BMW 3 Series 325i 1999-2005 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i Codes Chassis Code: E46 Engine Code: M54B25 👋 Introduction Market Position Market Position: The BMW 3 Series (E46) represented the compact executive car segment, known for its driving dynamics, premium quality, and performance. The 325i model was a popular mid-range offering within the E46 lineup. Competitive Analysis Competitors: Primary competitors included the Mercedes-Benz C-Class, Audi A4, Lexus IS, and Infiniti G35. Key Features Key Features: Rear-wheel drive bias, balanced chassis, responsive engines, premium interior appointments, and advanced technology for its era. Chassis Dynamics: The E46 platform is renowned for its well-engineered multi-link front suspension and independent rear suspension, contributing to its exceptional handling characteristics. 📋 Manual Details Coverage Areas Applicable Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Page Count: 1250 Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Instant Download) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, engine management (DME), emissions control. Transmission: Manual and Automatic transmission systems, clutch, driveline, drive axles. Brakes: Brake system (hydraulic, ABS, DSC), brake pad replacement, rotor replacement, caliper service. Electrical: Complete electrical system, wiring diagrams, fuses, relays, battery, charging system, starting system, lighting, instrumentation, body electronics (BCM, comfort modules). Suspension: Front and rear suspension components, shock absorbers, struts, control arms, bushings, steering system. Body: Body structure, body panels, doors, hood, trunk, interior trim, HVAC system, exterior lighting. Fuel System Detail: Fuel pump, fuel injectors, fuel pressure regulator, fuel filter, evaporative emissions control system. Ignition System Detail: Ignition coils, spark plugs, crankshaft position sensor, camshaft position sensors. Procedures Included Maintenance: Oil change, filter replacement, spark plug replacement, fluid checks and changes, belt inspection and replacement. Repair: Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component repair. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, diagnostic connector location. Exhaust System: Diagnosis and repair of exhaust system components, catalytic converter replacement, muffler service. Steering: Power steering system diagnosis and repair, steering rack replacement, tie rod end replacement. Climate Control: HVAC system diagnosis, refrigerant service, blower motor replacement, evaporator core replacement. Body And Trim: Interior and exterior trim removal and installation, door panel removal, seat removal, window regulator repair. Wheel And Tire: Wheel and tire replacement, torque specifications, alignment procedures. Chassis And Frame: Chassis component inspection and repair, rust prevention and repair guidance. Timing Belt Chain: While the M54 engine features a timing chain, the manual would cover inspection, tensioner service, and associated component replacement if needed, unlike timing belts. Technical Depth Depth: Comprehensive, covering routine maintenance, diagnostics, repair, and overhaul procedures for all major vehicle systems. Electrical Diagnostics Detail: Detailed wiring diagrams for all circuits, fuse and relay box locations, troubleshooting trees for electrical faults. Engine Performance Tuning: Information on engine control unit (ECU) parameters and potential adjustments, although primarily focused on stock specifications and repair. Transmission Rebuild: Detailed procedures for manual and automatic transmission overhaul, including component identification, torque specifications, and assembly sequences. Diagnostic Tool Interface: Information regarding the OBD-II diagnostic port and common diagnostic tools used for BMW vehicles of this era. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire document. