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BMW 325 325i 1999-2005 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 325i Platform: E46 Codes Chassis Codes: E46 (Sedan, Coupe, Convertible, Wagon) Engine Codes: M54B25 (2.5L Inline-6) 👋 Introduction Market Position Segment: Compact executive sedan/coupe/convertible. Target Audience: Enthusiasts, DIY mechanics, independent repair shops. Competitive Analysis Key Competitors: Mercedes-Benz C-Class, Audi A4, Lexus IS300, Acura TL. Key Features Driving Dynamics: Renowned for balanced chassis, responsive steering, and engaging driving experience. Powertrain Refinement: Smooth and powerful M54 inline-six engine. Build Quality: Typical BMW high-quality interior and exterior fit and finish. 📋 Manual Details Coverage Areas Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Page Count: Approx. 1500+ pages (typical for comprehensive workshop manuals) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel injection, ignition, exhaust, cooling system, lubrication Transmission: Manual (Getrag 250G), Automatic (Steptronic GM A5S360R/A5S325Z) Drivetrain: Driveshafts, differential, axles, rear-wheel drive system Suspension: Front struts, rear multi-link suspension, control arms, springs, dampers Brakes: Front and rear disc brakes, ABS, DSC, brake fluid service Steering: Hydraulic power steering system, steering column, steering rack Electrical: Battery, charging system, starter, lighting, fuses, relays, body control module (BCM) Body And Chassis: Body panels, doors, windows, HVAC, interior trim, chassis components Diagnostics: OBD-II diagnostics, fault code interpretation, diagnostic procedures Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection/replacement Scheduled Maintenance: Brake service, cooling system flush, transmission fluid service, differential fluid service Repair Procedures: Engine component replacement (e.g., VANOS, water pump, alternator), transmission overhaul, suspension component replacement, brake caliper replacement Troubleshooting: Step-by-step diagnostic flows for common and uncommon issues, electrical system fault finding Component Removal Installation: Detailed instructions for removing and reinstalling all major vehicle components Technical Depth Scope: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds. Diagnostic Level: Advanced: Includes detailed diagnostic strategies, wiring diagrams, and component testing procedures. Diagrams: Includes detailed exploded views, wiring schematics, and diagnostic flowcharts. 📊 Manual Specifications File Format Quality: High-resolution PDF, text-searchable, printable pages. Print Quality Readability: Clear text and legible diagrams suitable for printing. Binding Type Digital Format: N/A (Digital Download) Paper Type Digital Format: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-6 (M54B25) Displacement: 2494 cc (2.5 Liters) Bore X Stroke: 84.0 mm x 90.0 mm Compression Ratio: 10.2:1 Valvetrain: DOHC, 24 valves, Double VANOS (Variable Valve Timing) Performance Horsepower: 184 hp (137 kW) @ 6000 rpm (approx.) Torque: 235 Nm (173 lb-ft) @ 3500 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (Bosch Motronic DME) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Lubrication Oil Capacity: 6.5 liters (6.9 US quarts) with filter Oil Specification: BMW Longlife-01 (LL-01) approved synthetic oil, SAE 5W-30 or 0W-30 🔧 Transmission Standard Type: 5-Speed Manual Transmission (Getrag 250G) Optional Type: 5-Speed Automatic Transmission (GM A5S360R/A5S325Z) with Steptronic Features Manual Gear Ratios: Specific ratios for 1st-5th gear and reverse are detailed in the manual. Automatic Features: Sport mode, Steptronic manual shifting capability. Fluid Specifications Manual Transmission Fluid: BMW MTF LT-2 or equivalent, typically SAE 75W-80 GL-4. Automatic Transmission Fluid: BMW LT-2 or Dexron III (GM spec), capacity ~8.5 liters. 📐 Dimensions Exterior Wheelbase: Approx. 2760 mm (108.7 inches) Length: Approx. 4471 mm (176.0 inches) for Sedan Width: Approx. 1739 mm (68.5 inches) Height: Approx. 1415 mm (55.7 inches) for Sedan Weights Curb Weight: Approx. 1490 kg (3285 lbs) for Sedan (manual) Gross Vehicle Weight Rating: Detailed in manual, typically around 1900-2000 kg. Towing Capacity: Not typically specified or recommended for North American models. 