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BMW 3 Series (E46) 325XI CONVERTIBLE 1999-2005 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E46 Body Style: Convertible Trim Level: 325xi Model Years: 1999-2005 Codes Engine Code Range: M54B25 (2.5L) 👋 Introduction Market Position Segment: Premium Compact Executive Sports Sedan/Convertible Target Audience: Enthusiasts, DIY mechanics, owners seeking comprehensive maintenance and repair knowledge for their E46 325xi Convertible. Competitive Analysis Key Competitors: Audi A4 Cabriolet, Mercedes-Benz C-Class Coupe/Convertible (CLK-Class), Lexus IS Convertible, Infiniti G35 Coupe/Convertible. Key Features Manual Advantage: Provides dealership-level repair information, enabling owners to perform complex tasks, save on labor costs, and understand their vehicle intimately. Diy Focus: Emphasis on step-by-step guides, diagrams, and illustrations to facilitate DIY repairs, even for novice mechanics. Completeness: Covers all models and repairs A-Z for the specified E46 325xi Convertible, ensuring no gaps in information. 📋 Manual Details Coverage Areas Manual Coverage Scope: Complete Service and Repair for BMW 3 Series (E46) 325xi Convertible (1999-2005) Page Count Page Count: Not specified, but described as 'COMPLETE official full service repair manual' Manual Type Manual Type: Official Factory Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing, lubrication system, cooling system, fuel injection system (Bosch Motronic ME7.2), ignition system. Engine Management: Engine control unit (ECU) diagnostics, sensors, actuators, emissions control (OBD-II). Transmission Manual: Manual transmission (e.g., Getrag 5-speed) removal, installation, internal components, fluid specifications. Transmission Automatic: Automatic transmission (e.g., GM 5L40-E) removal, installation, internal components, torque converter, fluid specifications, mechatronics. Drivetrain: All-wheel drive system (xDrive), transfer case, driveshafts, front and rear differentials, CV joints, wheel bearings. Suspension: Front suspension (MacPherson struts, control arms, anti-roll bar), rear suspension (multi-link), shock absorbers, springs, bushings, alignment specifications. Steering: Power steering system (rack and pinion), steering column, linkages, fluid specifications, bleeding procedures. Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake calipers, rotors, pads, master cylinder, brake lines, fluid specifications, bleeding procedures, parking brake. Body And Chassis: Body panel removal and installation, chassis structure, corrosion protection, convertible top mechanism and operation, seals, weatherstripping. Electrical System: 12V battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams for all circuits. Climate Control: HVAC system, blower motor, heater core, evaporator, refrigerant (R134a), A/C compressor, climate control module, operation and servicing. Interior Trim: Dashboard, door panels, seats, carpeting, headliner, center console, airbag system components. Infotainment And Comfort: Radio/audio system, navigation system (optional), power windows, power locks, power mirrors, central locking system, remote keyless entry. Safety Systems: Airbag system (SRS), seat belt pre-tensioners, occupant detection sensors, basic safety features. Procedures Included Maintenance Procedures: Oil changes, filter replacements (oil, air, cabin), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes, power steering fluid changes, drive belt inspection and replacement, battery checks, tire rotation and balancing. Troubleshooting Diagnostics: Systematic diagnostic procedures for all major vehicle systems, fault code reading and interpretation, component testing, common issue diagnosis. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation for all major systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component replacement, convertible top repairs. Installation Procedures: Installation guidelines for replacement parts and accessories. Technical Specifications: Detailed technical data, torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameter values. Wiring Diagrams: Comprehensive electrical wiring schematics for all vehicle circuits, including engine management, lighting, power accessories, safety systems, and comfort features. Technical Depth Depth Of Coverage: Extensive, covering routine maintenance to major overhaul and component-level repair. Detailed diagnostic trees and procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full printable pages, allowing users to print specific sections or the entire manual. Zoom functionality for detailed examination of images and diagrams. Binding Type Binding Type: Digital (PDF format) Paper Type Paper Type: N/A (Digital) Searchability Searchable Text: Yes (typically PDF files of this nature are text-searchable) Requirements Software Requirements: Adobe PDF Reader, WinZip (for extraction if compressed) Compatibility Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Name: BMW M54B25 Engine Type: Inline 6-cylinder, Double VANOS, DOHC (Dual Overhead Camshafts) Displacement: 2494 cc (2.5 Liters) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 10.2:1 Performance Horsepower: 184 hp @ 6000 rpm Torque: 235 Nm (173 lb-ft) @ 3500 rpm Fuel System Fuel Delivery: Electronic Port Fuel Injection (Bosch Motronic ME7.2) Recommended Fuel: Premium Unleaded Gasoline (91 octane or higher) Other Engine Oil Capacity: 6.5 liters (approx. 6.9 US quarts) with filter. Refer to manual for exact specification. Cooling System Capacity: Approx. 9.0 liters (approx. 9.5 US quarts) of BMW Blue Antifreeze/Coolant. 🔧 Transmission Standard Transmission Type: 5-speed Manual (e.g., Getrag S5D 250G) Optional Transmission Type Optional: 5-speed Automatic (e.g., GM 5L40-E) Features Drivetrain Layout: All-Wheel Drive (xDrive) Fluid Specifications Manual Transmission Fluid:...
