BMW 325xi 2004 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 325xi Year: 2004 Chassis Code: E46 Platform: 3 Series (E46) Codes Engine Code Primary: M54B25 👋 Introduction Market Position Vehicle Segment: Compact Executive Sedan/Wagon Brand Philosophy: Driving pleasure, performance, luxury, and advanced engineering. Competitive Analysis Competitors: Audi A4 Quattro, Mercedes-Benz C-Class (W203), Lexus IS300, Acura TL Key Features Powertrain AWD: BMW's xDrive all-wheel-drive system for enhanced traction and stability. Engine Type: Smooth and powerful naturally aspirated inline-6 engine. Handling: Renowned for its balanced chassis and engaging driving dynamics. Build Quality: Typical BMW build quality with premium materials and fit-and-finish. Manual Value: Essential for owners and independent workshops to maintain and repair this complex vehicle. 📋 Manual Details Coverage Areas Models Covered: All 325xi Sedan (E46) models Engines Covered: 2.5L M54B25 Naturally Aspirated Inline-6 Transmissions Covered: All manual and automatic transmission types Drivetrain Covered: xDrive All-Wheel Drive (AWD) system Trim Levels Covered: All trim levels Page Count Estimated Pages: Approximately 3000+ pages (typical for comprehensive BMW workshop manuals) Manual Type Type: Workshop Repair Service Manual Purpose: Maintenance, diagnostics, repair, and troubleshooting Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valvetrain, pistons, crankshaft, lubrication system, cooling system, intake manifold, exhaust manifold Engine Management: Fuel injection, ignition system, DME (Digital Motor Electronics), sensors (MAF, O2, Crankshaft Position, Camshaft Position, Knock), emission controls Transmission Manual: Clutch, gearbox, shift mechanism, gear ratios, service procedures Transmission Automatic: GM 5L40-E automatic transmission, torque converter, valve body, electronic controls, service procedures Drivetrain AWD: xDrive transfer case, front differential, rear differential, driveshafts, CV joints, wheel bearings Suspension: Front struts, rear shocks, control arms, ball joints, bushings, springs, sway bars, xDrive specific suspension components Steering: Power steering system, steering rack, tie rod ends, steering column, steering angle sensor Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid, hydraulic system, parking brake Electrical System: Battery, alternator, starter, wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior lights), horn Body And Chassis: Body panels, doors, hood, trunk, bumpers, glass, seals, chassis components, sound deadening Climate Control: HVAC system, blower motor, A/C compressor, refrigerant, heater core, climate control module, automatic climate control (HVAC) Interior Trim: Seats, dashboard, door panels, headliner, carpets, interior lighting Infotainment Audio: Radio, CD player, speakers, amplifier, antenna, iDrive system (if equipped) Safety Systems: Airbags (SRS), seatbelts, ABS, DSC, tire pressure monitoring (if equipped) Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad/rotor replacement Troubleshooting: Diagnostic procedures, common fault codes, symptom-based troubleshooting guides Repair Engine: Engine overhaul, component replacement (e.g., water pump, thermostat, VANOS, coils), timing chain inspection/replacement Repair Transmission: Transmission fluid change, clutch replacement, automatic transmission component replacement (e.g., solenoids, valve body) Repair Drivetrain AWD: Transfer case service, differential fluid change, driveshaft balancing and repair, CV axle replacement Repair Suspension Steering: Strut/shock replacement, control arm replacement, bushing replacement, power steering pump/rack replacement Repair Brakes: Brake caliper overhaul, master cylinder replacement, ABS/DSC module diagnosis and replacement, brake line repair Repair Electrical: Wiring harness repair, component testing and replacement (alternator, starter, sensors), headlight/taillight repair, ECU/modules Repair Bodywork: Door panel removal/installation, bumper replacement, glass replacement, seal replacement, rust repair basic guidance Diagnostics: OBD-II scanner usage, diagnostic trouble codes (DTCs), BMW proprietary diagnostic tools (e.g., ISTA/D concepts, though manual predates full ISTA) Specifications Data: Torque specifications, fluid capacities, electrical system specifications, diagnostic data Technical Depth Level: Comprehensive: Covers everything from routine maintenance to full engine rebuilds and complex diagnostics. Detail Level: Detailed step-by-step instructions, exploded views, diagnostic flowcharts, wiring diagrams. Rebuild Procedures: Includes procedures for rebuilding major components like the engine, transmission, and differentials. Diagnostic Tools: References to diagnostic trouble codes (DTCs) and general diagnostic principles applicable to BMW's proprietary systems of the era. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (typically, depending on OCR quality) Printable: Yes Print Quality Quality: High-resolution scans providing clear text and diagrams. Binding Type Binding: N/A (Digital PDF download) Paper Type Paper Quality: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Type: M54B25 Inline-6, Naturally Aspirated Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 10.2:1 Valvetrain: DOHC, 4 valves per cylinder, Double VANOS Performance Horsepower Hp: 184 hp @ 6000 rpm Torque Lb-Ft: 245 Nm (181 lb-ft) @ 3500 rpm Fuel System Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Induction: Sequential Multi-Point Fuel Injection (MPFI) Emission Controls: Secondary air injection, catalytic converters, EWS (Electronic Immobilizer) 🔧 Transmission Standard Type: 5-speed GM 5L40-E Automatic Transmission Optional Type: 6-speed Manual Transmission (ZF GS6-37BZ) Features AWD System: xDrive Variable All-Wheel Drive with electronic torque distribution. Automatic Modes: Steptronic (manual shifting mode) Fluid Type Automatic Fluid: BMW ATF LT-3 (or equivalent approved Dexron VI-based fluid) Manual Fluid: BMW MTF-LT-2 (or equivalent approved synthetic...

