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BMW 325 325i 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i Production Year: 2002 Chassis Code: E46 Market Segment: Compact Executive Car 👋 Introduction Market Position Bmw Brand Heritage: BMW has a strong reputation for 'The Ultimate Driving Machine', emphasizing performance, luxury, and engineering. E46 3 Series Positioning: The E46 3 Series was a benchmark in the compact executive sedan and coupe segment, renowned for its driving dynamics and refined interior. Competitive Analysis Key Competitors 2002: Audi A4, Mercedes-Benz C-Class, Lexus IS300, Infiniti G35. Key Features Target Audience: DIY enthusiasts, independent repair shops, and BMW owners seeking detailed technical information. Manual Value Proposition: Provides authoritative, factory-level repair and maintenance data to save time and money on vehicle upkeep and repairs. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English Format: PDF Download Models Covered: All 325i (E46) models Engines Covered: All engine variants for 325i Transmissions Covered: All transmission types (e.g., Manual, Automatic) Trim Levels Covered: All trim levels Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for comprehensive workshop manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, timing, lubrication, cooling, fuel delivery, exhaust. Engine Management: ECU diagnosis, sensors, actuators, ignition system, emission control systems. Transmission Manual: Clutch, gearbox, drive shafts, shifter linkage, maintenance, repair. Transmission Automatic: Torque converter, valve body, transmission control unit (TCU), fluid service, rebuild procedures. Brakes: Front and rear brake systems, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid service, caliper, rotor, pad replacement. Suspension: Front and rear suspension components, struts, shocks, control arms, bushings, wheel alignment specifications. Steering: Power steering system, steering rack, tie rods, steering column, fluid service. Electrical System: Battery, alternator, starter, lighting, horn, power windows, central locking, fuses, relays. Body And Chassis: Body panels, doors, hoods, trunk, interior trim, rust prevention, jacking points. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant, blower motor, A/C compressor. Infotainment And Electronics: Radio, navigation system (if equipped), speaker replacement, onboard computer diagnostics. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and flushes, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation (OBD-II). Repair Procedures: Step-by-step instructions for component removal, installation, and repair. Diagnostic Testing: Testing of electrical circuits, sensors, actuators, and mechanical systems. Wiring Diagrams: Detailed electrical wiring schematics for various systems. Technical Depth Depth Level: Comprehensive (covering everything from basic maintenance to major overhauls and diagnostics). Diagnostic Tools Required: Specifies use of factory diagnostic tools (e.g., BMW ISTA/D, INPA) and generic OBD-II scanners. Torque Specifications: Precise torque values for all critical fasteners and components. Special Tools: Lists any specialized tools required for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text, allowing for quick information retrieval. Print Quality Resolution: High-resolution scans ensuring legibility of diagrams and text. Diagrams Clarity: Clear, detailed illustrations, diagrams, and schematics. Binding Type Digital Format Notes: Digital download, no physical binding. Accessible on various devices. Paper Type Digital Format Notes: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: M54B30 (for 325i) Engine Type: 3.0L Inline 6-Cylinder (I6), Naturally Aspirated Bore X Stroke: 84.0 mm x 89.6 mm Displacement: 2979 cc (3.0 liters) Compression Ratio: 10.2:1 Performance Horsepower Hp: 225 hp @ 6000 rpm Torque Lb-Ft: 214 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Bosch Motronic ME7.2 Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management Valve Train: Double VANOS (Variable Valve Timing), DOHC (Double Overhead Camshafts) Emission Control: Secondary air injection, catalytic converters, oxygen sensors. 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Getrag 420G Optional Optional Transmission Type: 5-Speed Steptronic Automatic (GM 5L40-E) Features Clutch Type: Hydraulic, single-plate dry clutch (for manual transmission) Automatic Features: Steptronic manual shifting mode. Fluid Type Manual Transmission Fluid: BMW recommends specific synthetic gear oil (e.g., Pentosin MTF LT-2 or equivalent GL-4/GL-5 rated synthetic). Automatic Transmission Fluid: BMW recommends specific ATF fluid (e.g., Esso JWS 3309 / Mobil ATF 3309 / Pentosin ATF 1). 📐 Dimensions Exterior Length: 4471 mm (176.0 inches) Width: 1739 mm (68.5 inches) Height: 1392 mm (54.8 inches) Wheelbase: 2725 mm (107.3 inches) Weights Curb Weight Manual: Approx. 1470 kg (3240 lbs) Curb Weight Automatic: Approx. 1490 kg (3285 lbs) Cargo Trunk Volume: 430 liters (15.2 cubic feet) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 5 Stars (for driver and passenger) IIHS Side Impact Rating: Good (for vehicles with side airbags) Active Features ABS: Standard Anti-lock Braking System (ABS). Dsc: Standard Dynamic Stability Control (DSC), includes traction control. Brake Assist: Standard Brake Assist. Passive Features Airbags: Standard front airbags, optional front side airbags and head protection system (HPS) curtain airbags. Seatbelts: Three-point inertia-reel seat belts with pre-tensioners and force limiters. Body Structure: Reinforced safety...
