BMW 1999-2005 M3 Service Manual Download Page 727

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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

Body - General

http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/4...

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Summary of Contents for 1999-2005 M3

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Page 2: ...hat might cause you injury damage your car or result in an unsafe repair If you have doubts for these or other reasons about your ability to perform safe repair work on your car have the work done at an authorized BMW dealer or other qualified shop The manual is divided into ten sections 0 GENERAL DATA AND MAINTENANCE 1 ENGINE 2 TRANSMISSION 3 SUSPENSION STEERING AND BRAKES 4 BODY 5 BODY EQUIPMENT...

Page 3: ...ation and troubleshooting The remainder of the repair groups contain the service and repair information The last two major sections contains detailed electrical wiring schematics and scan tool codes A master listing of the individual repair groups can be found on the inside front cover A comprehensive index can be found at the back of the manual Warnings cautions and notes Throughout this manual a...

Page 4: ... important Read them before you begin any maintenance or repair job WARNING Never run the engine in the work area unless it is well ventilated The exhaust should be vented to the outside Carbon monoxide CO in the exhaust kills Remove all neckties scarfs loose clothing or jewelry when working near running engines or power tools Tuck in shirts Tie long hair and secure it under a cap Severe injury ca...

Page 5: ...em is designed to retain pressure even when the ignition is off When working with the fuel system loosen the fuel lines slowly to allow the residual pressure to dissipate gradually Take precautions to avoid spraying fuel Illuminate the work area adequately and safely Use a portable safety light for working inside or under the car A fluorescent type light is best because it gives off less heat If u...

Page 6: ... the engine compartment or on top of the battery They may fall into confined spaces and be difficult to retrieve become caught in belts or other rotating parts when the engine is started or cause electrical shorts and damage to the electrical system Copyright 2006 Robert Bentley Inc All rights reserved General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 5 of 5 2 25 2009 10 07 PM ...

Page 7: ...l Lifting the car The proper jacking points should be used to raise the car safely and avoid damage The jack supplied with the car can only be used at the four side points arrows just behind the front wheels or just in front of the rear wheels WARNING Never work under a lifted car unless it is solidly supported on jack stands that are intended for that purpose When raising the car using a floor ja...

Page 8: ...m surface for the jack if necessary Raise car slowly while constantly checking position of jack and car Once car is raised block wheel that is opposite and farthest from jack to prevent car from unexpectedly rolling WARNING Do not rely on the transmission or the emergency brake to keep the car from rolling They are not a substitute for positively blocking the opposite wheel Never work under a car ...

Page 9: ... purpose of supporting a car For more information on jack stands see Tools WARNING A jack is a temporary lifting device and should not be used alone to support the car while you are under it Do not use wood concrete blocks or bricks to support a car Wood may split Blocks or bricks while strong are not designed for that kind of load and may break or collapse Place jack stands on firm solid surface ...

Page 10: ...at 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 Copyright 2006 Robert Bentley Inc All rights reserved General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 4 of 4 2 25 2009 10 07 PM ...

Page 11: ...m scratches and other damage Make sure the car finish is clean so that dirt under the cover does not scratch the finish Any repair job will be less troublesome if the parts are clean For cleaning old parts there are many solvents and parts cleaners commercially available For cleaning parts prior to assembly commercially available aerosol cans of parts cleaner or brake cleaner are handy to use and ...

Page 12: ...olts or nuts that attach a component it is always good practice to tighten the bolts gradually and evenly to avoid misalignment or over stressing any one portion of the component For components sealed with gaskets this method helps to ensure that the gasket will seal properly Where there are several fasteners tighten them in a sequence alternating between opposite sides of the component Repeat the...

Page 13: ...ss according to DIN 267 5 6 5 8 6 8 8 8 10 9 12 9 M5 2 5 3 5 4 5 6 8 10 M6 4 5 6 7 5 10 14 17 M8 11 15 18 24 34 40 M10 23 30 36 47 66 79 M12 39 52 62 82 115 140 M14 62 82 98 130 180 220 M16 94 126 150 200 280 340 M18 130 174 210 280 390 470 Gaskets and seals Gaskets are designed to crush and become thinner as the mating parts are bolted together Once a gasket has been used it is no longer capable ...

