BMW 3 Series (E46) 325i 1999-2005 Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i Chassis Code: E46 Production Years: 1999-2005 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Convertible Target Audience: Enthusiast drivers, DIY mechanics, BMW owners seeking detailed repair and maintenance information. Competitive Analysis Key Competitors: Mercedes-Benz C-Class, Audi A4, Lexus IS300, Infiniti G35. Key Features Driving Dynamics: Renowned for its balanced chassis, rear-wheel-drive platform, and engaging driving experience, characteristic of BMW's 'Ultimate Driving Machine' philosophy. Powertrain Options: Featured the smooth and potent M54 inline-six engine, offering a good balance of performance and refinement. Design: Clean, classic lines designed by Chris Bangle, with a focus on aerodynamic efficiency and BMW's signature styling cues. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Cooling System, Exhaust System, Clutch, Transmission (Manual & Automatic), Driveshaft, Differential, Suspension (Front & Rear), Steering, Brakes (Front & Rear), Electrical System, Bodywork, HVAC System, Interior Trim, Diagnostic Procedures, Specifications Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed procedures for engine overhaul, including cylinder head, pistons, connecting rods, crankshaft, valve train, timing chain, oil pump, and lubrication system. Fuel And Emissions: Diagnosis and repair of fuel injection system (DME - Digital Motor Electronics), fuel pump, injectors, fuel pressure regulator, evaporative emissions control (EVAP), and catalytic converter. Includes diagnostic trouble codes (DTCs). Cooling System: Maintenance and repair of radiator, water pump, thermostat, coolant expansion tank, hoses, and cooling fan. Includes coolant type and capacity. Exhaust System: Repair and replacement of exhaust manifolds, catalytic converters, mufflers, and pipes. Torque specifications for exhaust system fasteners. Drivetrain: Repair and overhaul of clutch assembly, manual transmission (Getrag 250G), automatic transmission (GM A5S360R/A5S325Z), driveshaft, universal joints, and rear differential. Includes fluid types and capacities. Suspension And Steering: Detailed procedures for front and rear suspension components: struts, shock absorbers, control arms, ball joints, bushings, springs, sway bars. Power steering system diagnosis and repair, including pump, rack and pinion, and fluid. Brakes: Front and rear brake system maintenance and repair: brake pads, rotors, calipers, brake lines, master cylinder, ABS system (Anti-lock Braking System), DSC (Dynamic Stability Control). Includes bleeding procedures and brake fluid specifications. Electrical System: Comprehensive wiring diagrams for all vehicle systems, including engine management, lighting, power windows, central locking, audio system, instrument cluster, and battery/charging system. Fuse box layouts and relay functions. Body And Chassis: Body panel repair, door mechanisms, window regulators, exterior trim, and underbody protection. Includes jacking points and towing procedures. HVAC System: Diagnosis and repair of heating, ventilation, and air conditioning (HVAC) system, including blower motor, evaporator, condenser, refrigerant system, and climate control unit. Procedures Included Preventive Maintenance: Oil and filter changes, air filter replacement, cabin filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid changes, differential fluid changes. Diagnostic Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, using diagnostic trouble codes (DTCs) and live data from the OBD-II (On-Board Diagnostics) system. Component Replacement: Step-by-step instructions for replacing all major and minor components, including engine parts, transmission, suspension elements, brake components, sensors, actuators, and interior trim. Rebuilding Overhauling: Detailed instructions for complete engine and transmission rebuilding, including torque specifications, clearances, and assembly sequences. Electrical Diagnostics: Troubleshooting electrical circuits using wiring diagrams, multimeters, and diagnostic tools. Repair of wiring harnesses, connectors, and electronic control modules (ECMs). Technical Depth Diagnostic Tools: Information on using BMW-specific diagnostic tools (e.g., DIS, ISTA) and generic OBD-II scanners for fault code retrieval and data analysis. Torque Specifications: Precise torque values for all critical fasteners, including engine components, suspension, brakes, wheels, and driveline. Clearances And Tolerances: Specifications for engine component clearances (e.g., piston ring gap, bearing clearances) and suspension alignment specifications. Wiring Diagrams: Comprehensive, high-resolution wiring diagrams for all electrical systems, color-coded for clarity. Special Tools: Identification and usage of specialized tools required for specific repair procedures, such as piston ring compressors, valve spring compressors, and bearing pullers. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Searchability: Fully searchable text for quick access to specific information. Print Quality Print Quality: High-resolution scans, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: M54B30 Engine Type: 3.0L Naturally Aspirated Inline-6 (Gasoline) Displacement: 2979 cc (3.0 liters) Bore X Stroke: 84.0 mm x 89.6 mm Compression Ratio: 10.2:1 Valve Train: DOHC (Double Overhead Camshafts), 24 valves, VANOS (Variable Valve Timing) Performance Horsepower: 225 hp @ 6,100 rpm Torque: 214 lb-ft @ 3,500 rpm Fuel System Fuel Induction: Sequential Multi-Port Fuel Injection (SMPI) Fuel Type: Premium Unleaded (91 Octane or higher recommended) Engine Management: Bosch Motronic ME7.2 or similar DME 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (Getrag 250G) Optional Transmission Type Optional:...