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BMW 325 325i 2002 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Model Variant:
325i
Production Year:
2002
Chassis Code:
E46
Market Segment:
Compact Executive Car
👋 Introduction
Market Position
Bmw Brand Heritage:
BMW has a strong reputation for 'The Ultimate Driving Machine', emphasizing performance, luxury, and engineering.
E46 3 Series Positioning:
The E46 3 Series was a benchmark in the compact executive sedan and coupe segment, renowned for its driving dynamics and refined interior.
Competitive Analysis
Key Competitors 2002:
Audi A4, Mercedes-Benz C-Class, Lexus IS300, Infiniti G35.
Key Features
Target Audience:
DIY enthusiasts, independent repair shops, and BMW owners seeking detailed technical information.
Manual Value Proposition:
Provides authoritative, factory-level repair and maintenance data to save time and money on vehicle upkeep and repairs.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Repair Service Manual
Language:
English
Format:
PDF Download
Models Covered:
All 325i (E46) models
Engines Covered:
All engine variants for 325i
Transmissions Covered:
All transmission types (e.g., Manual, Automatic)
Trim Levels Covered:
All trim levels
Page Count
Estimated Page Count:
Approximately 1500-2000 pages (typical for comprehensive workshop manuals of this era)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, overhaul, timing, lubrication, cooling, fuel delivery, exhaust.
Engine Management:
ECU diagnosis, sensors, actuators, ignition system, emission control systems.
Transmission Manual:
Clutch, gearbox, drive shafts, shifter linkage, maintenance, repair.
Transmission Automatic:
Torque converter, valve body, transmission control unit (TCU), fluid service, rebuild procedures.
Brakes:
Front and rear brake systems, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid service, caliper, rotor, pad replacement.
Suspension:
Front and rear suspension components, struts, shocks, control arms, bushings, wheel alignment specifications.
Steering:
Power steering system, steering rack, tie rods, steering column, fluid service.
Electrical System:
Battery, alternator, starter, lighting, horn, power windows, central locking, fuses, relays.
Body And Chassis:
Body panels, doors, hoods, trunk, interior trim, rust prevention, jacking points.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant, blower motor, A/C compressor.
Infotainment And Electronics:
Radio, navigation system (if equipped), speaker replacement, onboard computer diagnostics.
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks and flushes, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation (OBD-II).
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair.
Diagnostic Testing:
Testing of electrical circuits, sensors, actuators, and mechanical systems.
Wiring Diagrams:
Detailed electrical wiring schematics for various systems.
Technical Depth
Depth Level:
Comprehensive (covering everything from basic maintenance to major overhauls and diagnostics).
Diagnostic Tools Required:
Specifies use of factory diagnostic tools (e.g., BMW ISTA/D, INPA) and generic OBD-II scanners.
Torque Specifications:
Precise torque values for all critical fasteners and components.
Special Tools:
Lists any specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text, allowing for quick information retrieval.
Print Quality
Resolution:
High-resolution scans ensuring legibility of diagrams and text.
Diagrams Clarity:
Clear, detailed illustrations, diagrams, and schematics.
Binding Type
Digital Format Notes:
Digital download, no physical binding. Accessible on various devices.
Paper Type
Digital Format Notes:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M54B30 (for 325i)
Engine Type:
3.0L Inline 6-Cylinder (I6), Naturally Aspirated
Bore X Stroke:
84.0 mm x 89.6 mm
Displacement:
2979 cc (3.0 liters)
Compression Ratio:
10.2:1
Performance
Horsepower Hp:
225 hp @ 6000 rpm
Torque Lb-Ft:
214 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic ME7.2
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Management
Valve Train:
Double VANOS (Variable Valve Timing), DOHC (Double Overhead Camshafts)
Emission Control:
Secondary air injection, catalytic converters, oxygen sensors.
