Page 2: How To Use This Manual
BMW dealer or other qualified shop. The manual is divided into ten sections: 0 GENERAL DATA AND...
Page 3 MAINTENANCE covers general vehicle information (Repair Group 010) as well as the recommended maintenance schedules and service procedures to perform BMW scheduled maintenance work (Repair Group 020). The next seven sections (Repair Groups 1 through 7) are repair based and organized by three digit repair groups.
Page 4 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... the work or by increased risk of accident or mechanical failure while driving. CAUTION! A caution calls attention to important precautions to be observed during the repair work that will help prevent accidentally damaging the car or its parts.
Page 5 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... shorts, sparks, burns, or damage to the electrical system when accidentally contacting the battery or other electrical terminals. Disconnect the battery negative (–) cable whenever working on or near the fuel system or anything that is electrically powered. Accidental electrical contact may damage the electrical system or cause a fire.
Page 6 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... and any open flame away from the top of the battery. Hydrogen gas emitted by the battery is highly flammable. Any nearby source of ignition may cause the battery to explode. Never lay tools or parts in the engine compartment or on top of the battery.
Page 7: Getting Started
General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... 010-3 Getting Started Most of the necessary maintenance and minor repair that an automobile will need can be done with ordinary tools. Below is some important information on how to work safely, a discussion of what tools will be needed and how to use them.
Page 8 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... points. Watch the jack closely. Make sure it stays stable and does not shift or tilt. As the car is raised, it may roll slightly and the jack may shift. Raising car safely Park car on flat, level surface.
Page 9 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Working under car safely Disconnect negative (–) cable from battery so that no one can start car. Let others know what you will be doing. CAUTION! Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.
Page 10 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Lower car slowly until its weight is fully supported by jack stands. Watch to make sure that the jack stands do not tip or lean as the car settles on them. Observe all jacking precautions again when raising car to remove jack stands.
Page 11 010-4 Advice for the Beginner The tips in the paragraphs that follow are general advice to help any do-it-yourself BMW owner perform repairs and maintenance tasks more easily and more professionally. Planning ahead To prevent getting in too deep, know what the whole job requires before starting.
Page 12 (self-locking, nylock, etc.), cotter pins, studs, brake fittings, roll pins, clips and washers. Genuine BMW parts should be the only replacement parts used for this purpose. Some bolts are designed to stretch during assembly and are permanently altered rendering them unreliable once removed.
Page 13 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... values listed in the table are not intended to be used as a substitute for torques specifically called out in the text. Note: Metric bolt classes or grades are marked on the bolt head. Do not confuse wrench size with bolt diameter.
Page 14 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Some gaskets—such as head gaskets—are directional. Make sure that these are installed correctly. This same logic applies to any part used for sealing, including rubber O-rings and copper sealing washers. In places where a shaft must pass through a...
Page 15 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... switch is “open” when the circuit is interrupted, and “closed” when the circuit is completed. See 600 Electrical System– General for electrical troubleshooting. Wire repairs Repairs to a wiring harness require special care to make the repair permanent. The wire ends must be clean.
Page 16 Some genuine BMW parts have a limited warranty. Many independent repair shops make a point of using genuine BMW parts, even though they may at times be more expensive. They know the value of doing the job right with the right parts.
Page 17 The BMW parts organization is best equipped to deal with any BMW parts needs. Non-returnable parts Some parts cannot be returned, even for credit.
Page 18 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... of the warranty recalls are applicable to your car. The label on the driver’s door below the door latch will specify the month and year that the car was built. Vehicle Identification Number (VIN). This is a combination of letters and numbers that identify the particular car.
Page 19 These special tools are called out in the text and can be purchased through an authorized BMW dealer. As an alternative, some special tools mentioned may be purchased from the following tool manufacturers and/or distributors:...
Page 20 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... http://www.sptool.com Zelenda Machine and Tool Corp. 65-60 Austin Street, Forest Hills, NY 11374-4695 718-896-2288 http://www.zelenda.com Basic tool requirements The basic hand tools described below can be used to accomplish most of the simple maintenance and repair tasks. Screwdrivers. The common flat-blade type and the Phillips type will handle almost all screws used on BMWs.
Page 21 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Sockets. Sockets are used with a ratchet handle for speed and convenience and can be combined with extensions and universal joints (swivels) to reach fasteners more easily. The most common drive sizes are 1/4 in., 3/8 in., and 1/2 in.
Page 22 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... holding irregular objects, bending, or crimping. Some have special applications. Needlenose pliers are used for gripping small and poorly accessible objects, and are useful for wiring and other electrical work. Locking pliers such as the Vise-Grip® are useful because of their tight grip.
Page 23 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... to support the car for a long period. Always use jack stands to support a raised vehicle. Jack stands are available in several styles. The best ones are made of heavy material for strength, have a wide base for stability, and are equipped to positively lock in their raised positions.
Page 24 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... repair procedures in this manual include BMW-specified torque values in Newton-meters (Nm) and the equivalent values in foot-pounds (ft-lb). Several types of torque wrenches are available. An inexpensive beam-type (top) is adequate but must be read visually. A ratchet-type (bottom) can be preset to indicate (click) when the torque value has been reached.
Page 25 LED test light for all electrical testing. BMW special tools Many repairs covered in this manual call for the use of BMW special tools. This, however, does not automatically mean that the job is too complicated or out of reach of the do-it-yourselfer.
Page 26 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... 010-8 Emergencies Changing a tire Stop car on as flat a surface as possible, in a place where you can be easily seen by other drivers. Avoid stopping just over the crest of a hill. Turn on emergency flashers, and set out flares or emergency markers well behind car.
Page 27 CAUTION! On cars with manual transmission, push starting (or tow starting) a car is not recommended by BMW. If the engine is turning over at normal speed with the starter motor, the battery and starter are fine. If the...
Page 28 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... the rear of this manual for diagnostic code reading procedures. Jump starting Cars with discharged or dead batteries can be jump-started using the good battery from another car. When jump-starting the engine, always note the following warnings. WARNING!
Page 29: Indicator And Warning Lights
General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... other. Turn off engine of car with good battery. Turn off ignition switch of car with discharged battery. Connect one end of positive (+) cable to positive (+) post of good battery. Remove cover from the positive (+)
Page 30 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Many of the vehicle systems are self-monitored both statically and dynamically while driving. Generally, a red warning lamp that comes on during driving should be considered serious. If you cannot immediately determine the seriousness of the warning light, stop the vehicle in a safe place and turn the engine off as soon as possible.
Page 31 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... bumper. Note: A towing eye is provided in the luggage compartment tool kit. The towing eye can be screwed into the front or rear bumper. Install towing eye into threaded hole. Standard transmission: A maximum towing distance of 20...
Page 32 Spare parts kit – basic Poly-ribbed drive belt(s) Engine oil (one or two quarts) Engine coolant (1 gallon of premixed 50/50 BMW anti-freeze and water) Fuse assortment (7.5A, 10A, 15A, 20A, 30A, 50A) Radiator hoses (upper and lower) Spare parts kit –...
Page 33 General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Spare parts kit – additional contents Exterior lighting bulbs (headlight, brake light, turn signal, and taillight) Wiper blades Brake fluid (new unopened bottle, DOT 4 specification) Main relay for DME system Copyright © 2006 Robert Bentley, Inc. All rights reserved.
Page 34 General The information given in this repair group includes the routine checks and maintenance steps that are both required by BMW under the terms of the vehicle warranty protection and recommended by BMW to ensure long and reliable vehicle operation.
Page 35 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... mid-2000 models BMW introduced new service interval software which calculates service based on the amount of fuel used. When SII detects total fuel consumption that equals the preset limits (in gallons), the instrument cluster indicates that service is required.
Page 36 1999 to 6/2000 models In vehicles equipped with the DLC in the right side engine compartment, the SII may be reset using BMW service and scan tool DIS or MoDiC, or a specialty tool from another manufacturer. Plug the tool (arrow)
Page 37 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Aftermarket reset tools that can reset all models with the DLC can be purchased from one of the following suppliers: Assenmacher Specialty Tools 6440 Odell Place, Boulder, CO 80301 303-530-2424 http://www.asttool.com Baum Tools Unlimited, Inc. P.O. Box 5867, Sarasota, FL...
Page 38 Table b. Inspection II includes most of the tasks from Inspection I with additional Inspection II tasks. A complete listing of Inspection II tasks is in Table Note: For reference, the BMW Inspection I 5 of 6 2/25/2009 10:01 PM...
Page 39 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... and Inspection II requirements are approximately equivalent to the maintenance requirements that other European manufacturers specify. Inspection I is normally due at intervals with a maximum of 30,000 miles or 24 months. Inspection II is normally due at intervals with a maximum of 60,000 miles or 48 months.
Page 40 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Maintenance Tables The intervals for most tasks listed in the maintenance table below are determined by the SII. Except where noted, the maintenance items listed apply to all models and model years covered by this manual. The columns on the right side of each table give quick-reference information about the job.
Page 41 Check condition of front axle joints, steering linkage and steering shaft joints. Check overall thickness of front and rear brake pads using special BMW tool. If replacement is necessary: Examine brake disc surfaces. Clean brake pad contact points in calipers. Grease wheel...
Page 42 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Table b. Inspection I service Maintenance item Tools New parts Warm Dealer service Additional required required engine recommended repair required information centering hubs (alloy wheels only). Check thickness of parking brake linings only when replacing rear brake pads. Check operation of parking brake and adjust as necessary.
Page 43 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Table b. Inspection I service Maintenance item Tools New parts Warm Dealer service Additional required required engine recommended repair required information Check engine coolant system/heater hose connections for leaks. Check coolant level and antifreeze protection level. Add coolant as necessary.
Page 44 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Table b. Inspection I service Maintenance item Tools New parts Warm Dealer service Additional required required engine recommended repair required information system. Check aim of washer jets and adjust if necessary. Check condition and function of seat belts.
Page 45 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Table b. Inspection I service Maintenance item Tools New parts Warm Dealer service Additional required required engine recommended repair required information Check braking performance, steering, heating, air conditioner operation. Check manual transmission and clutch operation or automatic transmission operation.
Page 46 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Table c. Inspection II service Maintenance item Tools New parts Warm Dealer service Additional required required engine recommended repair required information Spark plug service Replace spark plugs every 100,000 miles. Copyright © 2006 Robert Bentley, Inc. All rights reserved.
Page 47 Fluid and lubricant capacities and specifications for E46 cars are listed in Table WARNING! The use of fluids that do not meet BMW's specifications may impair performance and reliability, and may void warranty coverage. Table d. Fluids and lubricants...
Page 48 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Table d. Fluids and lubricants Fluid Approximate Specification capacity ZF A5S Complete BMW 83 22 9 325Z refill: 407 807 9.0 liters (Exxon LT GM A5S (9.5 US qt.) 71141) 360R Oil and filter BMW 83 22 0...
Page 49 Note: 340 Brakes for more brake fluid information. Engine coolant (anti-freeze) BMW recommends coolant that is a 50/50 mixture of distilled water and phosphate/nitrate free anti-freeze containing ethylene glycol. Anti-freeze raises the boiling point and lowers the freezing point of the coolant. It also contains additives that help prevent cooling system corrosion.
Page 50 The transmission lubricant type can be found on the "type-plate" on the side of the transmission. See Automatic Transmission. Consult an authorized BMW dealer for alternate fluid use and the most-up- to-date information regarding transmission operating fluids. Transmission fluid, manual...
Page 51: Engine Oil Service
Note: Early style oil filter numbers with BMW part numbers 11 42 1 427 908 or 11 42 1 745 390 should not be used in the 1999 and later BMW models.
Page 52 If there is any doubt about what procedures apply to a specific model or model year, or what intervals should be followed, remember that an authorized BMW dealer has the latest information on factory-recommended maintenance. Engine oil, checking level Engine oil level is checked with a dipstick (arrow) in engine block.
Page 53 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... qt. capacity), are described in General. Note: If using a "fast-lube" service facility for oil changes, make sure the technician hand-starts and torques the engine oil drain plug using hand-tools. Power tools can strip the threads of the plug and the oil pan.
Page 54 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... CAUTION! Pull the loose plug away from the hole quickly to avoid being scalded by hot oil. It will run out quickly when the plug is removed. If possible, use gloves to protect your hands. When oil flow has diminished to...
Page 55 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Refill crankcase with oil. Approximate oil capacity is listed Table d. Use dipstick to check correct oil level. Start engine and check that oil pressure warning light immediately goes out. Allow engine to run for a few minutes to circulate new oil, then check for leaks at drain plug and oil filter.
Page 56 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... 020-5 Engine Compartment Maintenance The information under this heading describes routine maintenance other than oil change done in the engine compartment. It is not necessary for the car to be raised and supported off the ground. Information on oil change is given earlier in this group.
Page 57 CAUTION! Use only BMW approved phosphate-free anti-freeze when filling the cooling system. Use of anti-freeze containing phosphates is considered to be harmful to the cooling system.
Page 58 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... illustration shows examples of damage to coolant hoses. Any of conditions shown is cause for replacement. (Courtesy of Gates Rubber Company, Inc.) Engine drive belt service Drive belts and pulleys transfer power from the engine crankshaft to various accessories.
Page 59 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Similarly, turn main engine drive belt tensioner lug (B) clockwise and remove belt. WARNING! Observe care when replacing belts. Personal injury could result if a tensioner springs back into position uncontrollably. CAUTION! Mark drive belt rotation direction if removing and reusing an old belt.
Page 60 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... OBD II enhanced emission standards require the engine control module (ECM) to monitor the oxygen content in the exhaust both before and after the catalytic converter. This allows for tighter control of the tail pipe emissions and also allows the ECM to diagnose converter problems.
Page 61 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Park car on level ground with engine off. Level is correct if it is between MIN and MAX marks on dipstick. If level is below MIN mark, start engine and add fluid to reservoir to bring level up.
Page 62 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Remove plastic trim covers (arrows). Remove cover hold down bolts. Remove ignition coil grounding harnesses (arrows). Remove ignition coils: Pull up on spring clips to disconnect ignition coil harness connectors. Remove coil mounting bolts. Remove coils. Remove spark plugs.
Page 63 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Be sure to reinstall coil grounding harness. Spark plug recommendations Bosch FGR7 DQP BKR6 EQUP Tightening torque Spark plug to cylinder head 25 Nm (18 ft-lb) Ventilation microfilter, replacing Working at cowl housing inside engine compartment, twist microfilter cover retainers (arrows) 90°...
Page 64 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... 020-6 Other Mechanical Maintenance Battery, checking and cleaning The battery is located in the right side of the luggage compartment. Simple maintenance of the battery and its terminal connections will ensure maximum starting performance, especially in winter when colder temperatures reduce battery power.
Page 65 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Clean main chassis ground terminal next to battery. Corrosion can be washed away with a baking soda and water solution that will neutralize acid. Apply solution carefully, though, since it will also neutralize acid inside battery. Reconnect cable clamps, positive (+) cable first.
Page 66 Battery, replacing The original equipment BMW battery is equipped with a built-in hydrometer "magic eye" (arrow). Battery condition is determined by the color of the eye: Green: Adequate charge Black: Inadequate charge;...
Page 67 More battery and charging system information is in 121 Battery, Alternator, Starter. Brake fluid, replacing BMW strictly recommends replacing the brake fluid every two years. This will help protect against corrosion and the effects of moisture in the fluid. Note: 340 Brakes for brake fluid flushing procedures.
Page 68 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Disc brake pad wear can be checked through opening in caliper: Measure distance (A) of brake pad "ear" to brake rotor. See Brakes. Compare to specification below. Unbolt caliper from steering arm to properly inspect: Brake pad thickness (A)
Page 69 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Check that brake hoses are correctly routed to avoid chafing or kinking. Inspect unions and brake calipers for signs of fluid leaks. Inspect rigid lines for corrosion, dents, or other damage. Inspect flexible hoses for cracking. Replace faulty hoses or lines, see Brakes.
Page 70 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... up one more stop (click). Drive the car approximately 400 meters (1,300 ft.) and release the brake. To recheck the adjustment of the parking brake see Brakes. Clutch fluid, checking The hydraulic clutch and the brake system share the same reservoir and the same brake fluid.
Page 71 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... environmental conditions. If short- distance driving predominates, the moisture and condensation in the system will not fully dry out. This will lead to early corrosion damage and more frequent replacement. Scheduled maintenance of the exhaust system is limited to inspection:...
Page 72 Install and tighten oil filler plug when oil level is correct. The differential should be filled with a special BMW lubricant available through an authorized BMW dealer. Note: Use a 14 mm or 17 mm Allen socket to remove the drain plug.
Page 73 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... the driver's seat. A protective cover must be removed to access the filter. Fuel filter for M52 TU engine is shown in illustration. E46 cars with M54 engine are equipped with a fuel filter that has a built in fuel pressure regulator.
Page 74 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... is removed. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy. CAUTION! Clean thoroughly around the filter connections before removing them. Note: When installing fuel filter cover, take care to reinstall foam rubber seal in front of cover correctly to prevent flooding of filter with rain splash water.
Page 75 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Suspension, front, inspecting Inspection of the front suspension and steering includes a check of all moving parts for wear and excessive play. Inspect ball joint and tie-rod rubber seals and boots for cracks or tears that could allow the entry of dirt, water, and other contaminants.
Page 76 4 psi (0.3 bar) over their cold pressures. Tires, rotating BMW does not recommend tire rotation. Due to the car's suspension design, the front tires begin to wear first at the outer shoulder and the rear tires begin to wear first at the middle of the tread or inner shoulder.
Page 77 Note: Transmission fluid level checking and replacement procedures are covered in 230 Manual Transmission. Wheels, aligning BMW recommends checking the front and rear alignment once a year and 14 of 15 2/25/2009 10:03 PM...
Page 78 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... whenever new tires are installed. Note: 320 Steering and Wheel Alignment for a more detailed discussion of alignment requirements and specifications. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 15 of 15 2/25/2009 10:03 PM...
Page 79 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... 020-7 Body and Interior Maintenance Body and hinges, lubricating The door locks and lock cylinders can be lubricated with an oil that contains graphite. The body and door hinges, the hood latch, and the door check rods should be lubricated with SAE 30 or SAE 40 engine oil.
Page 80 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... wash product. Rinse using plenty of clear water. Wipe the body dry with a soft cloth towel or chamois to prevent water-spotting. Interior care Dirt spots can usually be removed with lukewarm soapy water or a dry foam cleaner.
Page 81 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... Seat belts Dirt and other abrasive particles will damage seat belt webbing. If it is necessary to clean seat belts, use a mild soap solution. Bleach and other strong cleaning agents may weaken the belt webbing and should be avoided.
Page 82 Clean the blades using soapy water. If cleaning the blades does not cure the problem, they should be replaced. BMW recommends replacing the wiper blades twice a year, before and after the cold season.
Page 83 Maintenance http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... alcohol or ammonia solution, or a non-abrasive cleanser to clean the windshield. Wiper blade chatter may be caused by dirty or worn blades, by a dirty windshield, or by bent or twisted wiper arms. Clean the blades and windshield as described above.
Page 84 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... OBD-2 On-Board Diagnostics (OBD II) OBD II is an acronym for On-Board Diagnostics II, the second generation of on-board self-diagnostic equipment requirements. These standards were originally mandated for California vehicles. Since 1996 they have been applied to all passenger vehicles sold in the United States.
Page 85: Malfunction Indicator Light
On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... reset using the special scan tool. Removing the connector from the ECM or disconnecting the battery will not erase the fault memory. The extra hardware needed to operate the OBD II system consists mainly of the following:...
Page 86 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... The MIL will come on under the following conditions. An engine management system fault is detected for two consecutive OBD II drive cycles. A catalyst damaging fault. A component malfunction (such as catalyst deterioration) causes emissions to exceed 1.5 times OBD II standards.
Page 87 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... Additional information, MIL: A fault code is stored within the ECM upon the first occurrence of a fault in the system being checked. Two complete consecutive drive cycles with the fault present illuminate the MIL. The exception...
Page 88 The aftermarket scan tools can be connected to either the 16-pin OBD II Data Link Connector (DLC) or the BMW 20-pin DLC in the engine compartment. Data from the OBD II DLC may be limited, depending on scan tool and vehicle.
Page 89 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... installed. Professional diagnostic scan tools available at the time of this printing include the BMW factory tools (DISplus and MoDiC) and a small number of aftermarket BMW-specific tools. The CS2000 from Baum Tools Unlimited, the Retriever from Assenmacher...
Page 90 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... required tests. The ECM must recognize the loss or impairment of the signal or component and determine if a signal or sensor is faulty based on 3 conditions: Signal or component shorted to ground Signal or component shorted to...
Page 91 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... ECM cannot determine the environment or engine operating conditions due to missing or faulty signals it will set a fault code and, depending on conditions, illuminate the MIL. Oxygen sensor monitoring: When drive conditions allow, response rate and switching time of each oxygen sensor is monitored.
Page 92 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... Specific cylinder(s) Severity of the misfire event Emissions relevant or catalyst damaging Misfire detection is an on-going monitoring process that is only disabled under certain limited conditions. Secondary air injection monitoring: Secondary air injection is used to reduce HC and CO emissions during engine warm up.
Page 93 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... set and identify the faulty bank(s). If after completing the next cold start a fault is again present, the MIL will be illuminated. Fuel system monitoring: This monitors receives high priority. It looks at the fuel delivery needed (long/short term fuel trim) for proper engine operation based on programmed data.
Page 94: Drive Cycle
On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... check system integrity. On MS 43.0 cars, a more sophisticated DMTL (Diagnostic Module - Leak Detection) pump is used. Drive cycle The OBD II drive cycle is an important concept in understanding OBD II requirements. The purpose of the drive...
Page 95 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... OBD-3 BMW Fault Codes (DTCs) Below is a comprehensive listing of BMW DTCs and the corresponding SAE P-codes. Table a. Diagnostic trouble codes (DTCs) P-code Fault type and Signal type and Explanation code function range Ignition coil cyl.2...
Page 96 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range P0101 Mass air flow Input analog Failed signal range check circuit range/perf. (0-5V) against predefined diagnostic limits. Engine coolant Input analog Signal range is checked temp. circuit...
Page 97 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range P0206 Injector circuit cyl. Output digital DME final stage will set flag pulse width (active whenever a short to ground, a low) short to battery voltage or a...
Page 98 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range P0205 Injector circuit cyl. Output digital DME final stage will set flag pulse width (active whenever a short to ground, a low) short to battery voltage or a...
Page 99 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range Multi functional Input binary Every 0.5 sec. a message that steering wheel, stream (0-12V) includes a toggle bit (toggles toggle-bit between 0->1 and 1->0) is transmitted. Change bit is monitored to indicate proper function.
Page 100 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range shunt resistor (limitation voltage) then secondary ignition voltage is detected and shunt resistor may be faulty. P0325 Knock sensor 1 Input analog Plausibility check between circuit, (Bank 1)
Page 101 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range transistor and component exists. AC compressor Output digital DME final stage will set flag relay on/off (active low) whenever a short to ground, a short to battery voltage or a...
Page 102 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range spring within motor throttle body. P1542 Pedal sensor Input analog Failed signal range check potentiometer 1 (0-5V) against predefined diagnostic limits. P1542 Pedal Sensor Input analog...
Page 103 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range P1542 Pedal sensor Input analog If there is a difference greater potentiometer (0-5V) than specified between two plausibility redundant signals from potentiometer, fault will be set.
Page 104 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range disconnection between output transistor and component exists. P1593 DISA, range/perf. Output digital DME final stage will set flag on/off (active low) whenever a short to ground, a...
Page 105 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range CAN time out (instr Input binary CAN message between stream bit data DME/EGS not received within (0-12V) expected time. CAN time out (instr Input binary CAN message between...
Page 106 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range switch is "low" for longer than predetermined time. MS 43 DMTL module fault DME internal values logical P1476 EVAP: clamped Input digital Frequency of LDP pumps...
Page 107 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range on input line. P0150 Oxygen sensor Input analog Oxygen sensor signal range pre-cat (Bank 2), (0-5V) is checked to determine if short to battery electrical shorts exist on input volt.
Page 108 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range MS 43 Throttle valve DME internal position controller values logical MS 43 Throttle valve DME internal position controller values logical MS 43 Throttle valve DME internal...
Page 109 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range P1132 Oxygen sensor Output digital DME internally calculated heater, pre-cat pulse width (active heater power is checked (Bank 1), low) against predefined diagnostic insufficient limits. P1133...
Page 110 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range signal. If more than two ignition signals are not recognized than there might be a problem in feedback line. P1510 Idle control valve DME internal Functional check against a...
Page 111 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range P0125 Insufficient coolant Input analog Comparison of actual coolant temp. to permit (0-5V) temperature against closed loop calculated DME value which operation varies with load signal.
Page 112 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range switch fault will set. P0179 Oxygen sensor Input analog (high Checks amount of time pre-cat (Bank 2), is lean) (0-5V) oxygen sensor takes to switch switch time too...
Page 113 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range for cylinder 2 is longer, fault will set. P0303 Cyl. 3 misfire DME internal Crankshaft detected values logical speed/acceleration is monitored by crank sensor. Time for each cylinder combustion is compared against avg.
Page 114 On-Board Diagnostics http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/8... P-code Fault type and Signal type and Explanation code function range P1423 Secondary air Input analog Checks to see if oxygen injection (Bank 1), (0-5V) sensor reacts to increase in flow too low unmetered airflow generated by secondary air pump operation.
Page 115 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 100-1 General This section covers system descriptions and general information on engines and engine management systems. Also covered is basic engine troubleshooting. For specific repair procedures, refer to the appropriate repair group: 110 Engine Removal and Installation 113 Cylinder Head Removal...
Page 116 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 3.0 liter) engines were introduced. This engine incorporates all the technical features of the M52 TU engines with addition of fully electronic throttle control and enhanced emission controls. Table a. Engine specifications lists engine specifications for the vehicles covered by this manual.
Page 117 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Model Engine No. of Displacement Bore/ Compression Torque Horsepower year code cylinders cc (cu. in.) stroke ratio lb-ft/rpm Hp/rpm in.) Torque/power graphs M52 TU 2.5 liter M52 TU 2.8 liter 3 of 19 2/25/2009 9:58 PM...
Page 118 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... M54 2.5 liter M54 3.0 liter 4 of 19 2/25/2009 9:58 PM...
Page 119 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Cylinder block and crankshaft The cylinder block is cast aluminum alloy (AlSi9Cu3) with cast iron cylinder liners. The cylinders are exposed on all sides to circulating coolant. The counterweighted crankshaft rotates in replaceable split-shell main bearings. Oilways drilled into the crankshaft provide bearing lubrication.
Page 120 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connecting rods and pistons The forged steel connecting rods use replaceable split-shell bearings at the crankshaft end and solid bushings at the piston pin end. The pistons are of the three-ring type with two upper compression rings and a lower one-piece oil scraper ring.
Page 121 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Each exhaust manifold assembly incorporates a catalytic converter. The converters are mounted close to the engine for faster heat up. Pre- and post-catalyst oxygen sensors are a mounted in each exhaust manifold. Cooling system The cooling system circulation is...
Page 122 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... allows the engine to be operated at higher controlled temperatures during low and part throttle. This optimizes operating temperatures in both cylinder head and block, reduces friction and thereby fuel consumption. The cooling system is designed to: Reduce operating temperatures of cylinder head.
Page 123 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... torque by changing the intake air flow configuration for varying engine speeds. This helps achieve optimum torque throughout the entire RPM range. During engine operation, a closed resonance valve gives the intake air charge the dynamic effect of long intake runners at low to mid-range RPM (up to 3750 rpm).
Page 124 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... The intake manifold includes intake turbulence ports. The 5.5 mm (0.217 in.) turbulence ports channel idle and low speed air directly from the idle speed control valved to one intake valve of each cylinder. Routing intake air to one intake valve per cylinder causes the air charge to swirl in the cylinder.
Page 125 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... converter and faster reduction in emissions. Overall improved fuel economy. 117 Camshaft Timing Chains VANOS system testing and repair information. Engine management system The Siemens engine management systems used in E46 cars combine fuel injection, ignition and other functions...
Page 126 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connector 1: Voltages and grounds Connector 2: Ancillary signals (oxygen sensors, CAN, etc.) Connector 3: Engine signals Connector 4: Vehicle signals Connector 5: Ignition signals Note: The flash EEPROM (chip) is specifically `programmed' to the vehicle. It has the capability to be programmed up to 13 times.
Page 127 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... (ECT) in cylinder head supplies coolant temperature information to the ECM. ECM outputs: Fuel injector opening duration. Intake and exhaust valve timing via the VANOS system. The radiator cooling fan and the heated coolant thermostat. Motor-driven throttle valve: MDK in MS 42.0 or EDK in MS 43.0.
Page 128 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Fuel purge valve and fuel tank leakage diagnosis pump (LDP or DM-TL). Fuel metering: The ECM meters pressurized fuel by changing the opening time (pulse width) of the fuel injectors. The exact amount of fuel injected is determined by the amount of time the injectors are open.
Page 129 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Control of cold air intake volume. For example, at air temperatures below 0°C (32°F), electronic throttle control (MDK/EDK) is also opened during idle. Smooth idle speeds regardless of load and inputs Lower rpm range Smooth transition from acceleration...
Page 130 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... If the fault causes increased air flow (actuator failed open), VANOS and knock control are deactivated. This reduces engine performance noticeably. Throttle control: The throttle valve plate is electronically operated for precise throttle operation, OBD II compliant for fault monitoring, and ASC/DSC and cruise control.
