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BMW E46 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series (E46) Year: 2004 Generation Generation Name: E46 Generation Years: 1998-2006 (Globally) 👋 Introduction Market Position Market Segment: Premium compact executive sedan/coupe/convertible/wagon. Competitive Analysis Competitors 2004: Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS300, Infiniti G35. Key Features Driver Focus: Renowned for its engaging driving dynamics, balanced chassis, and driver-centric cockpit. Powertrain Options: Available with a range of inline-four and inline-six M54 engines known for smoothness and performance. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for BMW E46 2004 models. Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Digital (likely PDF, searchable) 📖 Manual Coverage Systems Covered Engine Management: Detailed diagnostics, component testing, and repair procedures for DME (Digital Motor Electronics). Fuel System: Fuel pump, injectors, pressure regulation, fuel tank, EVAP system diagnosis and repair. Cooling System: Radiator, water pump, thermostat, hoses, fan clutch/electric fan, coolant specifications. Exhaust System: Catalytic converters, mufflers, oxygen sensors, exhaust manifold diagnosis and replacement. Ignition System: Spark plugs, ignition coils, crank and cam position sensors, troubleshooting. Transmission Manual: Clutch assembly, gearbox removal/installation, internal component repair, fluid specifications. Transmission Automatic: GM 5L40-E / ZF 5HP19 / ZF 6HP19 (depending on engine variant) - control modules, solenoid testing, fluid specifications, torque converter. Drivetrain Rear Axle: Differential, driveshafts, CV joints, limited-slip differential (if equipped), fluid specifications. Suspension Front: MacPherson struts, control arms, ball joints, bushings, sway bar, alignment specifications. Suspension Rear: Multi-link independent suspension, shock absorbers, control arms, bushings, alignment specifications. Steering System: Power steering pump, steering rack, tie rods, steering column, fluid type. Braking System: Brake discs, calipers, pads, ABS system, DSC (Dynamic Stability Control), EBD (Electronic Brake-force Distribution), fluid type and bleeding procedures. Wheel Speed Sensors: Diagnosis and replacement for ABS/DSC functionality. Electrical System General: Battery, alternator, starter motor, wiring diagrams, fuse/relay locations. Body Electrical: Lighting systems (headlights, taillights, interior), power windows, locks, mirrors, sunroof, horn. Climate Control: HVAC system, A/C compressor, refrigerant, blower motor, climate control modules, cabin filter. Infotainment Audio: Radio, CD player, speakers, amplifier (if equipped), antenna system. Instrument Cluster: Gauge operation, warning lights, troubleshooting. Srs Airbag System: Airbag modules, sensors, control unit, diagnostic procedures. Security System E46: Immobilizer system (EWS), remote key functions, alarm system. Body Panels: Hood, fenders, doors, trunk lid removal and installation, hinge adjustment. Glass And Seals: Windshield, side windows, rear window, seals, weatherstripping. Interior Trim: Dashboard, door panels, headliner, seats, carpet removal and installation. Lighting Exterior: Headlight aim, bulb replacement, taillight assembly, fog lights. Lighting Interior: Dome light, vanity mirrors, footwell lighting, trunk light. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, cabin), spark plug replacement, brake fluid flush, coolant flush. Component Removal Installation: Step-by-step guides for all major components across all systems. Disassembly Assembly: Detailed instructions for internal components of engines, transmissions, and other assemblies. Troubleshooting Diagnostics: Symptom-based diagnostics, fault code interpretation (OBD-II), electrical system tracing. Repair Procedures: Specific repair instructions for common failures and wear items. Specifications And Tolerances: Torque values, clearances, alignment settings, and other critical specifications. Wiring Diagrams: Comprehensive electrical schematics for all circuits. Special Tools And Procedures: Identification of BMW-specific tools and unique repair methods. Technical Depth Depth: Factory-level detail suitable for professional mechanics and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Format Details: Likely a PDF file, optimized for digital viewing and printing. Searchable text is a key feature of factory manuals. Print Quality Print Quality Recommendation: High-resolution images and clear diagrams ensure readability when printed. Binding Type Binding Type Description: For physical copies, typically coil-bound or perfect-bound for durability and lay-flat use. Paper Type Paper Type Recommendation: Durable, matte-finish paper is ideal for workshop environments to reduce glare and resist oil/grease. ⚙️ Engine Specifications Primary Engine Engine Code Common: M54B22, M54B25, M54B30 (inline-six); N42B18, N46B20 (inline-four) Performance Horsepower Range: 143 hp (N42) to 231 hp (M54B30) Torque Range: 190 Nm (N42) to 300 Nm (M54B30) Fuel System Fuel Injection Type: Sequential Electronic Fuel Injection (SEFI) Recommended Fuel: Premium Unleaded Gasoline (91 AKI or higher) Engine Management Dme Model: MS43 or MS45 (depending on engine and transmission) 🔧 Transmission Standard Standard Transmission: 5-speed Manual Getrag 250G Optional Optional Transmission Auto: 5-speed Automatic GM 5L40-E (RWD); 5-speed Automatic ZF 5HP19 (xDrive); 6-speed Automatic ZF 6HP19 (post-facelift models with M54) Features Steptronic: Available on automatic transmissions for manual shifting. Fluid Specifications Automatic Transmission Fluid: BMW ATF LT-3 (e.g., Pentosin ATF1 or equivalent) Manual Transmission Fluid: BMW MTF LT-2 (e.g., Castrol Syntrans B 75W-80 or equivalent) 📐 Dimensions Exterior Body Styles: Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon, 5-door) Weights Curb Weight Range: Approx. 1450 kg - 1700 kg (depending on body style and engine) 🛡️ Safety Features Ratings IIHS Frontal Impact: Good (for applicable models) NHTSA Side Impact: 5-star (for applicable models) Active Features ABS: Standard...
