BMW 3 Series 335xi 2006-2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 335xi Model Generation: E90/E91/E92/E93 Model Year Start: 2006 Model Year End: 2010 Codes Chassis Codes: E90 (Sedan), E91 (Wagon/Touring), E92 (Coupe), E93 (Convertible) 👋 Introduction Market Position Market Segment: Premium compact executive sports sedan/coupe/convertible. Competitive Analysis Key Competitors: Audi A4, Mercedes-Benz C-Class, Lexus IS, Infiniti G35/G37. Key Features Driving Dynamics: Renowned for sporty handling, balanced chassis, responsive steering, and powerful engine options. Powertrain: The 335xi variant features BMW's potent N54 twin-turbocharged 3.0-liter inline-6 engine, delivering significant horsepower and torque, coupled with BMW's xDrive all-wheel-drive system. Design Aesthetics: Classic BMW design language with a focus on driver-centric ergonomics and premium interior appointments. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Distribution: Instant Download Page Count Page Count: 2520 📖 Manual Coverage Systems Covered Engine Management: Comprehensive coverage including N54 twin-turbo inline-6 engine diagnostics, tuning, fuel injection, ignition systems, emissions control. Drivetrain: All-wheel drive (xDrive) system, differentials (front, center, rear), driveshafts, CV joints, wheel bearings, hub assemblies. Transmission: Detailed procedures for automatic (e.g., GA6HP19Z, GA6HP26Z) and manual (e.g., GS6-37BZ) transmissions, including removal, installation, overhaul, mechatronics, torque converter, clutch, and flywheel replacement. Suspension Steering: Front and rear suspension components (struts, shocks, control arms, bushings, sway bars), power steering system (electric or hydraulic), steering rack, tie rods, alignment specifications. Brakes: Front and rear brake systems (vented discs, calipers, pads), ABS, DSC (Dynamic Stability Control), EBD (Electronic Brake Force Distribution), parking brake, brake fluid specifications and bleeding procedures. Electrical Electronics: Complete electrical schematics, wiring diagrams, fuse box locations, relay assignments, component testing, diagnostic trouble codes (DTCs), comfort electronics, body control module (BCM), instrument cluster, lighting systems (Xenon headlights, LED taillights). Body Chassis: Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim, sound deadening, chassis repair, rust prevention, structural integrity. HVAC: Air conditioning system, climate control, refrigerant handling, evaporator, condenser, compressor, blower motor, cabin filter replacement, diagnostics. Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, high-pressure fuel pump (HPFP) for N54 engine, fuel pressure testing. Procedures Included Maintenance: Routine maintenance tasks such as oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid level checks and top-offs, tire rotation, brake pad/rotor replacement, belt inspections and replacement. Repair Overhaul: Detailed step-by-step instructions for engine rebuilding, transmission overhaul, suspension component replacement, brake system repairs, electrical component diagnostics and replacement, bodywork repairs, and interior component refurbishment. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and complex faults, including symptom-based troubleshooting guides, diagnostic flowcharts, and expected values for various sensors and actuators. Diagnostics: Guidance on using BMW's ISTA (Integrated Service Application) or DIS (Diagnostic Information System) diagnostic tools, reading and interpreting fault codes, live data stream analysis, actuator tests, and module programming/coding. Special Tools: Identification and usage instructions for specialized BMW tools required for specific repairs and diagnostics, ensuring factory-correct procedures. Technical Depth Depth: Comprehensive from basic DIY maintenance to professional-level diagnostics and major component overhauls. 📊 Manual Specifications File Format File Format: PDF Searchable: Yes, text-searchable content for quick information retrieval. Print Quality Print Quality: High-resolution, suitable for clear printing of text and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: N54B30 Engine Configuration: 3.0L (2979cc) Twin-Turbocharged Inline 6-cylinder Bore X Stroke: 84.0 mm x 89.6 mm Compression Ratio: 10.2:1 Valvetrain: DOHC, 24 valves, Double VANOS Performance Horsepower: 300 hp @ 5800-6000 rpm (approx.) Torque: 300 lb-ft @ 1300-5000 rpm (approx.) Fuel System Fuel Delivery: Direct Injection (High-pressure fuel pump - HPFP) and port injection (later N54 variants). Fuel Type: Premium Unleaded Gasoline (91 AKI or higher recommended) Turbocharging Turbocharger Type: Sequential twin-turbochargers (smaller turbo for low-end response, larger turbo for high-end power). 🔧 Transmission Standard Transmission Type: 6-Speed Manual (e.g., GS6-37BZ) or 6-Speed Steptronic Automatic (e.g., GA6HP19Z/GA6HP26Z) Optional Transmission Options: Available with either manual or automatic transmission. Features Drivetrain: xDrive All-Wheel Drive system with electronic torque distribution. Fluid Specifications Automatic Transmission Fluid: BMW ATF LT-5 (Shell M-1375.4) or equivalent (e.g., Pentosin ATF1). Manual Transmission Fluid: BMW MTF LT-2 or equivalent (e.g., Pentosin MTF2). 📐 Dimensions Exterior Wheelbase: E90 Sedan: 108.0 inches (2743 mm), E92 Coupe: 108.0 inches (2743 mm), E93 Convertible: 108.0 inches (2743 mm) Length: E90 Sedan: 180.7 inches (4590 mm), E92 Coupe: 181.9 inches (4620 mm) Width: E90 Sedan: 70.2 inches (1783 mm), E92 Coupe: 70.6 inches (1793 mm) Height: E90 Sedan: 57.2 inches (1453 mm), E92 Coupe: 55.9 inches (1420 mm) Weights Curb Weight: Approx. 3700-3900 lbs (1680-1770 kg) depending on body style and options. Gross Vehicle Weight Rating: Varies by model, consult specific vehicle documentation or manual. Wheels Tires Wheel Bolt Pattern: 5x120 mm Standard Tire Size: Typically 225/45R17 or 225/40R18 (front) and 255/40R18 (rear) for xDrive models, depending on specific configuration....

