BMW 325xi-3 Series (E46) 1999-2005 Full Service Repair Manual
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Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325xi Generation Chassis Code: E46 Production Years: 1999-2005 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Convertible/Wagon Competitive Analysis Key Competitors: Audi A4, Mercedes-Benz C-Class, Lexus IS, Infiniti G35 Key Features Performance Orientation: Known for sporty handling, engaging driving dynamics, and premium build quality. All Wheel Drive: The 'xi' designation signifies BMW's xDrive all-wheel-drive system, offering enhanced traction and stability. Manual Usability: Features easy-to-read text, high-quality diagrams, step-by-step instructions, and exploded views for efficient repairs. Manual Details Coverage Areas Covered Body Styles: Sedan, Coupe, Convertible, Sport Wagon Page Count Estimated Page Count: Varies by specific publication, but professional manuals are typically extensive (e.g., 500-1500+ pages for comprehensive coverage) Manual Type Type: Full Service & Repair Manual Language Language: English Format Format: PDF Manual Coverage Systems Covered Engine: Complete engine overhaul, including cylinder head, pistons, crankshaft, camshafts, timing, lubrication system, cooling system, fuel injection, ignition system, emission controls, and exhaust systems. Transmission: Detailed coverage of both manual and automatic transmissions, including gearbox disassembly, clutch service, torque converter, valve body, electronic controls, fluid specifications, and shift mechanisms. Drivetrain: Front and rear differentials, transfer case (for xi models), driveshafts, CV joints, wheel bearings, and axle components. Suspension: Front and rear suspension components, including shock absorbers, struts, springs, control arms, bushings, sway bars, and alignment specifications. Brakes: Front and rear brake systems (disc brakes), including caliper overhauls, rotor replacement, brake pads, ABS system diagnostics and repair, brake fluid specifications, and bleeding procedures. Steering: Power steering system, steering rack, tie rods, steering column, and associated components. Includes hydraulic system diagnostics and fluid recommendations. Electrical System: Comprehensive coverage of the vehicle's electrical architecture, including battery, charging system, starter, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, ECUs (Engine Control Units), sensors, and actuators. Climate Control: HVAC (Heating, Ventilation, and Air Conditioning) system, including refrigerant system diagnostics, component replacement (compressor, condenser, evaporator), blower motor, heater core, and control panel operation. Body And Interior: Body panel removal and installation, door mechanisms, window regulators, seat adjustments, dashboard disassembly, trim components, and convertible top mechanisms (where applicable). Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, and tire rotation. Troubleshooting: Step-by-step diagnostic procedures for common and uncommon problems, including symptom analysis, component testing, and fault code interpretation. Repair: Detailed repair procedures for virtually every component and system of the vehicle, from minor adjustments to major overhauls. Disassembly Reassembly: Complete step-by-step instructions for the complete disassembly and reassembly of the vehicle and its major components, aided by detailed exploded diagrams. Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission rebuilds. Manual Specifications File Format Format: PDF Print Quality Printability: Fully printable Zoom Functionality Zoom: Zoom IN/OUT enabled for detailed viewing of diagrams and text Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: Compatible with All Versions of Windows & Mac Engine Specifications Primary Engine Engine Code Common: M54B30 (3.0L inline-6) Engine Type: Inline 6-Cylinder, Naturally Aspirated Displacement: 2.5 Liters (for 325i/xi models, often using a variant of the M54, potentially M54B25 or similar with slight power differences from the 3.0L for some model years/markets, though the 325xi in North America primarily utilized the 3.0L M54B30) Performance Horsepower Estimated: Approximately 184-215 hp (depending on specific engine variant and market, with the 3.0L typically in the 215 hp range for later E46 models) Torque Estimated: Approximately 245-260 Nm (181-192 lb-ft) for the 3.0L variant Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (EFI) Recommended Fuel: Premium Unleaded Gasoline (91 octane or higher recommended) Transmission Standard Transmission Type Standard: 5-Speed Manual (Getrag GS5-39DZ or similar) Optional Transmission Type Optional: 5-Speed Automatic (Steptronic/Tiptronic with manual shifting mode) Features Drivetrain Type: