BMW 325xi 1999-2005 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: 325xi Generation: E46 Chassis Code: E46 Codes Engine Code: M54B25 👋 Introduction Market Position Segment: Compact Executive Sedan/Wagon Brand Philosophy: Ultimate Driving Machine, sport-luxury Competitive Analysis Key Competitors: Audi A4 Quattro, Mercedes-Benz C-Class, Lexus IS, Infiniti G35 Key Features Drivetrain: xDrive (All-Wheel Drive) system Engine Performance: Smooth and responsive inline-six engine Handling: Renowned BMW handling dynamics, balanced chassis 📋 Manual Details Coverage Areas Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Pages: 2000+ Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Cooling System, Fuel System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (AWD) Chassis: Suspension (Front & Rear), Steering System, Brakes (ABS, DSC), Wheels & Tires Electrical: Body Electronics, Powertrain Control Module (DME), Instrument Cluster, Lighting, Audio System, Navigation System, Climate Control, SRS Airbag System Body: Exterior Body Panels, Interior Trim, Seats, Doors, Windows, Sunroof Procedures Included Maintenance: Routine checks, fluid changes, filter replacements, tune-ups Diagnostics: Troubleshooting guides, fault code interpretation, diagnostic procedures Repair: Component removal and installation, sub-assembly repair, major component overhauls Special Procedures: Wheel alignment, airbag system service, ABS/DSC bleeding, fuel system pressure testing Technical Depth Depth: Comprehensive; covers from basic maintenance to complete engine and transmission rebuilds Diagnostic Tools: References for BMW-specific diagnostic tools (e.g., DIS, ISTA) 📊 Manual Specifications File Format Searchability: Searchable text content within PDF Printability: Printable pages Print Quality Image Resolution: High-resolution diagrams and photographs Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, 24-valve, Double VANOS Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 10.2:1 Performance Horsepower: 184 hp @ 6000 rpm Torque: 175 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) / Motronic ME 7.2 Fuel Type: Premium Unleaded Gasoline (91+ octane) Cooling System Coolant Type: BMW Blue Antifreeze/Coolant Coolant Capacity: 7.5 Liters (7.9 US Quarts) Exhaust System Emission Standards: LEVII (California)/BIN5 🔧 Transmission Standard Type: 5-speed Manual Transmission (Getrag S5D 250G) Optional Type: 5-speed Automatic Transmission (Steptronic) Features Drivetrain Type: All-Wheel Drive (xDrive - Permanent) Transfer Case Fluid: Refer to manual for specific BMW fluid P/N Automatic Transmission Fluid: BMW ATF LT-3 (or equivalent) 📐 Dimensions Exterior Length: 4471 mm (176.0 in) Width: 1739 mm (68.5 in) Height: 1415 mm (55.7 in) Wheelbase: 2760 mm (108.7 in) Interior Front Headroom: 975 mm (38.4 in) Rear Legroom: 859 mm (33.8 in) Cargo Trunk Volume: 440 Liters (15.5 cu ft) Weights Curb Weight: 1570 kg (3461 lbs) Gross Vehicle Weight Rating: 2040 kg (4497 lbs) Towing Capacity: Not Recommended Wheels Tires Wheel Bolt Pattern: 5x120 mm Standard Wheel Size: 16-inch Alloy Optional Wheel Size: 17-inch Alloy Standard Tire Size: 205/55R16 Optional Tire Size: 225/45R17 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (Driver/Passenger) NHTSA Side Impact: 4/5 Stars (Driver/Passenger - Front) Active Features Traction Control: Automatic Stability Control (ASC) / Dynamic Traction Control (DTC) Braking System: Anti-lock Braking System (ABS) Stability Control: Dynamic Stability Control (DSC) Passive Features Airbags: Frontal airbags, front side-impact airbags Seatbelts: 3-point inertia-reel seat belts with pretensioners Body Structure: Reinforced safety cell, crumple zones 💡 Technology Features Infotainment Audio System: BMW Business CD, BMW Professional CD/RDS with optional CD changer Navigation: Optional BMW Navigation System with separate display and control unit Driver Assistance Parking Sensors: Optional Park Distance Control (PDC) Cruise Control: Standard feature Connectivity Bluetooth: Optional Bluetooth interface and phone cradle Auxiliary Input: Optional AUX input jack 🔧 Maintenance Service Intervals Oil Change Interval: BMW Condition Based Service (CBS) system; typically 10,000-15,000 miles or annually Air Filter Replacement: Every 30,000 miles or as indicated by CBS Cabin Air Filter Replacement: Every 15,000-20,000 miles or annually Spark Plug Replacement: Approximately 100,000 miles (check manual for specific plug type) Brake Fluid Flush: Every 2 years Fluid Specifications Engine Oil Type: SAE 5W-30 Synthetic (BMW Longlife-01 or LL-04 approved) Engine Oil Capacity: 6.5 Liters (6.9 US Quarts) with filter Power Steering Fluid: Pentosin CHF 11S (or equivalent) Manual Transmission Fluid: Refer to manual for specific BMW manual transmission fluid P/N Known Issues Cooling System Failures: Cracked expansion tanks, failing water pumps, thermostat housing leaks (plastic components) Oil Leaks: Valve cover gasket, oil pan gasket, oil filter housing gasket, oil cooler seals Vanos System: Seals can degrade, leading to rough idle and reduced power ABS Wheel Speed Sensors: Frequent failures leading to ABS and DSC warning lights Pcv Valve System: Can clog, leading to oil leaks and rough running Subframe Mounts: Rear subframe mounts can wear, causing clunking noises and alignment issues 📚 Vehicle History Brand Heritage Brand Origin: Bayerische Motoren Werke AG, Germany Brand Reputation: Engineering excellence, sporty driving dynamics, premium quality Model Evolution E46 Introduction: Introduced globally in 1998 (as...