Page 131 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Ignition function: a distributorless ignition system with individual ignition coils for each cylinder is employed. The coils are mounted over the spark plugs and connect to the plugs via a short lead. The Siemens systems use multiple spark ignition to reduce emissions and extend spark plug life.
Page 132 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Siemens DME MS 43.0 18 of 19 2/25/2009 9:58 PM...
Page 134 Engine Soon' light [also known as the malfunction indicator lamp (MIL)] is illuminated, the first diagnostic test should be to hook up a BMW-compatible scan tool and check the fault memory. The powerful diagnostic capabilities of these systems have the potential to...
Page 135 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... volts for a battery with a 25% charge. Even a fully charged battery cannot deliver power unless it is properly connected to the electrical system. Check the battery terminals for corrosion or loose cable connections. If the battery does not maintain the proper voltage, the charging system may be at fault.
Page 136 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Good grounds are critical to proper DME operation. If a ground connection has no visible faults but is still suspect, measure the voltage drop across the connection. A large voltage drop indicates high resistance, indicating that the connection is corroded, dirty or damaged.
Page 137 Engine-General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... engine compartment, behind left headlight assembly (headlight assembly shown removed). Main fuel pump ground (arrow) behind right rear seat back rest. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 4 of 4 2/25/2009 9:59 PM...
Page 138 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 110-2 Engine Removal and Installation Be sure to cover all painted surfaces before beginning the removal procedure. As an aid to installation, label all components, wires and hoses before removing them. Do not reuse gaskets, O-rings or seals during reassembly.
Page 139 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove housing for interior ventilation microfilter. Remove upper cover and microfilter. Open wiring harness loom cover (A) and remove wires. Unfasten screws (B) and remove lower microfilter housing. Remove intake manifold cover: Remove plastic trim covers (arrows).
Page 140 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... If oxygen sensor harness connectors are separated, be sure to mark them so that they can be reassembled as before. Working at left rear of engine compartment: Peel rubber edge seal off top of panel.
Page 141 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Lift off connector loom and lay aside. Remove complete air filter housing: Detach vacuum line at intake boot (A). Disconnect electrical harness connector on mass air flow sensor (B). Release mass air flow sensor clips (C).
Page 142 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 8 - Hose clamp 28 - 33 mm 9 - Hose clamp 77 - 84 mm Where applicable: Pull throttle cable upwards out of rubber retainer (A) and unhook ball end of cable (B) from throttle actuator.
Page 143 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Detach electrical harness connector at fuel tank venting valve (A). Disconnect hose at quick disconnect fitting (arrow). Remove dipstick guide tube: Detach wiring harness brackets from tube (A). Detach fuel lines from tube (B). Remove lower guide tube mounting bolt (C).
Page 144 Detach fuel hose(s) from fuel line(s) (arrows) using special fuel line removal tool 16 1 050 or equivalent. Seal off fuel line(s) with BMW special 7 of 16 2/25/2009 9:36 PM...
Page 145 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... tools 13 5 281/13 5 282. CAUTION! Fuel may be expelled under pressure. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy. Before disconnecting fuel hoses, wrap a cloth around fuel hoses to absorb any leaking fuel.
Page 146 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Lift up manifold just enough to detach positive cables from starter motor terminal 50 (arrow). Remove intake manifold from cylinder head while carefully checking for electrical connections or hoses. CAUTION! Stuff clean rags into open intake ports to prevent any parts from falling into the engine intake.
Page 147 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Engine assembly, removing and installing Note: The intake manifold must be removed as described earlier to facilitate engine assembly removal. Remove cylinder head top cover: Remove plastic trim covers (arrows). Remove cover hold down bolts and lift off cover.
Page 148 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... humans and pets. Pets are attracted to coolant because of its sweet smell and taste. Consult a veterinarian immediately if coolant is ingested by an animal. Note: Catch and dispose of drained coolant according to local, state, and federal laws.
Page 149 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Detach coolant hose at front left side of engine by engine mount by releasing lock (arrow). Unbolt power steering fluid reservoir and pull aside without detaching hoses. Tie to fender with cord or stiff wire.
Page 150 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove power steering pump: Remove steering pump pulley. Remove front and rear pump mounting bolts (arrows). Hang pump from body using stiff wire. Remove A/C compressor mounting bolts (arrows) and A/C compressor from its mounting bracket without disconnecting, distorting, or deforming any refrigerant lines.
Page 151 (A) on right side of engine. Remove chassis ground strap (arrow) at right engine mounting pedestal. Install an engine lifting device (BMW 11 0 000 or equivalent) to the front and rear engine supports and raise engine until its weight is supported. Detach left and right engine mounts.
Page 152 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... When reinstalling, make sure locating pin on left engine mount (arrow) seats correctly in slot of subframe boss. Installation is reverse of removal, noting the following: Replace all gaskets, O-rings and seals. Change engine oil and filter and check all other fluid levels.
Page 153 Engine Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torques Coolant drain plug to cylinder block 25 Nm (18 ft-lb) Engine mount to subframe 45 Nm (33 ft-lb) Exhaust manifold to cylinder head 10 Nm (8 ft-lb) M7 or M8 20 Nm (15 ft-lb)
Page 154 See Diagnostic Testing later in this group. Special tools Special BMW service tools are required to properly remove and install the cylinder head on engines covered by this manual. The special tools are used to time the valvetrain to the crankshaft,...
Page 155 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Torque wrench w/ flex extension BMW special tool 00 9 250 E-12 Torx socket BMW special tool 11 2 250 Crankshaft locking tool BMW special tool 11 2 300 Camshaft locking tool BMW special...
Page 156 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Camshaft bearing cap removal tool BMW special tool 11 3 260 /11 3 270 Timing chain tensioner tool BMW special tool 11 4 220 VANOS adjustment plate BMW special tool 11 6 150 Secondary sprocket setup tool BMW...
Page 157 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Secondary chain tensioner lock pin BMW special tool 11 3 292 Copyright © 2006 Robert Bentley, Inc. All rights reserved. 4 of 4 2/25/2009 9:48 PM...
Page 158: Cylinder Head Removal
Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 113-2 Cylinder Head Removal WARNING! Due to risk of personal injury, be sure the engine is cold before beginning the removal procedure. Cylinder head removal and installation is a complicated repair procedure. VANOS control unit, timing chain, and camshaft removal and installation all require special tools.
Page 159 Disconnecting the battery may erase fault code(s) stored in control module memory. Check for fault codes using special BMW diagnostic equipment. Remove microfilter for interior ventilation. Remove housing for interior ventilation microfilter. Open wiring harness loom cover (A) and remove wires.
Page 160 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove cover hold down bolts from intake cover and lift off cover. Working above engine, disconnect the following: A Positive engine lead at B+ terminal B Manifold vacuum line C Oxygen sensor connectors (label connectors before...
Page 161 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Disconnect engine vent hose from cylinder head cover by squeezing sides of spring clip (arrows). Disconnect VANOS solenoid electrical harness connector (A). Disconnect fuel injector electrical connectors from injectors: Use small screwdriver to pry one corner of wire lock clip on fuel injector 1 connector.
Page 162 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... pulling it forward away from mass air flow sensor. Note: In this step, mass air flow sensor remains attached to rubber air duct. Loosen clamps 2 and 8 and remove mass air flow sensor and air duct.
Page 163 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Working at throttle housing: Turn harness plug (arrow) counterclockwise and remove. Disconnect electrical harness connector at idle speed control valve (arrow) directly above throttle housing. Working under front corner of intake manifold, disconnect electrical harness connector at fuel tank venting valve (A).
Page 164 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove dipstick guide tube: Disconnect wiring harness brackets from tube (A). Disconnect fuel lines from retaining clips (B). Remove lower dip stick guide tube mounting bolt (C). Pull out guide tube. Remove schræder valve cap (arrow).
Page 165 Disconnect fuel hose(s) from fuel line(s) (arrows) using special fuel line removal tool 16 1 050 or equivalent. Plug open fuel line(s) with BMW special tools 13 5 281/13 5 282. Working underneath car, remove lower intake manifold support mounting bolt (arrow), located adjacent to left (driver's side) engine mount.
Page 166 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Separate fuel line support bracket at rear of intake manifold. Thread fuel line(s) out of rear of engine compartment while lifting fuel rail out. Remove intake manifold mounting nuts (arrows). Lift up manifold enough to disconnect positive cables from starter motor terminal (arrow).
Page 167 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 2 of engine block (arrow). Drain radiator into a 3-gallon pail by removing plastic drain plug at lower left end of radiator (arrow). WARNING! Use caution when draining and disposing of engine coolant. Coolant is poisonous and lethal to humans and pets.
Page 168 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove bolt on top of reservoir. Lift tank and disconnect electrical connections to pump and to washer fluid level sensor. Disconnect hoses to windshield washer and headlight washer. Tilt reservoir to prevent fluid from leaking out.
Page 169 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove ignition coils. Disconnect ignition coil harness connectors. Remove coil mounting fasteners. Remove coils. Remove ground straps. Set coil harness to left side of engine compartment. Remove cylinder head cover mounting fasteners and remove cylinder head cover.
Page 170 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Double VANOS components (M52 TU, M54 engine) - Impulse wheel mounting nut - Exhaust camshaft impulse wheel - Spring plate - Thrust spacer (T = 3.5 mm) - Splined shaft - Torx screw - Exhaust...
Page 171 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 14 - Sprocket mounting nut 15 - Spring plate 16 - Splined shaft 17 - Intake camshaft sprocket 18 - Locating stud 19 - Thrust spacer 20 - Intake camshaft impulse wheel 21 - Chain tensioner...
Page 172 Remove banjo bolt from VANOS unit oil pressure line. Use banjo bolt to attach BMW special tool 11 3 450 (compressed air fitting) to VANOS control unit. Cover oil hole (arrow) in VANOS unit with shop towel to capture oil which will spray when compressed air is applied.
Page 173 Unscrew and remove two cylinder head cover studs (arrows) at rear of cylinder head. Secure camshafts in TDC position using BMW special tools 11 3 240 and 11 3 244. Disconnect compressed air line, leaving compressed air fitting attached to VANOS unit.
Page 174 Have a container and rags ready. Do not allow oil to run onto drive belts. Pull sealing caps straight out of VANOS unit with BMW special tool 11 6 170, or with short nose pliers. Note: Additional oil may drain from VANOS unit.
Page 175 (arrow). CAUTION! Primary camshaft chain tensioning piston is under spring pressure. Press down on secondary chain tensioner and lock into place using BMW special tool 11 3 292 or a similar size pin. 18 of 25 2/25/2009 9:39 PM...
Page 176 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove exhaust camshaft impulse wheel mounting nuts (arrows). Remove impulse wheel (A). Remove spring plate (A). Remove intake camshaft sprocket mounting nuts (arrows) and remove spring plate (labelled FRONT). Remove torx screws from exhaust camshaft sprocket (arrows).
Page 177 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Lift off exhaust and intake sprockets together with secondary chain, thrust spacer (A) from exhaust camshaft, and splined shaft (B) from intake camshaft. CAUTION! Splined shafts share the same part number for both intake and exhaust camshafts.
Page 178 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove primary chain sprocket mounting studs (arrows) on exhaust camshaft. Lift primary chain sprocket off exhaust camshaft. Remove sprocket from chain. Place timing chain on end of exhaust camshaft. Remove locating studs (arrows) from intake camshaft.
Page 179 CAUTION! To prevent damaging valves while working on camshafts, no pistons should be in the TDC position. Remove BMW special tools 11 3 240 and 11 3 244 from rear of cylinder head. Remove retaining nuts (arrows) and bearing cap 1 of intake camshaft.
Page 180 To avoid camshaft damage, it must be removed before any other caps. Fit BMW special tools 11 3 260 (A) and 11 3 270 (B) to cylinder head and screw long bolts (arrows) into spark plug threads.
Page 181 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Hydraulic lifters should be stored in an upright position. Used hydraulic lifters must be replaced into original lifter bores. Cylinder head assembly, removing Remove exhaust manifolds. See 180 Exhaust System. Remove intake camshaft position sensor (arrow) from side of cylinder head.
Page 182 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Using BMW special tool 11 2 250 or equivalent, loosen cylinder head bolts in several stages in sequence shown. Discard head bolts. Note: BMW special tool 11 2 250 is a thin-walled Torx E12 socket with an extended reach.
Page 183: Cylinder Head Installation
If the cylinder head has been machined, a special 0.3 mm (0.011 in.) thicker gasket should be installed. The thicker gasket is available from an authorized BMW dealer. Cylinder head and valve specifications are covered in 116 Cylinder Head and Valvetrain.
Page 184 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... operations. Please be advised that these individual jobs must be accomplished in the order in which they appear. Cylinder head assembly, installing Camshafts and valvetrain, installing VANOS control unit, installing Cylinder head cover, manifolds,...
Page 185 (1-14). CAUTION! The bolts should be tightened in three stages as listed below. The final stages require the use of a BMW special tool 11 2 110 or a suitable protractor to tighten the bolts to a specified torque angle.
Page 186 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torques Stage 2 +90° Stage 3 +90° Install intake camshaft position sensor (arrow). Install exhaust manifolds. See 180 Exhaust System. Install lower secondary chain guide. Tighten Torx bolts (arrows) to specifications. The bolt on the intake camshaft side is long and extends into the engine block.
Page 187 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... A minimum waiting time is required for the hydraulic lifters to "bleed down" after installing the camshafts into the cylinder head, but before synchronizing the crankshaft and valve train timing. When the camshafts are removed, the hydraulic lifters can expand.
Page 188 TDC. Place bearing caps on cams, but do not install retaining nuts. Fit BMW special tools 11 3 260 (A) and 11 3 270 (B) to cylinder head over intake camshaft and screw long bolts (arrows) into spark plug threads.
Page 189 11 minutes 32 - 50°F (0 - 10°C) 30 minutes Secure camshafts in TDC position using BMW special tools 11 3 240 and 11 3 244. If necessary, turn camshaft so that special tools are squarely seated on cylinder head.
Page 190 1 TDC position (0|T on front pulley lined up with pointer on lower timing chain cover). Secure crankshaft in TDC position with BMW special tool 11 2 300 (arrow). Slide impulse wheel on intake camshaft, aligning boss with raised portion on camshaft (arrow).
Page 191 Note: BMW special tool 11 4 220 is a dummy primary chain tensioner and simulates the function of the tensioner. Recheck that arrow on top primary sprocket is aligned with upper edge of cylinder head.
Page 192 20 Nm (15 ft-lb) Install secondary chain tensioner on cylinder head (arrows). Keep tensioner compressed using BMW special tool 11 3 292 or suitable pin. Fit exhaust camshaft splined sleeve. Confirm that gap in sleeve splines aligns with corresponding gap in camshaft splines (arrows).
Page 193 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Place intake and exhaust sprockets in BMW special tool 11 6 180. Position spline gap on intake sprocket (arrow) as shown and place secondary chain on sprockets. Remove chain and sprockets from tool and slide sprockets on camshafts.
Page 194 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... assembly. Initially tighten to approx. 5 Nm (44 in-lb) and then back off by half a turn. Fit thrust spacer (A) on exhaust camshaft. Install spring plate (A) to exhaust camshaft. Make sure that F mark is visible.
Page 195 Preload exhaust camshaft spring plate by pressing on impulse wheel while tightening mounting nuts (arrows) finger tight. Install BMW special tool 11 6 150 (VANOS setup bracket) to front of cylinder head timing case. Install nuts (arrows) finger tight, then tighten down uniformly until special tool is in full contact with cylinder head.
Page 196 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Make sure all gasket material is removed from face of cylinder head. Clean sealing face and keep free of oil. If any foreign material is present on the sealing surface, the camshaft timing will be incorrect.
Page 197 Secure crankshaft in TDC position with BMW special tool 11 2 300. Place BMW special tool 11 3 240 over camshafts and measure clearances. Note: If the exhaust side of the tool (A) is not flush with the head, camshaft timing is incorrect.
Page 198 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... removed from face of cylinder head. Clean sealing face and keep free of oil. If any foreign material is present on the sealing surface, the camshaft timing will be incorrect. Check locating dowel (A) and...
Page 199 Hydraulic piston to splined shaft M6 set screw 10 Nm (89 in-lb) Replace sealing caps inside VANOS unit with BMW special tool 11 6 170, or short flat nosed pliers. Insert and secure VANOS sealing plugs (arrows) with new sealing O-rings.
Page 200 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torque Oil line to VANOS unit (banjo bolt) 32 Nm (24 ft-lb) Remove BMW special tool 11 4 220 and reinstall chain tensioner cylinder. Tightening torque Primary chain tensioner cylinder to cylinder head...
Page 201 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torque Cylinder head cover to cylinder head (M6) 10 Nm (89 in-lb) Install exhaust manifolds using new gaskets and nuts. Coat manifold studs with copper paste prior to installing nuts. Tightening torque Exhaust manifold...
Page 202 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Carefully check intake manifold gasket and replace if necessary. Inspect O-ring seal between mass air flow sensor and air filter housing. To facilitate reassembly, coat seal with acid-free grease. CAUTION! When reattaching throttle assembly...
Page 203 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Reconnect battery. CAUTION! To prevent damaging engine electronic systems, install all ground wires previously removed, including the ground wires for the ignition coils. Tightening torques Coolant drain plug to cylinder block 25 Nm (18 ft-lb)
Page 204 ECM and may illuminate the engine service light. The light can only be turned out using either BMW special service scan tools or an equivalent aftermarket scan tool. Disconnecting the battery will not erase the fault memory nor turn out the light.
Page 205 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Failure to remove the DME main relay or attempting to disable the ignition system by other methods may result in damage to the engine control module (ECM). Remove housing for interior ventilation microfilter. Remove upper cover and microfilter.
Page 206 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... removed. Install compression gauge in first cylinder's spark plug hole, tight enough to form a good seal. With parking brake set, transmission in PARK or NEUTRAL, and accelerator pedal pressed to floor, crank engine with starter.
Page 207 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Low compression indicates a poorly sealed combustion chamber. Relatively even pressures that are below specification normally indicate worn piston rings and/or cylinder walls. Erratic values tend to indicate valve leakage. Dramatic differences between cylinders are often the sign of a failed head gasket, burned valve, or broken piston ring.
Page 208 Cylinder Head Removal and Installation http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Repeat compression test, this time with about a teaspoon of oil squirted into each cylinder. (The oil will temporarily help seal between piston rings and cylinder wall, practically eliminating leakage past rings for a short time.)
Page 209 For engine application information, see 100 Engine– General. Special tools BMW special tools are required for most cylinder head service described in this repair group. Many of these tools are expensive and only available through an authorized BMW dealer. If...
Page 210 Cylinder head jig BMW 00 1 490 Valve seat grinder BMW 00 3 520 Valve guide reamer BMW 00 4 210 Valve stem seal driver BMW 11 1 200 Valve stem seal puller BMW special tool 11 1 480 2 of 3...
Page 211 Cylinder Head and Valvetrain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Valve stem seal guide BMW special tool 11 1 960 Copyright © 2006 Robert Bentley, Inc. All rights reserved. 3 of 3 2/25/2009 9:47 PM...
Page 212: Cylinder Head
If a cracked cylinder head is suspected and no cracks are detected through the visual inspection, have the head further tested for cracks by an authorized BMW dealer or an ASE certified machinist. A cracked cylinder head must be replaced. Note:...
Page 213 Cylinder Head and Valvetrain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... given in Table Table a. Cylinder head height Minimum height (dimension A) 140.0 mm (5.512 139.7 mm (5.500 Valves, leak test To test the valves for leakage, the cylinder head must be disassembled with camshafts and camshaft carriers removed.
Page 214 Hydraulic lifters, checking and replacing Modern BMW 6 cylinder engines use self-adjusting hydraulic lifters to keep the valve clearances within a limited working range. (A) section view of camshaft , (B) hydraulic lifters are...
Page 215 Cylinder Head and Valvetrain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Open wiring harness loom (A), remove harness and lay aside. Unfasten screws (B) and take off lower microfilter housing. Remove engine cover. Detach positive and ground connections from intake manifold and cylinder head cover, as necessary.
Page 216 Cylinder Head and Valvetrain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Use a plastic or wooden stick to press down on top of lifter. If there is any noticeable clearance, the lifter is faulty and should be replaced. Note: When checking a hydraulic lifter, make sure the corresponding camshaft lobe is facing up so that there is no valve spring pressure on the follower.
Page 217 CAUTION! Do not let the hydraulic lifters fall out as the camshaft carrier is removed. Special suction cups are available from BMW to hold the hydraulic lifters in place during carrier removal. Hydraulic cam lifters should be stored in an upright position. If necessary, use a magnetic tool to aid in removal of the lifters.
Page 218 Cylinder Head and Valvetrain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... the valves using a wire brush or wire wheel. Table c. Valve specifications Specification M 52TU 2.5/2.8 engines (1999 - 2000) M 54 2.5/3.0 engines (2000 - 2001) Valve head dia. Intake 33.0 mm (1.299 in.)
Page 219: Valve Guides
Exhaust -0.040 -0.0016 (0.2441 in.) Valve guides BMW does not supply valve guides as replacement parts. If a valve guide is excessively worn, it should be reamed to accept oversized valve stems. Valve guide specifications are listed in Table Valve guides should be checked for wear using a new valve.
Page 220: Valve Stem Oil Seals
Cylinder Head and Valvetrain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... valve guides when replacing the guides. BMW supplies oversize valves. See Table d for additional information. Table d.Valve guide specifications Specifications M52TU / M54 engine(1999 - 2001) Valve guide wear, maximum (valve tilt clearance measured with 0.5 mm (0.020...
Page 221 Valves, removing and installing. Note: BMW special tools are available to remove the valve stem oil seals. As an alternative, standard valve seal removal tools are available from most automotive parts stores. Lubricate new seal and install using hand pressure only.
Page 222 Any spring that is significantly shorter than the others is worn and should be replaced. Note: Valve spring specifications and wear limits are not available from BMW. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 6 of 6 2/25/2009 9:48 PM...
Page 223 In addition, VANOS system diagnosis can only be carried out by using BMW specific electronic scan tools, such as BMW DIS or MoDiC or equivalent. CAUTION! The VANOS system must be removed and installed exactly as described later in this repair group.
Page 224 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Crankshaft hub locking tools BMW 11 2 150 /11 2 410 Crankshaft locking tool BMW 11 2 300 Seal extractor tool BMW 11 2 380 Camshaft locking tools BMW 11 3 240/11 3 244 Installer bush BMW 11 3 280...
Page 225 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Secondary chain tensioner locking pin BMW 11 3 292 Air line fitting BMW 11 3 450 Primary chain tensioner tool BMW 11 4 VANOS setup bracket BMW 11 6 150 Secondary sprocket tool BMW 11 6 180...
Page 226 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Puller for crankshaft hub BMW 11 8 Copyright © 2006 Robert Bentley, Inc. All rights reserved. 4 of 4 2/25/2009 9:50 PM...
Page 227: Crankshaft Front Oil Seal
Cars built from January 2000 use an integral vibration damper and hub assembly. If the early vibration damper needs to be replaced, only the single piece with integral hub is available from BMW. Disconnect negative (-) cable from battery. CAUTION! Disconnecting the battery may erase fault code(s) stored in control module memory.
Page 228 From 01/2000 production: use special tools 11 8 190 and 11 8 200. CAUTION! Do not use BMW special tool 11 2 300 to hold crankshaft stationary to loosen or tighten crankshaft hub center bolt. Use only the special tools specified, or equivalent hub holding tool.
Page 229 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... hub from crankshaft. Place special tool 11 2 383 on end of crankshaft to cover threaded hole, and fit special tool 11 2 385, aligning groove in 11 2 385 with keyway on crankshaft (arrow). Put special tool 11 2 380 over tools installed on crankshaft, and screw in until it makes firm contact with the seal.
Page 230 Tightening torque hub to crankshaft ft-lb) CAUTION! Do not use BMW special tool 11 2 300 to hold crankshaft stationary to loosen or tighten crankshaft hub center bolt. Use only the special tools specified, or equivalent hub holding tool.
Page 231 VANOS unit and disassembly of the intake and exhaust camshaft sprocket assemblies as described later in this repair group. Special BMW service tools are needed for timing chain removal and installation procedures. The special tools assure proper timing of the valvetrain.
Page 232 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... viii. Remove microfilter for interior ventilation. Remove microfilter housing: Open wiring harness loom (A), remove harness and lay aside. Unfasten screws (B) and take off lower microfilter housing. Remove complete air filter housing: Release mass air flow sensor clips (A).
Page 233 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove engine covers: Remove plastic trim covers (arrows). Remove cover hold down bolts. Drain engine coolant and remove coolant hoses. Remove expansion tank cap on radiator. Place a 3-gallon pail beneath engine to capture coolant. Remove engine block drain plug on exhaust side near cylinder 2 (arrow).
Page 234 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove radiator cooling fan shroud and viscous clutch cooling fan (cars with automatic transmission) or electric cooling fan (cars with manual transmission). See 170 Radiator and Cooling System CAUTION! On cars with viscous clutch, 32 mm cooling fan mounting nut has left hand threads.
Page 235 Loosen but do not remove crankshaft hub center bolt. CAUTION! Do not use BMW special tool 11 2 300 (flywheel locking tool) to hold crankshaft stationary to loosen or tighten crankshaft hub center bolt. Use only the special tools specified, or equivalent hub holding tool.
Page 236 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... fitting (arrows). Disconnect electrical connection at intake camshaft position sensor (A). Remove ignition coils and spark plugs: Pull up on retaining clips to disconnect ignition coil harness connectors. Remove grounding straps at coil mounting studs. Remove all ignition coils.
Page 237 VANOS control valve (arrows). Remove banjo bolt from VANOS control unit oil pressure line. Use banjo bolt to attach BMW special tool 11 3 450 (compressed air fitting) (arrow) to VANOS unit. Cover oil hole in VANOS unit (arrow)
Page 238 300 (arrow). Unscrew and remove threaded studs (arrows) at rear of cylinder head. Secure camshafts in TDC position using BMW special tools 11 3 240 and 11 3 244. Detach compressed air line, leaving compressed air fitting attached to VANOS unit.
Page 239 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Have a container and rags ready. Pull sealing caps straight out of VANOS unit with BMW special tool 11 6 170, or with short nose pliers. Note: Additional oil may drain from VANOS unit. Remove set screws (left hand thread) on ends of intake and exhaust camshafts.
Page 240 Primary camshaft chain tensioning piston is under spring pressure. Press down on secondary chain tensioner and lock into place using BMW special tool 11 3 292 or a similar size rod. Remove exhaust camshaft impulse wheel mounting nuts (arrows). Remove impulse wheel (A).
Page 241 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove spring plate (A). Remove intake camshaft sprocket mounting nuts (arrows) and remove spring plate (labelled FRONT). Remove torx screws from exhaust camshaft sprocket (arrows). Lift off exhaust and intake sprockets together with secondary chain, thrust spacer (A) and splined shaft (B).
Page 242 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... splined shafts in order to reinstall in original locations. Remove exhaust camshaft splined sleeve (A) and shaft (B). Remove secondary chain tensioner mounting bolts (arrows). Remove tensioner while keeping locking pin in place. Remove primary chain sprocket mounting studs (arrows) on exhaust camshaft.
Page 243 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Set timing chain on exhaust camshaft end. Working in cylinder head cavity, remove timing chain cover bolts (arrows). Remove secondary chain lower guide bolts (arrows). Remove chain guide. Note: Bolt on intake camshaft side is long and extends into timing chain cover.
Page 244 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... to rotate when the timing chains are loosened or removed. The pistons can contact the valves. Using a drift of less than 5 mm diameter, drive two locating dowels (A) in left and right sides of lower timing chain cover toward rear of car.
Page 245 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... - Primary chain tensioner - Torx screw - Exhaust secondary sprocket - Splined shaft - Secondary timing chain 10 - Splined sleeve 11 - Primary sprocket 12 - Threaded stud 13 - Secondary chain tensioner 14 - Sprocket...
Page 246 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 23 - Threaded stud 24 - Primary chain 25 - Threaded stud 26 - Guide rail 27 - Threaded stud 28 - Woodruff key Copyright © 2006 Robert Bentley, Inc. All rights reserved. 16 of 16...
Page 247 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 117-4 Camshaft timing chains, Installing CAUTION! The procedure outlined below assumes that the camshafts and the crankshaft are locked in the TDC installation position with special locking tools as shown earlier. Inspect timing chain sprockets. Inspect guide rail and tensioner rail for deep grooves caused by chain contact.
Page 248 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... upper end from exhaust camshaft. If necessary, replace crankshaft seal as described earlier. To install lower timing case cover: Clean cover and cylinder block sealing surfaces. Use new gaskets and coolant pipe O-ring. Drive timing cover dowels in until they just protrude slightly from sealing surface.
Page 249 Cars built from January 2000 use an integral vibration damper and hub assembly. If the early vibration damper needs to be replaced, only the single piece with integral hub is available from BMW. Tightening torque Vibration damper to crankshaft hub (M8)
Page 250 Note: BMW special tool 11 4 220 is a dummy primary chain tensioner and simulates the function of the tensioner. Make sure arrow on top primary sprocket is still lined up with upper edge of cylinder head.
Page 251 3 small slots in splined sleeve are centered on 3 threaded holes in sprocket. Place intake and exhaust sprockets in BMW special tool 11 6 180. Position spline gap on intake sprocket (arrow) as shown and place secondary chain on sprockets.