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Text Searchable: Yes Navigation Hyperlinked Sections: Typically Yes for PDF manuals of this caliber, allowing for easy navigation between sections and topics. ⚙️ Engine Specifications Primary Engine Engine Type: Inline-6 Cylinder, Naturally Aspirated Engine Displacement: 2.5 Liters (2494 cc) Performance Horsepower: 184 hp @ 6000 rpm Torque: 245 Nm (181 lb-ft) @ 3500 rpm Engine Code Designation: M54B25 signifies a 2.5-liter displacement (B25) M54 engine. Fuel System Fuel System Type: Multi-point Fuel Injection (Bosch Motronic ME 7.2) Recommended Fuel: Premium Unleaded Gasoline (91 Octane or higher) Engine Management Dme Model: Bosch Motronic ME 7.2 Engine Internals Bore X Stroke: 84.0 mm x 90.0 mm Compression Ratio: 10.2:1 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Optional Transmission Type Optional: 5-Speed Automatic (Steptronic) Features Drivetrain: Rear-Wheel Drive (RWD) 📐 Dimensions Exterior Length: 4471 mm (176.0 in) Width: 1739 mm (68.5 in) Height: 1412 mm (55.6 in) Wheelbase: 2760 mm (108.7 in) Front Overhang: 825 mm (32.5 in) Rear Overhang: 885 mm (34.8 in) Weights Curb Weight: 1480 kg (3263 lbs) - Manual Transmission Gross Vehicle Weight Rating Gvwr: Varies by model and configuration, but typically around 1950 kg (4300 lbs). Consult manual for precise rating. 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-Star NHTSA Front Impact Passenger: 5-Star IIHS Moderate Overlap Frontal Offset: Good Passive Features Airbags: Front dual-stage airbags, front side airbags. Seatbelts: 3-point inertia-reel seatbelts with pretensioners and force limiters. Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control:...
The BMW 3 Series (E46) represented the compact executive car segment, known for its driving dynamics, premium quality, and performance. The 325i model was a popular mid-range offering within the E46 lineup.
Competitive Analysis
Competitors:
Primary competitors included the Mercedes-Benz C-Class, Audi A4, Lexus IS, and Infiniti G35.
Key Features
Key Features:
Rear-wheel drive bias, balanced chassis, responsive engines, premium interior appointments, and advanced technology for its era.
Chassis Dynamics:
The E46 platform is renowned for its well-engineered multi-link front suspension and independent rear suspension, contributing to its exceptional handling characteristics.
Diagnosis and repair of exhaust system components, catalytic converter replacement, muffler service.
Steering:
Power steering system diagnosis and repair, steering rack replacement, tie rod end replacement.
Climate Control:
HVAC system diagnosis, refrigerant service, blower motor replacement, evaporator core replacement.
Body And Trim:
Interior and exterior trim removal and installation, door panel removal, seat removal, window regulator repair.
Wheel And Tire:
Wheel and tire replacement, torque specifications, alignment procedures.
Chassis And Frame:
Chassis component inspection and repair, rust prevention and repair guidance.
Timing Belt Chain:
While the M54 engine features a timing chain, the manual would cover inspection, tensioner service, and associated component replacement if needed, unlike timing belts.
Technical Depth
Depth:
Comprehensive, covering routine maintenance, diagnostics, repair, and overhaul procedures for all major vehicle systems.
Electrical Diagnostics Detail:
Detailed wiring diagrams for all circuits, fuse and relay box locations, troubleshooting trees for electrical faults.
Engine Performance Tuning:
Information on engine control unit (ECU) parameters and potential adjustments, although primarily focused on stock specifications and repair.
Transmission Rebuild:
Detailed procedures for manual and automatic transmission overhaul, including component identification, torque specifications, and assembly sequences.
Diagnostic Tool Interface:
Information regarding the OBD-II diagnostic port and common diagnostic tools used for BMW vehicles of this era.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire document.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Text Searchable:
Yes
Navigation
Hyperlinked Sections:
Typically Yes for PDF manuals of this caliber, allowing for easy navigation between sections and topics.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-6 Cylinder, Naturally Aspirated
Engine Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
184 hp @ 6000 rpm
Torque:
245 Nm (181 lb-ft) @ 3500 rpm
Engine Code Designation:
M54B25 signifies a 2.5-liter displacement (B25) M54 engine.
