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BMW 3 Series E46 2003 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E46 Model Year: 2003 Generation Generation Code: E46 (Fourth Generation) Generation Years: 1998-2006 (Global), 1999-2006 (North America) Codes Platform: BMW New Generation Sedan/Coupe Platform 👋 Introduction Market Position E46 Market Segment: Compact executive car, a benchmark in its segment for sporty handling and premium feel. Bmw 3 Series Legacy: The 3 Series is BMW's best-selling model globally and is considered the archetypal sport sedan. Competitive Analysis Key Competitors E46: Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS, Acura TL. Key Features E46 Distinctive Attributes: Excellent chassis dynamics (often cited as one of the best handling generations), refined interior, strong engine options, rear-wheel drive bias (with xDrive AWD available). Manual Value Proposition Manual Benefit: Empowers owners and independent mechanics with the same factory-level information used by BMW technicians, enabling accurate diagnosis, maintenance, and repair, thus saving money and ensuring vehicle longevity. 📋 Manual Details Coverage Areas All Models: Yes, covers all E46 models, engines, trims, and transmissions for 2003 Page Count Estimated Page Count: Over 2000 pages (typical for comprehensive BMW workshop manuals) Manual Type Manual Type: Workshop Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel delivery, emissions control. Engine Management: Engine Control Unit (ECU) diagnostics, sensor readings, ignition system, fuel injection system, VANOS system, emissions diagnostics (OBD-II). Transmission: Manual and automatic transmission service, repair, overhaul, clutch, torque converter, valve body, shift solenoids, transmission control module (TCM). Drivetrain: Driveshafts, CV joints, differential service, limited-slip differential (LSD) information (if applicable). Suspension: Front and rear suspension component replacement, shock absorbers, struts, control arms, bushings, springs, alignment procedures. Steering: Power steering system service, rack and pinion repair, steering column, tie rods, hydraulic system. Brakes: Brake system overhaul, disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid flush, caliper replacement, rotor replacement, pad replacement. Electrical System: Battery, charging system (alternator), starting system (starter), wiring diagrams, fuses, relays, lighting systems, horn. Body And Chassis: Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass replacement, chassis lubrication. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics, refrigerant service, blower motor, climate control unit, heater core, A/C compressor. Interior: Seat removal and installation, dashboard removal, instrument cluster, airbag system components, interior lighting. Exterior: Exterior lighting, mirrors, emblems, wiper system, sunroof operation. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspections and replacement. Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code explanations. Repair Procedures: Step-by-step instructions for component removal, installation, and repair for all major vehicle systems. Diagnostic Procedures: Detailed instructions for using diagnostic tools, reading fault codes, and interpreting sensor data. Torque Specifications: Precise torque values for all critical fasteners. Wiring Diagrams: Comprehensive and clear electrical wiring diagrams for all circuits. Special Tools: Identification and usage instructions for specialized BMW tools required for certain repairs. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic fluid checks and adjustments to full engine and transmission rebuilds. Includes advanced diagnostics and system-specific repairs. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick location of specific information. Print Quality Image Resolution: High-resolution images, diagrams, and schematics for clarity. Printable: Yes, designed to be printable for workshop use. Binding Type Binding For Printed: Not applicable for PDF, but original manuals typically use spiral-bound or case-bound for durability. Paper Type Paper Type For Printed: Not applicable for PDF, but original manuals use high-quality, durable paper. ⚙️ Engine Specifications Primary Engine Options 2003 320I: 2.2L M54B22 I6, 170 PS (125 kW), 210 Nm 325I/325Xi: 2.5L M54B25 I6, 184 PS (135 kW), 245 Nm 330I/330Xi: 3.0L M54B30 I6, 225 PS (165 kW), 289 Nm M3: 3.2L S54B32 I6, 343 PS (252 kW), 365 Nm Performance Engine Type: Inline-6 (I6) across most petrol variants, known for smoothness and balance. Engine Technology: Aluminum engine block and cylinder head, Double VANOS (Variable valve timing), sequential fuel injection, DISA intake manifold (on some variants). Fuel System Fuel Type: Premium Unleaded Gasoline (RON 95 or higher recommended) Fuel Delivery: Electronic Fuel Injection (EFI) with Bosch Motronic engine management. 🔧 Transmission Standard Standard Transmission Options: 5-speed manual transmission (Getrag GS5-39DZ on most models, ZF S5D 320Z on others). Optional Optional Transmission Options: 5-speed Steptronic automatic transmission (GM A5S360R/A5S390R), SMG (Sequential Manual Gearbox) for M3 models. Features Steptronic Functionality: Allows manual gear selection via shifter or steering wheel buttons (depending on option). Smg Features: Electro-hydraulic clutch and gear shift actuation, offering rapid gear changes for performance driving. 📐 Dimensions Exterior Body Styles: Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon, 5-door), M3 variants. Wheelbase: Approx. 2760 mm (108.7...