Page 252 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Install intake camshaft spring plate so that FRONT mark is visible. Install mounting nuts (arrows) finger tight. Working at exhaust side, insert sprocket mounting Torx screws into threaded holes (arrows). Initially tighten screws to approx. 5 Nm (44 in-lb).
Page 253 Pull out exhaust splined shaft until it stops. Press down on secondary chain tensioner and remove tensioner lock-down tool. Preload primary chain: Tighten adjusting screw on BMW special tool 11 4 220 to specified torque. 7 of 11 2/25/2009 9:51 PM...
Page 254 Preload exhaust camshaft spring plate by pressing on impulse wheel while tightening mounting nuts (arrows) finger tight. Install BMW special tool 11 6 150 (VANOS setup bracket) to front of cylinder head timing case. Tighten tool mounting nuts (arrows) by hand, and then...
Page 255 (arrows) face each other. Secure crankshaft in TDC position with BMW special tool 11 2 300. Place BMW special tool 11 3 240 over camshaft ends and measure clearance of tool to cylinder head surface. Note:...
Page 256 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... this repair group. Due to flexible sprocket design, VANOS unit tolerances, and play in the VANOS splines, when the camshaft timing is set correctly, the intake side of special tool 11 3 240 may be up to 1 mm (0.04 in) above the surface of the cylinder head (gap B).This is normal.
Page 257 11 2 150/11 2 410 (to 1/2000) or 11 8 190/11 8 200 (from 1/2000). CAUTION! Do not use BMW special tool 11 2 300 (flywheel locking tool) to hold crankshaft stationary to loosen or tighten crankshaft hub center bolt.
Page 258 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 117-5 Vanos The main components of the double VANOS system are: Intake and exhaust camshafts with helical spline inserts Camshaft sprockets with adjustable gears VANOS actuators (two position piston housing with internal/external helical spline cup) Three-way solenoid switching...
Page 259 (ECM) detects camshaft position before the engine starts, thereby adjusting camshaft timing immediately upon start-up Note: BMW does not provide diagnostic information or specifications for the Double VANOS system. VANOS system troubleshooting and diagnostics is best accomplished using a scan tool.
Page 260 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Table a. VANOS fault codes P-code Fault code description P1529 VANOS solenoid valve activation, exhaust P1525 VANOS solenoid valve activation, intake P1519 VANOS faulty reference value intake P1520 VANOS faulty reference value exhaust P1522 VANOS stuck...
Page 261 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... VANOS control unit - Bolt M6 - Exhaust camshaft position sensor - Sealing ring - Camshaft end sealing plug tighten to 50 Nm (37 ft-lb) - Camshaft seal - VANOS hydraulic piston set screw CAUTION: left hand...
Page 262 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... - Stud M7 10 - Nut M6 tighten to 10 Nm (89 in-lb) 11 - Gasket 12 - Cylinder head 13 - Sealing ring 14 - Intake camshaft sensor 15 - Bolt M6 16 - VANOS control...
Page 263 Camshaft Timing Chains, Removing. Remove banjo bolt from VANOS unit oil pressure line. Use banjo bolt to attach BMW special tool 11 3 450 (compressed air fitting) to VANOS unit. CAUTION! Oil will drain from pressure line. Have a container and rags ready.
Page 264 BMW special tool 11 2 300 (arrow). Unscrew and remove cylinder head cover studs at rear of cylinder head. Secure camshafts in TDC position using BMW special tools 11 3 240 ans 11 3 244. Detach compressed air line, leaving compressed air fitting attached to VANOS unit.
Page 265 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove sealing caps from inside VANOS unit with BMW special tool 11 6 170, or with short flat nose pliers. Note: Additional oil may drain from VANOS unit. Remove set screws (left hand thread) on ends of intake and exhaust camshaft hydraulic pistons.
Page 266 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Do not crank or turn over engine with VANOS unit removed. Piston/valve interference is possible. VANOS control unit, installing Clean contact edges of cylinder head face and VANOS unit and apply a thin coat of sealing compound (3-Bond®1209 or equivalent) to surfaces.
Page 267 M6 set screw 10 Nm (89 in-lb) Replace sealing caps inside VANOS unit with BMW special tool 11 6 170, or short flat nosed pliers. Insert and secure VANOS sealing plugs (arrows), using new sealing O-rings. Tightening torque...
Page 268 (banjo bolt) 32 Nm (24 ft-lb) Attach electrical harness connectors to camshaft position sensors and VANOS solenoid valves. Remove BMW special locking tools from rear of cylinder head. Remove BMW special locking tool from flywheel and replace dust guard.
Page 269 Insert BMW special tool 11 4 220 in cylinder head and bring adjustment screw into contact with tensioning rail. Note: BMW special tool 11 4 220 is a dummy primary chain tensioner and simulates the function of the tensioner. 12 of 19...
Page 270 Instead, complete another two complete rotations. Remove sealing plug from bore on lower left side of engine block near flywheel. Secure crankshaft in TDC position with BMW special tool 11 2 300 (arrow). 13 of 19 2/25/2009 9:52 PM...
Page 271 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Unscrew and remove cylinder head cover studs at rear of cylinder head. Place BMW special tool 11 3 240 over camshafts ends and measure clearance of tool to cylinder head surface. Note: If the exhaust side of the tool (A) is not flush with the head, retime the camshafts as described below.
Page 272 1 mm (0.04 in) of splines (arrows) can be seen. Pull out exhaust camshaft splined shaft to stop. Make sure camshafts are secured in TDC position using BMW special tools 11 3 240 and 11 3 244. 15 of 19 2/25/2009 9:52 PM...
Page 273 Tighten mounting nuts (arrows) by hand. Do not tighten fully. Install BMW special tool 11 6 150 (VANOS setup bracket) to front of cylinder head timing case. Tighten nuts (arrows) by hand, and then tighten down uniformly until special tool is in full contact with cylinder head.
Page 274 Secure crankshaft with BMW special tool 11 2 300. Place BMW special tool 11 3 240 over camshaft ends and measure clearance of tool to cylinder head surface. Note: If the exhaust side of the tool (A) is...
Page 275 This is normal. Otherwise, repeat camshaft timing procedure. Remove camshaft locking tools from rear of camshafts. Remove BMW special tool 11 4 220 (dummy primary chain tensioner). Reinstall primary chain tensioner. Tightening torque Primary chain...
Page 276 Camshaft Timing Chain http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... new seals. Attach oil line to VANOS unit. Tightening torque Oil line to VANOS unit (banjo bolt) 32 Nm (24 ft-lb) Remainder of engine assembly is reverse of disassembly. Tightening torques Radiator cooling fan (viscous clutch)
Page 277 A standard oil pressure gauge may be used for measuring oil pressure. If the BMW DIS tester system is to be used, a special adapter is needed. Note: Oil change procedure and oil filter...
Page 278 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Engine lubrication Oil pressure is generated by a gear-type pump bolted to the bottom of the engine block. The oil pump is chain driven off the front of the crankshaft. Oil passages in the cylinder block and...
Page 279 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Oil pressure, checking In some engines access to the oil pressure warning switch port may be extremely restricted. Unscrew oil filter cap in order to allow engine oil to drain back down into oil pan. Disconnect harness connector from oil pressure switch (arrow) and remove switch.
Page 280 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... oil should be the correct grade. Oil pressure Idle (minimum) 0.5 bar (7 psi) Regulated pressure (elevated engine speed) 4.0 bar (59 psi) Remove pressure gauge and reinstall pressure switch. Tightening torque Oil pressure switch to oil filter housing...
Page 281 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Warning light on instrument panel must light up. Remove connector from oil pressure switch. Warning light on instrument panel must go out. CAUTION! Running the engine with the oil pressure switch disconnected may set a fault code (DTC).
Page 282 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Replace a faulty switch. CAUTION! Keep in mind that low oil pressure may be preventing the switch from turning the light out. If the light remains on while the engine is running, check the oil pressure as described earlier.
Page 283: Oil Pan
Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 119-2 Oil Pan The oil pan removal procedure requires that the engine be supported from above and the front suspension subframe be unbolted and lowered from the chassis. Oil pan, removing and installing (rear wheel drive models) Raise car and place securely on jack stands.
Page 284 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Place drain pan under lines to catch ATF drips. Remove oil dipstick guide tube: Detach mounting bolt (A) from left engine mounting bracket. Detach fuel lines and wiring harness brackets (B). Disconnect oil separator hose (C) from base of guide tube and remove tube from oil pan.
Page 285 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove power steering pump pulley. Remove two mounting bolts from the front (arrows) Note: Do not detach power steering fluid lines from pump. Remove third power steering mounting bolt (arrow) and remove pump from its mounting bracket. Use stiff wire to suspend pump from chassis.
Page 286 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Right side is shown in photo. Left is similar. Loosen lower engine mount fasteners (arrows). Note: Right side is shown in photo. Left is similar. If applicable, remove front ride level sensor mounting bolt (arrow) and lay sensor aside.
Page 287 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove left control arm ball joint mounting nut (arrow) at front suspension subframe. Drive ball joint out from subframe using soft hammer. Push control arm aside. Repeat for left side. Support suspension subframe from below using appropriate jacking equipment.
Page 288 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... material from mating surfaces and use a new gasket. Apply a small amount of non-hardening sealer (3-Bond 1209® or equivalent) to oil pan gasket directly below joints (arrows) for end cover and front timing case cover. Apply a bead 3 mm wide by 2 mm high.
Page 289 After adding engine oil, start and run engine. Raise engine speed to 2,500 rpm until oil pressure warning lamp goes out (about 5 seconds). Note: BMW does not recommend a front end alignment following this procedure. Tightening torques Control arm ball joint to suspension subframe...
Page 290 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Oil pan, removing and installing (all wheel drive models) Raise car and place securely on jack stands. WARNING! Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose.
Page 291 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Detach mounting bolt (A) from left engine mounting bracket. Detach fuel lines and wiring harness brackets (B). Disconnect oil separator hose (C) from base of guide tube and remove tube from oil pan. Note: The guide tube is sealed in the block using an O-ring.
Page 292 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove third power steering mounting bolt (arrow) and remove pump from its mounting bracket. Use stiff wire to suspend pump from chassis. Detach electrical harness connector at oil level sensor. Remove lower engine mount fasteners. If applicable, remove front ride level sensor mounting bolt (arrow) and lay sensor aside.
Page 293 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove control arm rear bracket and ball joint mounting bolts (arrows) from subframe. Remove control arms and front drive axles as described in Front Suspension. Remove front differential and right axle inner bearing pedestal as described in...
Page 294 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Lower oil pan to remove. CAUTION! If the oil pan does not separate easily from the engine cylinder block, a few taps with a rubber mallet should break it free. Do not pry the oil pan loose.
Page 295 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torque M8 Torx 21 Nm (15 ft-lb) Reinstall front differential and right axle inner bearing pedestal. See Front Axle Final Drive. Fill differential to lower edge of fill plug. Tightening torques Fill or drain plug to...
Page 296 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... tab (arrow) is seated correctly in subframe slot. Tightening torques Engine mount to subframe M10 self-locking 45 Nm (33 ft-lb) Front of subframe to frame rail (M12 bolt, always replace) 8.8 grade 77 Nm (57 ft-lb) 10.9 grade...
Page 297 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Be sure to align the front end after this procedure. Tightening torques Stabilizer bar to frame rail (M8 nut) 22 Nm (16 ft-lb) Steering column universal joint clamping screw (M8 bolt, use new bolt)- 22 Nm (16 ft-lb)
Page 298 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 12.9 grade tighten to 105 Nm (77 ft-lb) - Bolt M12 (always replace) tighten to 110 Nm (81 ft-lb) - Bolt M10 (always replace) tighten to 59 Nm (44 ft-lb) - Bolt M10 (always replace) tighten to 59 Nm (44...
Page 299 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 119-3 Component Replacement Oil pressure warning switch The pressure warning switch is located under the intake manifold, in the rear of the oil filter housing. Note: Switch removal may require intake manifold removal. Tightening torque Oil pressure switch...
Page 300 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Oil pump removal requires lowering the front suspension subframe to remove the oil pan. Drain oil as described in Maintenance. Remove oil pan as described earlier. Remove oil pump sprocket mounting nut (left-hand thread) (arrow). Lift sprocket off together with drive chain.
Page 301 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 11 - Oil pick-up pipe 12 - Bolt M6 -tighten to 10 Nm (89 in-lb) On engines with integrated oil pump and oil scraper: Remove oil pump with scraper. On engines with separate oil pump and scraper: First remove mounting bolts and withdraw oil pump intake pipe.
Page 302 Lubrication System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torques pan (M12) Oil pan to engine block M6, 8.8 grade 10 Nm (89 in-lb) M6, 10.9 grade 12 Nm (106 in-lb) M8, 8.8 grade 22 Nm (16 ft-lb) Oil pump to engine block (M8) 22 Nm (16 ft-lb)
Page 303 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 120-1 General This repair group covers component replacement information for the ignition system. When diagnosing engine management problems, including on-board diagnostics (OBD II) fault code analysis, also refer to these repair groups: 100 Engine–General 130 Fuel Injection...
Page 304: Engine Management
Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Primary voltage test harness BMW 12 7 Secondary voltage test harness BMW 12 7 030 Ignition coil test adapters BMW 12 7 Engine management BMW E46 engines use an advanced engine management system known as Digital Motor Electronics (DME). DME...
Page 305: Ignition System
Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Additional information about DTCs and engine management system electronic system diagnosis is provided in On Board Diagnostics at the rear of this manual. Table a. Engine management systems Year: DME system Engine 1999 - 2000: M52 TU B25 Siemens MS 42.0...
Page 306 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Do not touch or disconnect any cables from the coils while the engine is running or being cranked by the starter. The ignition system produces high voltages that can be fatal. Avoid contact with exposed terminals. Use extreme caution...
Page 307 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... dimensional map similar to the one shown is digitally stored in the ECM. The initial ignition point is determined by the crankshaft speed sensor during cranking. Once the engine is running, timing is continually adjusted based on operating conditions.
Page 308 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... fundamentally working-delivering voltage to the spark plugs. A hard-starting or poor-running engine, however, may indicate a problem with how well the spark is delivered. Faulty or worn ignition components, such as old spark plugs, or an individual coil problem may be the cause.
Page 309 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 7 - Termination oscillations Note: Ignition coil assembly, testing and replacing as described later. Table b. Ignition trace diagnostics Parameter Ignition Ignition voltage voltage high Spark plug too small too big electrode Spark plug worn/burnt electrode condition...
Page 310 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Once engine misfire has been detected and the fault codes downloaded from the ECM, it is necessary to follow a diagnostic path to correct the problem. The ignition subset of the diagnostic path is shown in Table d. Ignition system problems Table c.
Page 311 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Component Condition Test Repair Secondary circuit Wet coil Secondary circuit Check for water leak. Corroded coil Check resistance connections values (see Table Ignition coil Primary or secondary Primary and Replace coil as circuit on or shorted secondary circuits necessary.
Page 312 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connect and disconnect the DME system wiring and test equipment leads only when the ignition is OFF. Before operating the starter without starting the engine (for example when making a compression test) always disable the ignition. CAUTION!
Page 313 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... only as specified by BMW, as described in this manual, or as described by the instrument manufacturer. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 11 of 11 2/25/2009 9:54 PM...
Page 314 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 120-2 Ignition System Service Ignition firing order Each ignition coil is mounted above the corresponding spark plug. Cylinder 1 is at the front of the engine. Ignition firing order M52 TU/M54 1 - 5 - 3 - 6 - 2 -...
Page 315 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... (ECM) or the ignition coils may result. Note: Spark plug replacement is covered in Maintenance. Checking for spark is difficult on engines with distributorless ignition systems. Try removing the spark plugs and inspecting for differences between them. A poor-firing plug may be wet with fuel and/or black and sooty, but not always.
Page 316 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Unfasten screws (B) and remove lower microfilter housing. Remove plastic engine cover from top of valve cover by prying off bolt covers and removing cover mounting bolts. Disconnect harness connector from coil. Connect multimeter between terminal 15 (+) in connector and ground.
Page 317 Replace ignition coil or spark plug connector if resistance readings do not meet specifications. Remove ignition coil to be tested. Install BMW special tool 12 7 030 (A) on coil to be tested. Connect ground jumper between coil mounting point and engine ground point (B).
Page 318 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Compare scope pattern with diagrams in Basic troubleshooting principles. Note: When replacing ignition coils, ensure that the replacements are from the same manufacturer with the same part/code numbers. If individual coils with the correct specifications are not available, all coils should be replaced.
Page 319 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Raise car and support in a safe manner. WARNING! Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support.
Page 320 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... ECM fault memory. Camshaft position sensors The camshaft position sensors are used by the engine management system for VANOS control, sequential fuel injection and knock control. Intake camshaft position sensor, replacing Make certain ignition has been turned off.
Page 321 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Disconnect cold air duct tube (E). Disconnect harness connector from VANOS solenoid and unscrew solenoid from VANOS control unit. Be prepared with shop rags to catch oil released from VANOS unit. Remove camshaft sensor (arrow) from left front of cylinder head, next to top of oil filter housing.
Page 322 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... sensor, replacing Make certain ignition has been turned off. Working at front of engine on exhaust (right) side, detach exhaust camshaft position sensor electrical harness connector (arrow). Remove camshaft sensor from right front of cylinder head. Installation is reverse of removal.
Page 323 Ignition System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove knock sensor mounting bolts (A) on side of cylinder block. Remove sensors. CAUTION! Note the installed angle of the knock sensor on the block before removing it. Reinstall the sensor in the same position. Be sure to use a torque wrench when tightening the sensor mounting bolt.
Page 324 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 130-1 General This repair group covers service and repair for the Siemens engine management systems used on the E46 models covered by this manual. Additional engine management information may also be found in the following repair groups: 100 Engine–General...
Page 325 Tools and test equipment If the equipment required to do the job is unavailable, it is recommended that these repairs be left to an authorized BMW dealer or other qualified BMW repair facility. Fuel pressure gauge Baum 1318 (Source: Baum Tools Unlimited) Automotive digital multimeter Fluke 87 Low current test light (“noid”) Baum...
Page 326 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Fuel line plugs BMW 13 5 281 / 13 5 Aftermarket DTC scan tool Baum CS2000 (Source: Baum Tools Unlimited) Fuel line clamp BMW 13 3 010 Fuel rail to pressure gauge fitting BMW 13 5 220...
Page 327 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... of quality OBD scan tools. In addition to the BMW professional line of scan tools, there are many inexpensive `generic' OBD II scan tool software programs and handheld units available. Although these tools have limited capabilities as compared to the dedicated tools, they are powerful diagnostic tools.
Page 328 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... motor driven throttle valve, double VANOS system, radiator cooling fan, electrically heated thermostat, as well as other outputs. The illustration on the following page shows the MS 42.0 ECM inputs and outputs. The MS 43.0 system is similar...
Page 329 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Warnings and cautions For personal safety, as well as the protection of sensitive electronic components, adhere to the warnings and cautions on the following pages. WARNING! Gasoline is highly flammable and its vapors are explosive. Do not...
Page 330 15 (+) of the ignition coil. The current flow may damage the ECM. In general, connect test equipment only as specified by BMW, or the equipment maker. Only use a digital multimeter for electrical tests. Only use an LED test light for...
Page 331 Fuel system cleaners and other chemical additives other than those specifically recommended by BMW may damage the catalytic converter, the oxygen sensor or other fuel supply components. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 8 of 8...
Page 332 (DTCs) in the ECM and illuminate the MIL. After all testing tests is completed, access and clear DTC fault memory using a BMW compatible scan tool. See OBD On Board Diagnostics the back of this manual. Only use a digital multimeter for electrical tests.
Page 333 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... left rear of engine compartment. Check for voltage at terminal 6 of main relay socket (30- red wire). If battery voltage is present continue testing. If battery voltage is not present, check large red wire in relay socket.
Page 334 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... If battery voltage is not present and all earlier tests are OK, relay is faulty and should be replaced. Fuel pump relay, testing The ECM energizes the fuel pump relay by providing the coil side of the relay with ground.
Page 335 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... The ground at terminal 4 is switched by the ECM. The ECM harness must be connected to check the switched ground connection. If no faults are found up to this point, turn ignition key off. Using a...
Page 336 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... The fuel system retains fuel pressure in the system when the engine is turned off. To prevent fuel from spraying on a hot engine, system fuel pressure should be relieved before disconnecting fuel lines. One method is to tightly wrap a shop towel around a fuel line fitting and loosen or disconnect the fitting.
Page 337 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove fuel rail cover by prying off nut covers (arrows) and removing nuts. Unscrew schræder valve cap (arrow) from fuel rail. Unscrew fuel tank cap to release pressure to vent tank. Using a brief burst of compressed air (maximum of 3 bar or 43.5 psi)
Page 338 130-3 Component Replacement After diagnosing and replacing a faulty engine management component, be sure to use a BMW-compatible scan tool to check and clear the fault memory in the ECM. Diagnostic trouble codes are given in OBD On Board Diagnostics at the back of this book.
Page 339 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Working above engine, disconnect electrical harness connectors: VANOS control unit harness connector (A) Connectors for oxygen sensors Connector for intake air temperature sensor (C) CAUTION! Mark oxygen sensor harness connectors in order to avoid reversing them during installation.
Page 340 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... WARNING! Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy. Before disconnecting fuel hoses, wrap a cloth around fuel hoses to absorb any leaking fuel. Catch and dispose of escaped fuel. Plug all open fuel lines.
Page 341 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... removal tool 16 1 050 or equivalent. Seal off fuel line(s) with BMW special tools 13 5 281/13 5 282. CAUTION! Fuel may be expelled under pressure. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy.
Page 342 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... bolts. Replace any wire ties removed during removal procedure. CAUTION! Replace any flexible fuel lines which were pinched shut during testing. Fuel pressure regulator, replacing E46 fuel pressure regulator location DME MS 42.0 under left side of...
Page 343 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove locking spring clip retaining fuel pressure regulator. Wrap a shop rag around regulator, then remove regulator from 3/2 way valve by pulling straight down. Installation is reverse of removal. Replace sealing O-rings. Mass air flow (MAF) sensor,...
Page 344 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... No adjustment to air flow sensor is possible. Engine coolant temperature (ECT) sensor, replacing The engine coolant temperature (ECT) sensor is located toward the rear of the cylinder head below intake runner no. 6. Intake manifold removal is required to access the ECT sensor.
Page 345 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torque ECT sensor to cylinder head 13 Nm (10 ft-lb) Intake air temperature (IAT) sensor, replacing The intake air temperature (IAT) sensor is located at the top center of the intake manifold. The intake air temperature...
Page 346 Throttle assembly, removing and installing Some throttle assembly faults will reset the engine control module (ECM) adaptation values. BMW's diagnostic tool (DIS or MoDiC) or aftermarket equivalent tool is necessary to reset ECM adaptations after throttle assembly replacement. CAUTION! After replacement of the throttle valve assembly, and/or on MS 43.0...
Page 347 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Disconnect vacuum line at intake boot (A). Disconnect electrical harness connector on mass air flow sensor (B). Release mass air flow sensor clips (C). Remove filter housing mounting screws (D). Disconnect air duct connections (E) and lift complete air filter...
Page 348 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... upwards out of rubber retainer (A) and unhook ball end of cable (B) from throttle actuator. Remove nuts and bolt (arrows) retaining wiring harness conduit to throttle body. Working at throttle housing: Turn harness plug (arrow) counterclockwise and remove.
Page 349 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Disconnect electrical harness connectors (arrows) at oil pressure sender and oil temperature sender at base of oil filter housing. Remove dipstick guide tube: Disconnect wiring harness brackets from tube (A). Unclip fuel lines from tube (B). Remove lower guide tube mounting bolt (C).
Page 350 On DME MS 42.0: Reattach throttle cable and adjust as described later. Use BMW scan tool to reset ECM adaptation values. Throttle cable, adjusting (MS 42.0) Models with DME MS 42.0 are equipped with a throttle cable. Cable adjustment should be adjusted any time it is disconnected or replaced.
Page 351 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Throttle cable clearance Max. play at throttle plate lever 3 mm (0.125 in.) Full throttle adjustment (manual transmission): With ignition key on press pedal fully to stop. Check throttle angle using scan tool. Adjust pedal stop if necessary.
Page 352 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Throttle angle specifications Kickdown stop contacted 76° - 80° Kickdown pressure point range 84° - 88° Full-load downshift 100% Idle speed control valve, replacing The idle speed control valve is mounted under the intake manifold adjacent to the dipstick tube bracket.
Page 353 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove filter housing mounting screws (D). Disconnect air duct connections (E) and lift complete air filter housing out of engine compartment, pulling it forward away from mass air flow sensor. Note: In this step, mass air flow sensor remains attached to intake duct.
Page 354 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Working at side of intake manifold, disconnect electrical harness connectors: Idle control valve (A) Intake manifold resonance valve Disconnect bypass hose from idle control valve. Remove idle control valve: Remove idle control valve bracket mounting fasteners. Slide control valve with bracket out from between intake manifold and throttle assembly.
Page 355 Replacement ECMs must be coded with application information (i.e. engine code, transmission type, etc.) prior to installation. Consult an authorized BMW dealer before replacing the ECM. Alternatively, coded ECMs may be available at an additional cost. Disconnect negative (-) battery cable.
Page 356 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Installation is reverse of removal. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 19 of 19 2/25/2009 9:55 PM...
Page 357 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 130-4 ECM Pin Assignments ECM pin assignments are given in Table b. ECM pin assignment-DME MS 42.0 and MS 43.0. This information may be helpful when diagnosing faults to or from the ECM. If all inputs and wiring are OK but operational problems still exist, the ECM itself may be faulty.
Page 358 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... in the connector. As an alternative, the harness connector housing can be separated so that electrical checks can be made from the back of the connector. Table b. ECM pin assignment-DME MS 42.0 and MS 43.0 Connector X60001 9-pin black...
Page 359 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connector X60002 24-pin black Signal Component/function Notes not used not used not used Input Signal, 3/2-way valve, 3/2 way valve, running losses running losses (MS (MS 42.0) 42.0) Input Heater, precatalyst Heated oxygen sensor 2 in oxygen sensor 2...
Page 360 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connector X60003 52-pin black Signal Component/function Notes sensor Input Signal, exhaust Camshaft position sensor II camshaft sensor 1 Input Signal, suction jet pump Suction jet pump valve valve (2.8 L, 3.0 L) Output Throttle valve supply Throttle valve (MS 42.0) (MS 42.0)
Page 361 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connector X60003 52-pin black Signal Component/function Notes Input Signal, throttle Throttle valve potentiometer 1 Ground Ground, throttle position Throttle valve sensor Ground Ground, crankshaft Crankshaft position sensor position sensor Output Signal, intake air Intake air temperature sensor...
Page 362 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connector X60003 52-pin black Signal Component/function Notes Input Signal, cylinder 6 fuel Cylinder 6 fuel injector injector Input Signal, oil level sensor Oil level sensor Input Signal, VANOS inlet VANOS inlet valve valve Input Signal, VANOS outlet...
Page 363 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connector X60004 40-pin black Signal Component/function Notes Input Feedback signal, Instrument cluster control engine start module Input Signal, secondary air Secondary air injection pump injection pump relay Input Signal, electric fan Auxiliary fan motor not used not used...
Page 364 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connector X60004 40-pin black Signal Component/function Notes Output Diagnostic module tank Leak detection (DMTL) (MS leak (DMTL) detection 43.0) (MS 43.0) Input Signal, oil level sensor Instrument cluster control module Input Signal, processed ABS/ASC module, ABS/DSC wheel speed, right rear...
Page 365 Fuel Injection http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Connector X60004 40-pin black Signal Component/function Notes Input/output CAN bus signal, low Connector, CAN bus Ground Ground, coolant outlet Temperature sensor temperature sensor Output Signal, coolant outlet Temperature sensor temperature not used Connector X60005 9-pin black Signal...
Page 366: Special Tools
Special tools are necessary for fan clutch removal and pressure testing the cooling system. Cooling fan counterhold wrench BMW 11 5 030 Cooling fan wrench BMW 11 5 040 Cooling system pressure tester BMW 17 0 002/17 0 005 1 of 6 2/25/2009 9:56 PM...
Page 367 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Expansion tank cap test adapter BMW 17 0 007 Cooling system (DME MS 42.0) 2 of 6 2/25/2009 9:56 PM...
Page 368 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Coolant pump A centrifugal-type coolant pump is mounted to the front of the engine. The belt-driven pump circulates coolant through the system whenever the engine is running. Thermostat An electrically heated thermostat regulates the engine coolant temperature and is controlled by the DME control module.
Page 369 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... application. On cars with automatic transmissions, the main fan is electric and mounted on the bumper side of the radiator. The fan is controlled by the DME control module via the output final stage. Additionally a...
Page 370: Warnings And Cautions
Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... values in the fan power output stage to confirm that the fan is operating correctly. Note: If the ECM stored a cooling fan fault, check that the fan is not seized and that is spins freely.
Page 371 To avoid excess silicate gel precipitation in the cooling system and loss of cooling capacity, use BMW coolant or equivalent low silicate antifreeze. If oil enters the cooling system, the radiator, expansion tank and heating circuit must be flushed with cleaning agent.
Page 372: Troubleshooting
If no visual faults are found, it is recommend that the DME system be checked for stored diagnostic fault codes (DTCs) using BMW scan tools DIS (Diagnostic Information System) or MoDiC (Mobile Diagnostic Computer) or an aftermarket equivalent.
