BMW E46 3 Series Non-M Service Manual, 1999–2005

This Bentley Publishers BMW 3 Series (E46) service manual carries a 2006 Robert Bentley, Inc. copyright and covers 1999–2001 non-M 323i/Ci, 325i/Ci/xi, 328i/Ci, and 330i/Ci/xi in Sedan, Coupe, Convertible, and Sport Wagon body styles. Although the cover lists 1999–2005 and M3, M3/S54 and 2002–2005-specific repair coverage are not included.

Searchable Repair Text and PDF Navigation

Text access and diagram detail: Repair text and tables support text search, with 174 embedded section bookmarks. Labels contained within diagram images are not searchable. Small diagram labels benefit from zooming, but some electrical diagrams have clipped edge labels that magnification cannot restore.

The ZIP contains one printable, 1,258-page PDF: 1,225 pages of service content, one cover page, one navigation page, and a repeated 31-page OBD section.

Engine, Driveline, Chassis, and Electrical Work

The following highlights are a selection of the contents, rather than a complete contents list. Further topics include remote-key initialization and instrument-cluster self-tests.

• Engine repair: Step-by-step engine and cylinder-head removal and installation, valvetrain service, timing-chain work, double-VANOS adjustment, oil-pan removal, and oil-pump replacement.

• Fuel and ignition diagnosis: Siemens DME testing, ignition-coil and sensor checks, fuel-pump relay tests, component replacement, and ECM connector-pin assignments.

• Cooling-system service: Pressure testing, thermostat diagnosis, coolant-pump and radiator replacement, cooling-fan service, and filling and bleeding procedures.

• Transmission and driveline: Getrag and ZF manuals, GM and ZF automatics, SAC clutch service, shift linkages, torque-converter handling, driveshafts, xi transfer-case removal, and final-drive service.

• Suspension, steering, and brakes: Rear-wheel-drive and xi struts, subframes, bushings, wheel bearings, rack-and-pinion steering, alignment, brake hydraulics, parking brakes, and ABS/DSC components.

• Body and equipment: Panel, glass, window-regulator, trim, and seat service, plus central locking, convertible-top components, climate control, lighting, audio, seat belts, and airbag components.

• Diagnostic references: OBD II code tables, circuit-testing methods, fuse and ground locations, component-location views, torque tables, fluid specifications, inspection limits, and electrical test data.

The manual suits DIY owners handling maintenance and experienced repairers undertaking more involved work, with specialized tools and BMW-compatible diagnostic equipment required for the applicable procedures.

Maintenance, Cylinder-Head Work, and VANOS

General Data and Maintenance, seven numbered repair groups, and OBD references organize the material. Application tables and cross-references help match parts and procedures to the correct engine, transmission, body, and drivetrain configuration.

Maintenance chapters cover shop safety, E46 lifting and support points, service schedules, and the Service Interval Indicator, including separate reset methods before and after June 2000.

Engine applications: The tables distinguish M52 TU B25/B28 engines with Siemens MS 42.0 management from M54 B25/B30 engines with MS 43.0. Cylinder-head reconditioning specifications accompany compression, wet-compression, and leak-down diagnosis; a complete procedural short-block overhaul is outside the included coverage.

Timing tools: References include camshaft-locking fixtures 11 3 240/11 3 244, VANOS setup bracket 11 6 150, and primary-chain tensioner 11 4 220. The timing chapters explain the risk of piston-to-valve contact if the engine is turned with the VANOS unit removed.

Cooling-system troubleshooting combines visual inspection, pressure testing, stored-fault checks, and electrically heated thermostat diagnosis.

Clutch, Transmission, and xi Driveline

Application tables identify Getrag S5D 250G, ZF S5D 320Z, and xi-specific ZF S5D 280Z manuals, plus GM A5S 360R/A5S 390R and ZF A5S 325Z automatics. For 323i/Ci and 328i/Ci applications, the notes distinguish the March 2000 automatic-transmission change.