🛡️ Safety Features Ratings NHTSA Front Impact: 5-star (for applicable model year testing) IIHS Side Impact: 'Good' (for applicable model year testing) Active Features Traction Control: Automatic Stability Control (ASC) / Dynamic Stability Control (DSC) Braking System: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) Passive Features Airbags: Front airbags (driver/passenger), optional side-impact airbags. Seatbelts: 3-point seatbelts with pre-tensioners, LATCH child seat anchors. Chassis Design: Reinforced passenger cell, crumple zones. 💡 Technology Features Infotainment Head Unit: BMW Business CD, BMW Professional CD/RDS, or optional Navigation system (MK III/MK IV). Audio System: Standard 6-speaker system, optional Hi-Fi or Harman Kardon premium sound. Driver Assistance Cruise Control: Standard cruise control system. Parking Sensors: Optional rear Park Distance Control (PDC). Connectivity Phone Integration: Optional Bluetooth hands-free system or older cellular phone cradles. Instrument Cluster: Halogen or Xenon headlights, on-board computer (OBC) for trip data and system checks. 🔧 Maintenance Service Intervals Oil Change: Variable based on Condition Based Service (CBS) system, typically 10,000-15,000 miles or 12-24 months, or when indicated by the vehicle. Spark Plugs: Typically 60,000-100,000 miles for long-life spark plugs (e.g., NGK BKR6EQUP). Coolant Flush: Every 2-4 years or 30,000-50,000 miles, using BMW's blue or pink coolant (G48). Brake Fluid: Every 2 years or 24,000 miles, using...
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BMW 325 325i 1999-2005 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
325i
Platform:
E46
Codes
Chassis Codes:
E46 (Sedan, Coupe, Convertible, Wagon)
Engine Codes:
M54B25 (2.5L Inline-6)
👋 Introduction
Market Position
Segment:
Compact executive sedan/coupe/convertible.
Target Audience:
Enthusiasts, DIY mechanics, independent repair shops.
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS300, Acura TL.
Key Features
Driving Dynamics:
Renowned for balanced chassis, responsive steering, and engaging driving experience.
Powertrain Refinement:
Smooth and powerful M54 inline-six engine.
Build Quality:
Typical BMW high-quality interior and exterior fit and finish.
📋 Manual Details
Coverage Areas
Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Estimated Page Count:
Approx. 1500+ pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals, fuel injection, ignition, exhaust, cooling system, lubrication
Transmission:
Manual (Getrag 250G), Automatic (Steptronic GM A5S360R/A5S325Z)
Drivetrain:
Driveshafts, differential, axles, rear-wheel drive system
Suspension:
Front struts, rear multi-link suspension, control arms, springs, dampers
Brakes:
Front and rear disc brakes, ABS, DSC, brake fluid service
Steering:
Hydraulic power steering system, steering column, steering rack
Electrical:
Battery, charging system, starter, lighting, fuses, relays, body control module (BCM)
Body And Chassis:
Body panels, doors, windows, HVAC, interior trim, chassis components
Diagnostics:
OBD-II diagnostics, fault code interpretation, diagnostic procedures
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection/replacement
Scheduled Maintenance:
Brake service, cooling system flush, transmission fluid service, differential fluid service
Repair Procedures:
Engine component replacement (e.g., VANOS, water pump, alternator), transmission overhaul, suspension component replacement, brake caliper replacement
Troubleshooting:
Step-by-step diagnostic flows for common and uncommon issues, electrical system fault finding
Component Removal Installation:
Detailed instructions for removing and reinstalling all major vehicle components
Technical Depth
Scope:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Level:
Advanced: Includes detailed diagnostic strategies, wiring diagrams, and component testing procedures.
Diagrams:
Includes detailed exploded views, wiring schematics, and diagnostic flowcharts.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, text-searchable, printable pages.
Print Quality
Readability:
Clear text and legible diagrams suitable for printing.
Binding Type
Digital Format:
N/A (Digital Download)
Paper Type
Digital Format:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-6 (M54B25)
Displacement:
2494 cc (2.5 Liters)
Bore X Stroke:
84.0 mm x 90.0 mm
Compression Ratio:
10.2:1
Valvetrain:
DOHC, 24 valves, Double VANOS (Variable Valve Timing)
Performance
Horsepower:
184 hp (137 kW) @ 6000 rpm (approx.)