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Description

🏷️ Basic Information

Identification

Make:

Model:

3 Series

Model Variant:

335xi

Model Generation:

E90/E91/E92/E93

Model Year Start:

Model Year End:

Codes

Chassis Codes:

E90 (Sedan), E91 (Wagon/Touring), E92 (Coupe), E93 (Convertible)

👋 Introduction

Market Position

Market Segment:

Premium compact executive sports sedan/coupe/convertible.

Competitive Analysis

Key Competitors:

Audi A4, Mercedes-Benz C-Class, Lexus IS, Infiniti G35/G37.

Key Features

Driving Dynamics:

Renowned for sporty handling, balanced chassis, responsive steering, and powerful engine options.

Powertrain:

The 335xi variant features BMW's potent N54 twin-turbocharged 3.0-liter inline-6 engine, delivering significant horsepower and torque, coupled with BMW's xDrive all-wheel-drive system.

Design Aesthetics:

Classic BMW design language with a focus on driver-centric ergonomics and premium interior appointments.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Distribution:

Instant Download

Page Count

Page Count:

📖 Manual Coverage

Systems Covered

Engine Management:

Comprehensive coverage including N54 twin-turbo inline-6 engine diagnostics, tuning, fuel injection, ignition systems, emissions control.

Drivetrain:

All-wheel drive (xDrive) system, differentials (front, center, rear), driveshafts, CV joints, wheel bearings, hub assemblies.

Transmission:

Detailed procedures for automatic (e.g., GA6HP19Z, GA6HP26Z) and manual (e.g., GS6-37BZ) transmissions, including removal, installation, overhaul, mechatronics, torque converter, clutch, and flywheel replacement.

Suspension Steering:

Front and rear suspension components (struts, shocks, control arms, bushings, sway bars), power steering system (electric or hydraulic), steering rack, tie rods, alignment specifications.