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Description

🏷️ Basic Information

Identification

Make:

Model:

325xi

Year:

Chassis Code:

Platform:

3 Series (E46)

Codes

Engine Code Primary:

M54B25

👋 Introduction

Market Position

Vehicle Segment:

Compact Executive Sedan/Wagon

Brand Philosophy:

Driving pleasure, performance, luxury, and advanced engineering.

Competitive Analysis

Competitors:

Audi A4 Quattro, Mercedes-Benz C-Class (W203), Lexus IS300, Acura TL

Key Features

Powertrain AWD:

BMW's xDrive all-wheel-drive system for enhanced traction and stability.

Engine Type:

Smooth and powerful naturally aspirated inline-6 engine.

Handling:

Renowned for its balanced chassis and engaging driving dynamics.

Build Quality:

Typical BMW build quality with premium materials and fit-and-finish.

Manual Value:

Essential for owners and independent workshops to maintain and repair this complex vehicle.

📋 Manual Details

Coverage Areas

Models Covered:

All 325xi Sedan (E46) models

Engines Covered:

2.5L M54B25 Naturally Aspirated Inline-6

Transmissions Covered:

All manual and automatic transmission types

Drivetrain Covered:

xDrive All-Wheel Drive (AWD) system

Trim Levels Covered:

All trim levels

Page Count

Estimated Pages:

Approximately 3000+ pages (typical for comprehensive BMW workshop manuals)

Manual Type

Type:

Workshop Repair Service Manual

Purpose:

Maintenance, diagnostics, repair, and troubleshooting

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, valvetrain, pistons, crankshaft, lubrication system, cooling system, intake manifold, exhaust manifold

Engine Management:

Fuel injection, ignition system, DME (Digital Motor Electronics), sensors (MAF, O2, Crankshaft Position, Camshaft Position, Knock), emission controls

Transmission Manual:

Clutch, gearbox, shift mechanism, gear ratios, service procedures

Transmission Automatic:

GM 5L40-E automatic transmission, torque converter, valve body, electronic controls, service procedures

Drivetrain AWD:

xDrive transfer case, front differential, rear differential, driveshafts, CV joints, wheel bearings

Suspension:

Front struts, rear shocks, control arms, ball joints, bushings, springs, sway bars, xDrive specific suspension components

Steering:

Power steering system, steering rack, tie rod ends, steering column, steering angle sensor

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid, hydraulic system, parking brake

Electrical System:

Battery, alternator, starter, wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior lights), horn

Body And Chassis:

Body panels, doors, hood, trunk, bumpers, glass, seals, chassis components, sound deadening

Climate Control:

HVAC system, blower motor, A/C compressor, refrigerant, heater core, climate control module, automatic climate control (HVAC)