Page 14: ...nstallation instructions apply Make sure a seal is installed with the lip facing the correct way Note the installation direction of the old seal before removing it Electrical testing Many electrical problems can be understood and solved with only a little fundamental knowledge of how electrical circuits function Electric current only flows in a complete circuit To operate every electrical device i...

Page 15: ... solder from traveling up the wire Always use a solder made specifically for electrical work rosin core Note Twisting wires together to make a repair is not recommended Corrosion and vibration will eventually spoil the connection and may lead to irreparable damage to sensitive electronic components Insulate the finished connection Electronics stores can supply heat shrinkable insulating tubing tha...

Page 16: ...ssembled Genuine BMW parts Genuine BMW replacement parts from an authorized BMW dealer are designed and manufactured to the same high standards as the original parts They will be the correct material manufactured to the same specifications and guaranteed to fit and work as intended by the engineers who designed the car Some genuine BMW parts have a limited warranty Many independent repair shops ma...

Page 17: ...to let an authorized BMW dealer or other qualified shop confirm your diagnosis before replacing an expensive non returnable part Information you need to know Model When ordering parts it is important that you know the correct model designation for your car Models covered in this E46 manual are 323i Ci 325i Ci 325Xi 328i Ci 330i Ci 330Xi in Sedan Coupe Convertible and Sport Wagon body styles Model ...

Page 18: ...nt arrow another in the lower left corner of the windshield Engine code 3 Series cars covered in this manual are powered by 6 cylinder engines For information on engine codes and engine applications see 100 Engine General Transmission code The transmission type with its identifying code may be important when buying clutch parts seals gaskets and other transmission related parts For information on ...

Page 19: ...source of good quality tools Some of the repairs covered in this manual require the use of special tools such as a custom puller or specialized electrical test equipment 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 Assenma...

Page 20: ...luding open end 12 point box end 6 point box end and flare nut The basic open end wrench is the most widely used but grips on only two sides The box end wrench has better grip on all six sides of a nut or bolt A 12 point box end can loosen a nut or bolt where there is less room for movement while a 6 point box end provides better grip For hex fasteners on fluid lines like brake lines and fuel line...

Page 21: ...nd the corresponding wrench sizes Common bolt diameters and wrench sizes M5 8 mm M6 10 mm M8 12 mm or 13 mm M10 17 mm M12 19 mm M14 22 mm Spark plug socket A special socket for spark plugs is the correct size is deep enough to accommodate a spark plug s length and includes a rubber insert to both protect the spark plug from damage and grip it for easier removal Pliers There are many types of plier...

Page 22: ...it It can substitute in a pinch if two wrenches of the same size are needed to remove a nut and bolt Use extra care with adjustable wrenches as they tend to loosen slip and damage fasteners Compared to a wrench of the correct size an adjustable wrench is always second best They should only be used when the correct size wrench is not available Choose one of average size range about 6 to 8 inches in...

Page 23: ...ide low drain pan will fit more easily under the car Use a funnel to pour the new oil into the engine The M52 M54 engines use an oil filter canister with a disposable filter cartridge insert Therefore an oil filter wrench is not required See 020 Maintenance for oil change instructions Feeler gauges Feeler gauges are thin metal strips of precise thickness used to measure small clearances They are n...

Page 24: ... 150 Nm 185 ft lb has adequate capacity for most of the repairs covered in this manual For recommended torque values of 10 Nm or below the English system equivalent is given in inch pounds in lb These small values may be most easily reached using a torque wrench calibrated in inch pounds To convert inch pounds to foot pounds divide by 12 Digital multimeter Many of the electrical tests in this manu...

Page 25: ... use to do the job correctly In these cases the tool is identified with a BMW part number See your authorized BMW dealer parts department for information on how to order special tools There are some jobs for which expensive special tools are essential and not a cost effective purchase for one time repair by the do it yourself owner This manual includes such repairs for the benefit of those with th...