Page 373 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... pulley and check for play in all directions. Spin pulley and check that shaft runs smoothly without play. Note: The coolant provides lubrication for the pump shaft, so an occasional drop of coolant leaking from the pump is acceptable.
Page 374 Release the cap slowly to allow safe release of pressure. With engine cold, install pressure tester (BMW special tools 17 0 002/17 0 005 or equivalent) to expansion tank. Pressurize system to specification listed in...
Page 375 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Table a. Cooling system test pressures Component Test pressure psi) Radiator cap 2 bar (29 psi) CAUTION! Exceeding the specified test pressure could damage the radiator or other system components. Combustion chamber leak test If you suspect that combustion...
Page 376 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... indicate trouble, the electrically heated thermostat may be faulty. Check for thermostat diagnostic fault codes (DTCs) using BMW scan tools DIS or MoDiC or equivalent. DTCs pertaining to cooling system malfunctions are listed in Table...
Page 377 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... 170-3 Cooling System Service Coolant, draining and filling WARNING! Allow the cooling system to cool before opening or draining the cooling system. Raise front of car and support safely. CAUTION! Make sure the car is stable and well supported at all times.
Page 378 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Coolant is poisonous. It is especially lethal to pets. Clean up spills immediately and rinse the area with water. Place empty 3-gallon pail underneath exhaust side of engine block. Loosen and remove engine block coolant drain plug (arrow).
Page 379 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tap water may cause corrosion of radiator, engine and coolant hoses. Coolant can often be reused provided it is clean and less than two years old. Do not reuse coolant when replacing damaged engine parts. Contaminated coolant may damage the engine or cooling system.
Page 380 Top up so that coolant level indicator is at MAX. CAUTION! Always use genuine BMW coolant or its equivalent to avoid the formation of harmful, clogging deposits in the cooling system. Use of other antifreeze solutions may be harmful to the cooling system.
Page 381 Note: The radiator cooling fan nut (32 mm wrench) has left-hand threads. If fan nut is difficult to loosen, use BMW special tool 11 5 030 to counterhold coolant pump pulley. Lift fan and shroud together out of engine compartment.
Page 382 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torques with BMW tool 11 5 040 30 Nm (22 ft-lb) Fan to viscous clutch 10 Nm (89 in-lb) Electric cooling fan, replacing (models with manual transmission) On models with manual transmission, the primary cooling fan is electrically operated and is mounted on the engine side of the radiator.
Page 383 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... transmission) The electric cooling fan on cars with automatic transmission is mounted behind the front bumper, in front of the A/C condenser. Remove air intake duct as described above. Remove front bumper. See Exterior Trim, Bumpers.
Page 384 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... The electrically-heated thermostat is an integral part of the thermostat housing. The operation of the thermostat is monitored by the DME control module. If a faulty thermostat is suspected, the DME control module should be interrogated for stored fault codes using an appropriate scan tool.
Page 385 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Use new sealing gasket. Fill system with coolant as described under Coolant, draining and filling Tightening torques Engine block drain plug to block 25 Nm (18 ft-lb) Radiator drain 2 - 3 Nm (18 - 27...
Page 386 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove engine drive belt: Lever tensioner hex (large arrow) in clockwise direction (facing engine) and slip belt off coolant pump pulley. Note: Mark direction of drive belt rotation if reusing belt. Remove coolant pump pulley bolts and remove pulley from pump.
Page 387 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torques Radiator drain 2-3 Nm (18-27 plug to radiator in-lb) Radiator, removing and installing Raise front of car and support safely. CAUTION! Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose.
Page 388 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Working on ride side of radiator, release hose retaining clips (A) and disconnect lower coolant hose fitting from radiator (B). Working underneath radiator, disconnect harness connector from coolant level sensor. Where applicable, disconnect automatic transmission fluid (ATF)
Page 389 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Note: Alternatively, detach ATF cooler from radiator by pulling up on quick release clips and pulling cooler from radiator tank. Remove plastic bolts at top of radiator (arrows). Pull radiator up and out of car.
Page 390 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... stands designed for the purpose. A floor jack is not adequate support. Remove splash shield from under engine. Drain radiator and engine block as described earlier. WARNING! Allow cooling system to cool before opening or draining system.
Page 391 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Remove coolant level sensor (9) by twisting counterclockwise and pulling out of bottom of tank. 1 - Thermostat (ATF heat exchanger) 2 - Expansion tank cap 3 - Label 4 - Radiator 5 - Mounting bracket...
Page 392 Radiator and Cooling System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/1... Tightening torques Radiator drain 2 - 3 Nm (18 - 27 plug to radiator in-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved. 16 of 16 2/25/2009 9:57 PM...
Page 393 Exhaust System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 200-1 General This section covers the repairs related to the clutch, manual and automatic transmissions, shift linkages, driveshafts, and transfer case (all wheel drive vehicles only). For repairs related to drive axles and front and rear final drive differentials, see...
Page 394 Exhaust System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... The manual transmissions use a single clutch disc with dual-mass flywheel. For further information, see Clutch. Manual transmissions have a metal ID plate mounted on the side of the transmission. Do not rely on numbers cast on the transmission case for identification.
Page 395 Exhaust System http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... manufactured from 08/98 to 03/00 are equipped with the A5S 360R automatic transmission. Vehicles produced after 03/00 use the A5S 325Z transmission. GM manufactured transmissions have the ID tag located on the left hand side of the transmission housing, behind the transmission selector cable, just above the transmission pan (arrow).
Page 396 SAC assembly to the dual mass flywheel. Flywheel locking tool BMW 11 2 170 Pilot bearing removal tool BMW 11 2 Pilot bearing installation tool BMW 11 2...
Page 397 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Clutch lining gauge BMW 21 2 080 Clutch centering mandrel BMW 21 2 SAC clutch lock tool BMW 21 2 150 Clutch diaphragm tensioning too BMW 21 2 160 SAC tensioning tool BMW 21 2 170 2 of 3...
Page 398 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... SAC locating ring BMW 21 2 180 Copyright © 2006 Robert Bentley, Inc. All rights reserved. 3 of 3 2/25/2009 10:15 PM...
Page 399 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 210-2 Clutch Hydraulics The clutch is hydraulically actuated by the master and slave cylinders. Clutch disc wear is automatically taken up through the self adjusting pressure plate springs, making periodic adjustments unnecessary. A soft or spongy feel to the clutch...
Page 400 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Attach pressure brake bleeder to fluid reservoir and pump bleeder a few times to pressurize hydraulic fluid system. CAUTION! Do not exceed 2 bar (29 psi) pressure at the fluid reservoir when bleeding or flushing the hydraulic system.
Page 401 Slowly operate clutch pedal about 10 times. Fill reservoir with clean fluid as necessary. Unbolt slave cylinder from transmission. Fit BMW special tool 21 5 030. Press slave cylinder pushrod completely into slave cylinder. Hold slave cylinder so that bleeder valve is at the highest point.
Page 402 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... replacing The clutch master cylinder is mounted to the pedal assembly directly above the clutch pedal. Disconnect negative (-) cable from battery. CAUTION! Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.
Page 403 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Disengage panel from hoses and wiring harnesses and remove from engine compartment. Separate brake booster vacuum hose at one way valve (A). Plug hose ends. Disconnect clutch pedal from clutch master cylinder push rod by removing securing pin.
Page 404 (15 + 4 ft-lb) Clutch slave cylinder, replacing Pinch off brake fluid supply hose to clutch master cylinder using BMW special tool 13 3 010 or equivalent fuel line clamp tool. Remove transmission splash guard if applicable. Disconnect fluid hose from slave cylinder.
Page 405 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... equivalent). During installation be sure pushrod tip engages recess in clutch release lever. Fill fluid reservoir with clean fluid. Bleed clutch hydraulics as described earlier. Tightening torques Clutch slave cylinder to transmission 22 Nm (16 ft-lb) Fluid line to slave...
Page 406 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 210-3 Clutch Mechanical The transmission must be removed from the engine to access the clutch mechanical components. It is recommended that the clutch disc, pressure plate and release bearing be replaced during a clutch overhaul. Be sure to check the bottom of the bellhousing for oil.
Page 407 Lock flywheel in position using BMW special tool 11 2 170 or equivalent. Install BMW special tool 21 2 160 or 21 2 170 with feet (arrows) clamping on to pressure plate at openings for self-adjusting springs. Tighten down head nut (A) to lock feet into position.
Page 408 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Turn tool handle in until clutch diaphragm spring is fully tensioned. Remove six bolts from perimeter of pressure plate. Remove self adjusting clutch unit and clutch disk. Clutch assembly and hydraulics Clutch, inspecting Inspect clutch disc for wear, cracks,...
Page 409 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... excessive runout (warping). Replace if necessary. Note: Measure the depth of clutch lining at lining rivets. If shallowest rivet depth is less than 1 mm (0.04 in.), replace clutch disk. Inspect flywheel for scoring, hot spots, cracks or loose or worn guide pins.
Page 410 Center clutch disk on flywheel using BMW special tool 21 2 142, or an equivalent clutch alignment tool. Note: The sides of a replacement clutch disk are labelled engine side and transmission side.
Page 411 Before installing a used Self Adjusting Clutch (SAC) pressure plate, be sure to reset self adjusting ring to the new position Locating hooks of BMW special tool 21 2 180 must engage in openings of SAC pressure plate Place self adjusting clutch pressure plate on clean work surface.
Page 412 Clutch http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Center clutch disk with BMW special tool 21 2 142. A comparable clutch alignment tool may be used. Remove threaded handle of clutch alignment tool WARNING! Be sure clutch disc is facing the correct way. The disc should be marked engine side or transmission side.
Page 413 BMW special tool 11 2 340 or equivalent puller. Press new bearing into place using BMW special tool 11 2 350 or equivalent driver. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 8 of 8...
Page 414 Special tools BMW specified tools are required for removal and installation of the manual transmission, as well as the removal and installation of seals at the transmission input, output, and selector shafts.
Page 415 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Selector seal drift BMW 23 0 22 Output seal drift BMW 23 2 300 Manual transmissions used are based on engine application. Consult Transmission–General for transmission application information. Table a. Manual transmission gear ratios lists gear ratio specifications.
Page 416 Manual transmissions installed in the 3 Series are normally filled with a "Lifetime" manual transmission fluid (BMW MTF LT-1) and do not require periodic fluid changes. Transmissions filled with MTF LT-1 lifetime oil are identified with a yellow label near the transmission fill plug labeled "Lifetime...
Page 417 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Install and torque drain plug. Remove fill plug (B) from side of transmission. Slowly fill transmission with fluid until fluid overflows fill hole. Install and torque fluid fill plug.nothing Fluid capacity Getrag 1.0 liter (1.1 US transmission...
Page 418 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 230-3 Transmission Service Back-up light switch, replacing Raise and safely support vehicle to access back-up light switch. Unscrew switch from transmission. Note: The back-up light switch (arrow) on Getrag transmissions is in the left side of the transmission.
Page 419 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Remove driveshaft. See Driveshaft. Remove transmission mount bolts (A). Remove transmission crossmember bolts (B) and tilt down rear of transmission. On all wheel drive cars: Remove front and rear driveshafts. 260 Driveshaft Remove transfer case crossmember bolts (arrows) and remove transfer case.
Page 420 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Coat new selector shaft seal with transmission fluid. Drive new seal in flush with housing. Use BMW special seal installation tool 23 1 140 or equivalent and a soft-faced (plastic) hammer. Installation is reverse of removal, noting the following;...
Page 421 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Tightening torques M10 (10.9 grade) 60 Nm (44 ft-lb) M12 (10.9 grade) 100 Nm (74 ft-lb) Transmission / transfer case crossmember to chassis (M8) 21 Nm (15 ft-lb) Transfer case to transmission (M10) 41 Nm (30 ft-lb)
Page 422 Use a seal puller to remove seal from transmission housing Coat new seal with transmission fluid and drive into position until it is flush with housing. Use seal driver (BMW special tool 23 2 300) or equivalent. Reinstall output flange (and shims, if applicable) to output shaft.
Page 423 Tighten collar nut in two stages. Install new lockplate. Bend tabs into flange grooves. Note: BMW recommends the use of a sealer ® such as Loctite 242 when installing the flange collar nut to prevent oil from leaking past the threads.
Page 424 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... (transmission removed) Replacement of the input shaft seal requires the removal of the transmission from the vehicle as describedlater in this repair group. Remove clutch release bearing and release lever from inside bellhousing. Remove bolts (arrows) for clutch...
Page 425 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Tightening torque Guide sleeve to transmission M6x12 bolt 10 Nm (89 in-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved. 8 of 8 2/25/2009 10:17 PM...
Page 426 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 230-4 Transmission Removal and Installation Removal and installation of the transmission is best accomplished on a lift using a transmission jack. The engine must be supported from above using appropriate support equipment. This allows the engine to pivot on its mounts to access the upper Torx-head bolts at the bellhousing.
Page 427 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Remove housing for interior ventilation microfilter. Remove upper cover and microfilter. Open wiring harness loom cover (A) and remove wires. Unfasten screws (B) and remove lower microfilter housing. Remove heater bulkhead cover. Remove engine compartment side trim panel. Turn locking knobs (A) and slide trim panel from mounting lip.
Page 428 All wheel drive models require no reinforcement due to the construction of the front subframe. Attach BMW special tool 11 8 022 to left and right lower control arms. Tighten knurled screws until tool makes contact with engine oil pan.
Page 429 CAUTION! Do not operate clutch pedal with slave cylinder removed from transmission. Loosen knurled screws of BMW special tool 11 8 022 until transmission/engine assembly is just above, but not in contact with fire wall and heater connections.
Page 430 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... When installing a new transmission, be sure to transfer parts from old transmission if applicable. Thoroughly clean input shaft and clutch disc splines. Lightly lubricate transmission input shaft before installing. Be sure bellhousing dowels (arrows) are correctly located.
Page 431 Manual Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Tightening torques (tubular style) 42 Nm (31 ft-lb) (pan style) 59 Nm (44 ft-lb) + 90° Rubber mount to transmission or bracket nut (M8) 21 Nm (15 ft-lb) Slave cylinder to transmission 22 Nm (16 ft-lb) Transmission crossmember to...
Page 432 BMW diagnostic equipment. Special tools Some special tools are required for the removal and installation of an automatic transmission on the E46 BMW models. While these tools are not 1 of 3 2/25/2009 10:17 PM...
Page 433 Engine support bracket BMW 00 0 200 / 208 Oil pan support bracket BMW 11 8 022 Torque converter socket BMW 24 1 100 Spline bore alignment tool BMW 24 2 Torque converter clamp BMW 24 4 131...
Page 434 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... dealer about a factory reconditioned unit or a transmission rebuild. 323i/Ci and 328i/Ci models manufactured from 08/98 to 03/00 are equipped with the A5S 360R automatic transmission. Vehicles produced after 03/00 are equipped with the A5S 325Z transmission.
Page 435 "Life-Time Oil". In addition, a sticker may be located on the fluid sump indicating the type of transmission lubricant used. If in doubt, consult an authorized BMW dealer for alternate fluid use and current information regarding transmission operating fluids. Automatic transmission fluid...
Page 436 ATF level checking Fluid temperature 30° - 50°C (85° - 120°F) Connect vehicle to BMW diagnostic scan tool DIS or MoDiC using the Data Link Connector (DLC) in the engine compartment, or under driver's side of dash (model year 2000 and later cars) in order to read transmission temperature.
Page 437 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... will spill from the filler hole when the fill plug is removed. Reinstall fill plug using new sealing ring. Tightening torques ATF drain plug to ATF sump A5S 360R / A5S 390R (M14) 20 Nm (15 ft-lb)
Page 438 Check fluid level as described under Automatic transmission fluid (ATF) level, checking Note: Use new sump bolts purchased from BMW. Alternatively, clean old bolts and coat with Loctite® thread locking compound or equivalent. Automatic transmission fluid capacity A5S 360R / A5S 390R...
Page 439 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Automatic transmission fluid capacity without torque converter 6.2 liters (6.5 qt) A5S 325Z (3.0 liter) with torque converter 8.7 liter (9.2 qt) without torque converter 6.1 liter (6.4 qt) Tightening torques ATF drain plug to ATF sump...
Page 440 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 240-3 Transmission Removal and Installation Removal and installation of the transmission is best accomplished on a lift using a transmission jack. Use caution and safe workshop practices when working beneath car and lowering transmission. CAUTION! Be sure the vehicle is properly supported.
Page 441 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... read the battery disconnection cautions given at the front of this manual on page viii. Remove engine cooling intake hood fasteners (arrows) at front of engine compartment. Remove engine driven cooling fan, unfasten cooling fan cowl and pull slightly upwards.
Page 442 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support. Removal of transmission will cause engine to tip unless engine support is used.
Page 443 Remove wiring harness(s) from transmission housing. Disconnect transmission cooler line clamps from engine. Disconnect cooler lines from transmission. Attach BMW special tool 11 8 022 to lower control arms. Support transmission with transmission jack. Remove transmission support crossmember. Lower transmission until engine cylinder head touches firewall.
Page 444 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Remove bellhousing-to-engine mounting bolts (arrows). Install BMW special tools 24 4 131 and 24 4 135 to secure torque converter in place during transmission removal. CAUTION! Do not allow the torque converter to fall off the transmission input shaft.
Page 445 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Install new O-rings on transmission cooler lines, where applicable. Inspect engine drive plate for cracks or elongated holes. Replace if necessary. Check to be sure torque converter is seated correctly in transmission during final installation. When mounting transmission to...
Page 446 Automatic Transmission http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Tightening torques Front suspension reinforcement to chassis (M10) 42 Nm (30 ft-lb) Torque converter to drive plate (M10) 45 Nm (33 ft-lb) Transmission support crossmember to chassis 23 Nm (17 ft-lb) Transmission to engine (Torx-head with washer)
Page 447 Special tools BMW suggests the use of one special tool in the removal of the gear shift lever for manual transmission equipped vehicles. Pin wrench BMW 25 1 110...
Page 448 Gearshift Linkage http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 250-2 Manual Transmission Gearshift Manual Transmission Gearshift Linkages - Rubber boot - Shift lever bearing - Shift arm bearing - Shift arm - Shift lever - Selector rod - Spacer ring - Circlip - Dowel pin 10 - Lock ring...
Page 449 Gearshift Linkage http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Use the above illustration as a guide when removing and installing the linkage. Remove shift knob by pulling knob straight off the manual gearshift. Note: Removal of the shift knob will require about 90 lbs. of force. Do not twist knob or locating key can be damaged.
Page 450 (1). Disengage shift rod from gearshift lever (2). Note washers on either side of shift rod end. Release gearshift lever retaining ring from below using BMW special tool 25 1 110. Turn tool 90° ( turn) counterclockwise. Raise transmission and temporarily install transmission crossmember.
Page 451 Gearshift Linkage http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Install rubber grommet correctly so that it seals out water. Connect shift rod to shift lever. Install transmission crossmember. Lift transmission and tighten crossmember bolts. Before connecting the shift rod to the lever, be sure the gearshift lever is facing the correct way as illustrated.
Page 452 Gearshift Linkage http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 250-3 Automatic Transmission Gearshift In E46 models, the electronic immobilizer (EWS) prevents starter operation unless the gear position is Park or Neutral. Gearshift mechanism, adjusting (automatic transmission) Position gearshift lever in Park. Raise vehicle to gain access to shift linkage.
Page 453 Gearshift Linkage http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Automatic shiftlock, checking function (automatic transmission) The automatic shiftlock uses an electric solenoid to lock the selector lever in Park or Neutral. Depressing the foot brake with the ignition on energizes the solenoid, allowing the lever to be moved into a drive gear.
Page 454 Gearshift Linkage http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... lever cannot be moved out of Park or Neutral. If any faults are found check the electrical operation of the shiftlock solenoid and check for wiring faults to or from the transmission control module (TCM). See 610 Electrical...
Page 455 Gearshift Linkage http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Shift interlock, checking function (automatic transmission) The shift interlock uses a cable between the ignition switch and the shift lever to lock the shift lever in the park position when the key is in the off position or removed.
Page 456 311 Front Axle Final Drive 331 Rear Axle Final Drive. Special tools BMW suggests the use of a special tool in the release of the clamping sleeve which acts as a grease seal for the splined shaft to the rear of the driveshaft center bearing.
Page 457 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... driveshaft runs from the transfer case to the front differential. The front driveshaft bolts to the transfer case and differential directly, using no flexible rubber disk. Rear wheel drive driveshaft assembly All wheel drive driveshaft assemblies - Front driveshaft...
Page 458 Check the universal joints for play. With the driveshaft installed, pull and twist the driveshaft while watching the joint. The BMW specification for play is very small, so almost any noticeable play could indicate a problem. Check the torque of the fasteners at the flange connections.
Page 459 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... tabs on the driveshaft tubes. In addition to inspecting for faulty driveshaft parts, the installed angles of the driveshaft should also be considered. Further inspection requires removal of the driveshafts. Check the front centering guide on the transmission output flange for damage or misalignment.
Page 460 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Table a. Driveshaft troubleshooting lists symptoms of driveshaft problems and their probable causes. Most of the repair information is contained within this repair group. Note: With the driveshaft installed, the actual amount that the universal joints pivot is limited.
Page 461 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Symptom Probable cause Corrective action Universal joints worn Check universal joint play and movement. or seized. Replace driveshaft if necessary. Sliding coupling Remove driveshaft and check movement of seized. sliding coupling. Clean coupling splines and replace parts as necessary.
Page 462 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Symptom Probable cause Corrective action Mounting flange Remove driveshaft and check transmission bolts loose or holes output flange and final drive input flange. worn. Replace if necessary. Driveshaft Check driveshaft for loose or missing balance unbalanced. weights. Have driveshaft rebalanced or replace if necessary.
Page 463 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 260-2 Rear Driveshaft Service Repair kits for the universal joints are not available for BMW driveshafts. Worn or damaged universal joints usually require replacement of the driveshaft. 1 - Hex bolt, M12 2 - Centering sleeve 3 - Flexible disk...
Page 464 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... final drive have been removed and installed. If all other parts of the driveshaft have been inspected and found to be okay, but there is still noise or vibration, driveshaft alignment should be checked. There are two important driveshaft alignment checks.
Page 465 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Rear driveshaft, removing WARNING! Be sure the wheels are off the ground before removing the driveshaft. Set the parking brake before removing the driveshaft. Once the driveshaft has been removed, the vehicle can roll regardless of whether the transmission is in gear or not.
Page 466 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Using BMW special tool 26 1 040, loosen threaded clamping sleeve on driveshaft a few turns. Remove center support bearing mounting bolts. Remove driveshaft but do not separate two halves. Pull down on center of driveshaft to facilitate removal.
Page 467 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... height of the center bearing or transmission support using shims is 3 mm (0.12 in.). Tighten threaded sleeve on driveshaft to proper torque. Install heat shields. Install exhaust system. See Exhaust System. Connect wiring harness to oxygen sensors.
Page 468 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Tightening torques (replace bolts) Flex-disc to driveshaft or transmission flangE M10 (8.8 grade) 48 Nm (35 ft-lb) M10 (10.9 grade) 60 Nm (44 ft-lb) M12 (10.9 grade) 100 Nm (74 ft-lb) Transmission crossmember to body (M8) 21 Nm (15 ft-lb) Note: Bolt grade is marked on the bolt head.
Page 469 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... unsupported, the rear universal joint may be damaged. Unbolt flex-disc from driveshaft. Note: Removal and installation of the bolts may be made easier by placing a large hose clamp around the flex-disc, and tightening the clamp slightly to compress the coupling.
Page 470 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Tightening torques M10 (10.9 grade) 60 Nm (44 ft-lb) M12 (10.9 grade) 100 Nm (74 ft-lb) Transmission crossmember to body (M8) 21 Nm (15 ft-lb) Center bearing assembly, replacing To replace the center bearing assembly, the driveshaft must be removed from the car.
Page 471 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... inner hub of bearing. Pulling on outer ring of mount may tear rubber, and entire bearing assembly will need to be replaced. Before installation, make sure dust guard is on driveshaft, and then press center mount onto driveshaft flush with dust guard.
Page 472 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... should fit snugly on the transmission output shaft. Note: Some driveshafts have a dust cap installed on the end of the driveshaft, over the centering guide. The dust cap may become bent or distorted when the driveshaft is removed or installed.
Page 473 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Install driveshaft as described earlier. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 11 of 11 2/25/2009 10:20 PM...
Page 474 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 260-3 Front Driveshaft Service Repair kits for the universal joints are not available for BMW driveshafts. Worn or damaged universal joints usually require replacement of the driveshaft. Front driveshaft, removing and installing CAUTION! Do not move vechicle using engine power once front driveshaft has been removed.
Page 475 Driveshafts http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Installation is reverse of removal. Tightening torques Driveshaft to drive flange (M10) 70 Nm (52 ft-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved. 2 of 2 2/25/2009 10:21 PM...
Page 476 Transfer Case http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 270-1 General This repair group covers removal and installation of the all wheel drive transfer case. Internal transfer case repair is not covered. Special press tools and procedures are required to disassemble and service the internal geartrain.
Page 477: Transfer Case
Transfer Case http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... 270-2 Transfer Case Transfer case, removing and installing Raise vehicle and safely support to access transfer case. WARNING! When raising the car using a floor jack or a hydraulic lift, carefully position the jack pad to prevent damaging the car body.
Page 478 Transfer Case http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... Remove transmission crossmember (arrows). Detach transfer case vent tube. Keeping the driveshaft in place, remove nuts retaining rear driveshaft to transfer case at flexible disc. CAUTION! Do not allow the driveshaft to hang down. This may damage universal joints at drive shaft ends.
Page 479 Transfer Case http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/2... before installing. On manual transmission cars: Replace sealing O-ring between transmission and transfer case. Note: When refilling transfer case, recheck oil level again after driving car approximately 200 meters (600 ft). Tightening torques Transmission crossmember to body (M8)
Page 480: Front Suspension
Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 300-1 General This section covers general information for front and rear suspension, steering system, and the electronic braking and stability control systems. Front and rear syspension systems (rear wheel drive) Front suspension In rear wheel drive cars, the control arm...
Page 481 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Each front strut assembly includes a tubular strut housing with an integrated shock absorber and a large coil spring. The upper strut mount includes a coil spring seat and strut bearing. A rubber bump stop limits suspension travel.
Page 482 The all wheel drive models are known as 325xi or 330xi. Note: The internal BMW designation of these models is E46/16. The all wheel drive system adds approx. 100 kg (220 lbs.) to the weight of the car.
Page 483 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... from the rear wheel drive version and have also been relocated to provide front axle clearance. The front stabilizer bar has been increased in diameter to accommodate the additional weight. See Table The struts are shorter than the rear wheel drive version.
Page 484 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... ease parking and city driving. At high speeds, assist is reduced to ensure stability. The steering linkage connects the rack-and-pinion unit through tie rods to the steering arms. The tie rod ends allow the wheels to pivot and react to suspension travel.
Page 485 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... the same layout as the rear wheel drive version. The rear suspension travel of the E46 all wheel drive is approx. 17 mm (0.67 in.) less than the rear wheel drive version. The reason for the reduced travel in the rear is to prevent excessive body roll as a result of the higher body profile.
Page 486: Tires And Wheels
Several different styles of wheels in 15, 16, and 17 inch diameters are available from an authorized BMW dealer. On all wheel drive cars, standard wheel size is 17x 7.0 to ensure there is enough room for the front axles and brakes. Tire size is 205/50 R17.
Page 487 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 300-2 Electronic Brake and Stability Control Systems All E46 vehicles are equipped with an Antilock Braking System (ABS). Early production models featured ABS with Automatic Stability Control (ABS/ASC). Later models came equipped with ABS and Dynamic Stability Control (ABS/DSC).
Page 488 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 1999 - 2000 Dynamic Stability Control Teves MK 20 DSC 1 - DSC control module and hydraulic unit, right rear of engine compartment 2 - Brake fluid reservoir, master cylinder and DSC brake pressure...
Page 489 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 4 - Front wheel speed sensor, at each front steering arm 5 - Steering angle sensor, at base of upper steering column 6 - Lateral acceleration sensor, behind driver’s kickpanel 7 - Rotational acceleration (yaw) sensor, under driver’s seat,...
Page 490 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... The electronically controlled ABS maintains vehicle stability and control during emergency braking by preventing wheel lock-up. ABS provides optimum deceleration and stability during adverse conditions. It automatically adjusts brake system hydraulic pressure at each wheel to prevent wheel lock-up.
Page 491 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... may also be referred to as ASC+T (Automatic Stability Control+Traction). The ASC system improves traction by electronically applying the rear brakes when the rear drive wheels are spinning at a faster rate than the front wheels.
Page 492 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... requires special test equipment and knowledge and should be performed only by an authorized BMW dealer. Table c. ASC indicator lamp function lists the conditions indicated by the ASC indicator light in the instrument cluster.
Page 493 Light flashes ASC active mode Normal ASC operation as it controls wheel speed Light stays on after start up or Defect in ASC Consult BMW dealer for comes on while driving diagnosis/repair (vehicle operation remains normal) Dynamic Stability Control (DSC)
Page 494 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 2 - Steering angle sensor 3 - Rotational rate (yaw) sensor 4 - Brake pressure sensor 5 - ABS wheel speed sensors 6 - Engine control module Outputs 7 - ABS/DSC hydraulic system...