Brakes:

Front and rear brake systems (vented discs, calipers, pads), ABS, DSC (Dynamic Stability Control), EBD (Electronic Brake Force Distribution), parking brake, brake fluid specifications and bleeding procedures.

Electrical Electronics:

Complete electrical schematics, wiring diagrams, fuse box locations, relay assignments, component testing, diagnostic trouble codes (DTCs), comfort electronics, body control module (BCM), instrument cluster, lighting systems (Xenon headlights, LED taillights).

Body Chassis:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim, sound deadening, chassis repair, rust prevention, structural integrity.

HVAC:

Air conditioning system, climate control, refrigerant handling, evaporator, condenser, compressor, blower motor, cabin filter replacement, diagnostics.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, high-pressure fuel pump (HPFP) for N54 engine, fuel pressure testing.

Procedures Included

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid level checks and top-offs, tire rotation, brake pad/rotor replacement, belt inspections and replacement.

Repair Overhaul:

Detailed step-by-step instructions for engine rebuilding, transmission overhaul, suspension component replacement, brake system repairs, electrical component diagnostics and replacement, bodywork repairs, and interior component refurbishment.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and complex faults, including symptom-based troubleshooting guides, diagnostic flowcharts, and expected values for various sensors and actuators.

Diagnostics:

Guidance on using BMW's ISTA (Integrated Service Application) or DIS (Diagnostic Information System) diagnostic tools, reading and interpreting fault codes, live data stream analysis, actuator tests, and module programming/coding.

Special Tools:

Identification and usage instructions for specialized BMW tools required for specific repairs and diagnostics, ensuring factory-correct procedures.

Technical Depth

Depth:

Comprehensive from basic DIY maintenance to professional-level diagnostics and major component overhauls.

📊 Manual Specifications

File Format

File Format:

Searchable:

Yes, text-searchable content for quick information retrieval.

Print Quality

Print Quality:

High-resolution, suitable for clear printing of text and diagrams.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

N54B30

Engine Configuration:

3.0L (2979cc) Twin-Turbocharged Inline 6-cylinder

Bore X Stroke:

84.0 mm x 89.6 mm

Compression Ratio:

10.2:1

Valvetrain:

DOHC, 24 valves, Double VANOS

Performance

Horsepower:

300 hp @ 5800-6000 rpm (approx.)

Torque:

300 lb-ft @ 1300-5000 rpm (approx.)

Fuel System

Fuel Delivery:

Direct Injection (High-pressure fuel pump - HPFP) and port injection (later N54 variants).

Fuel Type:

Premium Unleaded Gasoline (91 AKI or higher recommended)

Turbocharging

Turbocharger Type:

Sequential twin-turbochargers (smaller turbo for low-end response, larger turbo for high-end power).

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual (e.g., GS6-37BZ) or 6-Speed Steptronic Automatic (e.g., GA6HP19Z/GA6HP26Z)

Optional

Transmission Options:

Available with either manual or automatic transmission.

Features

Drivetrain:

xDrive All-Wheel Drive system with electronic torque distribution.

Fluid Specifications

Automatic Transmission Fluid:

BMW ATF LT-5 (Shell M-1375.4) or equivalent (e.g., Pentosin ATF1).

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent (e.g., Pentosin MTF2).

📐 Dimensions

Exterior

Wheelbase:

E90 Sedan: 108.0 inches (2743 mm), E92 Coupe: 108.0 inches (2743 mm), E93 Convertible: 108.0 inches (2743 mm)

Length:

E90 Sedan: 180.7 inches (4590 mm), E92 Coupe: 181.9 inches (4620 mm)

Width:

E90 Sedan: 70.2 inches (1783 mm), E92 Coupe: 70.6 inches (1793 mm)

Height:

E90 Sedan: 57.2 inches (1453 mm), E92 Coupe: 55.9 inches (1420 mm)

Weights

Curb Weight:

Approx. 3700-3900 lbs (1680-1770 kg) depending on body style and options.