Page 26: ...off the road Changing a tire on a busy street or highway is very dangerous If necessary drive a short distance on the flat tire to get to a safe place It is much better to ruin a tire or rim than to risk being hit Take jack and tools from tool area beneath trunk mat Remove spare tire from tire storage tray Loosen wheel bolts while car is on ground but leave them a little snug Place jack in lifting...

Page 27: ...car may help 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 starter will not operate see 121 Battery Alternator Starter for information on the starter and starter immobilization systems Check to make sure that there is fuel in the tank...

Page 28: ...r for several minutes and call a doctor Batteries produce explosive and noxious gasses Keep sparks and flames away Do not smoke near batteries Do not jump start the engine if you suspect that the battery is frozen Trapped gas may explode Allow the battery to thaw first Do not quick charge the battery for boost starting for longer than one minute and do not exceed 16 5 volts at the battery with the...

Page 29: ...posite end of negative cable to ground lug in engine compartment B Start car with good battery and run engine at about 2 000 rpm then start car with dead battery With engine at idle switch on blower motor and rear window defogger to avoid a damaging voltage surge from alternator Carefully disconnect jumper cables starting with negative cable on ground lug Turn all electrical consumers off Note The...

Page 30: ...or or a faulty fuel injector can cause the exhaust or evaporative emissions to exceed a specified limit When these limits are exceeded the MIL will be turned on The car can be safely driven with the light on although the emission systems should be checked as soon as possible See OBD On Board Diagnostics for more information on the MIL and the On board diagnostic system Towing The cars covered by t...

Page 31: ...d on dollies Automatic transmission If absolutely necessary car can be towed with rear wheels on ground but the tow should not exceed 25 miles 40 km at speeds at or below 30 mph 48 km h Be sure transmission fluid has been topped off before starting tow Always tow car with transmission lever in N neutral If tow must exceed 25 miles 40 km add one quart of ATF to transmission or better yet remove dri...

Page 32: ...oyance Many of the following items won t allow you to do major repair work on the car but they will help in the event of the failure of something that can disable the car or compromise its safety 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 uppe...

Page 33: ...ke 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 General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 8 of 8 2 25 2009 10 09 PM ...

Page 34: ...ater 3 Series E46 BMW introduced an extended oil change interval of approximately 15 000 miles depending on engine operating conditions The introduction of BMW High Performance Synthetic Oil has made this longer interval possible 1999 to 6 2000 models BMW uses a unique system to determine maintenance intervals BMW s Service Interval Indicator SII calculates maintenance intervals based not only on ...

Page 35: ... before service is due The type of service OIL SERVICE or INSPECTION is also illuminated in the display Note An OIL SERVICE interval will always be followed by an INSPECTION interval which will then be followed by an OIL SERVICE interval and so on When the ignition is turned on the service recommendation and miles remaining are displayed for a few seconds A flashing message and a negative symbol i...

Page 36: ...r 12 months When the specified maintenance has been carried out the SII memory should be reset 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 into the DLC CAUTION Follow the manufacturer s directions when resetting the SII...

Page 37: ...earch com 6 2000 and later models On vehicles without the data link connector DLC in the engine compartment the reset tool can no longer be used Instead the SII can be reset with the trip odometer reset button in the instrument cluster The ignition key must be in OFF position Press and hold trip odometer button in instrument cluster and turn ignition key to ACCESSORY position Keep button pressed f...

Page 38: ... of the ignition key Inspection I and Inspection II The Service Interval Indicator signals the need for more comprehensive maintenance and inspection There are two sets of inspection requirements These inspections alternate throughout a car s maintenance history If the last inspection interval was Inspection I the next inspection interval following an oil service will be Inspection II the next aft...

Page 39: ...cify 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 Copyright 2006 Robert Bentley Inc All rights reserved Maintenance http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 6 of 6 2 25 2009 10 01 PM ...

Page 40: ...ecommended Additional repair information Engine compartment maintenance Change oil and oil filter 020 Reset Service Interval Indicator SII 020 Replace interior ventilation microfilter 020 Under car maintenance Check overall thickness of front and rear brake pads If replacement is necessary Examine brake disc surfaces Clean brake pad contact points in calipers Grease wheel centering hubs alloy whee...