Page 495 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... System functions Each of the electronic braking and stability control systems include sub-systems which use the hydraulic unit/control module and sensors to carry out additional system functions. The foundation of the stability control...
Page 496 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... wheel brake circuit during cornering if activation threshold values are exceeded. Electronic brake proportioning (EBV) Electronic brake proportioning adjusts braking force to the rear wheels based upon the vehicle's loading, front to rear, to maximize the vehicle's braking power.
Page 497 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Pressure release When intervention is necessary: The changeover valve in the hydraulic unit energizes and closes inlet valves for the two front wheels and the rear wheel with traction. The rear brake circuit intake valve is energized and opened to rear wheel without traction.
Page 498 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Drag torque reduction (MSR) During deceleration and engine braking conditions engine drag torque can cause the rear wheels of a vehicle to lock on low traction surfaces, especially in high speed, low gear driving. This can lead to loss of traction in the rear.
Page 499 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... When DBC function is activated, braking pressure will increase at all wheels up to the ABS regulation point. DBC will continue until the driver releases the brake pedal, brake pressure drops, or the vehicle slows to under 3 mph.
Page 500 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... threshold Vehicle road speed drops below 3 Teves MK 20 ASC diagram 14 of 24 2/25/2009 10:24 PM...
Page 501 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Teves MK 20 DSC Diagram 15 of 24 2/25/2009 10:24 PM...
Page 502 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Vehicle network The hydraulic unit/control module communicates with some sensors and many other control modules over the CAN-bus. The CAN-bus is a system of wiring that functions like a computer network, allowing different components...
Page 503 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... from ASC/DSC switch on dash. ABS control module signals turn instrument cluster warning lamps on during ASC/DSC regulation. Hydraulic unit/control module The hydraulic unit is mounted in conjunction with the control module. While the hydraulic unit and control module function as one unit, they are replaceable individually.
Page 504 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 2001 Bosch DSC III 5.7: Hall effect 2001 Teves MK 60 DSC: Magnetoresistive 1 - Fastening element 2 - Ground contact 3 - Sensor wiring 4 - Sensor housing 5 - Metal pulse wheel...
Page 505 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... DSC lateral acceleration sensor The lateral acceleration sensor provides the DSC control module with an input signal based on the degree of lateral acceleration (g forces) that the vehicle experiences. Based on a 5 volt reference voltage, the sensor will return an output voltage that ranges between 0.5 and 4.5...
Page 506 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Bosch DSC III 5.7 diagram 20 of 24 2/25/2009 10:24 PM...
Page 507 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... DSC rotational rate (yaw) sensor The rotational rate sensor provides a analog voltage signal to the DSC control module to indicate the rotational speed (yaw) of the vehicle on its vertical axis. The control module supplies a 5 volt reference voltage to the sensor.
Page 508 This recalibration is performed using either the DIS or MoDiC BMW scan tools. DSC pressure sensor The DSC pressure sensor(s) provides the ABS/DSC control module an analog voltage signal in proportion to brake pressure in the master cylinder.
Page 509 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Brake light switch The brake light switch input signal is used by the control module to determine which stability control routine is necessary. The control module will interrupt Automatic Stability Control (ASC) functions if the brake pedal is depressed during ASC operation.
Page 510 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... control module. When fluid level is too low, the circuit is broken and the ASC/DSC functions are turned off. Normal braking and ABS remains unaffected. Warning lamps Braking and stability control warning lights 1 - ASC/DSC warning light.
Page 511 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 300-3 Troubleshooting Stable handling and ride comfort both depend on the integrity of the suspension and steering components. Any symptom of instability or imprecise road feel may be caused by worn or damaged suspension components.
Page 512 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Symptom Probable cause Repairs vibration or shimmy Worn suspension bushings Replace worn bushings. (control arm or trailing arm) 310, Worn front suspension ball Replace worn ball joints. joints (control arm, steering arm or steering tie-rod end) Unbalanced or bent Balance tires.
Page 513 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Symptom Probable cause Repairs Suspension noise, especially Worn front upper strut Replace upper strut mounts. over bumps (drumming, mounts rattling) Worn suspension bushings Replace worn bushings. (control arm or trailing arm) 310, Worn stabilizer bar rubber...
Page 514 Brake bleeding functions, as well as component coding and initialization must be completed using BMW scan tools DIS or MoDiC. ABS system inspection A visual inspection of the ABS system components may help to locate system faults.
Page 515 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... missing, clogged or corroded teeth, or other damage that could alter the clearance between the sensor tip and toothed wheel. Ride height Ride height measurement (A) at either axle is taken from center of wheel arch to bottom of wheel rim.
Page 516 Suspension, Steering and Brakes — General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Wheel size Standard Sport Rough road All wheel drive suspension suspension suspension suspension 16 inch 589 mm 574 mm 606 mm 606 mm (23.19 in.) (22.59 in.) (23.86 in.) (23.85 in.) 17 inch...
Page 517 Read the procedures through before beginning any job. Engine support bracket BMW 00 0 200/00 0 205 Bearing puller BMW 00 7 500/31 2 106 Wheel bearing installation tool BMW 31 2 110 1 of 5 2/25/2009 10:25 PM...
Page 518 31 2 210 Front coil spring compressor BMW 31 3 Ball joint puller (all wheel drive BMW 32 2 040 Ball joint puller BMW 32 3 090 Outer CV joint removal tool BMW 33 2 111/116/117 2 of 5 2/25/2009 10:25 PM...
Page 519 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Slide hammer with adapter BMW 33 4 201/202/203 33 2 116 Inner bearing race puller set BMW 33 4 Front suspension construction Some front suspension components are constructed of weight saving materials. For example, the control arms (in rear wheel drive models) are forged aluminum.
Page 520 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... self-locking fasteners any time they are loosened or removed. Do not install bolts and nuts coated with undercoating wax, as the correct tightening torque cannot be assured. Always clean the threads with solvent before installation, or install new parts.
Page 521 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... assembly (6 cylinder models) - Upper strut mount - Coil spring - Strut assembly - Control arm - Control arm bushing and mount - Tie rod - Steering rack - Front stabilizer - Front suspension subframe 10 - Steering arm...
Page 522 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 310-2 Shock Absorbers and Springs Note: Setting the ride height is covered in 300 Suspension, Steering and Brakes- General. The front suspension shock absorbers in E46 cars are McPherson struts. The strut is a major component of the suspension and supports the spring.
Page 523 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Note: Right side shown is in illustration. Left side bracket also holds brake pad wear sensor wire. Unbolt brake caliper assembly, keeping brake hose connected. Suspend brake caliper from chassis using stiff wire. See Brakes. Remove ABS wheel speed sensor mounting bolt (arrow).
Page 524 Remove tie rod outer end nut. Use BMW special tool 32 3 090 or equivalent to press tie rod end off steering arm. Remove lower ball joint nut. Use...
Page 525 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... strut tower slots (arrows). CAUTION! Do not remove center strut retaining nut. Lower strut assembly from car. When installing strut assembly into car: Make sure locating pin (arrow) of strut bearing is positioned correctly in strut tower.
Page 526 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Have car professionally aligned when job is complete. Tightening torques Brake caliper to 110 Nm (81 steering arm ft-lb) Road wheel to hub 100 ± 10 Nm (74 ± 7 ft-lb) Stabilizer bar link to strut 59 Nm (44 ft-lb)
Page 527 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... - Rivet (all wheel drive or rough road package only) - Strut bearing reinforcement (all wheel drive or rough road package only) - Self locking flanged nut M8 tighten to: 24 Nm (18 ft-lb) (18 mm flange)
Page 528 Make sure the spring compressor grabs the spring fully and securely before compressing it. Pry protective cover off top of strut assembly. Use BMW special tool 31 2 210 or equivalent socket to remove strut top (center) nut. Counterhold strut shaft using 6 mm Allen wrench.
Page 529 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... related components. Replace strut, upper strut mount or spring, as needed. Note: Springs and/or struts should always be replaced in pairs. Be sure that replacement struts are marked with the same code as the ones being removed.
Page 530 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Assembly is reverse of disassembly, noting the following: Line up slot in spring pad with corresponding slot in lower spring seat. Use a new upper strut self locking nut. Tighten nut fully before releasing spring compressor. Be sure upper spring pad is...
Page 531 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 10 - Strut housing 11 - Locating pin 12 - Protective cap 13 - Upper spring pad 14 - Washer 15 - Upper spring seat 16 - Spring 17 - Lower spring seat Tightening torque Upper strut mount...
Page 532 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 310-3 Front End Reinforcement In rear wheel drive models, a front end reinforcement is bolted to the rear of the subframe and attached to the frame rails. CAUTION! Do not drive vehicle without the front end reinforcement in place. Damage to the front suspension may result.
Page 533 B. When reinstalling front end reinforcement: Replace mounting bolts. Torque bolts in 2 stages, as shown below. Use BMW special tool 00 9 120 or equivalent torque angle protractor. Tightening torque Front end reinforcement to front...
Page 534 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 310-4 Front Subframe The front subframe provides rigid mounting points for the engine, suspension, and steering components. The subframe is not normally subject to wear and should only be replaced if structurally damaged. Rear wheel drive and all wheel drive models differ significantly in the design of the front subframe.
Page 535 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... stands beneath a structural chassis point. Do not place jack stands under suspension parts. Remove splash shield under engine compartment. Remove front end reinforcement. Front End Reinforcement earlier in this group. On cars equipped with xenon headlights: Remove front ride level sensor mounting fastener (arrow) and lay sensor aside.
Page 536 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Repeat for left side. Remove steering rack mounting bolts (arrows) at front of subframe. Suspend rack out of the way with stiff wire. Remove right lower engine mount fastener (arrow). Repeat on left side Support suspension subframe from below using appropriate jacking equipment.
Page 537 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... and mating surfaces are clean to ensure proper tightening and alignment. Use new self-locking nuts or bolts, where applicable. Lower engine onto engine mounts, allowing it to settle fully before tightening engine mount bolts. When the job is completed, have front end professionally aligned.
Page 538 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques M12-10.9 bolts 110 Nm (81 ft-lb) M12-12.9 bolts 105 Nm (77 ft-lb) Front subframe, removing and installing (all wheel drive models) Using engine support equipment, raise engine until weight of engine is supported. Raise car and remove front wheels.
Page 539 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Working at rear right corner of front subframe, unhook heatshield from subframe (arrow). Remove left engine mount fastener (arrow). Repeat for right side. Working at right front of subframe, detach power steering lines. Remove stabilizer bar anchor fasteners (arrows) from front corners of subframe.
Page 540 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Repeat for right side. Working at left side of subframe, remove inner control arm ball joint mounting bracket bolts (arrows) from subframe. Hang control arm using stiff wire. WARNING! Do not allow the control arm to hang from the outer (steering arm) ball joint.
Page 541 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Installation is reverse of removal, noting the following: Make sure all bolts, bolt holes, and mating surfaces are clean to ensure proper tightening and alignment. Use new self-locking nuts or bolts, where applicable. Lower engine onto engine mounts,...
Page 542 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques Steering rack to subframe (M10 bolt) 42 Nm (31 ft-lb) Subframe adapter to body M10 bolt (always replace) 59 Nm (44 ft-lb) Subframe front to body M12-8.8 bolt 77 Nm (57 ft-lb) M12-10.9 bolt 110 Nm (81 ft-lb) M12-12.9 bolt...
Page 543: Control Arms
Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... - Bolt M10 (always replace) tighten to 59 Nm (44 ft-lb) - Control arm rear bracket 10 - Bolt M12 (always replace) tighten to 110 Nm (81 ft-lb) 11 - Jack point 12 - Subframe mounting bolt...
Page 544 The control arm with ball joint(s) is available as a replacement unit from BMW. E46 cars have been equipped with three different styles of control arm. Make sure a replacement control arm is identical to the original.
Page 545 Remove self levelling headlight sensor mounting nuts (arrows) from right control arm. Working at steering arm, remove outer ball joint nut (arrow). Use BMW special tool 32 3 090 or equivalent to separate steering arm from control arm. 12 of 24...
Page 546 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove control arm inner ball joint mounting nut (arrow) at subframe. Drive ball joint shaft out of subframe using soft faced hammer. Support control arm while removing control arm bracket bolts (arrows) from frame rail. Remove control arm.
Page 547 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... If one control arm rear rubber bushing is damaged, bushings on both sides must be replaced. Note: Control arm rear bushing replacement is covered later in this group. Installation is reverse of removal, noting the following: Make sure all thread bores, bolts, nuts and mating surfaces are clean.
Page 548 Remove headlight vertical aim sensor mounting nuts (arrows) from right control arm. Working at steering arm, remove outer ball joint nut (arrow). Use BMW special tool 32 3 090 or equivalent to separate steering arm from control arm. 15 of 24...
Page 549 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove inner ball joint mounting bracket bolts (arrows) from subframe. Support control arm. Working at rear of subframe, remove control arm rear bracket mounting bolts (arrows). Remove control arm. Inspect rear bracket rubber bushing for wear. Check ball joints for damage, looseness, or torn boots.
Page 550 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Inner ball joint and control arm rear bushing replacement is covered later in this group. Installation is reverse of removal, noting the following: Make sure all thread bores, bolts, nuts and mating surfaces are clean. Use new self-locking nuts or bolts, where applicable.
Page 551 Remove nut (A) from ball joint shaft. Remove bolts (B) from subframe. Use BMW special tool 32 2 040 or equivalent to separate ball joint from control arm. Installation is reverse of removal, noting the following: Make sure thread bores, bolts, nuts and mating surfaces are clean.
Page 552 The rubber coated inner sleeve is destroyed when it is pulled off dry. Check with an authorized BMW parts dealer for the latest information about control arm bushing applications on E46 cars. Control arm bushings should always be replaced in pairs.
Page 553 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Inspect bushing bracket. Replace bracket if there is a center punch mark at boss A. WARNING! If a bushing bracket with the center punch mark is reused with a new bushing, the bushing may fall out. Use press tools to remove old bushing and press in new.
Page 554 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... protrusion (rear wheel drive models) Dimension 60 mm 66 mm bushing bushing A = Total 50.5 mm 53.5 mm bushing (1.99 in.) (2.11 in.) length (nominal) B = Bracket 34.0 mm (1.36 in.) width (nominal) 8.5 mm 12.0 mm...
Page 555 The rubber coated inner sleeve is destroyed when it is pulled off dry. Check with an authorized BMW parts dealer for the latest information about control arm bushing applications on E46 cars. Control arm bushings should always be replaced in pairs.
Page 556 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... CAUTION! Never reuse a rubber bushing that has been pulled off the control arm. The rubber coated inner sleeve is destroyed when it is pulled off dry. When installing bushing on control arm: Coat control arm pin and rubber mount with appropriate lubricant to facilitate installation.
Page 557 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... WARNING! After installation, the car must be left undisturbed for a minimum of 30 minutes. Leave car on the ground but avoid major movement. After approx. 30 minutes, the lubricant used to slide on the bushing will have evaporated and the control arm will be correctly seated in the rubber.
Page 558: Stabilizer Bar
Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 310-5 Stabilizer Bar Stabilizer bar, removing and installing On E46 models the stabilizer bar links attach to the strut assemblies. Raise car and support safely. WARNING! Make sure that the car is firmly supported on jack stands designed for the purpose.
Page 559 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... If necessary, loosen and remove stabilizer bar link mounting nut (arrow) from strut. Detach link from strut housing. Note: Use a thin wrench to counterhold shaft of stabilizer bar link ball joint while removing mounting nut. Installation is reverse of removal,...
Page 560: Front Wheel Bearings
Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 310-6 Front Wheel Bearings The front wheel bearings are permanently sealed and require no maintenance. On rear wheel drive models, the bearing is integral with the wheel hub and ABS pulse wheel and pressed on the steering arm stub axle.
Page 561 Remove wheel hub collar nut. Remove wheel hub with integral wheel bearing from steering arm using a slide hammer puller (BMW special tools 33 4 201, 33 4 202, 33 4 203 and 33 2 116) or conventional puller as illustrated.
Page 562 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... If outermost bearing inner race stays on steering arm stub axle, use BMW special tool set 33 4 400 or two-jaw puller to remove race. CAUTION! Do not reuse a wheel bearing assembly once it has been removed.
Page 563 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Mount wheel and lug bolts. Lower car to ground to gain leverage. Tightening torques Brake caliper to steering arm 110 Nm (81 ft-lb Brake rotor to wheel hub 16 Nm (12 ft-lb) Road wheel to hub 100 ± 10 Nm (74 ±...
Page 564 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... accomplished by removing the steering arm and wheel hub from the car and separating the components on the bench. Raise car and remove front wheel. WARNING! Make sure that the car is firmly supported on jack stands designed for the purpose.
Page 565 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove tie rod outer end nut. Use BMW special tool 32 3 090 or equivalent to press tie rod end off steering arm. Detach control arm from front axle subframe as described earlier. Remove outer ball joint nut. Use...
Page 566 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove circlip (3) from steering arm. 1 - Steering arm 2 - Wheel bearing 3 - Circlip (always replace) 4 - Dust guard 5 - Wheel hub Drive wheel bearing out of steering arm using a press with appropriate adapters.
Page 567 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Replace circlip, making sure ring is correctly seated. Place dust guard over steering arm hub. Drive wheel hub into bearing using a shop press. CAUTION! Press only on the inner race. The bearing is damaged if it is not pressed on using the inner race.
Page 568 Front Suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques Steering arm pinch bolt at strut housing 81 Nm (60 ft-lb) Road wheel to hub 100 ± 10 Nm (74 ± 7 ft-lb) Tie rod to steering 65 Nm (48 ft-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved.
Page 569 Commonly available pullers and drifts can often be substituted for the specified tools. Read the procedures through before beginning any job. Engine support bracket BMW 00 0 200 1 of 5 2/25/2009 10:27 PM...
Page 570: System Description
Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Transmission flange holder BMW 23 0 Inner CV joint puller BMW 31 1 170 Impact drift BMW 31 5 130 Outer CV joint removal tool BMW 33 2 111/116/117 System description The front axle final drive unit is integrated into the engine oil pan on all wheel drive equipped models.
Page 571 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... bearing pedestal bolt to each side of a modified oil pan. Power is transmitted to the front differential from the transfer case via a driveshaft, and out to front drive hubs through two drive axles.
Page 572 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... - Bolt M10 (always replace) tighten to 59 Nm (44 ft-lb) - Bolt M12 tighten to 77 Nm (57 ft-lb) 10 - Front control arm with ball joint and rear mounting bracket 11 - Front...
Page 574 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 311-2 Drive Axles The front drive axles for all wheel drive equipped models use two different types of constant-velocity (CV) joint. The outer CV joints are a traditional design that allows power to be delivered from the axle to the joint continuously through rotation.
Page 575 Unfasten stabilizer link from stabilizer bar. Remove collar nut from drive axle at steering arm. Using BMW special tool 33 2 111/116/117, or similar tool, press outboard end of axle out from drive flange at steering arm. Remove inner ball joint mounting bracket bolts (arrows) from subframe.
Page 576 (arrows). Tilt steering arm to one side, out of the way. Using BMW special tool 31 1 170 or equivalent pry bar, pry inboard CV joint out of front differential or bearing pedestal.
Page 577 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Be sure to restake new collar nut at outboard end of drive axle after tightening to correct torque specifications. Caulk axle threads. Top up differential fluid. See Front differential oil, checking and filling Tightening torques...
Page 578 (arrows). Tilt steering arm to one side, out of the way. Using BMW special tool 31 1 170 or equivalent pry bar, pry inboard CV joint out of front differential or bearing pedestal.
Page 579 Drive axle radial seal is equipped with protective covering to prevent sealing lip from damage during installation. Using BMW special tool 31 5 130 or equivalent drift, drive radial seal into differential housing or bearing pedestal. Coat sealing lip of radial seal with transmission fluid.
Page 580 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Insert inboard end of drive axle partially into differential housing or bearing pedestal. Withdraw protective sleeve from sealing lip, cut protective sleeve and remove sleeve. Continue installing drive axle until spring clip snaps audibly into place.
Page 581 A kit will include a new boot, clamping bands, special lubricant, and a new outer CV joint axle circlip. A kit is available from an authorized BMW dealer parts department. Remove drive axle from vehicle as described earlier.
Page 582 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Apply Loctite® 270 or an equivalent heavy-duty locking compound to drive axle splines. WARNING! Do not let locking compound contact balls in joint. Apply only a thin coat to cover splines. Pack outer CV joint with fresh grease.
Page 583 A kit will include a new boot, clamps, special lubricant, and a new inner universal joint circlip. A kit is available from an authorized BMW dealer parts department. Remove drive axle from vehicle as described earlier.
Page 584 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove circlip retaining triple roller bearing to drive axle and remove triple roller bearing. Slide boot off drive axle. Separate inner CV joint boot adapter from boot. Clean all old lubricant off axle splines and triple roller bearing splines.
Page 585 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... boot kit. Installation is reverse of removal, noting the following: Make sure inboard end of drive axle audibly snaps into place. Replace control arm bracket bolts. Be sure to restake new collar nut at outboard end of drive axle after tightening to correct torque specifications.
Page 586 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... - Circlip - Triple roller bearing - Inner CV joint boot adapter - Clamp - Inner CV joint boot - Drive axle shaft - Clamp Copyright © 2006 Robert Bentley, Inc. All rights reserved. 13 of 13...
Page 587 Right axle bearing pedestal, removing and installing. Front differential oil, checking and filling Note: BMW supplies the E46 all wheel drive models with lifetime lubrication in the front differential. Front differential drain plug and fill plug (arrows). Note: Use an Allen bit socket to remove drain plug.
Page 588 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Final drive drain and fill Oil specifications BMW SAF-XO synthetic oil Front axle differential oil 0.7 liters (0.74 capacity US qts.) Tightening torque Front axle differential drain / fill plug 65 Nm (48 ft-lb) Front axle differential,...
Page 589 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Release nut at top on right engine mount (arrow). Remove nut (arrow) at bottom on left engine mount. Raise engine approximately 10 mm (0.4 in.). Remove front wheels. Unbolt brake calipers and suspend from body using stiff wire. See Brakes.
Page 590 (arrows). Repeat for right side. Remove left tie rod outer end nut (arrow). Use BMW special tool 32 3 090 or equivalent to press tie rod end off steering are. Repeat for right side.
Page 591 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Note: Be prepared to catch oil drips from differential or right side bearing pedestal. Working on left side of car: Release pinch bolt (arrow) at top of steering arm. Pull steering arm down from strut assembly.
Page 592 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... harnesses and other under body components are clear during removal. Detach vent tube from port (A) on front axle differential. Remove mounting bolts (B) and remove front axle differential. Install new sealing ring, coating inside edge with assembly lubricant.
Page 593 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques Brake caliper to 110 Nm (81 steering arm ft-lb) Control arm bracket to front suspension subframe (replace bolts) 59 Nm (44 ft-lb) Engine mount to subframe M10 self locking nut 45 Nm (33 ft-lb)
Page 594 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques M12-10.9 bolt 110 Nm (81 ft-lb) M12-12.9 bolt 105 Nm (77 ft-lb) Subframe rear to adapter M12 bolt 110 Nm (81 (always replace) ft-lb) Right axle bearing pedestal, removing and installing Lift vehicle and support safely.
Page 595 Support control arm. Working at rear of subframe, remove control arm rear bracket mounting bolts (arrows). Using BMW special tool 31 1 170 or equivalent pry bar, pry inner CV joint out of bearing pedestal. Release pinch bolt at top of steering arm.
Page 596 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... on oil pan, the assembly ring is forced over sealing ring and remains in place. Installation is reverse of removal, noting the following: Always replace drive axle radial seal before installing drive axle. Top up differential fluid. See...
Page 597 Using a centerpunch, mark relation of input flange retaining nut to output shaft. Counterhold input flange in place using BMW special tool 23 0 020 and remove nut. Pull input flange out from differential using a hub puller. Remove input seal dust shields.
Page 598 Front Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... BMW special tool 31 5 130 or equivalent drift. Replace dust shields. Clean input flange and install into differential housing. Tighten down nut until punch marks align. Install new input flange retaining nut locking plate.
Page 599 Be sure to read the procedures through before starting work on the vehicle. Inner tie rod removal tool BMW 32 2 Rear toe adjusting tool BMW 32 3 030 1 of 4 2/25/2009 10:28 PM...
Page 600: Steering System
Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tie rod end removal tool BMW 32 3 090 Front camber adjusting tool BMW 32 3 Steering system The variable-assist power steering system consists of an engine-driven hydraulic pump, a rack-and-pinion steering rack assembly with an integral hydraulic control valve, and connecting linkage to the road wheels.
Page 601 WARNING! The BMW airbag system (MRS II) is complex. Special precautions must be observed when servicing the system. Serious injury may result if system...
Page 602 Note: The airbag system is traditionally referred to as Supplemental Restraint System (SRS). The BMW version of SRS used in 1999 to 2001 E46 models is known as the Multiple Restraint System (MRS II). Copyright © 2006 Robert Bentley, Inc. All rights reserved.
Page 603: Steering Wheel
Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 320-2 Steering Wheel Steering wheel, removing and installing Center steering wheel. Make sure front wheels are pointed straight ahead. Disconnect negative (-) cable from battery. CAUTION! Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.
Page 604 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... The steering column and steering wheel are matchmarked (arrow) at the factory. Confirm these marks before removing wheel from column. Remove steering wheel. When reinstalling steering wheel: Align steering wheel and column match marks. Align steering wheel to alignment pins located on steering column switch block.
Page 605: Steering Column
Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 320-3 Steering Column Steering column assembly - Hex bolt (M14 x 1.5) tighten to 63 Nm (46 ft-lb) - Cable duct - Steering column adjustment lever - Upper steering column - Lower steering column with...
Page 606 To remove the ring antenna prior to removing ignition lock cylinder, it is necessary to remove the upper and lower steering column trim. Use BMW special tool 61 3 300 to force off the ring antenna. Alternatively, remove the ignition switch key cylinder first.
Page 607 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Reinstallation is reverse of removal. Lower steering column, removing and installing Note: Once the lower steering column has been removed there will be no end stop for the steering wheel. In order to prevent damage to contact ring in steering column, follow procedural steps as listed.
Page 608 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Working near firewall, remove pinch bolt at universal joint and remove lower steering column. Note: Upper steering column is keyed to lower steering column universal joint. It can only be installed in one position. Installation is reverse of removal, noting...
Page 609 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Push in sides of upper trim cover (arrows) to release from lower trim. Pull back and up on upper trim. Pry gently to detach flexible cover from upper trim. Lift off trim. Remove left footwell (pedal cluster) trim panel.
Page 610 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Unplug connector at footwell interior light (A), if equipped. Slide lock at OBD II connector (B) in direction of arrow. Unplug connector at cellular phone speaker (C) if equipped. Remove lower steering column as described earlier.
Page 611 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove shift interlock cable (A) if necessary. Disconnect electrical harness connector at EWS 3.3 ring antenna (B). Working at steering column, detach wiring harness from cable duct. Drill out steering column mounting shear bolt (A), and remove mounting bolt (B).
Page 612 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... until bolt head shears off. Make sure lock of interlock cable snaps into place. When installing column top trim panel, replace expansion nut for trim retaining screw. When installing lower trim panel, push expansion rivet pin into rivet until pin head is flush with rivet head.
Page 613: Power Steering System
Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 320-4 Power Steering System The power steering fluid reservoir is located on the lower left front of the engine. CAUTION! Maintain clean conditions when working with open power steering fluid lines. Plug off power steering lines and connections to keep out contamination.
Page 614 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... - Banjo bolt M16 tighten to 40 Nm (30 ft-lb) - Power steering rack - Pressurized fluid line - Fluid return line 10 - Fluid cooler 11 - Rack boot kit 12 - Tie rod nut...
Page 615 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... fluid reservoir with clean fluid. Fill level to MAX mark on dip stick. Start engine. Slowly turn steering wheel from lock to lock a minimum of two times. Turn engine off and check fluid level, adding more if necessary.
Page 616 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove front stabilizer bar anchors and swing stabilizer bar down out of the way. See 310 Front Suspension. Remove pump mounting bolts (arrows) and remove pump. Rear wheel drive model shown. Installation is reverse of removal,...
Page 617 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Steering rack, removing and installing Empty power steering fluid reservoir using clean syringe. Do not reuse fluid. Raise front of car, and remove wheels. Remove splash shield from under engine. Make reference measurement (A) of left outer tie rod end to tie rod.
Page 618 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Working underneath car, remove fluid line banjo bolts (arrows) from steering rack. CAUTION! Plug off power steering lines and connections to keep out contamination. Note: It may be necessary to remove other components to gain access to steering rack.
Page 619 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Make sure all thread bores, bolts, nuts, splines and mating surfaces are clean. Use anti-seize paste on inner tie rod threads. Use new self-locking nuts wherever applicable. Use keyed components to reassemble steering column flexible joint to steering rack shaft.
Page 620 Remove outer tie rod ball joint nut. Separate outer tie rod end from steering arm using BMW special tool 32 3 090 or equivalent. Make reference measurement (A) of outer tie rod end to tie rod. Record measurement.
Page 621 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Note correct placement of inner taper on locking ring Loosen outer tie rod end lock nut (arrow). Unscrew tie rod end from tie rod shaft. Installation is reverse of removal. Make sure all threaded parts are clean.
Page 622 Replace if necessary. Note: New rack boot kit comes with new band clamp. Using BMW special tool 32 2 110 remove inner tie rod shaft from steering rack. CAUTION! To avoid damage to steering rack while removing tie rod, turn steering...
