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E46 MODELS
E46 Sedan and Coupe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E46/4 Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
E46/2 Coupe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Body Shell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Hood and Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Door Anchoring System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Door Handles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sunroof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Interior Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Driver Information Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
E46 Sport Wagon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Body Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Initial Print Date: 11/00
Revision Date:11/16/00
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Summary of Contents for BMW E46/4 Sedan
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Page 1: Table Of Contents
E46/4 Sedan ........ -
Page 2: Subject Page
Subject Page Rear Seats ......... 27 Center Arm Rest . -
Page 3: E46 Sedan And Coupe
E46 Sedan and Coupe Model: E46/4: Sedan, E46/2: Coupe Production Dates: E46/4 from 6/98, E46/2 from 6/99 Objectives: After Completing this module you should be able to: • Identify the location and purpose of the Door Anchoring Hooks. • Describe the Suspension Systems used on the E46. •... -
Page 4: E46/4 Sedan
The E46 is the successor to the E36 and is the next evolution in the 3 series development. The E46/4 Sedan was introduced as a 1999 model as both the 323i and 328i. The E46 3 series vehicle offers more comfort, safety, space and equipment than the previ- ous E36, without compromising the sporty characteristics of the 3 series vehicle. - Page 5 E46/4 Dimensions E46 Models...
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Page 6: E46/2 Coupe
E46/2 Coupe The E46/2 Coupe was introduced as a 2000 model year vehicle in both 323Ci and 328Ci variants. The body of the E46 /2 Coupe is not a modified sedan, but is a completely distinct body. There are no sheet metal parts shared between the Sedan and the Coupe Only the design technology of the E46/4 was used to create the E46 Coupe. - Page 7 E46/2 Dimensions E46 Models...
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Page 8: Body
The ranges match the E39 for twisting at 29 hertz and bending at 26 hertz. The E46 continues with BMW’s safety cage concept for passenger protection. The tubular impact structures continue to provide protection against body damage during front or rear impacts. -
Page 9: Hood And Headlights
Hood and Headlights The E46 follows the E38/E39 design with the kidney grille being integrated into the hood. The grille openings are more rounded and sweep down to the front bumper. The cowl opening is now integrated in the hood and is similar to the E38. The hood can be opened to a maximum of 90°, the workshop position, by disconnecting the gas struts and insert- ing a pin in the aligned holes. -
Page 10: Doors
Doors The doors on the E46 feature the door anchoring system introduced with the E38. The anchor consists of a horizontal bar in the door and a hook at the rear edge. The hook rests in a recess in the "B" and "C" pillars and it reinforces the body in the event of a side impact. The door seal design is copied from the E39 and is a single piece seal. -
Page 11: Door Anchoring System
Door Anchoring System Cross section of driver’s door and “B” pillar in the normal closed posi- tion. Upon severe impact, the hook locks into the recessed notch to provide a unitized side impact pro- tection system. After impact, the door springs back and unhooks the notch. -
Page 12: Door Handles
Door Handles The door handles and locking system on the E46 are of a new design. The new bow type handles allow the doors to be opened easier. The locks are fully encapsulated including the electrical components. The new door handle/latch/lock assembly offers improved reliability and security against theft. -
Page 13: Sunroof
Sunroof The sunroof design is similar to the E38/E39, however, the sunroof cassette is not service- able and must be replaced as a complete unit. The sunroof is an option on the E46 and will come with a glass panel (moon roof) instead of a steel panel. E46 Models... -
Page 14: Interior Features
Interior Features The interior of the E46 has been completely redesigned with an emphasis on more space, luxury and convenience without compromising the 3 series sporty characteristics. The new instrument panel/dash is similar in design to the E39 with a slightly less pro- nounced orientation to the driver. -
Page 15: Driver Information Displays
Driver information Displays The primary display for driver information is located in the instrument cluster. The coupe and sedan have different cluster lettering and faces. The secondary display in the console con- sists of the audio system and automatic climate control panel (if equipped with IHKA). 1/min 120 140 x1000... -
Page 16: Seats
Seats The front seats are similar in design to the E36 seats with new internal construction to improve their support and comfort. Memory for the drivers seat position is available. The seat controls, including memory storage buttons are located on the side of the seat base. An optional lumbar support is also available for the E46. - Page 17 A split folding (40/60) seat is available as an option on sedans and standard on coupe models. The release for the folding seat backs is located in the trunk on the left and right sides near the wheel arches. This increases the security aspect when keeping items locked in the trunk.
