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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...
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BMW 325xi 1999-2005 Service Repair Workshop Manual
🏷️ 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 a 1999 model year)
325Xi Introduction:
Introduced in 2000 as part of the E46 generation's expansion, offering xDrive AWD
Facelift:
Minor facelift (LCI) occurred for 2002 model year with updated styling and features
Production
Production Period:
1999-2006 (E46 generation overall), 325xi specific years as listed
Manufacturing Locations:
Germany, South Africa, USA (various plants)
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
3 Series consistently named to Car and Driver's 10 Best list during this era
Ratings
Consumer Reports:
Generally rated well for performance and driving dynamics, with some recurring noted issues
Certifications
Emission Certifications:
Meets EPA/CARB emissions standards for its model years
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