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BMW 3 Series E46 325xi Sport Wagon 1999-2005 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series E46 Trim: 325xi Sport Wagon Model Years Covered: 1999-2005 Product Name: BMW 3 Series E46 325xi Sport Wagon 1999-2005 Service Repair Manual 👋 Introduction Market Position Vehicle Segment: Compact Executive Sport Wagon Target Audience: Enthusiast owners seeking to perform their own maintenance and repairs, independent repair shops Competitive Analysis Competitors: Audi A4 Avant, Mercedes-Benz C-Class Wagon, Volvo V50/V70 Key Features Vehicle Appeal: Combines BMW's renowned driving dynamics and build quality with the practicality of a wagon and the added traction of xDrive. Manual Value Proposition Benefit: Empowers owners to maintain and repair their vehicle, potentially saving significant costs on dealership service and improving vehicle longevity. 📋 Manual Details Coverage Areas Maintenance: Scheduled maintenance, fluid changes, filter replacements, general upkeep Engine: Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, emissions Transmission: Automatic and manual transmission service, repair, and overhaul Drivetrain: All-wheel drive system (xDrive), differential service, driveshaft repair Brakes: Brake system diagnostics, repair, hydraulic components, ABS Suspension Steering: Front and rear suspension, steering system components, wheel alignment Electrical: Battery, charging system, starting system, lighting, instruments, ECUs, wiring diagrams Body Chassis: Body panels, doors, interior trim, glass, frame and chassis components Heating Ventilation Air Conditioning: HVAC system diagnosis, repair, refrigerant handling Comfort Systems: Seats, power windows, locks, mirrors, sunroof operation Troubleshooting: Diagnostic procedures for common problems and symptoms Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Comprehensive coverage of M54B30 inline-six engine, Getrag 5-speed manual (S5D250G) and Steptronic automatic transmission Chassis Control: xDrive all-wheel-drive system, DSC (Dynamic Stability Control), ABS (Anti-lock Braking System), ASC (Automatic Stability Control) Body Electrical: Detailed wiring diagrams, fuse and relay locations, control module functions (e.g., DME, EWS, ABS/DSC module) Procedures Included Engine Repair: Engine removal/installation, cylinder head service, piston and connecting rod replacement, crankshaft service, timing chain replacement Transmission Repair: Transmission fluid and filter changes, torque converter replacement, valve body service, clutch replacement (manual), seal and gasket replacements Brake System Overhaul: Brake pad/rotor replacement, caliper service, brake line bleeding, ABS modulator testing and replacement, DSC sensor calibration Suspension Component Replacement: Strut/shock absorber replacement, control arm bushings, ball joints, tie rod ends, sway bar links, rear axle bushings Electrical Diagnostics: Troubleshooting using wiring diagrams, component testing, diagnostic trouble code (DTC) retrieval and interpretation, EWS (immobilizer) system troubleshooting Fuel System Service: Fuel pump replacement, fuel injector cleaning/replacement, fuel pressure testing, EVAP system diagnosis HVAC Service: Cabin air filter replacement, refrigerant charging, blower motor replacement, evaporator core service Technical Depth Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and component-level repairs. 📊 Manual Specifications File Format File Type: Searchable PDF Printability: Printable individual pages or sections Print Quality Image Resolution: High-resolution images and clear diagrams Binding Type Binding: N/A (Digital Product) Paper Type Paper: N/A (Digital Product) Completeness Content: Contains all sections typically found in official BMW service manuals, including specifications, procedures, and diagrams. ⚙️ Engine Specifications Primary Engine Engine Code: M54B30 Engine Type: 3.0L Inline-6, DOHC, 24-valve Bore X Stroke: 84.0 mm x 89.6 mm Compression Ratio: 10.2:1 Performance Horsepower: 225 hp @ 6,000 rpm Torque: 214 lb-ft @ 3,500 rpm Fuel System Fuel Delivery: Sequential Multi-Point Fuel Injection (SFI) Recommended Fuel: Premium Unleaded Gasoline (91 AKI or higher) Cooling System Coolant Type: BMW Blue Antifreeze/Coolant (G48) Lubrication System Oil Type And Viscosity: SAE 0W-30 or 5W-30 (BMW Longlife-01 certified) Engine Management Engine Control Unit: MS43 (early models) / MS45 (later models) 🔧 Transmission Standard Transmission Type: Getrag 5-speed Manual Transmission (S5D250G) Optional Transmission Type: ZF 5-speed Steptronic Automatic Transmission Features Automatic Transmission Modes: Sport and Manual (SMG-like) shifting modes Fluid Specifications Manual Transmission Fluid: BMW MTF LT-2 (or equivalent Pentosin MTF2) Automatic Transmission Fluid: BMW ATF LT-4 (or equivalent ZF LifeguardFluid 5) 📐 Dimensions Exterior Length: 4471 mm (176.0 in) Width: 1739 mm (68.5 in) Height: 1409 mm (55.5 in) Wheelbase: 2760 mm (108.7 in) Cargo Cargo Volume Seats Up: 435 liters (15.4 cu ft) Cargo Volume Seats Down: 1315 liters (46.4 cu ft) Weights Curb Weight Manual: Approx. 1585 kg (3500 lbs) Curb Weight Automatic: Approx. 1620 kg (3570 lbs) Tires Wheels Wheel Bolt Pattern: 5x120 mm Standard Wheel Size: 17 x 7.0J Standard Tire Size: 225/45R17 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (Driver/Passenger) IIHS Side Impact: Good (for models equipped with side airbags) Active Features Stability Control: Dynamic Stability Control (DSC) standard Traction Control: Automatic Stability Control (ASC+T) Braking System: Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD) Passive Features Airbags: Front dual-stage airbags, optional front side-impact airbags, optional head protection system (HPS) Seatbelts: Front and rear three-point seatbelts with pretensioners and force limiters 💡 Technology Features Infotainment Head Unit Options: BMW Business CD, BMW Professional CD, optional navigation...
