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BMW 325 325xi 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 325i / 325xi Year: 2004 Generation Chassis Code: E46 Generation Name: Fourth Generation E46 Codes Engine Code Prefix: M54 👋 Introduction Market Position Vehicle Segment: Compact Executive Sedan/Coupe/Convertible/Wagon Brand Philosophy Alignment: Embodies BMW's 'Ultimate Driving Machine' ethos with balanced performance and luxury. Competitive Analysis Key Competitors: Mercedes-Benz C-Class, Audi A4, Lexus IS. Key Features Drivetrain Options: Rear-wheel drive (325i) and xDrive all-wheel drive (325xi). Engine Type: Naturally aspirated inline-six cylinder. Chassis Dynamics: Renowned for balanced weight distribution and precise handling. 📋 Manual Details Coverage Areas Comprehensive Scope: Covers all major mechanical, electrical, and body systems. Region Of Origin: North America (primarily, but applicable to global variants with minor regional differences noted). Page Count Estimated Pages: Hundreds (exact count varies based on internal pagination, but typically exceeding 1000 pages for a complete factory manual). Manual Type Manual Classification: Factory Service Repair Manual (FSM) Additional Manual Types Covered: Includes diagnostic procedures, repair instructions, and maintenance schedules. Language Primary Language: English Format Digital Format: Downloadable PDF Printability: Printable (allows printing entire manual or specific sections). 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling. Engine Management: Fuel injection, ignition system, emissions control, engine control unit (ECU) diagnostics and programming. Transmission Manual: Manual transmission (Getrag or ZF) repair, clutch, flywheel, driveshafts. Transmission Automatic: Automatic transmission (GM 5L40-E) overhaul, valve body, torque converter, mechatronics. Drivetrain: All-wheel drive (xi) system, differential, transfer case, axle shafts, wheel bearings. Suspension: Front and rear suspension, control arms, shock absorbers, struts, springs, bushings, subframes. Steering: Power steering system, steering rack, steering column, steering wheel removal. Brakes: Hydraulic system, ABS, DSC (Dynamic Stability Control), brake calipers, rotors, pads, lines, parking brake. Electrical System: Battery, alternator, starter, wiring diagrams, fuses, relays, body control module (BCM). Lighting: Headlights, taillights, interior lighting, fog lights, bulb replacement, headlight aiming. Comfort Systems: HVAC (Heating, Ventilation, and Air Conditioning), blower motor, climate control unit, refrigerant system. Interior Trim: Dashboard, door panels, seats, headliner, center console removal and installation. Exterior Body: Body panels, bumpers, doors, hood, trunk, glass, seals, exterior trim. Infotainment: Radio, CD player, navigation system (if equipped), speaker replacement. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs. Troubleshooting: Diagnostic flowcharts, common fault identification, symptom-based troubleshooting. Repair Procedures: Step-by-step instructions for component replacement and repair. Diagnostic Procedures: OBD-II scan tool usage, reading fault codes, live data interpretation. Installation Procedures: Component installation and adjustment. Technical Depth Diagnostic Level: Advanced diagnostics with detailed descriptions of sensor inputs, outputs, and control module logic. Repair Complexity: Covers everything from basic fluid changes to complete engine and transmission rebuilds. Electrical Diagrams: Detailed and comprehensive wiring schematics for all electrical systems. Torque Specifications: Precise torque values for all critical fasteners. Special Tools: Identification and usage instructions for specialized BMW tools. 📊 Manual Specifications File Format PDF Version: Typically PDF/A or a compatible version for broad software support. Searchable Text: Yes, the PDF is expected to have OCR (Optical Character Recognition) for full text searchability. Print Quality Image Resolution: High resolution for clear diagrams, illustrations, and photographs. Binding Type Digital Binding: N/A (digital format) Paper Type Digital Paper Type: N/A (digital format) ⚙️ Engine Specifications Primary Engine Engine Code: M54B30 Engine Type: Inline 6-cylinder, Naturally Aspirated Displacement: 2979 cc (3.0 Liters) Bore X Stroke: 84.0 mm x 89.6 mm Compression Ratio: 10.2:1 Performance Horsepower Peak: 225 hp @ 6000 rpm Torque Peak: 214 lb-ft (290 Nm) @ 3500 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPFI) Fuel Type Recommendation: Premium Unleaded (91+ Octane) Valvetrain Valvetrain Configuration: Dual Overhead Camshafts (DOHC), 4 valves per cylinder Valve Actuation: Double VANOS (Variable Valve Timing on intake and exhaust camshafts) 🔧 Transmission Standard Transmission Type 325I: 5-Speed Manual (Getrag 420G) Optional Transmission Type Optional: 5-Speed Automatic with Steptronic (GM 5L40-E) Features Automatic Features: Driver-selectable modes, manual shifting via Steptronic. Fluid Specifications Manual Transmission Fluid: BMW MTF LT-2 (or equivalent GL-4 SAE 75W-90) Automatic Transmission Fluid: Dexron III (or equivalent GM spec) Clutch Clutch Type: Hydraulically actuated, single dry plate. 📐 Dimensions Exterior Wheelbase: 107.4 inches (2728 mm) Length: 177.4 inches (4505 mm) Width: 68.5 inches (1740 mm) Height: 55.7 inches (1415 mm) Front Track: 58.5 inches (1486 mm) Rear Track: 59.1 inches (1501 mm) Cargo Sedan Trunk Volume: Approx. 12.4 cubic feet (350 Liters) Weights Curb Weight 325I: Approx. 3373 lbs (1530 kg) Curb Weight 325Xi: Approx. 3538 lbs (1605 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-Star (2004 model year) NHTSA Front Impact Passenger: 5-Star (2004 model year) IIHS Side Impact: Good (for models equipped with side airbags) Active Features Traction Control: Traction Control System (TCS) standard Stability Control: Dynamic Stability Control (DSC) standard Antilock Brakes: Anti-lock Braking System (ABS) standard Passive Features Airbags...