Page 41: ...condition position and mounting of exhaust system Visually check for leaks 180 Check power steering system for leaks Check power steering fluid level and adjust if necessary 320 Check steering rack and tie rods for tightness Check condition of front axle joints steering linkage and steering shaft joints 320 Check overall thickness of front and rear brake pads using special BMW tool If replacement ...

Page 42: ...and lines for leaks damage and incorrect positioning 340 Check parking brake actuator Adjust if necessary 340 Check all tire pressures including spare and correct if necessary Check condition of tires outer tread surfaces tread wear pattern in case of uneven tread wear perform a wheel alignment if requested 020 Inspect entire body according to terms of rust perforation limited warranty Must be per...

Page 43: ...ntilation microfilter Note reduce replacement intervals in dusty operating conditions 020 Reset service interval indicator 020 Body electrical Check operation of air conditioner 640 Check operation of headlights parking lights back up lights license plate lights interior lights glove box light engine compartment light trunk light turn signals emergency flashers stop lights horns headlight flasher ...

Page 44: ...al locking system and double lock 515 Replace batteries for alarm remote controls in all master keys 515 Check operation and condition of all door hood and trunk latches 410 515 Check heater air conditioner blower and rear window defogger operation 640 Convertible models Activate automatic roll over protection system via diagnostic link Note first remove hardtop or lower convertible top 541 Check ...

Page 45: ...ed Warm engine required Dealer service recommended Additional repair information Engine compartment maintenance Replace air filter element Note reduce replacement intervals in dusty operating conditions 020 Brake system service Replace brake fluid every 2 years time interval begins from vehicle production date 340 Cooling system service Replace coolant every 4 years time interval begins from vehic...

Page 46: ...ngine required Dealer service recommended Additional repair information Spark plug service Replace spark plugs every 100 000 miles 020 Copyright 2006 Robert Bentley Inc All rights reserved Maintenance http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 7 of 7 2 25 2009 10 02 PM ...

Page 47: ...Table d Fluids and lubricants Fluid Approximate capacity Specification Engine oil with filter change Rear wheel drive 6 5 liters 6 9 US qt Synthetic oil with API rating SH or higher All wheel drive 7 5 liters 8 US qt Manual transmission oil Getrag S5D 250G 1 1 liters 1 15 US qt BMW 83 22 9 408 942 MTF LT 1 ZF S5D 320Z 1 3 liters 1 37 US qt ZF S5D 280Z 1 35 liters 1 42 US qt Automatic transmission ...

Page 48: ...ed Front differential Fill 0 7 liter 0 74 US qt Refill 0 6 liter 0 63 US qt Rear wheel drive 0 9 liter 0 95 US qt All wheel drive 1 0 liter 1 06 US qt BMW SAF XO synthetic oil Rear differential Power steering fluid All models Permanently sealed no drain plug Dexron III ATF Brake fluid All models SAE DOT4 Engine coolant All models 8 4 liters 8 9 US qt 50 BMW anti freeze 50 distilled water CAUTION M...

Page 49: ...on 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 Differential gear oil BMW recommends using only a specially formulated synthetic gear ...

Page 50: ... lubricant type can be found on the type plate on the side of the transmission See 240 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 The manual transmissions installed in the E46 models are normally filled with a special lifetime fluid MTF LT 1 Consult 230 Manual ...

Page 51: ...gine oil level between oil changes as long as it meets the API classification SH Castrol is now the supplier of both the mineral based oil used in earlier models and the synthetic based oil used from model year 1999 Oil recommendation BMW High Performance Synthetic part number 07 51 0 017 866 5W 30 Note The use of engine oil additives is not recommended when using BMW High Performance Synthetic en...

Page 52: ...ck and wiping it clean Reinsert it all way and withdraw it again Oil level is correct if it is between two marks near end of stick Add oil through filler cap arrow on top of cylinder head Add only amount needed to bring oil level to MAX mark on dipstick using an oil of correct viscosity and grade Too much oil can be just as harmful as too little Engine oil and filter changing A complete oil change...