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Page 18: Power Distribution
Power Distribution The battery is installed in the trunk of the E46 and features lead/calcium plate material for true maintenance free operation. The water usage of this battery is low throughout its ser- vice life. The Battery Safety Terminal is installed at the positive terminal of the battery. A repair kit is available for the BST. - Page 19 There are three locations for fuses on the E46: • The fuse holder above the glove box • The E-Box in the engine compartment • In the trunk near the battery The E46 uses high amperage fuses for circuit protection. The battery power supply is pro- tected by a 250 amp fuse in the trunk.
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Page 20: Front Suspension
Front Suspension The single ball joint, strut axle of the E46 is based on the E36 design. Design and compo- nent changes were developed to improve the ride quality and handling characteristics. The following changes are incorporated into the E46 front suspension system: •... - Page 21 Front Camber Adjustment The top of the strut is mounted through elongated holes. The strut is fixed in position when the vehicle is assembled. If minor corrections need to be made to the front end alignment, the pin can be driven down and the strut can be moved in the slots to adjust the camber. Approximately .5 of adjustment is available by moving the strut in the slots.
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Page 22: Rear Suspension
Rear Suspension The design of the E46 rear suspension is based on the E36 "C" arm type. However, all components of the suspension are new and designed to suit the E46 for: • Comfort and convenience • Handling and stability •... -
Page 23: Final Drive
Final Drive The final drive is the compact (HAG 188K) type that is lighter in weight than the type used on the E36. Features of the compact final drive assembly include: • Compact housing • Shorter pinion shaft • Hollow drive flange shafts •... -
Page 24: E46 Sport Wagon
E46 SPORT WAGON Model: E46/3 Production: 1/00 Objectives: After completing this module you should be able to: • Identify the changes to the body of the E46 for the Sport Wagon. • List the changes to the interior of the E46 Sport Wagon. •... -
Page 25: Body Specifications
BODY SPECIFICATIONS 1471 mm 1478 mm 1932 mm 1739 mm 758 mm 995mm 2725 mm 4478 mm 41E46SPTWGNSPEC0000 The E46 Sport Wagon is 7 mm longer that the sedan and the unloaded height is 6 mm lower. The wheel base, width and turning radius are the same as the E46 sedan. The fol- lowing are the maximum cargo capacity/ loads: •... -
Page 26: Body
Body From the front bumper up to the “B” pillar the E46 Sport Wagon body is identical to the sedan. From the “B” pillar rearward, the body shell of the Sport Wagon is all new and includes: • New Rear doors •... -
Page 27: Interior
Interior Up to the “B” pillar, the interior equipment and trim level corresponds to the E46 sedan. The front seat options are the same as the E46 Sedan, while the rear seating area has been newly designed to provide an attractive package that offers optimum functionality and use- able space when the seats are folded down for cargo loading. -
Page 28: Center Arm Rest
Center Arm Rest The center arm rest incorporates the non-adjustable center head rest. The center arm rest is folded down to gain access to the storage compartment and cup holders , which are integrated into the rear of the head rest. CUPHOLDER STORAGE COMPARTMENT 52E46SPTWGNCUP0500... -
Page 29: Child Seat Restraint
Child Seat Anchor There are three child seat hold down anchors positioned behind the rear seat back rest. The plastic covers must be removed to access the hold down anchors, CHILD SEAT ANCHOR E46 Models... -
Page 30: Cargo Area
Cargo area The cargo area offers 435 liters of cargo space with the rear seat back rest raised and 1345 liters with it lowered. The cargo area offers a spring loaded - roller blind and cargo net sim- ilar to the E39 Sport Wagon. 51E46SPTWGNCARGONET0000 00E46SPTWGNCARGO0500 E46 Models... - Page 31 ANTENNA AMPLIFIER Storage Compartments Storage areas on the left and right in the rear are used to house the rear window washer fluid reservoir on the right and vari- ous sound system components on the left. Load Floor/Spare The load floor is removable to access the spare tire and control module mounting SPARE TIRE OOL KIT...