Page 623 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... When reassembling, grease tie rod taper so that rack boot support buffer or small end of rack boot (inset) slides on tie rod when tie rod is tightened, preventing rack boot from twisting. Installation is reverse of removal,...
Page 624: Wheel Alignment
This is known as a four-wheel or thrust-axis alignment. The BMW E46 uses a sophisticated multi-link suspension at the front and rear of the car. Proper alignment requires computerized alignment equipment.
Page 625 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... WARNING! While performing alignment procedures, make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support.
Page 626 (A) in upper strut housing. Loosen upper strut mount nuts (B). Use BMW special tool 32 3 140 to adjust position of upper strut mount studs in slotted holes (arrows). Tightening torque...
Page 627 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Note: Steering rack can be centered by aligning centering mark on steering shaft with lug on steering rack. To keep steering wheel centered, adjust both tie rods equal amounts. Make sure the rubber boot on the rack moves freely on the tie rod and does not become twisted.
Page 628 Steering and Wheel Alignment http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Install BMW special tool 32 3 030 over alignment lug (A) and adjacent bolt. Use tool to adjust position of bracket. Remove tool and tighten trailing arm bracket mounting bolts. Tightening torque Rear trailing arm...
Page 629 Most of these tools are specialized presses and pullers that might be replaced by standard pullers of various sizes. Read the procedures through before beginning any job. Bearing splitter BMW l 00 7 500 1 of 3 2/25/2009 10:30 PM...
Page 630 Drive axle press BMW set 33 2 115/116/119 Flange puller BMW set 33 2 116/4 201/4 202/4 203 Inner bearing race puller BMW set 33 4 Wheel bearing extractor B90 (Source: Baum Tools Unlimited) Rear suspension description BMW uses an independent rear...
Page 631 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... suspension. The rear subframe (final drive carrier) supports the rear differential and provides mounting points for the upper and lower control arms. The upper control arm on each side provide the lower spring perch for the coil spring.
Page 632 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 330-2 Rear Shock Absorbers and Springs Replace shock absorbers and springs in pairs only. Rear shock absorber, removing and installing Raise car and remove rear wheels. WARNING! Make sure that the car is firmly supported on jack stands designed for the purpose.
Page 633 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... compartment to access upper shock absorber mount. On Sport Wagon models: Working in cargo compartment, remove side trim next to rear seat backrests. Support shock absorber from below while removing upper mounting nuts. Lower shock absorber out of wheel housing.
Page 634 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Make sure rectangular thrust washer on lower mounting bolt is between bolt head and shock absorber rubber. Tighten lower shock absorber bolt to its final torque once car is on ground. Tightening torques Road wheel to hub 100 ±...
Page 635 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... subframe. Remove rear brake line bracket mounting bolt (arrow). Detach bracket from trailing arm. CAUTION! Avoid damaging the brake hose by stretching when the trailing arm is lowered. Support trailing arm from below using an adjustable jackstand. Remove shock absorber lower mounting bolt (arrow).
Page 636 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... To install spring: Coat top spring pad with anti-friction paste (e.g., tire mounting paste). Slowly lift suspension back into position, making sure coil spring is correctly seated in upper and lower spring seats. When suspension has been lifted sufficiently, reattach shock absorber to trailing arm.
Page 637 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques position) Copyright © 2006 Robert Bentley, Inc. All rights reserved. 6 of 6 2/25/2009 10:30 PM...
Page 638 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 330-3 Rear Suspension Arms, Subframe and Bushings The trailing arms, control arms and their mounting bushings control the position of the rear wheels. A damaged suspension arm or worn bushings will change the rear wheel alignment and may adversely affect handling and stability.
Page 639 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... - Upper control arm outer bolt self-locking M12 tighten to 110 Nm (81 ft-lb) - Trailing arm - Lower control arm eccentric bolt eccentric flat M12 washer self locking M12 tighten to 110 Nm (81 ft-lb) - Trailing arm...
Page 640 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 13 - Lower control arm inner M12 bolt lock plate tighten to 110 Nm (81 ft lb) Trailing arm, removing and installing Raise rear end of car and remove wheel. WARNING! Make sure that the car is firmly supported on jack stands designed for the purpose.
Page 641 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... CAUTION! Avoid damaging the brake hose by stretching when the trailing arm is lowered. Remove fuel tank protective panel, if equipped. Remove ABS pulse sensor from trailing arm. Unclip pulse sensor and pad sensor (if applicable) harnesses from control arm and lay aside.
Page 642 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Unbolt upper and lower control arms from trailing arm. Note direction of bolt insertion in both arms. To remove trailing arm: Make reference marks to locate trailing arm bracket to body in order to maintain alignment specifications.
Page 643 Brakes. Have car professionally aligned when job is complete. Note: BMW-supplied replacement trailing arms come with control arm bushings installed. A new wheel bearing will have to be installed. Tightening torques Drive axle collar nut to drive flange...
Page 644 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques normal loaded position) Trailing arm bracket to body (M12 bolt) 77 Nm (57 ft-lb) Trailing arm to upper or lower control arm (M12 bolt) 110 Nm (81 ft-lb) Upper control arm, removing and installing Remove drive axle as described in 331 Rear Axle Final Drive.
Page 645 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... If necessary, remove ride level sensor from upper control arm. Unbolt upper control arm from both trailing arm and rear subframe. Note direction of bolt insertion. Note: For clearance reasons, it may be necessary to unbolt the differential from...
Page 646 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques Road wheel to hub 100 ± 10 Nm (74 ± 7 ft-lb) Shock absorber to trailing arm car in normal loaded position 100 Nm (74 ft-lb) Upper control arm to rear subframe M12 bolt 77 Nm (57 ft-lb)
Page 647 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Use a soft hammer to tap control arm out of its mounting points. Installation is reverse of removal. Welded seam of control arm faces upward. To install mounting hardware at subframe, insert lock plate into opening in subframe from below.
Page 648 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Detach rear driveshaft from rear differential. See Driveshaft. Detach rear drive axles from rear differential. Remove rear differential. 331 Rear Axle Final Drive. Detach rear control arms as described earlier Remove rear subframe mounting fasteners (arrows) while supporting subframe securely.
Page 649 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques M10 compression 64 Nm (47 ft-lb) M10 Torx bolt 85 Nm (63 ft-lb) Lower control arm to subframe (M12) 110 Nm (81 ft-lb) Subframe to body (M12) 77 Nm (57 ft-lb) Upper control arm to subframe (M12)
Page 650 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... tighten to 77 Nm (57 ft-lb) - M8 bolt 8.8 grade tighten to 21 Nm (15 ft-lb) 10.9 grade tighten to 30 Nm (22 ft-lb) - M14 bolt tighten to 174 Nm (128 ft-lb) 10 - Bushing...
Page 651 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Support car securely before starting work underneath rear suspension. WARNING! Make sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.
Page 652 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques bracket Trailing arm bracket to body 77 Nm (57 ft-lb) Upper or lower control arm outer bushing (in trailing arm) Upper control arm bushing: Remove trailing arm from car as described earlier. Note direction of bolt insertion.
Page 653 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torques 250 Nm (184 ft-lb) 300 Nm (221 ft-lb) Drive axle to final drive flange M10x20 mm Torx bolt 83 Nm (61 ft-lb) M10x46 mm bolt (black) 100 Nm (74 ft-lb) M10x46 mm bolt (silver) (always...
Page 654 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Be sure that longer collar of bushing (A) is on same side as bevel in control arm. Outer bushing housing must be flush with control arm bore when fully pressed in. Have car professionally aligned when job is complete.
Page 655 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Rear subframe bushing Remove subframe as described earlier. In case of damage to subframe mounting stud threads, replace stud. In case of damage to subframe mounting stud threads in body, repair using Helicoil thread insert M12 x 1.5 x18.
Page 656 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torque M10x20 mm Torx bolt 83 Nm (61 ft-lb) M10x46 mm bolt (black) 100 Nm (74 ft-lb) M10x46 mm bolt (silver) (always replace) 80 Nm (59 ft-lb) Road wheel to hub 100 ± 10 Nm (74 ± 7 ft-lb)
Page 657 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 330-4 Rear Stabilizer Bar The rear stabilizer bar is mounted to the rear subframe and attached via stabilizer bar links to the rear upper control arms. 1 - Stabilizer bar 2 - Self-locking nut M8 3 - Rubber mounting...
Page 658: Rear Wheel Bearings
Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 330-5 Rear Wheel Bearings The rear wheel bearing is a unitized assembly and is not repairable separately. Special press tools, to be used with the trailing arm attached to the car, are required to replace a wheel bearing.
Page 659 The wheel bearing is destroyed when the drive flange is removed. Do not attempt to reuse bearing. Note: Use BMW special tool set 33 4 400 or equivalent to separate inner bearing race from drive flange. Remove bearing retaining circlip from bearing housing in trailing arm.
Page 660 (BMW special tools 33 3 261/262/263 or equivalent). CAUTION! BMW specifies special tools to pull the drive flange through the wheel bearing into position. If using alternative tools, be sure to support the bearing inner race when pressing or pulling the drive flange into place.
Page 661 Rear suspension http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Reinstall drive axle. Tightening torques Brake rotor to drive flange (M8) 16 Nm (12 ft-lb) Brake caliper to trailing arm (M12) 67 Nm (50 ft-lb) Drive axle collar nut to drive flange 250 Nm (184 ft-lb) 300 Nm (221...
Page 662 Some common pullers and drifts can often be substituted for these tools. Radial seal puller BMW 00 5 010 Flange counterhold tool BMW 23 0 020 Drive axle puller BMW 33 2 110 1 of 2...
Page 663 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Output flange seal drift BMW 33 3 400 Input flange seal drift BMW 33 3 430 Copyright © 2006 Robert Bentley, Inc. All rights reserved. 2 of 2 2/25/2009 10:32 PM...
Page 664 For replacement parts, only CV joints boots or complete axles are offered by BMW. To replace a CV joint boot, the drive axle must be removed from the car. The rear axle shafts are different in length.
Page 665 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Raise rear of car. Remove rear wheel. WARNING! Make sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.
Page 666 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Install road wheel and lower car to ground. With an assistant applying brakes, tighten drive axle collar nut to its final torque. Stake and caulk collar nut. Tightening torques Drive axle collar nut to drive flange...
Page 667 CV joint circlip. The kit is available from an authorized BMW dealer parts department. The outer CV joint cannot be removed from the axle shaft. In order to replace the outer CV boot, it is necessary to remove the inner joint and boot first.
Page 668 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... inner hub to axle shaft. Support inner hub at arrowswhen pressing axle shaft out of joint. Clean all old lubricant off shaft splines and inner joint's splines. CAUTION! If the CV joint must be disassembled...
Page 669 CV joint as far over as it will go. A small screwdriver inserted between the boot and the axle shaft will help the process. BMW recommends Bostik®1513 or Epple®4851 adhesive, and Epple®39 or Curil®T sealer. CV joint lubricant capacity Wheel hub end 80 gram (2.8 oz.)
Page 670 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... joint to shaft. CAUTION! If the joint and shaft are not reassembled in their original position the assembly may be out of balance and vibrate during operation. When reinstalling joint, push joint into shaft as far as it will go, then pull it out to measurement A(16 mm / 0.6 in.).
Page 671 330 Rear Suspension. Rear differential oil, checking and filling Note: BMW supplies the E46 rear differential with lifetime lubricant. To check rear differential oil level: Remove oil filler plug. Insert finger into fill hole. If finger is wetted from oil, level is correct.
Page 672 Differential oil capacity Rear wheel drive 0.9 liter (0.95 US qt.) All wheel drive 1.0 liter (1.06 US qt.) Oil specification BMW SAF-XO synthetic oil Tightening torques Differential drain or fill plug 70 Nm (52 ft-lb) Rear differential, removing and installing Raise rear end of car and support it securely on jack stands.
Page 673 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove heat shield between reinforcement brace and exhaust pipe. Remove bolts (A) mounting brace to undercarriage. Remove nuts (B) mounting brace and front of rear subframe to undercarriage. Lower and remove reinforcement. Note: If necessary, tilt rear half of exhaust system down.
Page 674 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... differential mounting bolts: Install bolts finger tight. Tighten front bolts (B). Tighten rear bolt (A). Tightening torques Differential drain or fill plug 70 Nm (52 ft-lb) Differential to rear subframe Front mount (M12 bolts) 95 Nm (70 ft-lb)
Page 675 Note: BMW uses bushings from different manufacturers in the course of production. Always check with an authorized BMW dealer for the latest information on suspension bushings. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 5 of 5 2/25/2009 10:33 PM...
Page 676 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 331-4 Rear Differential Oil Seals Low oil level caused by faulty oil seals may be the cause of noisy differential operation. The drive flange (side) and input shaft (front) oil seals can be replaced while the differential is installed.
Page 677 Replace the flange if there is a groove worn in the shaft. Pry old oil seal from its recess using BMW special tool 00 5 010 or equivalent seal puller. CAUTION! Be careful not to mar the differential housing when removing the seal.
Page 678 Rear Axle Final Drive http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Tightening torque Drive axle to differential flange M10x20 mm Torx bolt 83 Nm (61 ft-lb) M10x46 mm bolt (black) 100 Nm (74 ft-lb) M10x46 mm bolt (silver) (always replace) 80 Nm (59 ft-lb) Input drive flange oil seal, replacing Raise car and support safely.
Page 679 Make matching marks on differential input shaft, collar nut and driveshaft flange. Pry lock plate from nut. Counterhold input flange with BMW special tool 23 0 020 or equivalent and remove collar nut. If necessary, use puller to remove input flange. Note: Be prepared to catch dripping oil in a pan.
Page 680 Differential oil capacity Rear wheel drive 0.9 liter (0.95 US All wheel drive 1.0 liter (1.06 US qt.) Oil specification BMW SAF-XO synthetic oil Remainder of assembly is reverse of disassembly. Tightening torques Driveshaft to differential flange M10 compression 64 Nm (47 ft-lb...
Page 681 Suspension, Steering and Brakes- General. Special tools BMW requires the use of either the DIS or the MoDiC diagnostic tool to safely and completely bleed the braking and traction control systems. Read all procedures through before beginning a job.
Page 682 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Brake pad lining gauge BMW 34 1 260 Vacuum tester BMW 34 3 100 Factory diagnostic tool DISplus or MoDiC E46 brake system BMW E46 models are equipped with vacuum power-assisted four-wheel disc brakes with an integral Antilock Brake System (ABS).
Page 683 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... conjunction with engine management controls to control wheel spin and maintain vehicle stability while braking. Added midway through the 1999 model year was Dynamic Stability Control (DSC). This system uses ASC technology, but implements wheel speed modulation throughout all stages of driving.
Page 684 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Year System Identifiers (model) (manufacturer) 2001 Dynamic Stability Control (rear wheel drive) Control module/hydraulic unit (Teves MK 60 DSC) mounted under master cylinder. No precharge pump 2001 Dynamic Stability Control (all wheel drive) Control module/hydraulic unit (Bosch DSC III 5.7)
Page 685 Check brake booster: Remove vacuum hose (A) from brake booster and install BMW special tool 34 3 100 between connection and hose on non-return valve (B). Start engine and check build-up of partial vacuum.
Page 686 Unless it is noted otherwise, relevant repairs are described later in this repair group WARNING! All E46 cars require special BMW service equipment to properly bleed either the ABS/ASC or the ABS/DSC system. For safety reasons, the brake system on...
Page 687 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... water, as brake fluid will remove paint. Always use new brake fluid from a fresh, unopened container. Brake fluid will absorb moisture from the air. This can lead to corrosion problems in the braking system, and will also lower the brake fluid's boiling point.
Page 688 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Symptom Probable cause Repairs Low pedal after Master cylinder faulty Replace master cylinder. system bleeding Pedal spongy or Air in brake fluid Bleed system using factory or compatible brakes work only diagnostic tool when pedal is Master cylinder or Replace master cylinder.
Page 690 Be sure to have the special equipment needed before beginning the job. WARNING! E46 cars require special BMW service equipment to properly bleed either the ABS/ASC or the ABS/DSC system. For safety reasons, the brake system on these cars must not be bled without the use of a factory diagnostic computer.
Page 691 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... connect BMW Diagnosis and Information System (DIS) to 20 pin Data Link Connector (DLC) under hood (1999 models), or 16 pin DLC/OBD II connector under dash (2000- 2001 models). Call up service function Bleeding ABS/ASC or service function...
Page 692 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Proceed with remaining wheels in order as listed earlier. Tightening torques Bleeder screws (wrench size): 7 mm screw 3.5 - 5 Nm (2.5 - 3.7 ft-lb) 11 mm screw 12 - 16 Nm (9 - 12 ft-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved.
Page 693 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 340-3 Brake Pads, Calipers, and Rotors Brake pads can be replaced without disconnecting the brake fluid hose from the caliper or having to bleed the brakes. The rotors can be replaced without disassembling wheel hub and bearing. Always machine or replace rotors in pairs.
Page 694 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Torque to 30 Nm (22 ft-lb) - Brake caliper Brake line: torque to 18 Nm (13 ft-lb) Caliper removal - Brake pad wear sensor Brake pad wear sensor - Brake pad anti-rattle clip Brake pad anti-rattle clip - Brake pads Replacement warning at 3.0 mm...
Page 695 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... and free from grease See Front brake rotor - Rear brake rotor retaining screw Torque to 16 Nm (12 ft-lb) - Rear brake rotor Make sure contact surfaces are clean and free from grease. Parking brake drum dia. 160 mm (6.3 in.)
Page 696 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Make sure contact surfaces are clean and free from grease See Brake pad carrier 13 - Brake pad carrier retaining bolts Front: torque to 110 Nm (81 ft-lb) Rear: torque to 65 Nm (48 ft-lb) Oil bolts lightly.
Page 697 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... caliper piston will have to be pressed back into caliper before caliper can be removed. CAUTION! Pressing caliper piston in may cause brake fluid reservoir to overflow. To prevent this, use a clean syringe to first remove some fluid from reservoir.
Page 698 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Brake pad wear sensor Carefully pry pad wear sensor from brake pad. Insert brake pad wear sensor into cutout in new pad where applicable. If brake lining indicator light illuminated prior to brake pad replacement, replace wear sensor.
Page 699 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Brake pad lining thickness To measure brake pad lining thickness: Insert BMW special tool 34 1 260 at either front right wheel or left rear wheel Move wheel until notch for brake wear indicator can be seen through wheel opening.
Page 700 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Table c. Brake rotor reconditioning specifications Front Rear Vented rotor 20.4 mm 17.4 mm wear limit (0.80 in.) (0.68 in.) (min. thickness) Max. 0.8 mm 0.8 mm machine (0.03 in.) (0.03 in.) limit per friction ring side WARNING!
Page 701 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... before installing. When installing new rear brake rotors, the parking brake should be adjusted. See Parking brake. Tightening torque Brake rotor to hub mounting screw 16 Nm (12 ft-lb) Brake pad carrier removal Remove brake pad carrier mounting bolts (arrows) and remove pad carrier from steering arm or trailing arm.
Page 702: Master Cylinder
Stability Control (ASC) or Dynamic Stability Control (DSC). Replacing the master cylinder requires that the braking system be properly bled by an authorized BMW repair facility. This procedure is necessary for the braking and stability controls to function properly. Master cylinder, removing and...
Page 703 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove side trim panel from left rear of engine compartment: Remove rubber strip from top of trim panel at brake booster. Detach vacuum line (A) from brake booster Y-connector, unhook from trim panel and push to side. Unhook plastic vacuum line and...
Page 704 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... precharge pump supply hose. Plug hose and reservoir to prevent fluid leakage or contamination. Remove brake fluid reservoir. Working at master cylinder: Disconnect brake fluid lines and electrical harness connectors from master cylinder as needed. On vehicles equipped with Teves...
Page 705 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... pushrod and booster pushrod. Use care not to over-torque master cylinder mounting nuts. This could damage brake booster and prevent proper vacuum build-up. Connect brake fluid lines to master cylinder. Tightening torque Brake fluid lines to master cylinder...
Page 706: Brake Booster
Brake booster, removing and installing CAUTION! On cars with Automatic Stability Control (ASC) or Dynamic Stability Control (DSC), special BMW service equipment is required to properly bleed the brakes. Removal of the hydraulic unit is not recommended unless this equipment is available. For...
Page 707 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... connections before disconnecting. Disconnect negative (-) cable from battery. CAUTION! Prior to disconnecting the battery, read the battery disconnection cautions given at front of this manual on page viii. Using a clean syringe, empty brake fluid reservoir. WARNING! Brake fluid is highly corrosive and dangerous to the environment.
Page 708 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Disconnect electrical harness connectors at left footwell trim panel and remove panel: Unplug connector at footwell interior light (A), if equipped. Slide lock at OBD II connector (B) in direction of arrow. Unplug connector at speaker (C). Remove clip (A) and slide brake booster pushrod off brake pedal pin.
Page 709 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... mounting nuts. Replace sealing O-ring between master cylinder and brake booster. Bleed brake system as described earlier. CAUTION! Do not over-torque the master cylinder mounting bolts. This could damage the brake booster and prevent proper vacuum build-up. Tightening torques...
Page 710: Parking Brake
Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 340-6 Parking brake The parking brake is a brake drum system integrated into the rear brake rotors. The parking brake can be adjusted with the wheels installed, although the rear wheels will have to be raised off the ground.
Page 711 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Do not place jack stands under suspension parts. Remove one lug bolt from each rear wheel. Turn road wheel until lug bolt hole lines up with parking brake adjuster (approximately 65° to rear of wheel centerline). Use flat-bladed screwdriver to turn adjuster.
Page 712 Unhook upper return spring from brake shoes. Remove shoe retainers by pushing them in and rotating turn. BMW special tool 34 4 000 can be used to remove retainers, if needed. Spread shoes apart and lift them out.
Page 713 Use BMW special tool 34 1 030 or equivalent deep 10 mm socket to remove parking brake cable lock nuts (A) at base of parking brake handle.
Page 714 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Remove complete exhaust system as described in 180 Exhaust System. Remove center tunnel heat shield. Pull parking brake cable out of body guide tube (arrows) and detach from routing brackets, noting correct routing for reinstallation. Remove one lug bolt from rear wheel.
Page 715 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Pull cable out of back of backing plate. To reinstall: Push new cable housing into hole in back of backing plate. Push free (parking brake handle) end of cable into housing until end of cable snaps audibly into holder inside brake drum.
Page 716 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... 340-7 ABS Component Replacement CAUTION! If the tires on the car are of different makes, the ASC system may over-react. Only fit tires of the same make and tread pattern. In adverse conditions, such as trying to rock the car out of deep...
Page 717 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... WARNING! Make sure the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts. Front sensor: Unscrew mounting bolt at steering arm (arrow).
Page 718 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... of Molykote® Longterm 2 or an equivalent grease to impulse sensor and housing. Installation is reverse of removal. Tightening torque ABS wheel speed sensor to steering arm / trailing arm 8 Nm (6 ft-lb) ABS impulse wheel ABS impulse wheel replacement may be needed in case of damage or impulse teeth corrosion.
Page 719 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... not replaceable separately. 331 Rear Axle Final Drive for CV joint and drive axle replacement procedures. DSC lateral acceleration sensor, replacing Rear wheel drive cars: The lateral accleration sensor is located on the left side driver's footwell, under the panel trim on rear wheel drive vehicles.
Page 720 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... rotational rate sensor is located on the left side of the car, under the driver's seat. All wheel drive cars: The rotational rate sensor is combined into one unit with the lateral acceleration sensor. It is mounted under the driver's seat, in front of the left seat rail.
Page 721 After removal or replacement the steering angle sensor requires calibration using BMW scan tools DIS or MoDiC. Once calibrated, the sensor sends a confirmation ID code to the DSC control module to indicate proper calibration.
Page 722 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... removing and installing CAUTION! E46 cars require special BMW service equipment to properly bleed the brakes. Removal of the hydraulic unit is not recommended unless this equipment is available. For safety reasons, the brake system on cars with ABS must be bled using the procedures described in this repair group.
Page 723 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... C - Right front D - Rear from master cylinder E - Right rear F - Left rear Remove brake fluid input and output lines. Seal open brake fluid lines and bores with suitable plugs to prevent contamination.
Page 724 8 Nm (6 ft-lb) DSC precharge pump, removing and installing CAUTION! E46 cars require special BMW service equipment to properly bleed the brakes. Removal of hydraulic components is not recommended unless this equipment is available. For safety reasons, the brake system...
Page 725 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... Using a clean syringe, empty brake fluid reservoir. WARNING! Brake fluid is highly corrosive and dangerous to the environment. Dispose of it properly. Remove interior ventilation microfilter housing. Remove upper cover and microfilter. Open wiring harness loom (A) and remove wires.
Page 726 Brakes http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/3... output lines from pump. Remove electrical harness connector. Lift pump to release from lower mounting pad. Slide pump out of retaining ring. Installation is reverse of removal, noting the following: Be sure to replace rubber pump mounts if damaged or worn.
Page 727 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 400-1 General This section covers system descriptions and general information for the repair groups found in 4 Body and 5 Body Equipment. E46 Sedan Copyright © 2006 Robert Bentley, Inc. All rights reserved. 1 of 1...
Page 728: E46 Sport Wagon
Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 400-2 Body Assembly The body styles of E46 cars covered by this manual are the 4-door Sedan, 4-door Sport Wagon, 2-door Coupe and 2-door Convertible. Body dimensions vary slightly among models. Dimensions are given in inches.
Page 729: E46 Convertible
Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... E46 convertible E46 Coupe 2 of 8 2/25/2009 10:37 PM...
Page 730 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Body shell The BMW 3 Series chassis is a unibody design constructed of high strength steel. Attaching parts, such as the front fenders, rear quarter panels, doors, trunk lid and hood are also constructed of steel.
Page 731 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... The E46 body shell was designed so that the vibrations of torsional twisting and bending are separated into discrete components and in the inaudible range. The current Sedan design ensures that the body twists at 29 hertz and bends at 26 hertz.
Page 732 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... approximately 0.31 for the Sedan and 0.32 for the Coupe models. Fenders. The exterior panels are corrosion-resistant zinc coated (galvanized) steel. The front fenders are bolted on. For front fender replacement information, see 410 Fenders, Engine Hood.
Page 733 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... refinement. Interior materials and colors, the soft top and the light-alloy wheels have been carefully matched. Although the automatic Convertible roof is standard, a hard-top in body color with heated rear window is available as an option for the cold season.
Page 734 A Convertible body normally flexes and vibrates, transferring oscillations to the passenger compartment. In the E46 Convertible, BMW utilizes a unique battery tray in the trunk as a vibration dampening system to counteract this oscillation. CAUTION!
Page 735 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Sport Wagon capacities Cargo capacity: Rear seat backrest 435 liters (15.4 cu. ft.) Rear seat backrest 1345 liters folded down (47.5 cu. ft.) Load capacity: In cargo compartment 540 Kg (1191 lb.) On roof 75 Kg (165 lb.) Copyright ©...
Page 736 E46 cars. Safety cage The body safety cage is a continuation of an established BMW concept for passenger protection. Tubular impact structures built into the body provide protection against passenger injury during front or rear impacts.
Page 737 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Electrical components in the locks are fully encapsulated and cannot be picked easily. The new door handles, latches and lock assemblies offer improved reliability and security against theft. Door position and lock condition are detected by hall sensors.
Page 738 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Airbags As many as 8 airbags are installed in E46 cars, depending on model. The front airbags operate without sodium azide propellant, widely considered an irritant when an airbag is deployed. Starting with 2000 models, "smart"...
Page 739 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Always disconnect the battery and cover the negative (-) battery terminal with an insulator before starting diagnostic, troubleshooting or service work on cars fitted with SRS, and before doing any welding on the car. Battery safety terminal (BST)
Page 740 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... system. Anti-theft alarm (DWA). This is a dealer-installed option for which the E46 vehicles are factory-wired. When armed, the system monitors door lock contacts and trunk and engine hood locks and sounds a siren if it detects tampering.
Page 741: Interior Features
Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 400-4 Interior Features E46 interiors have a unique character, with a combination of sporty features and innovative design. All body versions were made in a wide choice of interior and exterior colors. New colors with matching leather or leatherette...
Page 742 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... adjustable front seats, and electrically adjustable and heated rear-view mirrors. Inside the car there are reading lights at four seating positions. The seats have a passive internal ventilation system: Cylindrical cavities within the cushions and backrests generate a pumping effect as the car's ride motions cause occupant motion.
Page 743 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... For security reasons, the release lever to fold the rear seat backrest forward is installed in the trunk. In Sport Wagon models: Rear seat backs are split 60/40 with the center arm rest on the left seat back.
Page 744 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... displays. Service Interval Display calculates vehicle service needs, based on current driving patterns, and indicates to the driver when the car requires service. Integrated on-board navigation system, based on Global Positioning System (GPS) technology, is optionally available on E46 cars.
Page 745 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Washers. Central locking with power trunk release. See 515 Central Locking and Anti-theft. Keyless entry (FZV) Power window control. See Door Windows. Car/key memory Interior lighting Alarm system (DWA) Electronic consumer sleep mode. 600 Electrical System–...
Page 746: Heating And Air Conditioning
Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Note: All 1999 models and cars produced through June 2000 are equipped with the DLC socket in the rear right corner of the engine compartment. In cars produced after June 2000, the DLC socket in the engine compartment has been discontinued.
