to manual for specific BMW P/N)
๐Ÿ“ Dimensions
Exterior
Wheelbase:
2760 mm (108.7 inches)
Length:
4471 mm (176.0 inches)
Width:
1739 mm (68.5 inches)
Height:
1415 mm (55.7 inches)
Ground Clearance:
Approximately 140 mm (5.5 inches)
Weights
Curb Weight:
1550 kg (3417 lbs) approx.
Gross Vehicle Weight Rating:
2000 kg (4409 lbs) approx.
๐Ÿ›ก๏ธ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
NHTSA Side Impact Front Driver:
5 Stars
NHTSA Side Impact Front Passenger:
5 Stars
NHTSA Side Impact Rear Driver:
4 Stars
NHTSA Side Impact Rear Passenger:
4 Stars
IIHS Moderate Overlap Front:
Good
IIHS Side Impact:
Good
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Dynamic Stability Control (DSC), Traction Control System (TCS), Electronic Brakeforce Distribution (EBD), All-Season Traction (from xDrive)
Passive Features
Passive Safety Features:
Front airbags, front side-impact airbags, front and rear head protection system (HPS), 3-point safety belts with pretensioners, LATCH (Lower Anchors and Tethers for Children) system
๐Ÿ’ก Technology Features
Infotainment
Infotainment System:
Available BMW Business CD or Professional CD radio, optional navigation system (MKIII/MKIV based), Harman Kardon audio system
Driver Assistance
Driver Assistance Features:
Dynamic Stability Control (DSC), Anti-lock Braking System (ABS), Cruise Control
Connectivity
Connectivity Features:
Optional Bluetooth integration (often via aftermarket adapter or later model updates), optional Sirius Satellite Radio
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Condition Based Service (CBS) system, typically around 10,000-15,000 miles or 12 months, whichever comes first. Refer to CBS indicator.
Air Filter Replacement:
Every 30,000 miles or as per CBS. Inspect more frequently in dusty conditions.
Cabin Filter Replacement:
Every 15,000 miles or annually.
Spark Plug Replacement:
Every 100,000 miles (Long-life spark plugs).
Coolant Flush Interval:
Initial fill is long-life; typically replaced every 4 years or 100,000 miles.
Brake Fluid Flush Interval:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Type:
SAE 0W-40 Synthetic (BMW Longlife-01 approved)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48) or equivalent silicate-free, ethylene glycol-based
Power Steering Fluid Type:
BMW Power Steering Fluid (Pentosin CHF 11 S or equivalent G002000)
Transfer Case Fluid Type:
BMW Transfer Case Fluid (ATF) or equivalent (refer to manual for specific P/N)
Known Issues
Known Issues:
Oil separator (PCV) system failure (clogging/leaks), VANOS solenoid issues, cooling system leaks (expansion tank, hoses), rear main crankshaft seal leaks, strut mount wear, front control arm bushings wear, "limp mode" transmission issues
๐Ÿ“š Vehicle History
Brand Heritage
Brand Heritage:
Bayerische Motoren Werke AG (BMW) is a German luxury vehicle manufacturer with a long history of producing performance-oriented vehicles, renowned for their driving dynamics and engineering excellence.
Model Evolution
Model Evolution:
The E46 generation, produced from 1998-2006 (with variants extending beyond), represented BMW's focus on sporty handling, refined styling, and technological advancement in the compact executive segment. The 'xi' designation signifies BMW's all-wheel-drive system.
Production
Production Period:
2001-2006 (for E46 325xi)
Manufacturing Locations:
Germany (Dingolfing, Munich), South Africa (Rosslyn)
๐Ÿ† Awards & Recognition
Recognitions
Awards:
While specific awards for the 2003 325xi are not individually cataloged, the E46 generation as a whole consistently received praise from automotive publications like Car and Driver and MotorTrend for its handling, performance, and overall value within the luxury segment.
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