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BMW 3 Series E46 325xi Sport Wagon 1999-2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series E46
Trim:
325xi Sport Wagon
Model Years Covered:
1999-2005
Product Name:
BMW 3 Series E46 325xi Sport Wagon 1999-2005 Service Repair Manual
👋 Introduction
Market Position
Vehicle Segment:
Compact Executive Sport Wagon
Target Audience:
Enthusiast owners seeking to perform their own maintenance and repairs, independent repair shops
Competitive Analysis
Competitors:
Audi A4 Avant, Mercedes-Benz C-Class Wagon, Volvo V50/V70
Key Features
Vehicle Appeal:
Combines BMW's renowned driving dynamics and build quality with the practicality of a wagon and the added traction of xDrive.
Manual Value Proposition
Benefit:
Empowers owners to maintain and repair their vehicle, potentially saving significant costs on dealership service and improving vehicle longevity.
📋 Manual Details
Coverage Areas
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, general upkeep
Engine:
Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, emissions
Transmission:
Automatic and manual transmission service, repair, and overhaul
Drivetrain:
All-wheel drive system (xDrive), differential service, driveshaft repair
Brakes:
Brake system diagnostics, repair, hydraulic components, ABS
Suspension Steering:
Front and rear suspension, steering system components, wheel alignment
Electrical:
Battery, charging system, starting system, lighting, instruments, ECUs, wiring diagrams
Body Chassis:
Body panels, doors, interior trim, glass, frame and chassis components
Heating Ventilation Air Conditioning:
HVAC system diagnosis, repair, refrigerant handling
Comfort Systems:
Seats, power windows, locks, mirrors, sunroof operation
Troubleshooting:
Diagnostic procedures for common problems and symptoms
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Comprehensive coverage of M54B30 inline-six engine, Getrag 5-speed manual (S5D250G) and Steptronic automatic transmission
Chassis Control:
xDrive all-wheel-drive system, DSC (Dynamic Stability Control), ABS (Anti-lock Braking System), ASC (Automatic Stability Control)
Body Electrical:
Detailed wiring diagrams, fuse and relay locations, control module functions (e.g., DME, EWS, ABS/DSC module)
Procedures Included
Engine Repair:
Engine removal/installation, cylinder head service, piston and connecting rod replacement, crankshaft service, timing chain replacement
Transmission Repair:
Transmission fluid and filter changes, torque converter replacement, valve body service, clutch replacement (manual), seal and gasket replacements
Brake System Overhaul:
Brake pad/rotor replacement, caliper service, brake line bleeding, ABS modulator testing and replacement, DSC sensor calibration
Suspension Component Replacement:
Strut/shock absorber replacement, control arm bushings, ball joints, tie rod ends, sway bar links, rear axle bushings
Electrical Diagnostics:
Troubleshooting using wiring diagrams, component testing, diagnostic trouble code (DTC) retrieval and interpretation, EWS (immobilizer) system troubleshooting
Fuel System Service:
Fuel pump replacement, fuel injector cleaning/replacement, fuel pressure testing, EVAP system diagnosis
HVAC Service:
Cabin air filter replacement, refrigerant charging, blower motor replacement, evaporator core service
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and component-level repairs.
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Printability:
Printable individual pages or sections
Print Quality
Image Resolution:
High-resolution images and clear diagrams
Binding Type
Binding:
N/A (Digital Product)
Paper Type
Paper:
N/A (Digital Product)
Completeness
Content:
Contains all sections typically found in official BMW service manuals, including specifications, procedures, and diagrams.