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BMW 3 Series (E46) 325XI CONVERTIBLE 1999-2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E46
Body Style:
Convertible
Trim Level:
325xi
Model Years:
1999-2005
Codes
Engine Code Range:
M54B25 (2.5L)
👋 Introduction
Market Position
Segment:
Premium Compact Executive Sports Sedan/Convertible
Target Audience:
Enthusiasts, DIY mechanics, owners seeking comprehensive maintenance and repair knowledge for their E46 325xi Convertible.
Competitive Analysis
Key Competitors:
Audi A4 Cabriolet, Mercedes-Benz C-Class Coupe/Convertible (CLK-Class), Lexus IS Convertible, Infiniti G35 Coupe/Convertible.
Key Features
Manual Advantage:
Provides dealership-level repair information, enabling owners to perform complex tasks, save on labor costs, and understand their vehicle intimately.
Diy Focus:
Emphasis on step-by-step guides, diagrams, and illustrations to facilitate DIY repairs, even for novice mechanics.
Completeness:
Covers all models and repairs A-Z for the specified E46 325xi Convertible, ensuring no gaps in information.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Complete Service and Repair for BMW 3 Series (E46) 325xi Convertible (1999-2005)
Page Count
Page Count:
Not specified, but described as 'COMPLETE official full service repair manual'
Manual Type
Manual Type:
Official Factory Service and Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing, lubrication system, cooling system, fuel injection system (Bosch Motronic ME7.2), ignition system.
Engine Management:
Engine control unit (ECU) diagnostics, sensors, actuators, emissions control (OBD-II).
Transmission Manual:
Manual transmission (e.g., Getrag 5-speed) removal, installation, internal components, fluid specifications.
Transmission Automatic:
Automatic transmission (e.g., GM 5L40-E) removal, installation, internal components, torque converter, fluid specifications, mechatronics.
Drivetrain:
All-wheel drive system (xDrive), transfer case, driveshafts, front and rear differentials, CV joints, wheel bearings.
Suspension:
Front suspension (MacPherson struts, control arms, anti-roll bar), rear suspension (multi-link), shock absorbers, springs, bushings, alignment specifications.
Steering:
Power steering system (rack and pinion), steering column, linkages, fluid specifications, bleeding procedures.
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake calipers, rotors, pads, master cylinder, brake lines, fluid specifications, bleeding procedures, parking brake.
Body And Chassis:
Body panel removal and installation, chassis structure, corrosion protection, convertible top mechanism and operation, seals, weatherstripping.
Electrical System:
12V battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams for all circuits.
Climate Control:
HVAC system, blower motor, heater core, evaporator, refrigerant (R134a), A/C compressor, climate control module, operation and servicing.
Interior Trim:
Dashboard, door panels, seats, carpeting, headliner, center console, airbag system components.
Infotainment And Comfort:
Radio/audio system, navigation system (optional), power windows, power locks, power mirrors, central locking system, remote keyless entry.
Safety Systems:
Airbag system (SRS), seat belt pre-tensioners, occupant detection sensors, basic safety features.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements (oil, air, cabin), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes, power steering fluid changes, drive belt inspection and replacement, battery checks, tire rotation and balancing.
Troubleshooting Diagnostics:
Systematic diagnostic procedures for all major vehicle systems, fault code reading and interpretation, component testing, common issue diagnosis.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation for all major systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component replacement, convertible top repairs.
Installation Procedures:
Installation guidelines for replacement parts and accessories.
Technical Specifications:
Detailed technical data, torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameter values.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle circuits, including engine management, lighting, power accessories, safety systems, and comfort features.
Technical Depth
Depth Of Coverage:
Extensive, covering routine maintenance to major overhaul and component-level repair. Detailed diagnostic trees and procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Full printable pages, allowing users to print specific sections or the entire manual. Zoom functionality for detailed examination of images and diagrams.
Binding Type
Binding Type:
Digital (PDF format)
Paper Type
Paper Type:
N/A (Digital)
Searchability
Searchable Text:
Yes (typically PDF files of this nature are text-searchable)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for extraction if compressed)
Compatibility
Operating System Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Name:
BMW M54B25
Engine Type:
Inline 6-cylinder, Double VANOS, DOHC (Dual Overhead Camshafts)
Displacement:
2494 cc (2.5 Liters)
Bore X Stroke:
84.0 mm x 75.0 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
184 hp @ 6000 rpm
Torque:
235 Nm (173 lb-ft) @ 3500 rpm
Fuel System
Fuel Delivery:
Electronic Port Fuel Injection (Bosch Motronic ME7.2)
Recommended Fuel:
Premium Unleaded Gasoline (91 octane or higher)
Other
Engine Oil Capacity:
6.5 liters (approx. 6.9 US quarts) with filter. Refer to manual for exact specification.