xDrive All-Wheel Drive Automatic Features: Steptronic functionality allowing manual gear selection via shifter or steering wheel buttons (on some models). Dimensions Exterior Wheelbase: Approximately 2760 mm (108.7 inches) Length Sedan: Approximately 4471 mm (176.0 inches) Width: Approximately 1739 mm (68.5 inches) Height: Approximately 1415 mm (55.7 inches) Weights Curb Weight Xi: Approximately 1550-1600 kg (3417-3527 lbs), depending on body style and equipment Safety Features Ratings NHTSA Front Impact Driver: 5 Stars (for E46 generation) NHTSA Front Impact Passenger: 5 Stars (for E46 generation) IIHS Front Offset Crash Rating: Good (for E46 generation, in original testing) Active Features Traction Control: Standard (ASC+T - Automatic Stability Control and Traction) Stability Control: Standard (DSC - Dynamic Stability Control) ABS: Standard Anti-lock Braking System Passive Features Airbags: Front dual-stage airbags, front side-impact airbags, available front and rear head protection system (HPS) airbags. Seatbelts: 3-point inertia-reel seatbelts with pretensioners and force limiters. Technology Features Infotainment Radio Options: Various audio systems, including cassette and CD players, with optional premium...
Detailed coverage of both manual and automatic transmissions, including gearbox disassembly, clutch service, torque converter, valve body, electronic controls, fluid specifications, and shift mechanisms.
Drivetrain:
Front and rear differentials, transfer case (for xi models), driveshafts, CV joints, wheel bearings, and axle components.
Suspension:
Front and rear suspension components, including shock absorbers, struts, springs, control arms, bushings, sway bars, and alignment specifications.
Brakes:
Front and rear brake systems (disc brakes), including caliper overhauls, rotor replacement, brake pads, ABS system diagnostics and repair, brake fluid specifications, and bleeding procedures.
Steering:
Power steering system, steering rack, tie rods, steering column, and associated components. Includes hydraulic system diagnostics and fluid recommendations.
Electrical System:
Comprehensive coverage of the vehicle's electrical architecture, including battery, charging system, starter, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, ECUs (Engine Control Units), sensors, and actuators.
Climate Control:
HVAC (Heating, Ventilation, and Air Conditioning) system, including refrigerant system diagnostics, component replacement (compressor, condenser, evaporator), blower motor, heater core, and control panel operation.
Body And Interior:
Body panel removal and installation, door mechanisms, window regulators, seat adjustments, dashboard disassembly, trim components, and convertible top mechanisms (where applicable).
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, and tire rotation.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon problems, including symptom analysis, component testing, and fault code interpretation.
Repair:
Detailed repair procedures for virtually every component and system of the vehicle, from minor adjustments to major overhauls.
Disassembly Reassembly:
Complete step-by-step instructions for the complete disassembly and reassembly of the vehicle and its major components, aided by detailed exploded diagrams.
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission rebuilds.
Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Fully printable
Zoom Functionality
Zoom:
Zoom IN/OUT enabled for detailed viewing of diagrams and text
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Compatibility
Operating Systems:
Compatible with All Versions of Windows & Mac
Engine Specifications
Primary Engine
Engine Code Common:
M54B30 (3.0L inline-6)
Engine Type:
Inline 6-Cylinder, Naturally Aspirated
Displacement:
2.5 Liters (for 325i/xi models, often using a variant of the M54, potentially M54B25 or similar with slight power differences from the 3.0L for some model years/markets, though the 325xi in North America primarily utilized the 3.0L M54B30)
Performance
Horsepower Estimated:
Approximately 184-215 hp (depending on specific engine variant and market, with the 3.0L typically in the 215 hp range for later E46 models)
Torque Estimated:
Approximately 245-260 Nm (181-192 lb-ft) for the 3.0L variant
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (EFI)
Recommended Fuel:
Premium Unleaded Gasoline (91 octane or higher recommended)
Transmission
Standard
Transmission Type Standard:
5-Speed Manual (Getrag GS5-39DZ or similar)
Optional
Transmission Type Optional:
5-Speed Automatic (Steptronic/Tiptronic with manual shifting mode)
Features
Drivetrain Type:
xDrive All-Wheel Drive
Automatic Features:
Steptronic functionality allowing manual gear selection via shifter or steering wheel buttons (on some models).