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BMW 3 Series E46 2003 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Model Year:
2003
Generation
Generation Code:
E46 (Fourth Generation)
Generation Years:
1998-2006 (Global), 1999-2006 (North America)
Codes
Platform:
BMW New Generation Sedan/Coupe Platform
👋 Introduction
Market Position
E46 Market Segment:
Compact executive car, a benchmark in its segment for sporty handling and premium feel.
Bmw 3 Series Legacy:
The 3 Series is BMW's best-selling model globally and is considered the archetypal sport sedan.
Competitive Analysis
Key Competitors E46:
Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS, Acura TL.
Key Features
E46 Distinctive Attributes:
Excellent chassis dynamics (often cited as one of the best handling generations), refined interior, strong engine options, rear-wheel drive bias (with xDrive AWD available).
Manual Value Proposition
Manual Benefit:
Empowers owners and independent mechanics with the same factory-level information used by BMW technicians, enabling accurate diagnosis, maintenance, and repair, thus saving money and ensuring vehicle longevity.
📋 Manual Details
Coverage Areas
All Models:
Yes, covers all E46 models, engines, trims, and transmissions for 2003
Page Count
Estimated Page Count:
Over 2000 pages (typical for comprehensive BMW workshop manuals)
Manual Type
Manual Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel delivery, emissions control.
Engine Management:
Engine Control Unit (ECU) diagnostics, sensor readings, ignition system, fuel injection system, VANOS system, emissions diagnostics (OBD-II).
Transmission:
Manual and automatic transmission service, repair, overhaul, clutch, torque converter, valve body, shift solenoids, transmission control module (TCM).
Drivetrain:
Driveshafts, CV joints, differential service, limited-slip differential (LSD) information (if applicable).
Suspension:
Front and rear suspension component replacement, shock absorbers, struts, control arms, bushings, springs, alignment procedures.
Steering:
Power steering system service, rack and pinion repair, steering column, tie rods, hydraulic system.
Brakes:
Brake system overhaul, disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid flush, caliper replacement, rotor replacement, pad replacement.
Electrical System:
Battery, charging system (alternator), starting system (starter), wiring diagrams, fuses, relays, lighting systems, horn.
Body And Chassis:
Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass replacement, chassis lubrication.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics, refrigerant service, blower motor, climate control unit, heater core, A/C compressor.
Interior:
Seat removal and installation, dashboard removal, instrument cluster, airbag system components, interior lighting.
Exterior:
Exterior lighting, mirrors, emblems, wiper system, sunroof operation.
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspections and replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code explanations.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair for all major vehicle systems.
Diagnostic Procedures:
Detailed instructions for using diagnostic tools, reading fault codes, and interpreting sensor data.
Torque Specifications:
Precise torque values for all critical fasteners.
Wiring Diagrams:
Comprehensive and clear electrical wiring diagrams for all circuits.
Special Tools:
Identification and usage instructions for specialized BMW tools required for certain repairs.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic fluid checks and adjustments to full engine and transmission rebuilds. Includes advanced diagnostics and system-specific repairs.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF, allowing for quick location of specific information.
Print Quality
Image Resolution:
High-resolution images, diagrams, and schematics for clarity.
Printable:
Yes, designed to be printable for workshop use.
Binding Type
Binding For Printed:
Not applicable for PDF, but original manuals typically use spiral-bound or case-bound for durability.
Paper Type
Paper Type For Printed:
Not applicable for PDF, but original manuals use high-quality, durable paper.
⚙️ Engine Specifications
Primary Engine Options 2003
320I:
2.2L M54B22 I6, 170 PS (125 kW), 210 Nm
325I/325Xi:
2.5L M54B25 I6, 184 PS (135 kW), 245 Nm
330I/330Xi:
3.0L M54B30 I6, 225 PS (165 kW), 289 Nm
M3:
3.2L S54B32 I6, 343 PS (252 kW), 365 Nm
Performance
Engine Type:
Inline-6 (I6) across most petrol variants, known for smoothness and balance.
Engine Technology:
Aluminum engine block and cylinder head, Double VANOS (Variable valve timing), sequential fuel injection, DISA intake manifold (on some variants).
Fuel System
Fuel Type:
Premium Unleaded Gasoline (RON 95 or higher recommended)
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch Motronic engine management.