Interior Trim:

Seats, dashboard, door panels, headliner, carpets, interior lighting

Infotainment Audio:

Radio, CD player, speakers, amplifier, antenna, iDrive system (if equipped)

Safety Systems:

Airbags (SRS), seatbelts, ABS, DSC, tire pressure monitoring (if equipped)

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad/rotor replacement

Troubleshooting:

Diagnostic procedures, common fault codes, symptom-based troubleshooting guides

Repair Engine:

Engine overhaul, component replacement (e.g., water pump, thermostat, VANOS, coils), timing chain inspection/replacement

Repair Transmission:

Transmission fluid change, clutch replacement, automatic transmission component replacement (e.g., solenoids, valve body)

Repair Drivetrain AWD:

Transfer case service, differential fluid change, driveshaft balancing and repair, CV axle replacement

Repair Suspension Steering:

Strut/shock replacement, control arm replacement, bushing replacement, power steering pump/rack replacement

Repair Brakes:

Brake caliper overhaul, master cylinder replacement, ABS/DSC module diagnosis and replacement, brake line repair

Repair Electrical:

Wiring harness repair, component testing and replacement (alternator, starter, sensors), headlight/taillight repair, ECU/modules

Repair Bodywork:

Door panel removal/installation, bumper replacement, glass replacement, seal replacement, rust repair basic guidance

Diagnostics:

OBD-II scanner usage, diagnostic trouble codes (DTCs), BMW proprietary diagnostic tools (e.g., ISTA/D concepts, though manual predates full ISTA)

Specifications Data:

Torque specifications, fluid capacities, electrical system specifications, diagnostic data

Technical Depth

Level:

Comprehensive: Covers everything from routine maintenance to full engine rebuilds and complex diagnostics.

Detail Level:

Detailed step-by-step instructions, exploded views, diagnostic flowcharts, wiring diagrams.

Rebuild Procedures:

Includes procedures for rebuilding major components like the engine, transmission, and differentials.

Diagnostic Tools:

References to diagnostic trouble codes (DTCs) and general diagnostic principles applicable to BMW's proprietary systems of the era.

📊 Manual Specifications

File Format

File Type:

Searchable:

Yes (typically, depending on OCR quality)

Printable:

Print Quality

Quality:

High-resolution scans providing clear text and diagrams.

Binding Type

Binding:

N/A (Digital PDF download)

Paper Type

Paper Quality:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

M54B25 Inline-6, Naturally Aspirated

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

10.2:1

Valvetrain:

DOHC, 4 valves per cylinder, Double VANOS

Performance

Horsepower Hp:

184 hp @ 6000 rpm

Torque Lb-Ft:

245 Nm (181 lb-ft) @ 3500 rpm

Fuel System

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Induction:

Sequential Multi-Point Fuel Injection (MPFI)

Emission Controls:

Secondary air injection, catalytic converters, EWS (Electronic Immobilizer)

🔧 Transmission

Standard

Type:

5-speed GM 5L40-E Automatic Transmission

Optional

Type:

6-speed Manual Transmission (ZF GS6-37BZ)

Features

AWD System:

xDrive Variable All-Wheel Drive with electronic torque distribution.

Automatic Modes:

Steptronic (manual shifting mode)

Fluid Type

Automatic Fluid:

BMW ATF LT-3 (or equivalent approved Dexron VI-based fluid)

Manual Fluid:

BMW MTF-LT-2 (or equivalent approved synthetic manual transmission fluid)

📐 Dimensions

Exterior

Length:

4521 mm (178.0 in)

Width:

1739 mm (68.5 in)

Height:

1427 mm (56.2 in)

Wheelbase:

2760 mm (108.7 in)

Weights

Curb Weight Kg:

Approximately 1565 kg (3470 lbs) for automatic transmission

Gross Weight Kg:

Approximately 2030 kg (4475 lbs)

Cargo

Trunk Volume Liters:

445 Liters (15.7 cu ft)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (for driver and passenger)

NHTSA Side Impact:

4-Star (for front seats)

Active Features

Standard Anti-lock Braking System

Standard Dynamic Stability Control (includes DTC - Dynamic Traction Control)

Brake Assist:

Standard

Passive Features

Airbags:

Frontal airbags (driver and passenger), front side-impact airbags, available head curtain airbags

Seatbelts:

3-point inertia-reel seatbelts with pretensioners and force limiters

Child Seat Anchors:

LATCH system (Lower Anchors and Tethers for Children)

💡 Technology Features

Infotainment

System Name:

BMW Professional Radio, available with CD player and optional navigation system.