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Page 32: Tailgate
Tail gate The tail gate is similar in design to the E39 Sport Wagon, including the rear glass that is hinged separately and can be opened independently from the tail gate. TAILGATE RELEASE SWITCH Rear Actuator The actuator for the tailgate release is mounted on the rear apron behind the trim panel. -
Page 33: Emergency Release
Emergency Release The tailgate does not feature a lock cylinder so an emergency release mechanism is incor- porated into the tail gate latch. It allows mechanical opening of the gate actuator in the event of an electrical failure. The release is located along the lower edge of the rear apron behind a small access cover. -
Page 34: Rear Window
Rear Window The Frameless rear window is bonded to a metal carrier which is hinged to the body. If the rear window needs replacement, it is supplied with the glass bonded to the metal carrier. The release switch for opening the rear glass is incorporates into the rear wiper arm cover under the triangle trim plate. - Page 35 Rear Glass Hinge The hinges are a new design (torsional coil spring) that are compact in shape for space saving reasons. 41460001 The rear window is adjusted through the slotted mounted bolts. The gap of the window should be uniform on all sides. The height of the rear window is adjust- ed using shims on the hinge mounts.
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Page 36: E46 Convertible
E46 Convertible Model: E46/2C Production: 01/00 Objectives: After completing this module, you should be able to: • Describe how the body shell is reinforced to improve Torsional Rigidity • Identify the floor pan reinforcements for energy absorption on the SGS seats. •... -
Page 37: Introduction
Introduction The E46 Convertible is the replacement for the E36 Convertible and is based on the E46 Coupe. It is initially being introduced in March 2000, as a 323 Model only with the M52 TU 2.5 liter engine. The 3 liter version of the E46iC will begin production starting in 6/2000. The E46 323 features a new design top that consists of a three layer top and all glass rear window. -
Page 38: Technical Data
TECHNICAL DATA E46 Models... - Page 39 TECHNICAL DATA Convertible Convertible Convertible Convertible (323i) (323i) Length (mm) 4433 4488 Outside Car Dimensions Width (mm) (with mirror) 1710 (1875) 1757 (1947) Length (mm) 4433 4488 Height (mm) 1348 1372 Width (mm) (With Mirrors) 1710 (1875) 1757 (1947) Height (mm) 1648 1672 Shoulder Room, front (mm)
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Page 40: Body Shell
Body Shell The body shell of the E46iC has been developed specifically for the convertible to improve crash performance which is similar to the E46 Coupe. This was achieved by the use of reinforcements on the body shell that improved torsional rigidity (body twisting). In the main body floor pan, reinforcements were necessary to accommodate the new SGS (Seat Integrated Belt System) seat system. -
Page 41: Rear Bulkheads
Rear Bulkheads The rear bulkheads are redesigned to support the roll- over protection and seat belts. They are welded to increase structural rigidity and to secure rear seat, rear seat belts and the mounting point for the ISO child seat. ART-E46BODY5 Variable Top Storage Compartment The variable top storage compartment is reinforced to make the top storage compartment... -
Page 42: Rear Seats
REAR SEATS The E46iC is designed as a four passenger vehicle. Only two seat belts are installed in the rear that correspond to the seat belt system of the E36iC. The E46iC is equipped with child seat mounting brackets on the left and right sides below the seat base. -
Page 43: Variable Top Storage Compartment
VARIABLE CONVERTIBLE TOP STORAGE COMPARTMENT FLOOR Purpose of the System: The trunk of the E46 convertible offers a new feature called the “Variable Convertible Top Storage Compartment Floor”. This feature allows the luggage storage area to be enlarged by approximately 40 liters when the soft top is raised or removed for hard top installation. Components of the system: Variable Compartment Floor The variable compartment floor is constructed of plastic with fabric covering. - Page 44 Actuating Lever An actuating lever is integrated in the variable com- partment floor on the right side. It allows the com- partment floor to be opened and closed using the actuating lever. It also locks the compartment floor into position. Dampening Piston A dampening piston is also integrated in the variable compartment floor on the right side.