Fuel System
Fuel System Type:
Multi-point Fuel Injection (Bosch Motronic ME 7.2)
Recommended Fuel:
Premium Unleaded Gasoline (91 Octane or higher)
Engine Management
Dme Model:
Bosch Motronic ME 7.2
Engine Internals
Bore X Stroke:
84.0 mm x 90.0 mm
Compression Ratio:
10.2:1
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual
Optional
Transmission Type Optional:
5-Speed Automatic (Steptronic)
Features
Drivetrain:
Rear-Wheel Drive (RWD)
📐 Dimensions
Exterior
Length:
4471 mm (176.0 in)
Width:
1739 mm (68.5 in)
Height:
1412 mm (55.6 in)
Wheelbase:
2760 mm (108.7 in)
Front Overhang:
825 mm (32.5 in)
Rear Overhang:
885 mm (34.8 in)
Weights
Curb Weight:
1480 kg (3263 lbs) - Manual Transmission
Gross Vehicle Weight Rating Gvwr:
Varies by model and configuration, but typically around 1950 kg (4300 lbs). Consult manual for precise rating.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star
NHTSA Front Impact Passenger:
5-Star
IIHS Moderate Overlap Frontal Offset:
Good
Passive Features
Airbags:
Front dual-stage airbags, front side airbags.
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Dynamic Stability Control (DSC) or Traction Control System (ASC+T) depending on model year and options.
💡 Technology Features
Infotainment
Infotainment System:
Optional BMW Business or Professional CD radios, optional navigation system. Basic audio controls and display. Later models may feature more advanced displays.
Driver Assistance
Driver Assistance Features:
Cruise control, optional parking sensors (Park Distance Control - PDC).
Connectivity
Connectivity Features:
Limited connectivity by modern standards. CD player, optional cassette player, potential for aftermarket Bluetooth integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system or approximately every 7,500-15,000 miles (12,000-24,000 km) depending on driving conditions and oil type.
Spark Plug Replacement:
Typically around 100,000 miles (160,000 km) for iridium spark plugs (check specific recommendation for original equipment).
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) approved synthetic oil, typically SAE 0W-30 or 5W-30. Consult manual for precise specification.
Coolant Type:
BMW Blue Antifreeze (G48 ethylene glycol based). Mix 50/50 with distilled water.
Brake Fluid Type:
DOT 4 High Performance brake fluid.
Automatic Transmission Fluid Type:
BMW ATF LT-71141 (for earlier models) or Esso LT 71141 / Shell LA2634 (for later models). Refer to manual for specific transmission type.
Known Issues
Cooling System:
Plastic expansion tank prone to cracking, water pump failure, thermostat housing leaks.
Suspension:
Worn control arm bushings (specifically the front lower control arm bushings, often referred to as 'RTABs' for rear trailing arm bushings as well), worn sway bar links.
CCV (Crankcase Ventilation) system issues leading to oil consumption and seal failures, VANOS (Variable Valve Timing) solenoid issues, oxygen sensor failures.
Fluid Capacities
Engine Oil Capacity:
Approx. 6.5 Liters (6.9 US Quarts) with filter change. Consult manual for exact capacity.
Coolant Capacity:
Approx. 8.0 Liters (8.5 US Quarts). Consult manual for exact capacity.
Automatic Transmission Fluid Capacity:
Approx. 5.5-6.5 Liters (5.8-6.9 US Quarts) for a pan drop and fill. Full refill capacity will be higher. Consult manual.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Bayerische Motoren Werke AG (BMW) has a long-standing reputation for producing sporty, luxurious, and technologically advanced vehicles, particularly known for its focus on driving pleasure ('The Ultimate Driving Machine').
Model Evolution
Model Evolution:
The E46 generation, produced from 1998 to 2006, succeeded the E36 3 Series. It was praised for its refined chassis, improved interior quality, and advanced engineering over its predecessor. The 325i model replaced the 328i from the previous generation, offering a balance of performance and efficiency.
Primarily produced at BMW's manufacturing plants in Germany (e.g., Munich, Regensburg, Dingolfing) and also in other global locations for specific markets.