🔧 Transmission
Standard
Standard Transmission Options:
5-speed manual transmission (Getrag GS5-39DZ on most models, ZF S5D 320Z on others).
Optional
Optional Transmission Options:
5-speed Steptronic automatic transmission (GM A5S360R/A5S390R), SMG (Sequential Manual Gearbox) for M3 models.
Features
Steptronic Functionality:
Allows manual gear selection via shifter or steering wheel buttons (depending on option).
Smg Features:
Electro-hydraulic clutch and gear shift actuation, offering rapid gear changes for performance driving.
📐 Dimensions
Exterior
Body Styles:
Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon, 5-door), M3 variants.
Wheelbase:
Approx. 2760 mm (108.7 in) for Sedan/Coupe/Touring, 2690 mm (105.9 in) for Convertible.
Overall Length:
Varies by body style, e.g., Sedan approx. 4471 mm (176.0 in).
Weights
Curb Weight:
Starts around 1400 kg (3086 lbs) for 320i manual, up to 1650 kg (3638 lbs) for 330xi automatic or M3.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-star rating (for models tested).
IIHS Side Impact:
Good rating (for models tested).
Active Features
Standard Safety Features:
ABS, Traction Control (ASC+T), front airbags, side airbags.
Optional Safety Features:
Dynamic Stability Control (DSC), Xenon headlights, front and rear curtain airbags (depending on model year and options).
Passive Features
Passive Safety Systems:
Reinforced chassis structure, crumple zones, seatbelt pretensioners, rollover protection system (for convertibles).
💡 Technology Features
Infotainment
Available Infotainment Systems:
BMW Professional Radio, Business CD Player, optional Navigation system (MKIII or MKIV), Harman Kardon audio system.
Connectivity Options:
Optional Bluetooth hands-free system, CD changer.
Driver Assistance
Driver Assistance Features:
Cruise control, parking sensors (Park Distance Control - PDC).
Control Systems:
ABS, ASC+T (Automatic Stability Control + Traction), optional DSC (Dynamic Stability Control).
Connectivity
Bmw Connecteddrive Precursor:
Early systems offering mobile phone integration and navigation aids.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles (15,000-25,000 km) or annually, as indicated by the Condition Based Service (CBS) system or manufacturer recommendation.
Inspection Ii Interval:
Around 60,000 miles (100,000 km), includes a more comprehensive check of vehicle systems.
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) approved synthetic oil, e.g., 5W-30 or 5W-40, depending on ambient temperature and specific engine.
Coolant:
BMW G48 Antifreeze/Coolant (Ethylene Glycol based) with rust inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 Low Viscosity (LV) or DOT 5.1 brake fluid.
Transmission Fluid Auto:
BMW ATF LT71141 or equivalent synthetic ATF (specific to transmission type).
Transmission Fluid Manual:
Typically BMW Synchromesh Transmission Fluid or equivalent API GL-4, SAE 75W-80.
Known Issues
Common E46 Issues:
Cooling system failures (plastic expansion tank, water pump, thermostat housing), VANOS solenoid issues, oil leaks (valve cover gasket, oil pan gasket), subframe cracking (rear), CCV system issues (crankcase ventilation), ABS/DSC sensor failures, window regulator failures, starter motor issues, ignition coil failures.
M54 Engine Specifics:
CCV system (can cause oil consumption and rough running), oil separator failure, intake manifold runner flaps (DISA).
S54 Engine Specifics M3:
Rod bearing wear (critical issue requiring proactive inspection/replacement), VANOS system issues, throttle actuator issues.
📚 Vehicle History
Brand Heritage
Bmw Brand Philosophy:
Sheer Driving Pleasure – BMW has a long history of building driver-focused vehicles with excellent engineering.
Model Evolution
E46 Predecessor:
E36 3 Series (1990-1999).
E46 Successor:
E90 3 Series (Sedan, 2005-2011), E91 Touring (2005-2012), E92 Coupe (2006-2013), E93 Convertible (2006-2013).
Production
Production Period:
1998-2006.
Manufacturing Locations:
Primary manufacturing in Dingolfing, Germany. Some assembly also occurred in other global locations.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
BMW 3 Series models frequently appeared on Car and Driver's 10Best lists during the E46's production run, acknowledging its exceptional driving dynamics.
Ratings
Consumer Reports Reliability:
Varies by year and specific model; some years and engine variants received above-average reliability ratings, while others had average or below-average ratings due to specific known issues.
Certifications
Epa Fuel Economy Examples:
e.g., 325i Sedan (2003) estimated EPA MPG: 18 City / 26 Highway (manual).
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