Torque:
235 Nm (173 lb-ft) @ 3500 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic DME)
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
Lubrication
Oil Capacity:
6.5 liters (6.9 US quarts) with filter
Oil Specification:
BMW Longlife-01 (LL-01) approved synthetic oil, SAE 5W-30 or 0W-30
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission (Getrag 250G)
Optional
Type:
5-Speed Automatic Transmission (GM A5S360R/A5S325Z) with Steptronic
Features
Manual Gear Ratios:
Specific ratios for 1st-5th gear and reverse are detailed in the manual.
Automatic Features:
Sport mode, Steptronic manual shifting capability.
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent, typically SAE 75W-80 GL-4.
Automatic Transmission Fluid:
BMW LT-2 or Dexron III (GM spec), capacity ~8.5 liters.
📐 Dimensions
Exterior
Wheelbase:
Approx. 2760 mm (108.7 inches)
Length:
Approx. 4471 mm (176.0 inches) for Sedan
Width:
Approx. 1739 mm (68.5 inches)
Height:
Approx. 1415 mm (55.7 inches) for Sedan
Weights
Curb Weight:
Approx. 1490 kg (3285 lbs) for Sedan (manual)
Gross Vehicle Weight Rating:
Detailed in manual, typically around 1900-2000 kg.
Towing Capacity:
Not typically specified or recommended for North American models.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-star (for applicable model year testing)
IIHS Side Impact:
'Good' (for applicable model year testing)
Active Features
Traction Control:
Automatic Stability Control (ASC) / Dynamic Stability Control (DSC)
Braking System:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)
Passive Features
Airbags:
Front airbags (driver/passenger), optional side-impact airbags.
Seatbelts:
3-point seatbelts with pre-tensioners, LATCH child seat anchors.
Chassis Design:
Reinforced passenger cell, crumple zones.
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD, BMW Professional CD/RDS, or optional Navigation system (MK III/MK IV).
Audio System:
Standard 6-speaker system, optional Hi-Fi or Harman Kardon premium sound.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Sensors:
Optional rear Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional Bluetooth hands-free system or older cellular phone cradles.
Instrument Cluster:
Halogen or Xenon headlights, on-board computer (OBC) for trip data and system checks.
🔧 Maintenance
Service Intervals
Oil Change:
Variable based on Condition Based Service (CBS) system, typically 10,000-15,000 miles or 12-24 months, or when indicated by the vehicle.
Spark Plugs:
Typically 60,000-100,000 miles for long-life spark plugs (e.g., NGK BKR6EQUP).
Coolant Flush:
Every 2-4 years or 30,000-50,000 miles, using BMW's blue or pink coolant (G48).
Brake Fluid:
Every 2 years or 24,000 miles, using DOT 4 fluid.
Fluid Specifications
Coolant:
BMW Blue Antifreeze/Coolant (G48) or equivalent.
Power Steering Fluid:
ATF Dexron III or CHF 11S (check specific model year/type for accuracy), refer to manual.
Known Issues
Ccv System:
Crankcase Ventilation system (CCV) can clog, leading to oil leaks, rough idle, and increased oil consumption.
Vanos:
Variable Valve Timing (VANOS) solenoids and seals can fail, causing rough idle, power loss, and hesitation.
Cooling System:
Plastic coolant expansion tanks and water pumps are prone to cracking/failure. Thermostat failures are also common.
Oil Leaks:
Valve cover gasket, oil pan gasket, and oil filter housing gasket commonly leak.
Suspension Components:
Front control arm bushings, ball joints, and rear trailing arm bushings can wear out, causing steering looseness and poor handling.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused, performance-oriented luxury vehicles.
Model Evolution
E46 Introduction:
The E46 generation replaced the E36 and introduced significant refinements in chassis dynamics, interior design, and technology.
325I Positioning:
The 325i was positioned as a potent, yet refined, mid-range model in the 3 Series lineup, offering a balance of performance and comfort.
Production
Production Years:
E46 production ran from 1998 to 2006, with the 325i model variant spanning the specified years.
Manufacturing Locations:
Primarily Dingolfing, Germany, and other BMW global facilities.
🏆 Awards & Recognition
Recognitions
Car And Driver:
Car and Driver's 10Best list multiple times during its production run.
Ward S Auto:
Recognized for its inline-six engine ('Ward's 10 Best Engines').
Ratings
Ownership Satisfaction:
Generally high ownership satisfaction for driving dynamics, though maintenance costs can be higher than non-luxury brands.
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