⚙️ Engine Specifications
Primary Engine
Engine Code:
M54B30
Engine Type:
3.0L Inline-6, DOHC, 24-valve
Bore X Stroke:
84.0 mm x 89.6 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
225 hp @ 6,000 rpm
Torque:
214 lb-ft @ 3,500 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Point Fuel Injection (SFI)
Recommended Fuel:
Premium Unleaded Gasoline (91 AKI or higher)
Cooling System
Coolant Type:
BMW Blue Antifreeze/Coolant (G48)
Lubrication System
Oil Type And Viscosity:
SAE 0W-30 or 5W-30 (BMW Longlife-01 certified)
Engine Management
Engine Control Unit:
MS43 (early models) / MS45 (later models)
🔧 Transmission
Standard
Transmission Type:
Getrag 5-speed Manual Transmission (S5D250G)
Optional
Transmission Type:
ZF 5-speed Steptronic Automatic Transmission
Features
Automatic Transmission Modes:
Sport and Manual (SMG-like) shifting modes
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 (or equivalent Pentosin MTF2)
Automatic Transmission Fluid:
BMW ATF LT-4 (or equivalent ZF LifeguardFluid 5)
📐 Dimensions
Exterior
Length:
4471 mm (176.0 in)
Width:
1739 mm (68.5 in)
Height:
1409 mm (55.5 in)
Wheelbase:
2760 mm (108.7 in)
Cargo
Cargo Volume Seats Up:
435 liters (15.4 cu ft)
Cargo Volume Seats Down:
1315 liters (46.4 cu ft)
Weights
Curb Weight Manual:
Approx. 1585 kg (3500 lbs)
Curb Weight Automatic:
Approx. 1620 kg (3570 lbs)
Tires Wheels
Wheel Bolt Pattern:
5x120 mm
Standard Wheel Size:
17 x 7.0J
Standard Tire Size:
225/45R17
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (Driver/Passenger)
IIHS Side Impact:
Good (for models equipped with side airbags)
Active Features
Stability Control:
Dynamic Stability Control (DSC) standard
Traction Control:
Automatic Stability Control (ASC+T)
Braking System:
Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD)
Passive Features
Airbags:
Front dual-stage airbags, optional front side-impact airbags, optional head protection system (HPS)
Seatbelts:
Front and rear three-point seatbelts with pretensioners and force limiters
💡 Technology Features
Infotainment
Head Unit Options:
BMW Business CD, BMW Professional CD, optional navigation system (MKIII or MKIV).
Audio System:
Standard 6-speaker system, optional Harman Kardon premium audio.
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Cellular Integration:
Optional Bluetooth preparation with integrated hands-free functionality (often via a snap-in adapter in the center armrest).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable, typically every 10,000-15,000 miles (15,000-25,000 km) or 1-2 years, based on CBS (Condition Based Service) system or oil quality.
Spark Plug Replacement:
Approx. 60,000 miles (100,000 km) for original iridium plugs.
Coolant Flush:
Every 2-4 years or 30,000-50,000 miles (50,000-80,000 km).
Brake Fluid Flush:
Every 2 years.
Fluid Specifications
Power Steering Fluid:
BMW PSF (Power Steering Fluid) or Pentosin CHF 11S
Differential Fluid Front Rear:
API GL-5, SAE 75W-90 synthetic gear oil
Transfer Case Fluid:
BMW ATF D3 or equivalent (e.g., Pentosin ATF 1)
Known Issues
Cooling System:
Plastic expansion tank and radiator leaks, water pump failure, thermostat housing leaks (common failure points due to aging plastic components).
Suspension:
Front control arm bushings (RTABs), rear trailing arm bushings (RTABs), and front sway bar links are common wear items, leading to clunking noises and poor handling.
Engine Oil Leaks:
Valve cover gasket, oil pan gasket, and CCV (Crankcase Ventilation) system are prone to leaks and blockages, often leading to oil consumption and smoke.
Electrical Systems:
Window regulator failures, headlight leveling module issues, LCM (Light Control Module) problems, and ABS/DSC sensor failures.
Transmission:
Automatic transmission torque converter lock-up issues, mechatronic sleeve leaks (for automatic transmissions).
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Focus on 'The Ultimate Driving Machine', blending performance, luxury, and engineering.
Model Evolution
E46 Generation Introduction:
The E46 platform (introduced in 1998 for sedans/coupes) represented a significant evolution in BMW's compact executive line, known for improved chassis dynamics and refined styling.
Wagon Introduction:
The E46 Touring (wagon) variant was introduced later in the E46 lifecycle, offering increased versatility. The 325xi designation signifies the all-wheel-drive variant.
Production
Production Period:
1999-2005 (E46 generation)
Production Locations
Manufacturing Plants:
Primarily Dingolfing, Germany, and other BMW plants worldwide.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E46 3 Series platform, in various configurations, was a frequent recipient of Car and Driver's '10Best' awards during its production run, highlighting its exceptional driving characteristics.
Ratings
Jd Power Initial Quality:
Generally rated well for initial quality within its segment, reflecting BMW's build standards.
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