Dimensions
Exterior
Wheelbase:
Approximately 2760 mm (108.7 inches)
Length Sedan:
Approximately 4471 mm (176.0 inches)
Width:
Approximately 1739 mm (68.5 inches)
Height:
Approximately 1415 mm (55.7 inches)
Weights
Curb Weight Xi:
Approximately 1550-1600 kg (3417-3527 lbs), depending on body style and equipment
Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars (for E46 generation)
NHTSA Front Impact Passenger:
5 Stars (for E46 generation)
IIHS Front Offset Crash Rating:
Good (for E46 generation, in original testing)
Active Features
Traction Control:
Standard (ASC+T - Automatic Stability Control and Traction)
Stability Control:
Standard (DSC - Dynamic Stability Control)
ABS:
Standard Anti-lock Braking System
Passive Features
Airbags:
Front dual-stage airbags, front side-impact airbags, available front and rear head protection system (HPS) airbags.
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters.
Technology Features
Infotainment
Radio Options:
Various audio systems, including cassette and CD players, with optional premium sound systems (e.g., Harman Kardon).
Navigation:
Optional MK III or MK IV navigation system with CD-ROM or DVD-ROM based maps.
Driver Assistance
Parking Assist:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Bluetooth:
Optional Bluetooth integration for hands-free calling was available on later models or as an aftermarket addition.
Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles or 12-24 months, based on Condition Based Service (CBS) system, but manual will provide precise intervals and recommendations.
Spark Plug Replacement:
Around 60,000-100,000 miles, depending on spark plug type (e.g., long-life iridium).
Coolant Flush:
Recommended every 2-4 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) specification, typically 5W-30 or 5W-40 synthetic oil. Manual will specify exact viscosity and spec based on climate and engine type.
Transmission Fluid Auto:
Specific ATF (Automatic Transmission Fluid) for ZF transmissions, often ZF LifeguardFluid 5 or similar. Critical to use correct fluid to avoid transmission damage. Manual will specify exact fluid type and quantity.
Transmission Fluid Manual:
Gear oil for manual transmissions, often a synthetic GL-4 or GL-5 specification. Manual will specify viscosity and type.
Coolant:
BMW Blue Antifreeze/Coolant (G48 or similar ethylene glycol-based coolant with silicate corrosion inhibitors). Never mix with other coolant types.
Brake Fluid:
DOT 4 High Performance brake fluid. Must be changed every 2 years to maintain performance and prevent moisture absorption.
Known Issues
Common Issues Engine:
Vanos system issues (solenoids, seals), oil leaks from valve cover and oil pan gaskets, intake manifold vacuum leaks, coolant expansion tank cracks, DISA valve flap wear.
Common Issues Suspension:
Front control arm bushings (bushings wear out, causing steering looseness), rear subframe bushings (can crack or tear, leading to clunking noises), strut mount wear.
Automatic transmission 'limp mode' or harsh shifting due to mechatronic sleeve leaks or solenoid wear. Clutch release bearing noise on manual transmissions.
Vehicle History
Brand Heritage
Brand Focus:
BMW, Bayerische Motoren Werke AG, known for its 'Ultimate Driving Machine' slogan and focus on performance, luxury, and engineering.
Model Evolution
E46 Introduction:
The E46 generation of the 3 Series replaced the E36 and was produced from 1998 to 2006 (though the specified manual covers up to 2005). It represented a significant step forward in design, technology, and chassis dynamics.
E46 Xi Introduction:
The 'xi' all-wheel-drive variants were introduced during the E46 generation, offering enhanced all-weather capability while retaining much of the RWD 3 Series' driving character.
Production
Manufacturing Locations:
Primarily produced at BMW's main plant in Munich, Germany, and other global facilities.
Awards & Recognition
Recognitions
Car And Driver 10Best:
The E46 3 Series generation consistently received accolades, including multiple appearances on Car and Driver's '10Best' lists for its driving dynamics and overall excellence.
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