Page 747 Body - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Sport Wagon interior features Child seats. There are three child seat hold down anchors behind the rear seat back rest. Plastic trim covers are used to hide the anchors. Cargo area. There is a spring-loaded blind and a cargo safety net installed behind the rear seat.
Page 748 Some BMW special tools are required to set body pieces into the service positions. Service position hood props BMW 51 2 Copyright © 2006 Robert Bentley, Inc. All rights reserved. 1 of 1 2/25/2009 10:39 PM...
Page 749 Fenders, Engine Hood http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 410-2 Front Fenders Front fender, removing and installing Raise hood. Raise and safely support front of vehicle. WARNING! When raising the car using a floor jack or a hydraulic lift, carefully position the jack pad to prevent damaging the car body.
Page 750 Fenders, Engine Hood http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... and remove retaining screw (arrow). Remove lower fender attaching bolts (arrows) at rear of wheel housing. With door open remove upper fender to door post attaching bolt (arrow). Remove screw (arrow) at front of fender. 2 of 3...
Page 751 Fenders, Engine Hood http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Remove bolts (arrows) along top edge of fender. Carefully remove fender from body. Installation is reverse of removal, noting the following: Before installing new fender, clean old sealant and protective coating from mounting surfaces. Position new fender and loosely install all mounting bolts.
Page 752: Engine Hood
(arrow) on upper end of pressurized lifting struts. Pull struts off hood. Raise hood higher and install BMW special tool 51 2 160 in between hood lift struts and hood brackets to hold hood in service position. Hood, removing and installing...
Page 753 Fenders, Engine Hood http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... electrical harness connector (B) from heated nozzles. Detach gas-charged hood supports from hood. CAUTION! The hood is heavy. Before removing the hood supports or hood retaining bolts, be sure to have an assistant help support the hood.
Page 754 Fenders, Engine Hood http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Clearance specification Hood edges to adjoining body 5.5 mm (0.216 panel (gap) in.) If height adjustment at rear of hood cannot be completed using upper hinge, loosen lower hinge bolts (arrows) and reposition as necessary. Plastic coating on top of hinge stop screw must not be damaged or missing.
Page 755 Fenders, Engine Hood http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... minimal clearance. Turn stop disk to move hood front stop further out. Height at front of hood is set using spring pins and rubber stop buffers. Hood release cable and spring pins, adjusting Before adjusting hood pins, be sure the hood is aligned evenly to fenders and front panel.
Page 756 Fenders, Engine Hood http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Loctite®270 or equivalent, and reinstall. Unscrew rubber stop buffers above headlight assemblies until they support hood when closed without movement. Test hood for correct closure and opening. If hood does not spring open, lengthen spring pins.
Page 757 Fenders, Engine Hood http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... - Stop buffer - Spring pin 10 - Lower hood lock 11 - Saucer head screw 12 - Eccentric wheel 13 - Hex nut with plate 14 - Hood catch 15 - Bowden cable, center Copyright © 2006 Robert Bentley, Inc. All rights reserved.
Page 758 BMW > 328 > 2000 > 2.5L L6 (M52) Welcome tethoma@gmail.com Logout 1 of 1 2/25/2009 10:40 PM...
Page 759 http://ebahn.bentleypublishers.com/main-website-loading.html?page=B... Vehicle Tech Info Search 411-1 Enter Vehicle Indentification Number (VIN): General This repair Choose vehicle: group covers front and rear door repair information. It includes removal and installation DTC Xpress of interior Choose Diagnostic Trouble Code (DTC): front door trim panels, rear door trim panels...
Page 760 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 411-2 Doors WARNING! E46 cars are fitted with side-impact airbags in the front doors. When servicing doors on cars with front side-impact airbags, always disconnect the negative (-) battery terminal. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system.
Page 761 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... With door fully open, remove pin bolts (arrow) from top and bottom door hinges. Remove door check mounting bolt (arrow). Remove door by lifting up off lower hinge halves. CAUTION! Be careful not to damage door or other painted body surfaces. Make sure no load is placed on wiring harness.
Page 762 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Adjust door striker so that trailing edge of front door is slightly higher (1 mm / 0.04 in.) than leading edge of rear door. See 515 Central Locking and Anti-theft. Repair any paint damage and paint any exposed metal.
Page 763 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... airbags in the front doors and as an option on 4-door models. When servicing doors on cars with front side-impact airbags, always disconnect the negative (-) battery terminal. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system.
Page 764 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Installation is reverse of removal. Lubricate door check before installing. Use new mounting bolts when reinstalling the side-impact airbag to the door (where applicable). Tightening torque Door check to door 24 Nm (16 ft-lb) Door hinge adjustment If the installed door is uneven or out of parallel, shims can be used to correct its position.
Page 765 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Tightening torques Door hinge to door 20 Nm (15 ft-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved. 6 of 6 2/25/2009 10:40 PM...
Page 766: Door Panels
Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 411-3 Door Panels WARNING! E46 cars are fitted with side-impact airbags in the front doors and as an option on 4-door models. When servicing doors on cars with front side-impact airbags, always disconnect the negative (-) battery terminal. See...
Page 767 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... For rear trim panel: Pry out window switch at top of armrest. Pry off concealing plugs (arrows) from under armrest. Remove door panel retaining screws (arrows). Unclip door panel from door perimeter using a trim panel tool. Pull panel retaining clips off one at a time.
Page 768 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Pry off inside door release Bowden cable at end of clip (arrow). Pull off panel: Detach cable from interior door release lever. Disconnect radio speaker harness connector. Installation is reverse of removal, noting the following: Replace any damaged plastic parts or clips.
Page 769 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Rear side trim panel, removing and installing (Coupe model) Remove rear seat cushion. Remove rear backrest side section. See Seats. Using a trim tool, gently pry up door threshold trim. Starting at A-pillar, press radius of trim downwards while sliding trim forward off trim clips.
Page 770 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Remove trim plugs on side panel armrest. Remove insert panel retaining screws. Gently pry side panel insert from upper and lower side panels. Disconnect electrical harness connectors as necessary. Remove upper side trim panel: Remove trim retaining rivet from upper corner at door.
Page 771 Doors http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Installation is reverse of removal. Make sure to replace any broken trim clips. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 6 of 6 2/25/2009 10:41 PM...
Page 772 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 412-1 General This repair group covers trunk lid and tailgate removal and installation. Also included here are replacement procedures for the gas-charged support struts that hold the trunk lid or tailgate in the open position. Note: The body is painted at the factory after assembly.
Page 773: Trunk Lid
Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 412-2 Trunk Lid Trunk lid, removing and installing Raise trunk lid. Open tool kit and remove screws attaching tool kit to trunk lid (white arrows). Unclip retaining strap at trunk lid and remove tool kit. Remove insulating liner expansion rivets (black arrows), by prying upper portion out (inset).
Page 774 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Trunk lid, aligning Raise trunk lid. Working at lower corners of trunk lid, unscrew out rubber buffers (arrows) on left and right sides. Inspect pads (arrows) on each side of latch assembly for damage or wear and replace if necessary.
Page 775 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... screw and protective cap. If stop screw has removable protective cap (arrow) remove protective cap from stop screw. Adjust stop screw so that head is set to (A) 10 mm (0.40 in.) above bore height. To adjust trunk lid gap at rear fender:...
Page 776 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... To adjust trunk lid at lock: Remove protective caps from trim panel and loosen screws retaining latch assembly until it can just be moved. Inspect pads (arrows) on each side of latch assembly for damage or wear and replace if necessary.
Page 777 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... top of stop screw, and gently close trunk lid. Adjust height of stop screw until paper strip can be removed with slight resistance. Once stop screw height has been adjusted, lower adjusted height of stop screw 2.5 mm (0.1 in.) to accommodate for...
Page 778 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Remove strut from trunk lid. Installation is reverse of removal. Replace retaining clips damaged during removal. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 6 of 6 2/25/2009 10:41 PM...
Page 779 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... 412-3 Tailgate (Sport wagon models) Tailgate, removing and installing Raise complete tailgate. Remove interior trim and disconnect wiring harnesses. Disconnect left and right support struts as detailed below. While supporting tailgate, remove hinge bolts for tailgate on left and right sides.
Page 780 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... case of an electrical failure. The release is located in the rear cargo area, along the lower edge of the rear apron behind a small access cover. Working inside car, at base of tailgate: Remove release cover.
Page 781 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Raise rear window. Remove inner trim from glass panel by releasing clips on trim from retainers (arrows). For clarity, trim is removed in photo. Note: Use two plastic prying wedge tools to release each pin retaining trim.
Page 782 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Support window in open position. Working at top of tailgate, loosen screws (arrows) on each window hinge. Note positions of any spacers for reinstallation. CAUTION! Rear window is heavy. Use a second person to support window prior to releasing from hinges.
Page 783 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Clearance of the rear window is adjusted by adding or removing shims between hinge bracket and rear window (maximum of three shims). Adjust spoiler gap to body last. Height of spoiler is set by alignment of the rear hatch. Gap of spoiler to body is set by adjusting spoiler attachment bolts.
Page 784 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Tailgate and rear window position gap adjustment Rear window / 4 ± 1 mm tailgate (F) (0.16 ± 0.04 in.) Rear window / 5.4 ± 1 mm tailgate (G) (0.21 ± 0.04 in.) To adjust fit of tailgate to body: Close tailgate and open rear window.
Page 785 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Tightening torques Lock nut for stop buffer (M8) 15 Nm (11 ft-lb) Loosen screws (arrows) and reposition rear latch to further adjust gap between tailgate and body at sides, and to assure smooth operation. To adjust striker position: Close tailgate slowly, allowing striker to center itself on lock.
Page 786 Trunk Lid, Tailgate http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4... Retighten lock nut when window latch operates smoothly. To adjust rear window lock position, initially loosen lock mounting bolts (arrows). Close window slowly, allowing lock to center itself on striker. Tighten mounting bolts, then check rear window to body gaps as shown above.
Page 787 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 510-1 General This repair group includes repair information for the outside rear view mirror, front and rear bumpers, and the easily removable exterior trim parts. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 1 of 1...
Page 788: Outside Rear View Mirrors
510-2 Outside Rear View Mirrors Many of the mirror components are separately available from an authorized BMW dealer, including the glass and outside plastic housing. Outside mirror glass, replacing CAUTION! Mirror should be at or above room temperature before removal.
Page 789 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... above. Remove housing retaining screws (arrows) and lift off rear housing. Tilt mirror housing forward and compress plastic retainers (arrows) and lift off front housing. Note: The front mirror housing is retained by either three or four clips, depending on model.
Page 790 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Gently pry off door inner trim panel from retaining clips (arrows). Disconnect electrical harness connectors for window anti-trapping protection and speaker (arrows), if equipped. Remove inner door panel trim. On sedan models, trim strip extends around window to door latch area.
Page 791 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Check mirror function before installing covering parts. Tightening torque Outside mirror to door (M6) 6 Nm (4.5 ft-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved. 4 of 4 2/25/2009 10:43 PM...
Page 792: Front Bumper Assembly
Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 510-3 Bumpers Front bumper assembly - Impact absorber - Spacer - Cap - Support bracket - Bumper bracket bolt tighten to 41 Nm (30 ft-lb) - Protective rubber strip - License plate bracket - Tow eye cover...
Page 793 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Front bumper, removing and installing Raise and properly support vehicle. WARNING! Make sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.
Page 794 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... outside temperature sensor at rear of left side of bumper and temperature switch at rear of right side of bumper. Slide bumper straight off side brackets. Installation is reverse of removal, noting the following: Slide side brackets on bumper and body carefully together.
Page 795 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Rear bumper assembly - Cap - Casket - Impact absorber - Carrier bumper - Support bracket - Bracket - Protective rubber strip - Bumper cover - Lower part cover 10 - Tow eye cover 11 - ASA bolt...
Page 796 Remove wheel well liner from left and right sides. Release bumper bar retaining bolt (arrow) from impact absorber using BMW special tool 00 2 150, or similar Torx head socket. CAUTION! Protect possible contact areas to prevent damage or scratches to vehicle bumper and paint.
Page 797 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Install the bumper bracket bolt with thread locking compound such as Loctite®270 or equivalent. Tightening torque Bumper bracket to impact absorber (M10 bolt) 41 Nm (30 ft-lb) Rear bumper impact absorber, replacing Remove bumper as described above.
Page 798 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Bumper height, adjusting. Tightening torques Bumper bracket to impact absorber (M10 bolt) 41 Nm (30 ft-lb) Impact absorber to chassis (M8 nut) 22 Nm (16 ft-lb) Bumper height, adjusting The adjustment procedure applies to either front or rear bumpers. A 14 mm allen socket is needed to make adjustments.
Page 799 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... bolt at impact absorber. Using a 12-inch extension and a 14 mm Allen socket, turn adjusting collar clockwise or counterclockwise as needed to change height of adjusting collar. Reinstall mounting bolts and check bumper height. Refit front bumper.
Page 800 Be sure to have necessary fasteners on hand when reinstalling exterior trim pieces. BMW emblem, removing and installing The procedure given below applies to both front and rear emblems. Wrap end of a screwdriver with tape.
Page 801 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Installation is reverse of removal. Replace any clips or clip covering boots damaged during removal. Radiator grill, removing and installing Open hood. Gently pry out tab on left or right side of grill trim ring (A), as well as tabs on bottom.
Page 802 Exterior Trim, Bumpers http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Headlight housing trim panel, removing and installing Open hood. Remove spray nozzle of vehicles equipped with headlight cleaning systems. See 611 Wipers and Washers. Unclip inner tab at radiator support. Press pane downward, out of retaining brackets. Feed out retaining hook at fender.
Page 803 BMW service facility or an automotive glass installer. Special tools Some window repair operations require the use of special tools. 2-door window adjustment tool BMW 41 6 120 Window height gauge BMW 51 3 080 1 of 8 2/25/2009 10:44 PM...
Page 804 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Power windows Power window features in E46 models include: Control of the front and rear door window motors is carried out directly by the General Module (GM V). One-touch operation in both directions on all four windows, where applicable.
Page 805 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... customized with the Car Memory function. See 515 Central Locking and Anti-theft. After the ignition is switched off, electric windows can be operated until a door is opened or until 16 minutes has elapsed. The GM V bases window motor end position on current draw (load).
Page 806 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Window switches The push-pull type window switch provides the GM V with a coded ground signal. Holding a switch at the first detent provides a single ground signal on one wire requesting the GM V to open the window. When released, the ground signal is removed and the window motor stops.
Page 807 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... In 4-door models, the rear window child lockout switch (arrow) is incorporated in the driver's window switch block to the left of the shifter. When activated, it provides a constant ground signal to the GM V, preventing the windows from being operated from the rear door switches.
Page 808 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... door lock. If the GM receives a request to operate convenience closing or opening for more than 110 seconds, the function is deactivated and a fault code is stored. Window anti-trap protection In 4-door models, a rubber pressure...
Page 809 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... a window motor is activated. It counts each cycle and stores the number in memory. After the stop function limit is reached and the window motor is deactivated, the GM V slowly reverses the stored count of activation until the stored number equals 0, thus allowing the window motor to cool down.
Page 810 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... to the window regulator should always be disconnected to prevent pinching fingers in the moving window mechanism. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 8 of 8 2/25/2009 10:44 PM...
Page 811 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 512-2 Window Service, 4-door Models Sedan and Sport Wagon doors are similar. Use the following procedures for window service on these models. WARNING! E46 cars are fitted with side-impact airbags in the front doors. Some are equipped with airbags in the rear doors as well.
Page 812 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Window should contact block, then immediately reverse direction and lower by approx. 25 mm (1 in.). Note: Anti-trap strip is integrated into the molding strip of the door window frame. Front window anti-trap strip, removing Remove front door panel and vapor barrier as described in Doors.
Page 813 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 1 - Window frame molding 2 - Clip 3 - Door corner speaker cover 4 - Foam insulation 5 - Mounting clip After installation, recheck anti-trap protection. Rear window anti-trap strip, removing Remove rear door panel and vapor barrier as described in Doors.
Page 814 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... against the window seal uniformly. Note: If the window does not contact the window seal uniformly, wind noise or water infiltration may result. Remove front door panel as described in Doors. Disconnect negative (-) cable from battery. Then remove airbag unit and vapor barrier from door.
Page 815 Detach plastic window retainers from glass: Push expander nut (1) out of plastic retainer. Squeeze retainer tabs (2) and remove from glass. Note: BMW recommends replacing the plastic 5 of 8 2/25/2009 10:45 PM...
Page 816 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... window retainers every time the glass is removed from the door. Turn window glass carefully inside door cavity and lift out of door. Installation is reverse of removal. Replace plastic window retainers once glass is inside door.
Page 817 Push expander nut (1) out of plastic retainer. Squeeze retainer tabs (2) and remove from glass. Note: BMW recommends replacing the plastic window retainer every time the glass is removed from the door. Pull window glass straight up to lift out of door.
Page 818 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Tightening torque Side-impact airbag 8.5 Nm (75 to door in-lb) Window to regulator guide 8 Nm (71 in-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved. 8 of 8 2/25/2009 10:45 PM...
Page 819 2-door cars with frameless windows makes window adjustment critical. CAUTION! There is risk of window glass breakage if correct adjustment procedures are not used. If in doubt, this procedure should be left to a trained BMW technician. 1 of 13 2/25/2009 10:45 PM...
Page 820 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... The following adjustments can be made to the window: Longitudinal adjustment Pretension (or window rake) Parallelism (or window tilt) Vertical adjustment (or retraction depth) Glass protrusion (when open) Distance between side window and door window Emergency operation Adjusting the "close with door shut"...
Page 821 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Close door as far as possible without forcing. Coupe models: Top edge of glass must rest on door seal (A). Convertible models: Gap between door and B-pillar (B) must be 25 mm (1 in.). Note: Window must seal with water drain at mirror triangle in A-pillar.
Page 822 Reach through door bores (A) using Torx driver E7 on extension with ratchet wrench (BMW special tool 41 6 120 or equivalent). Loosen but do not remove longitudinal adjustment screws. Raise glass to top. Move glass fore or aft to attain correct adjustment.
Page 823 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... of window outer sealing lip. If necessary, replace side window trim. Window longitudinal adjustment 1 - 2 mm Dimension A (0.04 - 0.08 in.) Door window rear edge to side window seal 6 ± 0.75 mm (Coupe) (0.24 ±...
Page 824 Latch door to first catch of door lock (A). Check that top of window rests on rubber door seal (B). Reach through rear bore in door with BMW special tool 41 6 120 or equivalent ratchet wrench. Loosen window adjustment Torx screw (A) 180° counterclockwise.
Page 825 Window parallelism is also referred to as window tilt. Retraction depth. With door closed, raise window to top. Use BMW special tool 51 3 080 or equivalent device to measure depth of window in rubber seal. Window retraction At A-pillar or roof...
Page 826 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Pry out rubber plugs at base of door. Starting at rear of door, reach through bore in door to turn Torx screw (A). Note: Torx screw size is T20. Repeat at front bore. Raise window and check for parallelism and correct depth of retraction.
Page 827 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... arrow. Lift off window inner lip seal. If necessary, replace any defective retaining clip (arrow). Position door window approximately 80 mm (3.15 in.) below roofline. If necessary, temporarily reconnect battery cable. WARNING! Once the window is lowered,...
Page 828 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Window rear mounting hardware will stay with glass. Tilt rear edge of window glass up and out of door. If glass is being replaced, transfer window rear mounting hardware (mounting shim, threaded sleeve and clamping retainer) from lower rear corner of glass to new window.
Page 829 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Refer to accompanying illustration when removing Coupe rear vent window or vent latch mechanism. 1 - Vent window drive 2 - Inner cap 3 - Retainer 4 - Washer 5 - Washer 6 - Shim 7 - Glass support...
Page 830 If the final adjustment is incorrect glass breakage may result. This job is best left to be done by a trained technician at a qualified BMW repair facility. Rear side window, adjusting (Convertible models) The Convertible rear side window shares a version of "close with door...
Page 831 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... window. Distance to front door window (longitudinal adjustment) (A) must be set by loosening Torx bolt through bore in outer shell of car, after removing exterior side trim strip. To set retraction depth (submersion) into top rubber seal...
Page 832 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 512-4 Window Regulator Service WARNING! E46 cars are fitted with side-impact airbags in the front doors. Some are equipped with airbags in the rear doors as well. When servicing the door windows on cars with side-impact airbags, always disconnect the negative (-) battery cable.
Page 833 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... harness connector (A). Remove motor mounting bolts (B). Twist motor slightly (arrows) to clear window regulator mounting tabs. When reinstalling: Make sure window has not travelled fully downward. Manipulate spring-loaded window control cable (C) to engage motor teeth to regulator gears.
Page 834 Otherwise the front and rear regulators are similar. Note: BMW recommends removing the window regulator and motor as one unit, then separating the two on the bench. Remove door panel as described in Doors.
Page 835 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Remove vapor barrier. Detach window from window regulator as described earlier. Do not remove window from door. Push window up and use wedge to hold in position. Detach window regulator from door: Disconnect electrical harness connector (A) to power window motor.
Page 836 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Door window regulator and motor, removing and installing, (2-door models) Remove door panel as described in Doors. Disconnect negative (-) cable from battery. Then remove airbag unit and vapor barrier from door. See 721 Airbag System (SRS).
Page 837 Door Windows http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... removal. Installation is reverse of removal, noting the following: Inspect rubber insulators. Replace if brittle. After inserting window regulator into door cavity, install and tighten down mounting nuts on rear window rail. Install front window rail mounting nuts but do not tighten.
Page 838 650 Radio 721 Airbag System (SRS) Special tools Use plastic prying tools or wrap the screwdriver tip with tape to avoid marring interior trim. Plastic prying tool BMW 00 9 321 Interior trim repairs 1 of 3 2/25/2009 10:46 PM...
Page 839 Note: The BMW E46 is equipped with SRS airbags mounted in the steering wheel, the dashboard on the passenger side, the front doors, the A-pillars, and as an option in rear doors on four door models.
Page 840 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... CAUTION! When working on electrical switches or lights, always disconnect the negative (-) cable from the battery and insulate the cable end to prevent accidental reconnection. Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.
Page 841: Center Console
Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 513-2 Center Console The console between the two front seats starts behind the shifter housing. It houses the parking brake handle, optional telephone and oddments storage tray. The rear portion of the console houses the ashtray and covers the emergency brake cable ends.
Page 842 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Remove trim panel retaining screws (arrows) under transmission selector boot/trim. Slide center console back and lift up. Disconnect electrical harness connector from hazard light and central locking switch. If applicable disconnect wiring for factory installed cellular telephone. To release phone connector, press catch (A) and slide lock (B) forward.
Page 843 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 513-3 Dashboard The E46 dashboard assembly includes the instrument cluster, passenger side airbag, glove compartment, fuse and relay panel, radio, IHKA control panel or on-board monitor (if equipped with GPS), front ashtray, shifter assembly, and window control switches.
Page 844 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 11 - Glove compartment hinge 12 - Steering column cover 13 - Left glove compartment (optional) 14 - Center knee protector 15 - Steering column knee protector 16 - Left footwell (pedal cluster) trim panel 17 - Footwell light...
Page 845 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... right side strap. Pull out pin from bottom of left side dampening rod. Remove glove compartment hinge mounting bracket screws (arrows). Lift glove compartment over mounting rod to remove. Remove glove compartment housing: Remove insert mounting screws (arrows).
Page 846 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Steering column trim, removing and installing Remove steering wheel as described earlier. Fully lower and extend (arrows) adjustable steering column. Remove retaining screw from top of steering column upper trim cover. Push in sides of upper trim cover (arrow) to release from lower trim.
Page 847 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... to release. Pull down on trim. Installation is reverse of removal. Replace any broken or missing fasteners. Left footwell (pedal cluster) trim panel, removing and installing Move steering column to maximum extended position. Working at trim panel, remove screws (arrows) and expansion rivets (A).
Page 848 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Dashboard/shifter console assembly, removing and installing Disconnect negative (-) cable from battery and cover terminal with insulating material. CAUTION! Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.
Page 849 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Remove shifter knob by pulling straight Note: Apply approx. 90 lb. of force to pull off knob from shift rod. Lift up and remove shifter bezel by prying gently. Unclip bottom of shifter boot from center console trim by pushing forward.
Page 850 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... instruments to remove trim or finisher strip Remove screws beneath finishing strip. Carefully pull away A-pillar trim. Remove headlight switch. See Switches. Remove instrument cluster. See Instruments. Remove IHKA control panel and module. See 640 Heating and Air Conditioning.
Page 851 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... dashboard. Similarly, remove left side dashboard mounting screw or expansion rivet. Remove dashboard mounting nut (arrow) at shifter console. Remove mounting nuts and screw (arrows) at dashboard face. To remove dashboard: Pull up parking brake fully. Push seats fully back.
Page 852 Interior Trim http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... tightening fasteners. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 10 of 10 2/25/2009 10:46 PM...
Page 853 Electrical Wiring Diagrams. Special tools A few special tools may be necessary for repairs in this section. Ring antenna removal tool BMW 61 3 Front door lock adjustment tool 4 mm Allen wrench 1 of 2 2/25/2009 10:47 PM...
Page 855: Central Locking
Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 515-2 Central Locking Note: There is a door lock key cylinder on the driver's door only Central locking in E46 vehicles controls the door locks, trunk or cargo compartment lock and fuel filler flap lock. The Central Body Electronics...
Page 856: Central Locking System
Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... from being opened from the inside regardless of lock-button position. The General Module (GM V) and Electronic Immobilization (EWS 3.3) interface via the K-bus to monitor double lock status and to initiate double lock override. This feature...
Page 857: Central Locking Switch
Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Central locking switch The central locking switch is housed in a combined housing with the hazard flasher switch. The central switch locks all vehicle locks except for the fuel filler flap. The switch provides a momentary ground input signal to the GM V.
Page 858 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Single lock and double lock function Each door lock actuator incorporates two motors: Single lock motor controls the mechanical lock mechanism when the central lock switch is pressed to single lock the vehicle. The lock mechanism is...
Page 859 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... footwell area. The button provides the GM V with a ground signal when pressed. The vehicle must be unlocked or single locked from the central lock switch for the remote unlock to work. The remote...
Page 860 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Remote entry (FZV) The E46 remote (keyless) entry system (usually called FZV) uses a tiny radio transmitter in the vehicle key to lock and unlock the doors and the trunk by remote control. Press once:...
Page 861 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... panic mode (alarm if equipped) There are a number of other features incorporated in FZV: Locking/unlocking of fuel filler lid Selective unlocking of driver's door (as with key in lock) Arming/disarming of DWA alarm system (if equipped)
Page 862 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Key incorporates an LED that signals operator of signal transmitting, key initialization status and key self-test indication Keys delivered with four different colored labels. This is helpful to differentiate FZV keys during initialization, preventing possibility...
Page 863 Car Memory The owner is provided with a list of systems that can be customized. Prior to vehicle delivery, the BMW scan tool DIS or MoDiC is used to code the driver preferences into the appropriate control modules. Thereafter these choices cannot be changed without recoding with a BMW scan tool.
Page 864 Memory functions such as heating/A/C (IHKA) settings or memory seat position adjustment. Most programming of Key Memory requires the use of BMW scan tools DIS or MoDiC. However, features such as IHKA blower speed and temperature store automatically without the use of scan tools.
Page 865 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... received at the GM V. Therefore Car Memory/Key Memory features will not be activated. Remote key initialization Initialization of FZV keys is required to establish lock/unlock signal synchronization with the GM V. The initialization procedure provides the GM V with a key identification number and a "rolling code"...
Page 866 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... the key memory functions activated by the keys will not be assigned correctly. Always initialize the keys in the same order. Convertible central locking In Convertible models, the glove compartment lock is integrated into central locking functions. An additional...
Page 867 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Interior tailgate release button at driver's kickpanel Unlock microswitch above rear license plate Any of these input requests to the GM V activate the tailgate latch motor. The GM V will also switch on the interior lights with a tailgate unlock request.
Page 869 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 515-3 Door Handles and Locks Any time a door lock is removed and reinstalled, be sure to check and reset: Unlocking of rotary latch Outside door handle overtravel These adjustments and measurements must be made by closing the door lock...
Page 870 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... release Bowden cable - Lock button and - 9/2000 and later models: Bowden cable bracket - 9/2000 and later models: Door handle inner mechanism 5a - Models to 9/2000: Door handle inner mechanism - Inner handle...
Page 871 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... cylinder and cover 14a - Rear or right door: Outer handle rear anchor 15 - Door striker cover 16 - Torx bolt M8 tighten to 24 Nm (18 ft-lb) 17 - Door lock striker 18 - Lock plate Rotary latch unlocking, resetting With door open, close rotary latch.
Page 872 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... adjustment screw, then retighten. Carry out check again. Note: The right side latch adjusting screw is threaded left-handed. Tightening torque Door lock 3 + 2 Nm adjustment screw (27 + 18 in-lb) Outside handle overtravel, resetting With door open, close rotary latch with a screwdriver.
Page 873 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Door lock, removing and installing The front and rear door locks for all E46 models are similar. Early production cars, up to 9/2000, use a lock actuator with an external lever which couples with the outside door handle mechanism.
Page 874 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Raise window to top. CAUTION! Guide the window up manually in order to avoid binding. Remove window regulator rear rail: Remove top and bottom rail mounting fasteners (arrows). Slide rail down, allowing it to hang to the side out of the way.
Page 875 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Installation is reverse of removal, noting the following: Insert lock button up through inner door plate, taking care to avoid bending linkage. On models produced to 9/2000: Tilt lock assembly outward while lifting it into position inside the door. This...