Enthusiast drivers, DIY mechanics, BMW owners seeking detailed repair and maintenance information.
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS300, Infiniti G35.
Key Features
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel-drive platform, and engaging driving experience, characteristic of BMW's 'Ultimate Driving Machine' philosophy.
Powertrain Options:
Featured the smooth and potent M54 inline-six engine, offering a good balance of performance and refinement.
Design:
Clean, classic lines designed by Chris Bangle, with a focus on aerodynamic efficiency and BMW's signature styling cues.
Detailed procedures for engine overhaul, including cylinder head, pistons, connecting rods, crankshaft, valve train, timing chain, oil pump, and lubrication system.
Fuel And Emissions:
Diagnosis and repair of fuel injection system (DME - Digital Motor Electronics), fuel pump, injectors, fuel pressure regulator, evaporative emissions control (EVAP), and catalytic converter. Includes diagnostic trouble codes (DTCs).
Cooling System:
Maintenance and repair of radiator, water pump, thermostat, coolant expansion tank, hoses, and cooling fan. Includes coolant type and capacity.
Exhaust System:
Repair and replacement of exhaust manifolds, catalytic converters, mufflers, and pipes. Torque specifications for exhaust system fasteners.
Drivetrain:
Repair and overhaul of clutch assembly, manual transmission (Getrag 250G), automatic transmission (GM A5S360R/A5S325Z), driveshaft, universal joints, and rear differential. Includes fluid types and capacities.
Suspension And Steering:
Detailed procedures for front and rear suspension components: struts, shock absorbers, control arms, ball joints, bushings, springs, sway bars. Power steering system diagnosis and repair, including pump, rack and pinion, and fluid.
Brakes:
Front and rear brake system maintenance and repair: brake pads, rotors, calipers, brake lines, master cylinder, ABS system (Anti-lock Braking System), DSC (Dynamic Stability Control). Includes bleeding procedures and brake fluid specifications.
Electrical System:
Comprehensive wiring diagrams for all vehicle systems, including engine management, lighting, power windows, central locking, audio system, instrument cluster, and battery/charging system. Fuse box layouts and relay functions.
Body And Chassis:
Body panel repair, door mechanisms, window regulators, exterior trim, and underbody protection. Includes jacking points and towing procedures.
HVAC System:
Diagnosis and repair of heating, ventilation, and air conditioning (HVAC) system, including blower motor, evaporator, condenser, refrigerant system, and climate control unit.
Systematic diagnostic procedures for common and uncommon issues, using diagnostic trouble codes (DTCs) and live data from the OBD-II (On-Board Diagnostics) system.
Component Replacement:
Step-by-step instructions for replacing all major and minor components, including engine parts, transmission, suspension elements, brake components, sensors, actuators, and interior trim.
Rebuilding Overhauling:
Detailed instructions for complete engine and transmission rebuilding, including torque specifications, clearances, and assembly sequences.
Electrical Diagnostics:
Troubleshooting electrical circuits using wiring diagrams, multimeters, and diagnostic tools. Repair of wiring harnesses, connectors, and electronic control modules (ECMs).
Technical Depth
Diagnostic Tools:
Information on using BMW-specific diagnostic tools (e.g., DIS, ISTA) and generic OBD-II scanners for fault code retrieval and data analysis.