Page 53: ... off With car on level ground place drain pan under oil drain plug Using a 36 mm wrench loosen and remove oil filter housing cover arrow Remove filter cartridge and discard any O rings On Coupe or Convertible model Remove oil drain plug access panel in center of front end reinforcement plate below engine Using a socket or box wrench loosen drain plug at oil drain pan Remove plug by hand and let oi...

Page 54: ...ug Tightening torques Engine oil drain plug M12 bolt 25 Nm 18 ft lb Working at oil filter housing Lubricate and install new oil filter O rings Install a new filter cartridge and housing cover Tighten cover 1 Filter housing 2 filter housing cover tighten to 25 Nm 18 ft lb 3 O ring always replace 4 O rings always replace 5 Filter element Tightening torque Oil filter cover filter housing 25 Nm 18 ft ...

Page 55: ...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 Stop engine and recheck oil level Copyright 2006 Robert Bentley Inc All rights reserved Maintenance http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 5 of 5 2 25 2009 9 28 PM ...

Page 56: ...linkage Use a multipurpose grease on the bearing points of the throttle plate Air filter replacing The specified replacement intervals for the air filter are based on normal use If the car is operated primarily in dusty conditions the air filter should be serviced more frequently Release mass air flow sensor clips A and pull sensor assembly out of air filter upper housing arrow Release upper air f...

Page 57: ...inspected while the coolant is cold When the upper mark on the float is level with the top of the filler neck coolant is at the minimum allowable level When the lower mark on the float is level with the top of the filler neck the coolant is at the maximum level Hose connections should be tight and dry Coolant seepage indicates either that the hose clamp is loose that the hose is damaged or that th...

Page 58: ...perly Unless a tensioner mechanism malfunctions the poly ribbed belts do not require tension adjustment Inspect drive belts with the engine off If the belt shows signs of wear cracking glazing or missing sections it should be replaced immediately To reduce the chance of belt failure while driving replacement of the belts every four years is recommended Note When belts are replaced with new ones st...

Page 59: ...r The idle speed in E46 models is electronically adaptive and non adjustable See 130 Fuel Injection for more information Oxygen sensors The engine management system in E46 models is equipped with multiple oxygen sensors A regulating sensor is mounted before each catalytic converter and a monitoring sensor downstream of each converter The regulating sensor monitors engine combustion efficiency and ...

Page 60: ...stems Replacement of oxygen sensors at the specified intervals ensures that the engine and emission control system will continue to operate as designed Extending the replacement interval may void the emission control warranty coverage See 180 Exhaust System for information on replacing the oxygen sensors Tightening torque Oxygen sensor to exhaust manifold 50 Nm 37 ft lb Note A special socket for r...

Page 61: ... ATF Spark plugs replacing E46 engines use a coil over configuration with one ignition coil above each spark plug Remove microfilter housing Remove microfilter for interior ventilation See Ventilation microfilter replacing Open wiring harness loom A remove harness and lay aside Unfasten screws B and take off lower microfilter housing Remove engine cover over ignition coils Remove oil filler cap Ma...

Page 62: ...arness connectors Remove coil mounting bolts Remove coils Remove spark plugs Installation is reverse of removal bearing in mind the following Lightly lubricate new spark plug threads with copper based anti seize compound Thread plugs into cylinder head by hand to prevent cross threading Maintenance http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 7 of 8 2 25 2009 10 03 PM ...

Page 63: ...25 Nm 18 ft lb Ventilation microfilter replacing Working at cowl housing inside engine compartment twist microfilter cover retainers arrows 90 each and pull cover up Pull filter out and replace Copyright 2006 Robert Bentley Inc All rights reserved Maintenance http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 8 of 8 2 25 2009 10 03 PM ...

Page 64: ...y designed for constant vibration When replacing the battery be sure the replacement is designed specifically for the Convertible Battery cables should be tight The terminals the cable clamps and the battery case should be free of the white deposits that indicate corrosion and acid salts Even a thin layer of dust containing conductive acid salts can cause battery discharge To remove battery corros...