Page 876 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Tightening torques Window to guide 8 Nm (71 in-lb) Driver's door lock cylinder, removing and installing Only the driver's door is equipped with a lock cylinder. The procedure for removing the door handle rear anchor on the other three doors is similar to that for removing the driver's door lock cylinder.
Page 877 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... On Sedan or Sport Wagon: Replace cylinder mounting bolt access hole trim cover if necessary. Door handle, removing and installing (to production date 9/2000) On driver's door: Remove door lock cylinder as described earlier. Other doors: Remove door handle rear anchor.
Page 878 Procedure is similar to removing driver's door lock cylinder described earlier. Pull outside door handle out and wedge BMW special tool 00 9 322 under handle. Working in lock cylinder mounting bolt access hole, tighten down screw (counterclockwise direction).
Page 879 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... exceed measurement A. If measurement exceeds specification, pull lever outward with fingers until measurement is correct. Installation distance: inner door handle lever to door less than 8 mm Measurement A (0.32 in.) Insert handle and snap into place.
Page 880 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Working inside door opening, slide inner handle toward front and remove. Installation is reverse of removal. Note: Inspect mounting bolt and replace if necessary. Door handle inner mechanism, removing and installing (from production date 9/2000) Remove outside door handle as described earlier.
Page 881 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Take care to not damage inner door guide during removal and installation. Loosen handle mounting bolt. Working inside door opening, slide inner handle toward front and remove. Installation is reverse of removal. Note: Inspect handle mounting bolt and replace if necessary.
Page 882 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Set position of striker: When closed, rear edge of front door must be even with front edge of rear door (Sedan or Sport Wagon) or with rear quarter panel (Coupe or Convertible). Maximum deviation allowed measured at A.
Page 883 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Tightening torque body pillar Trunk locking mechanism Trunk lock assembly 1 - Trunk release microswitch 2 - Connecting rod 3 - Lock with microswitch 4 - Torx screw M6 5 - Striker plate 6 - Trim screw...
Page 884 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... license plate light strip The trunk lock cylinder does not actuate central locking control. To remove the trunk lock microswitch: Remove licence plate light strip. Separate electrical harness connector from strip. Separate microswitch from strip.
Page 885 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Remove lock cylinder cover mounting screws (arrows). Slide cover to right to remove. Note: On Convertible models: Remove third brake light to access trunk lock mechanism. Use new self-tapping screws to reinstall trunk lock cylinder.
Page 886 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Note: Do not lubricate lock or lock striker with grease. Tailgate lock, emergency release The Sport Wagon tailgate can be unlocked using the central locking switch, the left door key or the FZV remote entry system. The tailgate can be...
Page 887 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 6 - Rear window lock striker 7 - Tailgate lock 8 - Torx bolt M8 9 - Tailgate lock striker 10 - Lock plate 11 - Tailgate release microswitch 12 - Tailgate grip 13 - Tailgate grip gasket...
Page 888 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... To remove tailgate lock striker: Open tailgate and pry out lock striker trim from bottom of tailgate. Remove one striker mounting screw (arrows). Thread in M8 stud to keep striker lock plate from falling inside door.
Page 889 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... To remove rear window lock: Open tailgate. Remove tailgate trim panel. Detach window lock electrical harness connector (A). Remove lock mounting screws (arrows). Slide lock out from under rear window wiper motor. Reinstall lock mounting bolts finger tight.
Page 890 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Tailgate and rear window position gap adjustment Rear spoiler / side 3.75 ± 1.3 mm panel (A) (0.15 ± 0.05 in.) Rear window / side 3.5 ± 1.4 mm panel (B) (0.14 ± 0.06 in.) Tailgate / side 3.6 mm ±...
Page 891 Driveaway Protection. If a vehicle key is lost or stolen, the electronic authorization for that key can be cancelled using the BMW scan and diagnostic tools DIS or MoDiC. Force applied to a key can damage the electronic circuitry. A damaged key will not start the engine.
Page 892 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... ten keys. Only an authorized BMW dealer can provide replacement keys. Note: It is possible to damage the electronic circuitry in the key, rendering it unusable. In that case, a new key should be purchased and initialized by an authorized BMW dealer.
Page 893 EWS markings. Installation is reverse of removal. Ring antenna To remove the ring antenna using BMW special tool 61 3 300, it is necessary to remove the upper and lower steering column trim. Alternatively, remove the ignition switch key cylinder.
Page 894 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Gently work ring antenna off key cylinder. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 4 of 4 2/25/2009 11:00 PM...
Page 895 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 515-5 Anti-Theft Alarm (DWA) The DWA anti-theft system is a dealer installed accessory option. All E46 vehicles are factory prepared to provide the DWA function. This means that the vehicle is prewired and the General Module (GM V) is preprogrammed for the system.
Page 896 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Anti-theft and alarm system (DWA) (Sedan models) DWA alarm arming/disarming The DWA alarm is armed every time the vehicle is locked from the outside with the door lock cylinder or FZV key. The LED in the rear view mirror flashes...
Page 897 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... an activation component. If after 3 seconds any input signal not in CLOSED status is excluded (this is acknowledged by the DWA LED) preventing false alarm activation. If the DWA is armed a second time...
Page 898 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Door contacts The door lock Hall effect sensors provide status of door OPEN/CLOSED: When the door latch is CLOSED, current flow through the sensor is <5 mA. When the door is OPEN, current flow through the sensor is >12 mA.
Page 899 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... the key, this switch provides a ground signal to the GM V preventing the DWA from activating if armed. Hood contact switch Located on the right side engine compartment, the hood contact switch (arrow) provides a ground signal to the GM V signifying an open hood.
Page 900: Tilt Sensor
Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Table a. DWA LED status DWA status DWA LED condition Armed with one or Rapid flash for 10 more monitored seconds, then inputs not in continual slow CLOSED position flash (trunk not closed, etc.) Alarm activated...
Page 901 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... and is currently monitoring the vehicle angle. b. If the tilt sensor detects a change in the vehicle angle when DWA is armed, the NG signal is switched to inform the GM V to activate the siren.
Page 902 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... partially open window) and adapts for this. If the echoes are consistently similar, no movement is detected. If the echoes are altered or inconsistent, the UIS changes to a constant cycle and the echo is compared again.
Page 903 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... The module operates in pulse mode. The radar unit transmits a signal, then pauses for the reflected signals to be received by the module. The detection range of the radar is adjusted by rapid switching when the system is armed.
Page 904 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... the alarm system: KL 30 (power) KL 31 (ground) STDWA signal (arm/disarm signal from GM V) NG signal (activate siren output signal to the GM V) The arm/disarm output signal from the GM V (STDWA) is provided to the tilt sensor, UIS sensor and the siren simultaneously.
Page 905 Central Locking and Anti-Theft http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... The EWS signals the GM V to unlock the doors and to deactivate the DWA. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 11 of 11 2/25/2009 11:00 PM...
Page 906 Seats http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 520-1 General This repair group covers removal and installation of the front and rear seats. Seat design and upholstery The front seats installed in E46 cars come in either manual or powered versions. They offer firm support and comfort.
Page 907 Seats http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Cushion height Head restraints. Seat memory system In cars with seat memory, the driver's front seat incorporates two control modules: One in the seat adjusting switch (arrow) and the second under the seat cushion. The two modules process the following:...
Page 908 Seats http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... of the seat memory system are monitored for faults. Access the fault codes using BMW scan tool DIS or MoDiC. In Coupe and Convertible models, the easy entry feature facilitates access to the rear seats. When a front backrest is folded over, the entire seat moves forward 90 mm (3.54 in.) to facilitate...
Page 909 Seats http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Passenger seat memory module 4 of 5 2/25/2009 11:03 PM...
Page 910 Seats http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Rear seat configuration Split rear folding seats are optional in the Sedan and standard in the Sport Wagon and Coupe. They are split 1/3 right to 2/3 left with a folding center armrest in the left portion. The armrest, when folded down, is equipped with a storage compartment and cupholders.
Page 911: Front Seats
BMW recommends that all repair or replacement work on pyrotechnic devices must be carried out by a qualified BMW technician. Be sure to disconnect the battery and wait 5 seconds before attempting to work on pyrotechnic devices.
Page 912 Do not fire a pyrotechnic gas generator prior to disposal. It must be fired by a special disposal company or shipped back to BMW in the packaging of the new components. During body straightening and welding with an electric arc...
Page 913 Seats http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Remove plastic caps over front seat mounting nuts, then remove mounting nuts (arrows). Disconnect negative (-) cable from battery. CAUTION! Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.
Page 915: Rear Seats
Seats http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 520-3 Rear Seats Rear seat cushion and backrest, removing and installing (fixed seat back models) Pull front of rear seat cushion up to release clips. While holding front of cushion up, pull cushion forward to remove. Remove rear seat backrest:...
Page 916 Seats http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Pull front of rear seat cushion up and out of clips. While holding front of cushion up, pull cushion forward to remove. Tilt backrests forward. Note: Remove rear headrests, if equipped, by pulling straight up. Remove backrest side section by pulling out (A) and up (B).
Page 917 Sunroof http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 540-1 General This repair group covers the slide-tilt sunroof assembly. Component locations, initialization, sunroof panel replacement, and sunroof height adjustment are covered. Replacement of the cable assembly or frame require that the headliner be removed. Removal and repair of the...
Page 918 Characteristic curve The characteristic resistance curve of the E46 sunroof is learned using coding software. This resets the safety (anti-trapping) feature. See your BMW dealer service department. Sunroof panel, emergency closing Remove access panel from below sunroof motor by gently prying at the rearmost edge with a plastic tool.
Page 919 Sunroof http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Insert hex key into drive in sunroof motor, and turn hex key to manually close sunroof. Note: The hex key for manually (emergency) closing the sunroof can be found in the tool kit located in the trunk lid (sedan, coupe and convertible) or under the cargo area floor panel (Sport Wagon).
Page 920 Sunroof http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Sunroof has been removed Whenever the top of the closed sunroof becomes misaligned with the roof of the car, if it does not close squarely, if there are wind noises at speed, if there are water leaks, or if the sunroof has been removed.
Page 921 Sunroof http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... The sunroof panel is retained by three Torx screws (arrows) on each side. To adjust sunroof height: Loosen Torx screws until sunroof can just be moved. Push sunroof panel forward. Push sunroof panel up or down until correct height is achieved.
Page 922 Sunroof http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 540-2 Sunroof Components Sunroof assembly removal and installation involves headliner removal, and is not covered in this manual. After sunroof repairs be sure to follow initialization and adjustment procedures given earlier. Sunroof assembly - Torx bolt M5 - Slider...
Page 923 Sunroof http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... (31 in-lb) 16 - Emergency operation crank handle 17 - Hex bolt with washer 18 - Torx bolt M4 Sunroof panel, removing and installing To remove sunroof panel, open sunroof and remove wind blocker by removing Torx screw (arrow) on each side.
Page 924 Sunroof http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Adjust sunroof height and gap as described earlier. Tightening torque Wind blocker to roof (Torx) 1 Nm (9 in-lb) Sunroof panel to roof (Torx) 4.5 Nm (40 in-lb) Sunroof panel gasket, replacing Remove sunroof panel as shown above.
Page 925 Sunroof http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... rearmost edge with a plastic tool. Remove sunroof motor mounting screws (arrows). Installation is the reverse of removal. Perform intitialization procedure as described earlier. Tightening torque Sunroof motor to sunroof carrier 2.8 Nm (25 in-lb) Copyright © 2006 Robert Bentley, Inc. All rights reserved.
Page 926 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 541-1 General This repair group covers the automatic electro-hydraulic convertible top. Information on the Rollover Protection System is also included here. Note: The convertible top control module (CVM II) is located behind the left rear side trim panel. For the...
Page 927 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Convertible battery BMW has designed a special battery tray for the Convertible which serves to dampen Convertible body flexing and vibration. CAUTION! The E46 Convertible requires a special battery which is designed for constant vibration. A battery not designed for this will fail much earlier.
Page 928 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Top monitoring during operation using Hall sensors and angle Hall sensors Emergency operation Manually unlock top storage cover: Remove center arm rest. Lift seat upholstery below ski bag. Press button on motor assembly to release motor from gear linkage.
Page 929 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Working in trunk, remove trunk trim liner and soundproofing. If necessary, partially remove hydraulic unit to gain view of fill plug and fluid reference mark (circle). DO NOT detach hydraulic lines. To check: Level must be between MAX and MIN marks.
Page 930 10 Nm (89 in-lb) Note: The convertible top hydraulic fluid is supplied in the spare parts kit. To restock fluid, check with an authorized BMW dealer parts department. Convertible top switch The convertible top switch assembly is in the center console below the IHKA control panel.
Page 931 The CVM II is fully self-diagnostic and is capable of storing monitored faults. Fault code access and diagnosis is carried out over the K-bus with BMW diagnostic scan tools DIS or MoDiC. Convertible top electronic control module (CVM II) 6 of 11...
Page 932 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Fault memory storage Convertible Top Module (CVM II) fault memory is stored in NVRAM. Up to 16 fault codes can be stored in order of occurrence. A distinction is made between permanent and sporadic faults. If a fault occurs during raising or...
Page 933 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... cease operation if the hydraulic fluid temperature exceeds 95°C (203°F). However, any functions that have been started will be completed before the system is switched off. If the temperature exceeds 105°C (221°F) the system is immediately switched off. Close the top using the emergency closing procedure.
Page 934 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Windshield lock sensor provides low signal when top frame is unlocked from windshield. LED in convertible top switch will flash. Tension point position sensor provides high signal when top frame is raised past tension point. The angle sensor provides a linear voltage signal input to CVM II (approx.
Page 935 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... The convertible top storage compartment cover lock motor is on driveshaft tunnel under rear seat. It consists of a motor with Hall sensor, gear assembly and two bowden cables connected to cover locks on two sides of cover. The Hall sensor detects locked/unlocked position of cover.
Page 936 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... when soft top is raised or removed for hard top installation. The plastic variable compartment floor is hinged at four point so that it can articulate and be rotated up into top storage space. A lever on right side of variable floor actuates and locks floor into position.
Page 937 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... 541-2 Convertible Top Components Mechanical top components The metal folding frame of the top is bolted to the sides of the car behind the door pillars (B-pillars). The three layer soft top consists of: Fabric outer layer...
Page 938 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... frame cover - Emergency mechanism cover - Emergency operation crank - Tension rope Insulation 10 - Tension bow 11 - Hall sensor 12 - Gas pressurized spring 13 - Main pillar Hall sensor 14 - Console 15 - Windshield...
Page 939 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Once hydraulic lines have been disconnected from hydraulic components, top must not be moved. Fluid will leak from separated coupling. Avoid scratching hydraulic piston rods. Even paint mist and welding spots are harmful. When working around hydraulic cylinders, cover with a protective cloth.
Page 940 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... cylinders: Operate on top frame linkage to raise and lower bow Located on two sides of tension bow, at sides of rear window Angle Hall sensor on left tension bow linkage detects bow position Hydraulic lines for...
Page 941 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... - Top storage compartment cover hydraulic cylinders: Open and close storage compartment cover Located in trunk Left cylinder equipped with Hall sensor to detect fully opened position of cover - Solenoid valve block on left side of top...
Page 942 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... In left side of trunk behind trim Mounted on rubber bushings and covered by sound insulation Unit consists of: Hydraulic motor and pump, Storage cover solenoid valve, Drain solenoid valve, Hydraulic fluid reservoir, Hydraulic fluid temperature sensor...
Page 943 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Table a. Definition of hydraulic system terms Term Action Notes Hydraulic system at zero Turn ignition to 0 position. Hydraulic system has no or pressure Wait 15 seconds. very low pressure. Untensioned state Mechanical (emergency) Open or close top by hand.
Page 944 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... Operation Procedures lid. Fluid topping up or draining Follow directions in Hydraulic fluid level, checking or filling, earlier in this group. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 8 of 8 2/25/2009 11:05 PM...
Page 945: Rollover Protection System
Note: Diagnosis of convertible top and Rollover Protection System are beyond scope of this book. Your authorized BMW dealer has proper diagnostic equipment and tools to carry out these tasks. After deployment, the detent pawl in a rollover protection cassette can be...
Page 946 Convertible Top http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/5... forward so that rollbar can be pushed down and locked into the solenoids. WARNING! Ensure that area above and adjacent to rollover bars remains clear and unobstructed at all times. CAUTION! It is not possible to close convertible top with rollover bars extended.
Page 947 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... 600-1 General A brief description of the principal parts of the electrical system is presented here. Also covered here are basic electrical system troubleshooting tips. See also 121 Battery, Alternator, Starter. Electrical test equipment Many electrical tests described in this...
Page 948 Automotive digital multimeter Fluke 87 LED tester with thin spade probes Baum 1115 (Source: Baum Tools Unlimited) Scan tools BMW DIS/MoDiC Aftermarket scan tool Baum CS2000 (Source: Baum Tools Unlimited) Copyright © 2006 Robert Bentley, Inc. All rights reserved. 2 of 2...
Page 949 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... 600-2 E46 Electrical System E46 cars are electrically complex. Many vehicle systems and subsystems are interconnected or integrated. In addition, the requirements of second generation On-Board Diagnostics (OBD II) are such that there are now many more circuits and wires in the vehicle than ever before.
Page 950 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Table a. E46 busses Circuits covered Coded anti-theft (EWS III) and anti-theft (DWA) Remote entry (FZV) Park distance control (PDC) M-bus Heating and air conditioning (IHKA) components CAN-bus Engine management system (DME) Transmission control (AGS)
Page 951 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Voltage and polarity The vehicle electrical system is a 12-volt direct current (DC) negative-ground system. A voltage regulator controls system voltage at approximately 12-volts. All circuits are grounded by direct or indirect connection to the negative (-) terminal of the battery.
Page 952 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... main fuse box (arrow) above the glove compartment. Fuses are color coded to indicate current capacities. The relays and control modules are mounted in various places throughout the vehicle. See 610 Electrical Component Locations. Central Body Electronics (ZKE...
Page 953 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Other functions are not directly controlled by the GM V but interconnected: Rain sensor (AIC). See Wipers and Washers. Sunroof operation (SHD). See Sunroof. Seat memory (SM) and electrical operation. See Seats. Outside rear-view mirror control and heating.
Page 954 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... a fault code (DTC) will be set. Resetting and resynchronizing of codes and data requires the use of BMW scan tools DIS or MoDiC. Car Memory/Key Memory A number of features and functions can be customized to the driver(s) preference.
Page 955 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... K-bus Door jamb sensors Trunk lid lock cylinder microswitch Interior trunk lid release push-button microswitch Central locking button Engine hood latch microswitch Trunk key position switch Interior light switch Internal motion sensor Tilt sensor Driver's door lock sensors...
Page 956 Disconnecting the battery may erase fault code(s) stored in control module memory. Check for fault codes using special BMW diagnostic equipment. Prior to disconnecting the battery, read the battery disconnection cautions given at...
Page 957 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... the front of this manual on page viii. Connect and disconnect ignition system wires, multiple connectors and ignition test equipment leads only while the ignition is off. Do not disconnect the battery with the engine running.
Page 958 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Do not try to start the engine of a car which has been heated above 176F/80C, (for example, in a paint drying booth). Allow it to cool to normal temperature. Disconnect the battery before doing any electric welding on the car.
Page 959: Wiring Diagrams
Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... 600-3 Wiring Diagrams The wiring diagrams shown in Electrical Wiring Diagrams have been specially designed to enable quick and efficient diagnosis and troubleshooting of electrical malfunctions. Wiring codes and abbreviations A lot of information is included in each wiring diagram if you know how to read them.
Page 960 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Table b. Wire color codes German English Color code code Grey Orange Violet White Yellow Most terminals are identified by numbers on components and harness connectors. Terminal numbers for major electrical connections are shown in the diagrams. Though many terminal...
Page 961 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Table c. Terminal and circuit numbers Number Circuit description Battery positive (+) voltage. Supplies power whenever battery is connected. (Not dependent on ignition switch position, unfused) Ground, battery negative (-) terminal Supplies power from battery to starter...
Page 962 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Abbreviation Component or system Abbreviation Component or system ADB, ADB-X automatic differential lock low emission vehicle adaptive transmission control LSZ light switch module rain sensor mass air flow sensor traction control maximum braking control automatic air recirculation...
Page 963 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Abbreviation Component or system Abbreviation Component or system general module (see ZKE) supplemental restraint system-airbag head protection system transmission control module IHKA automatic heating and air top dead center conditioning system IHKR manual heating and air...
Page 964 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... 600-4 Electrical Troubleshooting Four things are required for current to flow in any electrical circuit: a voltage source, wires or connections to transport the voltage, a load or device that uses the electricity, and a connection to ground.
Page 965 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... components or connections in the wiring harness. When connecting jumper wires, use blade connectors at the wire ends that match the size of the terminal being tested. The small internal contacts are easily spread apart, and this can cause intermittent or faulty connections that can lead to more problems.
Page 966 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... resistance as small as 0.02 ohms would results in a 3 volt drop in a typical 150 amp starter circuit. (150 amps x 0.02 ohms =3 volts). Keep in mind that voltage with the key on and voltage with the engine running are not the same.
Page 967 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Voltage drop, testing Voltage drop can only be checked when there is a load on the circuit, such as when operating the starter motor or turning on the headlights. A digital multimeter should be used to ensure accurate readings.
Page 968 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... for faults using an ohmmeter. An open circuit or a circuit with high resistance will not allow current to flow. A circuit with little or no resistance allows current to flow easily. When checking continuity, the ignition should be off.
Page 969 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... battery voltage), a fuse will blow and the circuit may possibly be damaged. Shorts to ground can be located with a digital multimeter. Short circuits are often difficult to locate and may vary in nature. Short circuits can be found using a logical approach based on current path.
Page 970 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... panel and move or wiggle wires while observing meter. Continue to move down harness until meter displays a reading. This is the location of short to ground. Visually inspect wire harness at this point for any faults. If no faults...
Page 971 Electrical System - General http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... this point for any faults. If no faults are visible, carefully slice open harness cover or wire insulation for further inspection. Repair any faults found. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 8 of 8...
Page 972 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... 610-1 General This repair group covers fuse, relay and control module location information. Ground points and other component locations are also covered, primarily via photos or illustrations. For additional E46 electrical system information, see: 600 Electrical System–...
Page 973 Relay and fuse positions are subject to change and may vary from car to car. If questions arise, an authorized BMW dealer is the best source for the most accurate and up-to-date information. A good way to verify a relay...
Page 974 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Only use a digital multimeter for electrical tests. Copyright © 2006 Robert Bentley, Inc. All rights reserved. 3 of 3 2/25/2009 11:08 PM...
Page 975 Fuse panel above glove compartment E-box in engine compartment left side Note: In BMW repair information, fuses are numbered F1 through F108. There are two fuses with the same designation: F5 in the main fuse panel is rated 5A and protects the horn circuit.
Page 976 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Peel back liner to access F108 (200 amp) fuse (arrow) in main power distribution circuit. Electronics box (E-box) fuse carrier Fig. 2 Engine electronics fuse pack in E-box: Working in left rear of engine compartment, remove E-box plastic cover.
Page 977 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Table a. E-box fuse pack Fuse Rating Protected circuits (2001 models) DME control module (ECM) Evaporative emissions valve Fuel injectors Idle speed control valve Resonance valve, intake manifold Secondary air injection pump Suction jet pump valve, LDP system...
Page 978 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Main fuse panel Fig. 3 Fuse panel above glove compartment: Open glove compartment door. Working inside compartment, twist each plastic lock tab (arrows) at top of compartment 90°. Pull down on fuse panel to swing it down.
Page 979 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... found on top of the glove compartment fuse panel beneath an access panel. Lower glove compartment fuse panel fully. Slide harness connector block off top of panel (curved arrow). Detach access panel by squeezing retaining clips (arrows).
Page 980 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Table b. High amperage fuse positions Fuse Rating Protected circuits Light switching center control module Light switching center control module Trailer module 200A Main harness fuse (in trunk, see Fig. E46 main fuse panel Table c. 1999 fuse positions...
Page 981 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fuse Rating Protected circuit Navigation (see also fuse 41) On-board monitor (see also fuse 41) Radio (see also fuse 41) Telephone (see also fuse 39) not used Brake light Light module (see also fuse 32) On-board computer...
Page 982 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fuse Rating Protected circuit Heater-A/C (see also fuses 62, 63) Heater-A/C blower (see also fuse 37) Engine control (see also fuse 30) 7.5A Engine control (see also fuse 29) OBD II system Outside mirror Tire pressure control (see also fuse 69)
Page 983 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fuse Rating Protected circuit Power window, front (see also fuse 48) Windshield washer system (see also fuses 52, Seat heating Headlight cleaning system Central locking system, trunk Glove box light Interior light (see also fuse 49)
Page 984 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fuse Rating Protected circuit Passenger seat adjustment Hinged window (Coupe) (10A Coupe) Window, rear Table d. 2000-2001 fuse positions Fuse Rating Protected circuit not used Horn (see also fuse 55) Make-up mirror light Power top (Convertible, see also fuses 12, 35,...
Page 985 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fuse Rating Protected circuit Seat heating (see also fuse 42) Roller sun blind (see also fuse 42) Tire pressure control (see also fuses 31, 42, 69) 7.5A Roll-over protection system (Convertible) Electronic immobilizer (EWS) (see also fuse 67)
Page 986 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fuse Rating Protected circuit Outside mirror (see also fuse 57) Tire pressure control (see also fuses 12, 42, 69) Light module (see also fuse 9) ABS/ASC (see also fuses 12, 42, 53, 56) ABS/DSC (see also fuses 12, 40, 42, 53, 56, 61)
Page 987 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fuse Rating Protected circuit Power top (Convertible, see also fuses 6, 12, 35, (20A convertible) Manual top (Convertible, see also fuses 12, 42) Sunroof Cigarette lighter / power outlet (Australia, see (20A) also fuse 26) Power window, front (see also fuse 49)
Page 988 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fuse Rating Protected circuit Central locking (see also fuses 49, 52, Sport Wagon, see fuse 58) ABS/DSC (see also fuses 12, 33, 40, 42, 53, 56, 7.5A Heater-A/C (see also fuses 28, 63) Heater (see also fuses 23, 28) 7.5A...
Page 989 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... 610-3 Ground Locations Grounds are widely distributed throughout the vehicle body. Several are found under the interior carpets. Lugs and connectors attached to ground are susceptible to damage and corrosion. Clean or renew them as necessary.
Page 990 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fig. 8 Under left front carpet on door sill 1 - Ground connector X173 Fig. 9 On door sill, under driver seat carpet 1 - Ground connector X1108 2 - Side impact airbag crash sensor Fig. 10 Under right front carpet on door...
Page 991 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fig. 12 Right side trunk, behind trim 1 - Ground X498 Fig. 13 Left side trunk, behind trim 1 - Ground X13016 Copyright © 2006 Robert Bentley, Inc. All rights reserved. 3 of 3 2/25/2009 11:09 PM...
Page 992: Component Locations
Every component is not installed in every car. Due to changes in production, component locations may vary from what is illustrated. Consult your BMW dealer for the latest information. The automatic transmission range switch is also sometimes referred to as the gear-position switch.
Page 993 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... 1 - A/C relay 2 - Secondary air pump relay 3 - Fuel pump relay 4 - A/C relay 5 - Foglight relay 6 - Horn relay 7 - General module (GM V) Fig. 15 Behind glove compartment...
Page 994 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Fig. 16 E-box 1 - Engine control module (ECM) 2 - Automatic transmission control module (TCM) 3 - DME main relay 4 - Windshield washer double relay 5 - E-box temperature sensor 6 - B+ connector...
Page 995 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Table e. E46 component locations Component Year, model Location Refer to 12 volt auxiliary see Power socket, 12-volt power socket 3/2-way valve 1999 - 2000 Under car ahead of fuel filter, under protective cover A/C blower final...
Page 996 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Component Year, model Location Refer to ABS/ASC/DSC 1999 - 2001 In instrument cluster warning lights ABS/DSC charge 1999 - 200 Base of master cylinder, left side Fig. 18 pressure sensor rear wheel drive with DSC ABS/DSC charge...
Page 997 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Component Year, model Location Refer to recirculation system) Airbag connector, 1999 - 2001 Right side dashboard support Fig. 41 passenger side Airbag connector, 1999 - 2001 Under steering wheel airbag Fig. 34 steering wheel Airbag control...
Page 998 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Component Year, model Location Refer to Antenna amplifier, Convertible On convertible top storage cover diversity Antenna amplifier, Sport Wagon Behind left side cargo area storage Fig. 57 diversity cover Antenna amplifier, Convertible Below mast antenna in trunk...
Page 999 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Component Year, model Location Refer to ASC/DSC switch 1999 - 2001 Bottom of center console, left of shifter see ABS/ASC entries Automatic climate see A/C entries control (IHKA) Automatic 1999 - 2001 Left rear engine compartment in Fig.
Page 1000 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Component Year, model Location Refer to Blower see A/C blower Body electronics see General module (GM V) control module Brake fluid level 1999 - 2001 Top of brake fluid reservoir, left rear Fig. sensor engine compartment Fig.
Page 1001 Electrical Component Locations http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/6... Component Year, model Location Refer to Charge pressure see ABS/DSC charge pressure sensor sensor Child protection see Window lock-out switch, rear window control Chime module, park 1999 - 2001 In left footwell top trim distance control...

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