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BMW 325 325xi 2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Model Variant:
325i / 325xi
Year:
2004
Generation
Chassis Code:
E46
Generation Name:
Fourth Generation E46
Codes
Engine Code Prefix:
M54
👋 Introduction
Market Position
Vehicle Segment:
Compact Executive Sedan/Coupe/Convertible/Wagon
Brand Philosophy Alignment:
Embodies BMW's 'Ultimate Driving Machine' ethos with balanced performance and luxury.
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS.
Key Features
Drivetrain Options:
Rear-wheel drive (325i) and xDrive all-wheel drive (325xi).
Engine Type:
Naturally aspirated inline-six cylinder.
Chassis Dynamics:
Renowned for balanced weight distribution and precise handling.
📋 Manual Details
Coverage Areas
Comprehensive Scope:
Covers all major mechanical, electrical, and body systems.
Region Of Origin:
North America (primarily, but applicable to global variants with minor regional differences noted).
Page Count
Estimated Pages:
Hundreds (exact count varies based on internal pagination, but typically exceeding 1000 pages for a complete factory manual).
Manual Type
Manual Classification:
Factory Service Repair Manual (FSM)
Additional Manual Types Covered:
Includes diagnostic procedures, repair instructions, and maintenance schedules.
Language
Primary Language:
English
Format
Digital Format:
Downloadable PDF
Printability:
Printable (allows printing entire manual or specific sections).
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling.
Engine Management:
Fuel injection, ignition system, emissions control, engine control unit (ECU) diagnostics and programming.
Transmission Manual:
Manual transmission (Getrag or ZF) repair, clutch, flywheel, driveshafts.
Transmission Automatic:
Automatic transmission (GM 5L40-E) overhaul, valve body, torque converter, mechatronics.
Drivetrain:
All-wheel drive (xi) system, differential, transfer case, axle shafts, wheel bearings.
Suspension:
Front and rear suspension, control arms, shock absorbers, struts, springs, bushings, subframes.
Steering:
Power steering system, steering rack, steering column, steering wheel removal.
Brakes:
Hydraulic system, ABS, DSC (Dynamic Stability Control), brake calipers, rotors, pads, lines, parking brake.
Electrical System:
Battery, alternator, starter, wiring diagrams, fuses, relays, body control module (BCM).
Lighting:
Headlights, taillights, interior lighting, fog lights, bulb replacement, headlight aiming.
Comfort Systems:
HVAC (Heating, Ventilation, and Air Conditioning), blower motor, climate control unit, refrigerant system.
Interior Trim:
Dashboard, door panels, seats, headliner, center console removal and installation.
Exterior Body:
Body panels, bumpers, doors, hood, trunk, glass, seals, exterior trim.
Infotainment:
Radio, CD player, navigation system (if equipped), speaker replacement.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs.
Troubleshooting:
Diagnostic flowcharts, common fault identification, symptom-based troubleshooting.
Repair Procedures:
Step-by-step instructions for component replacement and repair.
Diagnostic Procedures:
OBD-II scan tool usage, reading fault codes, live data interpretation.
Installation Procedures:
Component installation and adjustment.
Technical Depth
Diagnostic Level:
Advanced diagnostics with detailed descriptions of sensor inputs, outputs, and control module logic.
Repair Complexity:
Covers everything from basic fluid changes to complete engine and transmission rebuilds.
Electrical Diagrams:
Detailed and comprehensive wiring schematics for all electrical systems.
Torque Specifications:
Precise torque values for all critical fasteners.
Special Tools:
Identification and usage instructions for specialized BMW tools.
📊 Manual Specifications
File Format
PDF Version:
Typically PDF/A or a compatible version for broad software support.
Searchable Text:
Yes, the PDF is expected to have OCR (Optical Character Recognition) for full text searchability.
Print Quality
Image Resolution:
High resolution for clear diagrams, illustrations, and photographs.