Gross Vehicle Weight Rating:

Varies by model, consult specific vehicle documentation or manual.

Wheels Tires

Wheel Bolt Pattern:

5x120 mm

Standard Tire Size:

Typically 225/45R17 or 225/40R18 (front) and 255/40R18 (rear) for xDrive models, depending on specific configuration.

🛡️ Safety Features

Ratings

NHTSA Ratings:

Generally received high safety ratings from NHTSA and IIHS, consult specific model year reports for exact figures.

Active Features

Active Safety Systems:

ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), DTC (Dynamic Traction Control), Run-flat tires, tire pressure monitoring system.

Passive Features

Passive Safety Features:

Front airbags, front side-impact airbags, curtain airbags (sedan/coupe), rollover protection system (convertible), active head restraints, front and rear crumple zones.

💡 Technology Features

Infotainment

Infotainment System:

iDrive system with professional navigation (optional), Bluetooth connectivity, auxiliary audio input, and often SiriusXM satellite radio.

Driver Assistance

Driver Assistance Features:

Park Distance Control (PDC), Adaptive Headlights (optional), Rain Sensor, Cruise Control.

Connectivity

Connectivity Options:

BMW Assist with Bluetooth mobile interface, USB/Audio adapter (optional).

Performance Tech

Engine Control Unit:

MSV80 Engine Management System (or similar, depending on exact build date), controlling fuel injection, ignition timing, boost pressure, and VANOS operation.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 miles or as indicated by the Condition Based Service (CBS) system, which monitors driving conditions and oil life.

Spark Plug Replacement:

Recommended every 60,000 miles for the N54 engine (check specific interval in manual).

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Coolant Replacement:

BMW recommends BMW Blue Coolant, often cited as a lifetime coolant but replacement every 5-7 years or 100,000 miles is advisable.

Fluid Specifications

Engine Oil:

BMW Longlife-01 (LL-01) or BMW Longlife-01 FE (LL-01 FE) specification, typically SAE 0W-30 or 5W-30 synthetic oil. Consult manual for exact viscosity by climate.

Engine Coolant:

BMW Blue Antifreeze/Coolant (G48).

Power Steering Fluid:

Pentosin CHF 11S or BMW ATF Dexron III (depending on specific steering system, consult manual).

Known Issues

N54 Engine:

Potential issues include High-Pressure Fuel Pump (HPFP) failure, fuel injector issues, turbo wastegate rattle/failure, PCV system issues, and carbon buildup on intake valves due to direct injection.

Electrical:

Water pump failures (electric), thermostat failures, idrive system glitches, various sensor failures.

Suspension:

Worn control arm bushings, strut mounts, and rear subframe bushings are common wear items.

📚 Vehicle History

Brand Heritage

Brand Legacy:

BMW, established in 1916, is renowned for its 'Ultimate Driving Machine' philosophy, focusing on performance, luxury, and engineering excellence.

Model Evolution

3 Series Lineage:

The 3 Series, introduced in 1975, is BMW's best-selling model line and has consistently set benchmarks in the compact executive segment for driving dynamics and innovation. The E90 generation succeeded the E46 and introduced a more sophisticated chassis, advanced technology, and more powerful engine options like the N54.

Production

Production Period:

E90 generation produced from 2005 (for 2006 model year) to 2011 (for 2012 model year) in various global plants, including Germany, Mexico, and South Africa.

335Xi Introduction:

The 335xi variant, featuring the N54 twin-turbo engine and xDrive AWD, was introduced for the 2007 model year.

🏆 Awards & Recognition

Recognitions

Ward Awards:

The N54 engine powering the 335i/xi was a multiple-time winner of Ward's 10 Best Engines award for its power, efficiency, and technology.

Vehicle Awards:

The E90 generation 3 Series consistently received accolades from automotive journalists and organizations for its driving dynamics, performance, and overall refinement.