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BMW E46 2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series (E46)
Year:
2004
Generation
Generation Name:
E46
Generation Years:
1998-2006 (Globally)
👋 Introduction
Market Position
Market Segment:
Premium compact executive sedan/coupe/convertible/wagon.
Competitive Analysis
Competitors 2004:
Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS300, Infiniti G35.
Key Features
Driver Focus:
Renowned for its engaging driving dynamics, balanced chassis, and driver-centric cockpit.
Powertrain Options:
Available with a range of inline-four and inline-six M54 engines known for smoothness and performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for BMW E46 2004 models.
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, searchable)
📖 Manual Coverage
Systems Covered
Engine Management:
Detailed diagnostics, component testing, and repair procedures for DME (Digital Motor Electronics).
Fuel System:
Fuel pump, injectors, pressure regulation, fuel tank, EVAP system diagnosis and repair.
Cooling System:
Radiator, water pump, thermostat, hoses, fan clutch/electric fan, coolant specifications.
Exhaust System:
Catalytic converters, mufflers, oxygen sensors, exhaust manifold diagnosis and replacement.
Ignition System:
Spark plugs, ignition coils, crank and cam position sensors, troubleshooting.
Transmission Manual:
Clutch assembly, gearbox removal/installation, internal component repair, fluid specifications.
Transmission Automatic:
GM 5L40-E / ZF 5HP19 / ZF 6HP19 (depending on engine variant) - control modules, solenoid testing, fluid specifications, torque converter.
Drivetrain Rear Axle:
Differential, driveshafts, CV joints, limited-slip differential (if equipped), fluid specifications.
Suspension Front:
MacPherson struts, control arms, ball joints, bushings, sway bar, alignment specifications.
Suspension Rear:
Multi-link independent suspension, shock absorbers, control arms, bushings, alignment specifications.
Steering System:
Power steering pump, steering rack, tie rods, steering column, fluid type.
Braking System:
Brake discs, calipers, pads, ABS system, DSC (Dynamic Stability Control), EBD (Electronic Brake-force Distribution), fluid type and bleeding procedures.
Wheel Speed Sensors:
Diagnosis and replacement for ABS/DSC functionality.
Electrical System General:
Battery, alternator, starter motor, wiring diagrams, fuse/relay locations.
Body Electrical:
Lighting systems (headlights, taillights, interior), power windows, locks, mirrors, sunroof, horn.
Climate Control:
HVAC system, A/C compressor, refrigerant, blower motor, climate control modules, cabin filter.
Infotainment Audio:
Radio, CD player, speakers, amplifier (if equipped), antenna system.
Instrument Cluster:
Gauge operation, warning lights, troubleshooting.
Srs Airbag System:
Airbag modules, sensors, control unit, diagnostic procedures.
Security System E46:
Immobilizer system (EWS), remote key functions, alarm system.
Body Panels:
Hood, fenders, doors, trunk lid removal and installation, hinge adjustment.
Glass And Seals:
Windshield, side windows, rear window, seals, weatherstripping.
Interior Trim:
Dashboard, door panels, headliner, seats, carpet removal and installation.
Lighting Exterior:
Headlight aim, bulb replacement, taillight assembly, fog lights.
Lighting Interior:
Dome light, vanity mirrors, footwell lighting, trunk light.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, cabin), spark plug replacement, brake fluid flush, coolant flush.
Component Removal Installation:
Step-by-step guides for all major components across all systems.