Binding Type
Digital Binding:
N/A (digital format)
Paper Type
Digital Paper Type:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M54B30
Engine Type:
Inline 6-cylinder, Naturally Aspirated
Displacement:
2979 cc (3.0 Liters)
Bore X Stroke:
84.0 mm x 89.6 mm
Compression Ratio:
10.2:1
Performance
Horsepower Peak:
225 hp @ 6000 rpm
Torque Peak:
214 lb-ft (290 Nm) @ 3500 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPFI)
Fuel Type Recommendation:
Premium Unleaded (91+ Octane)
Valvetrain
Valvetrain Configuration:
Dual Overhead Camshafts (DOHC), 4 valves per cylinder
Valve Actuation:
Double VANOS (Variable Valve Timing on intake and exhaust camshafts)
🔧 Transmission
Standard
Transmission Type 325I:
5-Speed Manual (Getrag 420G)
Optional
Transmission Type Optional:
5-Speed Automatic with Steptronic (GM 5L40-E)
Features
Automatic Features:
Driver-selectable modes, manual shifting via Steptronic.
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 (or equivalent GL-4 SAE 75W-90)
Automatic Transmission Fluid:
Dexron III (or equivalent GM spec)
Clutch
Clutch Type:
Hydraulically actuated, single dry plate.
📐 Dimensions
Exterior
Wheelbase:
107.4 inches (2728 mm)
Length:
177.4 inches (4505 mm)
Width:
68.5 inches (1740 mm)
Height:
55.7 inches (1415 mm)
Front Track:
58.5 inches (1486 mm)
Rear Track:
59.1 inches (1501 mm)
Cargo
Sedan Trunk Volume:
Approx. 12.4 cubic feet (350 Liters)
Weights
Curb Weight 325I:
Approx. 3373 lbs (1530 kg)
Curb Weight 325Xi:
Approx. 3538 lbs (1605 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star (2004 model year)
NHTSA Front Impact Passenger:
5-Star (2004 model year)
IIHS Side Impact:
Good (for models equipped with side airbags)
Active Features
Traction Control:
Traction Control System (TCS) standard
Stability Control:
Dynamic Stability Control (DSC) standard
Antilock Brakes:
Anti-lock Braking System (ABS) standard
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front side-impact airbags and front and rear head protection system (HPS) airbags.
Seatbelts:
Pretensioning front seat belts with force limiters.
💡 Technology Features
Infotainment
Audio System:
Standard BMW Business CD radio or optional BMW Professional CD/Radio. High-fidelity options available.
Navigation System:
Optional MKIV DVD-based navigation system.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Sensors:
Optional Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional Bluetooth mobile phone preparation with cradle or snap-in adapter.
Comfort Features
Climate Control:
Manual or optional Automatic Climate Control (ACC).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 15,000 miles or annually, depending on driving conditions and oil quality (as per CBS - Condition Based Service). Manual will provide specific guidance.
Brake Fluid Flush:
Recommended every 2 years, regardless of mileage.
Coolant Flush:
Recommended every 2-4 years or as indicated by the vehicle's condition monitoring system.
Spark Plug Replacement:
Approximately every 60,000 - 100,000 miles for iridium spark plugs, depending on specific plug type and service recommendations.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) approved synthetic oil, typically SAE 5W-30 or 0W-30.
Engine Oil Capacity:
6.5 US quarts (6.2 Liters) with filter change.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 formulation) or equivalent ethylene glycol-based coolant with appropriate corrosion inhibitors.
Power Steering Fluid:
BMW Power Steering Fluid (or Pentosin CHF 11S for models with Servotronic).
Brake Fluid:
DOT 4 Low Viscosity (LV)
Known Issues
Cooling System:
Plastic coolant expansion tank failure, water pump failure (plastic impeller), thermostat housing leaks.
Suspension:
Control arm bushings (FCABs) wear, rear shock mounts, subframe bushings.
Electrical:
Window regulator failure, VANOS solenoid issues, heater control valve leaks, CCFL angel eye failure (if equipped).
Engine:
Oil pan gasket leaks, valve cover gasket leaks, oil separator (CCV) system clogging leading to potential crank seal failure.
Differential:
Rear differential mount bushings wear.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW, Bayerische Motoren Werke AG, has a long-standing reputation for producing performance-oriented luxury vehicles with advanced engineering.
Model Evolution
E46 Introduction:
The E46 generation of the 3 Series was introduced in 1998 (as a 1999 model in North America) and represented a significant technological and design evolution over its E36 predecessor.
Facelift Impact:
The 2004 model year is part of the E46's LCI (Life Cycle Impulse) or facelift period, which included subtle styling revisions and updated technology.
Production
Production Period:
The E46 generation was produced from 1998 to 2006, with coupes and convertibles continuing slightly longer.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E46 3 Series (various models) was a consistent recipient of Car and Driver's 10Best awards during its production run, including for 2004 models.
Automotive Journalism Accolades:
Widely praised by automotive journalists for its driving dynamics, build quality, and refined performance.
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