Cooling System Capacity:
Approx. 9.0 liters (approx. 9.5 US quarts) of BMW Blue Antifreeze/Coolant.
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (e.g., Getrag S5D 250G)
Optional
Transmission Type Optional:
5-speed Automatic (e.g., GM 5L40-E)
Features
Drivetrain Layout:
All-Wheel Drive (xDrive)
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent GL-4 gear oil (e.g., 75W-90). Refer to manual for exact part number.
Automatic Transmission Fluid:
Dexron III or Dexron VI ATF. Refer to manual for exact part number.
📐 Dimensions
Exterior
Length:
Approx. 4471 mm (176.0 inches)
Width:
Approx. 1739 mm (68.5 inches)
Height:
Approx. 1375 mm (54.1 inches)
Wheelbase:
Approx. 2760 mm (108.7 inches)
Weights
Curb Weight:
Approx. 1660 kg (3660 lbs) for manual; 1690 kg (3726 lbs) for automatic.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-star (for E46 Coupe/Convertible, specific ratings for xi may vary slightly).
IIHS Side Impact:
Good (for E46 Coupe/Convertible).
Active Features
ABS:
Standard Anti-lock Braking System
Dsc:
Standard Dynamic Stability Control (DSC-III)
Traction Control:
Standard Automatic Stability Control + Traction (ASC+T) or DSC
Passive Features
Airbags:
Front airbags, side airbags (optional in early models, standard later).
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners and force limiters.
Rollover Protection:
Automatic pop-out rollover protection system behind the rear headrests.
💡 Technology Features
Infotainment
Audio System:
BMW Business CD or Professional CD/Radio systems, optional Harman Kardon sound system, CD changer preparation.
Navigation:
Optional MK III or MK IV navigation systems with CD-ROM map updates. Manual covers system operation and basic troubleshooting.
Driver Assistance
Stability Control:
DSC-III (Dynamic Stability Control) with integrated ABS and traction control.
Parking Sensors:
Optional rear parking distance sensors (PDC).
Connectivity
Remote Keyless Entry:
Standard remote key fob with central locking and trunk release.
Cruise Control:
Standard cruise control system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable Service Interval (VSI) system, typically 10,000-15,000 miles or annually, depending on driving conditions.
Major Service:
Around 60,000 miles for spark plug replacement, coolant flush, and thorough inspection of belts, hoses, and suspension components.
Fluid Specifications
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based). Must use correct type to avoid corrosion.
Brake Fluid Type:
DOT 4 (Low Viscosity, LV, or Super DOT 4 recommended). Replace every 2 years.
Power Steering Fluid:
CHF 11S (Pentosin) or BMW's recommended equivalent.
Known Issues
Common Issue Ccv System:
Crankcase Ventilation (CCV) system failure can lead to oil consumption, vacuum leaks, and engine damage. The manual covers diagnosis and replacement.
Common Issue Cooling System:
Plastic coolant expansion tanks and radiator end caps are prone to cracking. Water pump and thermostat failures can also occur. Manual details replacement.
Common Issue Oil Leaks:
Valve cover gasket, oil pan gasket, and front crankshaft seal (gasket or OFHG) are common leak points. Manual provides detailed repair procedures.
Common Issue Suspension:
Worn control arm bushings (e.g., M3 control arms with rubber bushings are a popular upgrade, detailed in manual), sway bar links, and rear trailing arm bushings can cause steering and ride quality issues.
Common Issue Convertible Top:
Hydraulic pump issues, sensor failures, fabric wear, and hydraulic line leaks can affect convertible top operation. The manual covers troubleshooting and repair of the top mechanism.
Common Issue Electrical:
ABS/DSC sensor failures, alternator issues, and failure of the central body module (CAS) or other control units can occur. Wiring diagrams are crucial for diagnosis.
📚 Vehicle History
Brand Heritage
Brand Focus:
BMW is renowned for its 'Ultimate Driving Machine' philosophy, emphasizing performance, luxury, and engineering precision.
Model Evolution
E46 Generation:
The E46 generation (1998-2006) represented a significant evolution in BMW's 3 Series, featuring improved chassis dynamics, advanced technology, and refined styling over its predecessor (E36).
325Xi Introduction:
The 'xi' designation signifies BMW's all-wheel-drive system, introduced to the 3 Series line-up, offering enhanced traction and stability, particularly in adverse weather conditions.
Production
Production Period:
E46 Convertible production ran from late 1999 to 2006. The 325xi Convertible specifically covered the 1999-2005 model years.
Manufacturing Locations:
Primarily manufactured in Germany (e.g., Dingolfing plant).
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E46 3 Series (including various iterations) was a consistent recipient of Car and Driver's '10Best' awards during its production run for its exceptional driving dynamics.
Ward S 10 Best Engines:
The M54 inline-six engine family received multiple 'Ward's 10 Best Engines' awards for its smoothness, power delivery, and efficiency.
Certifications
Safety Ratings:
Consistently high safety ratings from IIHS and NHTSA for its segment and era.
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