Disassembly Assembly:
Detailed instructions for internal components of engines, transmissions, and other assemblies.
Troubleshooting Diagnostics:
Symptom-based diagnostics, fault code interpretation (OBD-II), electrical system tracing.
Repair Procedures:
Specific repair instructions for common failures and wear items.
Specifications And Tolerances:
Torque values, clearances, alignment settings, and other critical specifications.
Wiring Diagrams:
Comprehensive electrical schematics for all circuits.
Special Tools And Procedures:
Identification of BMW-specific tools and unique repair methods.
Technical Depth
Depth:
Factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format Details:
Likely a PDF file, optimized for digital viewing and printing. Searchable text is a key feature of factory manuals.
Print Quality
Print Quality Recommendation:
High-resolution images and clear diagrams ensure readability when printed.
Binding Type
Binding Type Description:
For physical copies, typically coil-bound or perfect-bound for durability and lay-flat use.
Paper Type
Paper Type Recommendation:
Durable, matte-finish paper is ideal for workshop environments to reduce glare and resist oil/grease.
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
M54B22, M54B25, M54B30 (inline-six); N42B18, N46B20 (inline-four)
Performance
Horsepower Range:
143 hp (N42) to 231 hp (M54B30)
Torque Range:
190 Nm (N42) to 300 Nm (M54B30)
Fuel System
Fuel Injection Type:
Sequential Electronic Fuel Injection (SEFI)
Recommended Fuel:
Premium Unleaded Gasoline (91 AKI or higher)
Engine Management
Dme Model:
MS43 or MS45 (depending on engine and transmission)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Getrag 250G
Optional
Optional Transmission Auto:
5-speed Automatic GM 5L40-E (RWD); 5-speed Automatic ZF 5HP19 (xDrive); 6-speed Automatic ZF 6HP19 (post-facelift models with M54)
Features
Steptronic:
Available on automatic transmissions for manual shifting.
Fluid Specifications
Automatic Transmission Fluid:
BMW ATF LT-3 (e.g., Pentosin ATF1 or equivalent)
Manual Transmission Fluid:
BMW MTF LT-2 (e.g., Castrol Syntrans B 75W-80 or equivalent)
📐 Dimensions
Exterior
Body Styles:
Sedan (4-door), Coupe (2-door), Convertible (2-door), Touring (Wagon, 5-door)
Weights
Curb Weight Range:
Approx. 1450 kg - 1700 kg (depending on body style and engine)
🛡️ Safety Features
Ratings
IIHS Frontal Impact:
Good (for applicable models)
NHTSA Side Impact:
5-star (for applicable models)
Active Features
ABS:
Standard Anti-lock Braking System
Dsc:
Standard Dynamic Stability Control (on most models)
Passive Features
Airbags:
Front, side, and curtain airbags (availability varies by model year and trim)
Seatbelts:
Pretensioning seatbelts with force limiters
💡 Technology Features
Infotainment
Head Unit Options:
BMW Business CD, BMW Professional CD, Navigation systems (MKIII/MKIV)
Driver Assistance
Parking Assist:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Bluetooth:
Optional, via aftermarket adapters or specific factory options (e.g., TCU upgrade).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil used (refer to Condition Based Service).
Spark Plug Interval:
60,000-100,000 miles (depending on plug type - iridium recommended)
Brake Fluid Flush Interval:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-04 (depending on region/fuel) 0W-30 or 5W-30 synthetic oil.
Coolant Specification:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)
Power Steering Fluid:
Pentosin CHF 11S or ZF Servolenkungsspezifikation (green)
Known Issues
Cooling System Leaks:
Cracked plastic expansion tank, failing water pump (plastic impeller), thermostat housing leaks.
Vanos System:
Failure of the Variable Valve Timing system (solenoids, seals) leading to rough idle and power loss.
Oil Pan Gasket Leaks:
Common leak point, especially on higher mileage vehicles.
Subframe Mounts:
Cracking and separation of rear subframe mounting points, particularly in coupes and convertibles.
Window Regulator Failure:
Common issue with plastic components breaking.
ABS Wheel Speed Sensors:
Frequent failures leading to ABS/DSC warning lights.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Sheer Driving Pleasure - emphasis on performance, handling, and driver engagement.
Model Evolution
E46 Predecessor:
E36 3 Series
E46 Successor:
E90 (Sedan/Wagon), E92 (Coupe), E93 (Convertible)
Production
Production Years E46:
1998-2006
Manufacturing Locations:
Germany (Dingolfing, Regensburg), Austria, South Africa, Mexico, Thailand
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
3 Series models frequently featured on Car and Driver's 10Best list during its production run.
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