🔧 Transmission
Standard
Standard Transmission Type:
5-Speed Manual Getrag 420G
Optional
Optional Transmission Type:
5-Speed Steptronic Automatic (GM 5L40-E)
Features
Clutch Type:
Hydraulic, single-plate dry clutch (for manual transmission)
Automatic Features:
Steptronic manual shifting mode.
Fluid Type
Manual Transmission Fluid:
BMW recommends specific synthetic gear oil (e.g., Pentosin MTF LT-2 or equivalent GL-4/GL-5 rated synthetic).
Automatic Transmission Fluid:
BMW recommends specific ATF fluid (e.g., Esso JWS 3309 / Mobil ATF 3309 / Pentosin ATF 1).
📐 Dimensions
Exterior
Length:
4471 mm (176.0 inches)
Width:
1739 mm (68.5 inches)
Height:
1392 mm (54.8 inches)
Wheelbase:
2725 mm (107.3 inches)
Weights
Curb Weight Manual:
Approx. 1470 kg (3240 lbs)
Curb Weight Automatic:
Approx. 1490 kg (3285 lbs)
Cargo
Trunk Volume:
430 liters (15.2 cubic feet)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
5 Stars (for driver and passenger)
IIHS Side Impact Rating:
Good (for vehicles with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Dsc:
Standard Dynamic Stability Control (DSC), includes traction control.
Brake Assist:
Standard Brake Assist.
Passive Features
Airbags:
Standard front airbags, optional front side airbags and head protection system (HPS) curtain airbags.
Seatbelts:
Three-point inertia-reel seat belts with pre-tensioners and force limiters.
Body Structure:
Reinforced safety cell, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Standard BMW Business CD stereo, optional BMW Professional CD radio with enhanced features.
Navigation:
Optional BMW Navigation System (MK III or MK IV navigation computer).
Speakers:
Standard 6-speaker system, optional 10-speaker Hi-Fi system.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Assist:
Optional rear Park Distance Control (PDC).
Connectivity
Bluetooth:
Optional Bluetooth mobile phone integration (requiring specific BMW cradle or adapter).
Onboard Computer:
Standard OBC displaying fuel economy, range, average speed, etc.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system typically recommends every 10,000-15,000 miles or annually, whichever comes first.
Air Filter Replacement:
Recommended every 30,000 miles or as indicated by CBS.
Cabin Air Filter Replacement:
Recommended every 15,000-30,000 miles.
Spark Plug Replacement:
Typically around 60,000-100,000 miles depending on plug type (e.g., long-life platinum/iridium).
Coolant Flush:
Recommended every 2-4 years or 30,000-60,000 miles.
Fluid Specifications
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-04 synthetic oil, typically 5W-30 or 0W-40 viscosity.
Engine Oil Capacity:
6.5 liters (approx. 6.9 US quarts) with filter change.
Brake Fluid Specification:
DOT 4 Low Viscosity (LV) or DOT 4 Plus.
Coolant Specification:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol-based).
Known Issues
M54 Engine Common Issues:
PCV (Positive Crankcase Ventilation) system failure (leading to vacuum leaks), oil filter housing gasket leaks, VANOS solenoids, oil consumption.
E46 Chassis Common Issues:
Subframe mounting point cracks, cooling system components (water pump, thermostat, expansion tank), ABS/DSC sensor failures, window regulator issues, "death rattle" of the lower intake manifold support bracket.
Cooling System Part Numbers:
Water Pump: 11517527799, Thermostat: 11531437771, Expansion Tank: 17111437170 (typical part numbers, always verify).
📚 Vehicle History
Brand Heritage
Bmw History:
Founded in 1916, BMW (Bayerische Motoren Werke AG) is a German multinational company that produces luxury vehicles and motorcycles. Known for its engineering prowess and sporty driving characteristics.
Model Evolution
E46 Generation Introduction:
The E46 generation of the 3 Series was introduced in 1998 for the 1999 model year, replacing the E36.
E46 Facelift:
The E46 received a significant facelift in 2001, which included updated styling for the headlights, taillights, front bumper, and interior enhancements.
325I Positioning In E46 Lineup:
The 325i typically sat above the 320i and 325xi, and below the 330i, offering a balance of performance and refinement.
Production
E46 Production Years:
1998-2006
Manufacturing Locations:
Primarily Germany (Munich, Dingolfing), but also plants in the USA, South Africa, and China.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E46 3 Series (including variants like the 325i) was a perennial recipient of Car and Driver's 10Best award throughout its production run, lauded for its driving dynamics.
Ward Automotive Top Engine:
The M54 engine family received recognition from Ward's AutoWorld as one of the best engines in the industry during its tenure.
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