I Drive:

Early generation iDrive system available on some models, controlling navigation, audio, climate, and vehicle settings.

Speakers:

Standard 6-speaker system, optional Harman Kardon surround sound system.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Connectivity

Phone Integration:

Optional Bluetooth phone preparation with voice control.

Aux Input:

Optional AUX input for audio devices.

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) system typically recommends every 10,000-15,000 miles or 12-24 months, whichever comes first. Consult manual for exact CBS reset procedures.

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Coolant Flush:

BMW Blue Antifreeze/Coolant. Initial change at ~7 years or 100,000 miles, then every 2-4 years or 30,000-50,000 miles thereafter, depending on fluid type and condition.

Spark Plug Replacement:

Typically around 60,000-100,000 miles, depending on plug type (e.g., NGK BKR6EQUP or equivalent).

Fluid Specifications

Engine Oil:

BMW Longlife-01 (LL-01) specification, SAE 0W-30 or 0W-40 synthetic oil. Capacity: ~6.5 liters (with filter).

Power Steering Fluid:

Pentosin CHF 11S or equivalent approved hydraulic fluid. Capacity: ~1.0-1.2 liters.

Differential Fluid Front:

BMW Hypoid Gear Oil G2 (SAF-XJ) or equivalent SAE 75W-140. Capacity: ~0.75 liters.

Differential Fluid Rear:

BMW Hypoid Gear Oil G2 (SAF-XJ) or equivalent SAE 75W-140. Capacity: ~1.0 liter.

Transfer Case Fluid:

BMW Transfer Case Fluid (ATF type), often a Dexron III H equivalent. Capacity: ~0.6 liters.

Known Issues

Crankcase Ventilation:

Clogged PCV (Positive Crankcase Ventilation) system can lead to oil leaks, rough idle, and performance issues. The integrated PCV system in the valve cover is often replaced as an assembly.

Cooling System:

Plastic expansion tanks can become brittle and crack. Water pump and thermostat failures are also common. Ensure proper bleed procedure is followed after service.

Vanos System:

The VANOS (Variable Valve Timing) system solenoids can fail, leading to rough idle, low-end torque loss, and check engine lights. Seals on the VANOS unit can also degrade.

Ignition Coils:

Coil-on-plug ignition coils can fail, causing misfires. Replacement is typically done individually or in sets.

ABS Wheel Speed Sensors:

These sensors can fail, triggering ABS and DSC warning lights. They are integrated into the hub assembly.

Oil Pan Gasket Leaks:

Common due to age and material degradation. Often requires removal of subframe for access.

Subframe Bushings:

Rear subframe bushings can wear out, causing clunking noises and imprecise handling.

📚 Vehicle History

Brand Heritage

Manufacturer:

Bayerische Motoren Werke AG (BMW), Germany

Foundation:

Model Evolution

E46 Generation:

Fourth generation of the BMW 3 Series, produced from 1998 to 2006 (globally).

325Xi Introduction:

The 'xi' designation signifies the all-wheel-drive variant, introduced to enhance all-weather capability. The 2004 model year is part of the facelifted E46 generation (LCI - Life Cycle Impulse).

Production

Production Years:

2001-2005 (for E46 325xi Sedan)

Manufacturing Locations:

Primary assembly in Munich, Germany; also produced in South Africa and various other BMW plants globally.

🏆 Awards & Recognition

Recognitions

Sales Success:

The E46 generation was a significant sales success for BMW, reinforcing its position in the premium compact sedan market.

Car And Driver 10Best:

While not specifically for the 325xi, the E46 3 Series platform was a perennial recipient of Car and Driver's '10Best' list during its production run, highlighting its exceptional driving dynamics.

Consumer Reports:

Generally received positive ratings for performance and driving dynamics, though some years and models had specific reliability concerns that this manual would help address.

Certifications

Manual Standard:

This manual adheres to industry standards for technical service documentation, providing accurate and detailed information for professional use.