Torque Specifications:
Precise torque values for all critical fasteners, including engine components, suspension, brakes, wheels, and driveline.
Clearances And Tolerances:
Specifications for engine component clearances (e.g., piston ring gap, bearing clearances) and suspension alignment specifications.
Wiring Diagrams:
Comprehensive, high-resolution wiring diagrams for all electrical systems, color-coded for clarity.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures, such as piston ring compressors, valve spring compressors, and bearing pullers.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Searchability:
Fully searchable text for quick access to specific information.
Print Quality
Print Quality:
High-resolution scans, suitable for printing individual pages or the entire manual.
Hydraulically actuated clutch, close-ratio gearsets for sporty feel.
Automatic Transmission Features:
Steptronic with manual shift mode, adaptive shift logic.
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent (e.g., Red Line D4 ATF)
Automatic Transmission Fluid:
Dexron III (GM spec) or ZF LifeguardFluid5
📐 Dimensions
Exterior
Length:
4,471 mm (176.0 in)
Width:
1,739 mm (68.5 in)
Height:
1,372 mm (54.0 in)
Wheelbase:
2,725 mm (107.3 in)
Front Track:
1,471 mm (57.9 in)
Rear Track:
1,479 mm (58.2 in)
Weights
Curb Weight:
Approx. 1,480 kg (3,263 lbs) for manual transmission
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
4 Stars (driver and passenger)
IIHS Side Impact:
Good (for models equipped with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Dynamic Traction Control (DTC) or optional Automatic Stability Control (ASC+T) on earlier models, later DSC (Dynamic Stability Control).
Passive Features
Airbags:
Frontal airbags for driver and front passenger, optional front side-impact airbags.
Seatbelts:
3-point inertia-reel seat belts with pre-tensioners and force limiters.
Body Structure:
High-strength steel safety cage, crumple zones designed to absorb impact energy.
💡 Technology Features
Infotainment
Audio System:
Standard BMW Business CD radio with AM/FM and CD player. Optional BMW Professional CD/Radio, or optional navigation system with integrated CD player. Harman Kardon premium audio system available.
Navigation:
Optional BMW Professional Navigation system with older CRT displays and CD-ROM map updates.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Sensors:
Optional Park Distance Control (PDC) for front and rear.
Connectivity
Bluetooth:
Optional Bluetooth mobile phone integration with TCU (Telematics Control Unit) on later models.
Auxiliary Input:
Limited; some later models or aftermarket installations may feature an auxiliary input jack.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles (or as indicated by the vehicle's Condition Based Service - CBS system).
Air Filter Replacement:
Recommended every 30,000 miles or as needed based on driving conditions.
Cabin Filter Replacement:
Recommended every 15,000 to 30,000 miles.
Spark Plug Replacement:
Typically every 60,000 miles (for original equipment platinum/iridium plugs).
Brake Fluid Flush:
Recommended every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40 Synthetic Oil meeting BMW LL-01 specification (e.g., Castrol Syntec, Mobil 1)
Engine Oil Capacity:
6.5 liters (6.9 US quarts)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 formulation) mixed 50/50 with distilled water.
BMW (Bayerische Motoren Werke AG) is a German luxury and performance automobile manufacturer known for its engineering prowess, driving dynamics, and premium quality.
Model Evolution
E46 Generation:
The E46 generation of the 3 Series (produced from 1998 to 2006, with the 325i specific to 1999-2005 model years in many markets) succeeded the E36 and was praised for its improved handling, refined interior, and advanced technology. It marked a significant step forward in BMW's design language.
325I Placement:
The 325i model typically occupied the mid-range of the E46 lineup, offering a balance of performance and luxury above the 320i/323i and below the 330i.
Production
Manufacturing Locations:
Primarily manufactured at BMW's Dingolfing plant in Germany, with some production also occurring in South Africa and other global facilities.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E46 3 Series was a frequent recipient of Car and Driver's '10Best' list during its production run, recognized for its exceptional driving dynamics and overall performance.
General Reception:
Widely lauded by automotive journalists for its superior handling, build quality, and refined driving experience, solidifying its reputation as a benchmark in its class.
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