SAC clutch procedures distinguish installation with new and reused pressure plates, with tools 21 2 150, 21 2 170, and 21 2 180 referenced. Driveline coverage includes clutch hydraulics, external seals, CV joints and boots, and assembly removal; internal transmission, transfer-case, and differential rebuilding is outside scope.

The service cautions explain how mixing automatic-transmission fluids can cause transmission failure and how overtightening the rear differential input-flange collar nut beyond its match marks can damage internal components.

Chassis and Stability-Control Variants

The application data distinguishes Teves MK20 ASC and DSC on 1999–2000 cars, Teves MK60 DSC on 2001 rear-wheel-drive models, and Bosch DSC III 5.7 on 2001 all-wheel-drive models.

Bosch Hall-effect and Teves magnetoresistive rear wheel-speed sensors fit the same location but are electrically different. That distinction matters when identifying replacement sensors. BMW DIS/MoDiC equipment is specified for ABS bleeding and steering-angle sensor calibration.

Body Controls, Convertible Top, and Climate Control

Body electronics: GM V/ZKE V central locking and the EWS 3.3 immobilizer receive system descriptions and component-service information. Sunroof coverage includes initialization, panel and motor work, and height adjustment; complete assembly removal and roof-cavity repairs are outside scope.

Convertible systems: CVM II coverage explains Hall sensors, emergency operation, hydraulic components, and fault-memory access. Full convertible-top and rollover-protection diagnosis requires BMW diagnostic equipment and is outside the book’s stand-alone troubleshooting scope.

IHKA and restraints: Climate-control chapters cover controls, blower and heater components, and A/C component removal and installation. Refrigerant recovery, evacuation, charging, and full A/C diagnosis require separate equipment procedures. Airbag component removal is covered, while SRS fault diagnosis and system repair are reserved for trained BMW service technicians.

OBD Tables, Electrical References, and Coverage Limits

The OBD II section explains the MIL, drive cycles, readiness monitoring, fault storage, and catalyst, misfire, and evaporative-system monitors. BMW fault numbers are paired with SAE P-codes, fault functions, signal types and ranges, and explanatory notes.

Diagnostic-port information distinguishes earlier cars with the engine-compartment BMW connector from June 2000 production onward, when diagnostic, coding, and programming functions use the under-dash OBD II port.

Illustrated references include the 1999 E46 vehicle-bus diagram, Teves MK20/MK60 and Bosch DSC III diagrams, camshaft-timing and VANOS views, MS 42.0/MS 43.0 pin-assignment tables, IHKA air-distribution diagrams, and electrical component-location views.

Wire-color and terminal-number tables accompany voltage, resistance, continuity, and voltage-drop testing. The separate full ELE Electrical Wiring Diagrams section is not included. Some procedures also reference dedicated groups 121 Battery, Alternator, Starter; 160 Fuel Tank and Fuel Pump; and 180 Exhaust System, which are not included in this file.

Fluid references cover engine, transmission, transfer-case, final-drive, steering, brake, coolant, and A/C requirements. Related chapters provide capacities, alignment data, wear limits, adjustment specifications, and component-specific tightening torques.

Engine, transmission, subframe, brake, SRS, convertible-top hydraulic, and A/C repair can involve heavy assemblies, stored pressure, pyrotechnic restraint components, and refrigerant. Apply the manual’s lifting, support, pressure-release, battery-isolation, and system-specific safety procedures before beginning work.

Examples of Compression and Oil-Pressure Test Data

For the covered M52 TU/M54 engines, the compression-test data specifies a maximum difference between cylinders of 0.5 bar (7 psi), with the engine at normal operating temperature and cranking speed of at least 300 rpm.

The lubrication section lists minimum idle oil pressure of 0.5 bar (7 psi) and regulated pressure of 4.0 bar (59 psi) at elevated engine speed, alongside instructions for checking pressure cold and hot.