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Page 45: E46 All-Wheel Drive
E46 ALL-WHEEL DRIVE SYSTEM Model: E46/16 (330xi/A, 325xi/A, 325xi/A Sport Wagon). Production date: 330xi 8/00, 325xi 9/00. Objectives After completing this module you should be able to: • Identify the changes made to the E46 to accommodate all-wheel drive. • Understand the construction of the NV124 transfer case. E46 Models... -
Page 46: Introduction
Introduction The E46/16 introduces the return of the BMW all-wheel drive car to the United States. This time all-wheel drive will be an option (SA 203), available on E46 sedans and Sport Wagons beginning 2001M.Y. Vehicles with the all-wheel drive option have been given the engineering designation of E46/16. - Page 47 Changes from the standard drive version are: • A specially designed body pan with a widened transmission tunnel and modifications on the driver’s side to accept the transfer case. • Modified oil pan and engine mounts to provide access for the front axles. •...
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Page 48: Front Axle
Chassis Front Axle The front axle has been completely re-designed over the standard drive E46. All components are constructed of steel. The front axle carrier consists of two square frame sections welded to two tubes to form a box structure. The axle carrier is bolted to the vehicle frame at both the front and rear attachment points. -
Page 49: Steering
The struts are shorter than the 2wd and there are reinforcement plates between the strut bearing and the sheet metal of the strut towers to prevent deformation when traveling on very poor road surfaces. The spring travel of the E46/16 is approximately 20mm less than the 2wd version. -
Page 50: Differential And Front Axles
Differential and Front Axles The differential for the front axle is bolted to left side of the engine oil pan. The differential is driven by a 40mm single piece drive shaft. The drive shaft has universal Right Side Support Housing joints at both ends. -
Page 51: Rear Axle
Rear Axle The complete rear axle and the rear differential are the same as the 2wd version of the 325i and 330i. Type: HAG 188N Axle ratios: 330xi 325xi Auto: 3,46:1 3,46:1 Man: 3,07:1 3,23:1 Max torque: 3000Nm Weight: 84 lbs Lifetime fluid fill: SAF-XO The rear spring/strut travel of the E46/16 is approximately 17mm less than the 2wd version. -
Page 52: Transmissions
Transmissions There are two transmission variants for the 325xi and 330xi. The manual transmission for both versions is the S5D-280Z direct gear transmission. The extension housing is modified to accept the transfer case. The transmission has a lifetime fill of MTF-LT1 S5D-280Z synthetic transmission fluid. -
Page 53: Transfer Case
Transfer Case The Transfer case for the E46/16 is the NV 124 manufactured by New Venture. The primary difference between the NV 124 and the NV 125 used in the X5 SAV is that it uses gears instead of a drive chain for torque transfer to the front axle. The reason gears are used is to produce a compact low profile transfer case that could fit in the transmission tunnel of an E46 with-... - Page 54 Output to Rear Axle Planetary Ring Gear From the Ring Gear , the power is transmitted via the driveshaft to the rear axle differential. Torque Transfer from the Planetary Gear Set. The transfer case is filled with a lifetime fill of MTF-LT1 P/N 83-22-9-408-942.
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Page 55: Review Questions
Review Questions 1. How is the hood of an E46 placed into the workshop position? 2. Explain the door anchoring system of the E46. 3. Describe the fuse locations of the E46. 4. Describe the changes made to the E46 front and rear suspension from the previous 3 series (E36).