Page 65: ... of this manual on page viii Battery acid is extremely dangerous Take care to keep it from contacting eyes skin or clothing Wear eye protection Extinguish all smoking materials and do not work near any open flames Battery electrolyte should be maintained at the correct level just above the battery plates and their separators The correct level is approximately 5 mm 1 4 in above the top of battery p...

Page 66: ...s Ah the number of hours a specific current drain can be sustained before complete discharge or by cold cranking amps CCA the number of amps available to crank the engine in cold weather conditions In general replacement batteries should always be rated equal or higher than the original battery CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of...

Page 67: ...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 See 340 Brakes for brake fluid flushing procedures Brake pad rotor wear checking All E46 cars are fitted with disc brakes at all four wheels Although the brakes are equipped with a brake pad warning system ...

Page 68: ...bolts C Note Brake caliper removal and installation procedures are given in 340 Brakes Brake pad lining minimum thickness Front or rear pad Dimension A 3 0 mm 0 12 in Brake system inspecting Routine maintenance of the brake system includes maintaining the brake fluid in the reservoir checking brake pads for wear checking parking brake function and inspecting the system for fluid leaks or other dam...

Page 69: ...king brake system is independent of the main braking system and may require periodic adjustment depending on use Adjust the parking brake if the brake lever can be pulled up more than 8 clicks Check that the cable moves freely A description of the parking brake and parking brake adjustment can be found in 340 Brakes Note The parking brake may lose some of its effectiveness if it is not used freque...

Page 70: ...hydraulic clutch operating system Drive axle joint CV joint boots inspecting CV joint protective boots must be closely inspected for cracks and any other damage that will allow contaminants to get into the joint If the rubber boots fail the water and dirt that enter the joint will quickly damage it Note Replacement of the CV joint boots and inspection of the joints are described in 311 Front Axle ...

Page 71: ...t the system does not strike the body Check for restrictions due to dents or kinks Check for weakness or perforation due to rust Note Alignment of the system and the location of the hangers are described in 180 Exhaust System Differential oil level checking The differential units in E46 models are filled with lifetime oil that ordinarily does not need to be changed All wheel drive models Check fro...

Page 72: ...illed 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 If the car is raised in the air it should be level Tightening torques Front differential filler plug to housing 65 Nm 48 ft lb Rear differential filler plug to housing 70 Nm 52 ft lb Fuel filter replacing The fuel filter is located beneath the center of the ...

Page 73: ...e into a container and inspect drained fuel Check for rust moisture and contamination When replacing fuel filter Clamp filter inlet and outlet hoses to lessen fuel spillage Loosen center clamping bracket and hose clamps on either end of filter Note arrow or markings indicating direction of flow on new filter Install new filter using new hose clamps WARNING Fuel will be expelled when the filter Mai...

Page 74: ...mpartment Check for faulty flexible fuel lines by bending them If any leaks are present fuel should be expelled Check for any evaporative emissions hoses that may have become disconnected checking carefully at the charcoal canister and evaporative emissions purge system WARNING When checking for fuel leaks the engine must be cold A hot exhaust manifold or exhaust system could cause the fuel to ign...

Page 75: ... consists of checking and changing the gear oil inspecting for leaks and checking the rear drive axle rubber boots for damage The areas where leaks are most likely to occur are around the drive shaft and drive axle mounting flanges Note For more information on identifying oil leaks and their causes see 330 Rear Suspension and 311 Front Axle Final Drive Tires checking inflation pressure Correct tir...

Page 76: ... 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 Rotating the tires may adversely affect road handling and tire grip Transmission service automatic The automatic transmission is not equipped with a dipstick Therefore checking the ATF level is an involved procedure which includes measuring and maintaining a specifie...

Page 77: ...ssion fluid checking and filling manual transmission The manual transmission in E46 models is filled with lifetime oil that ordinarily does not need to be changed Check manual transmission oil level at transmission filler plug arrow Make sure car is on level surface Note Transmission fluid level checking and replacement procedures are covered in 230 Manual Transmission Wheels aligning BMW recommen...

Page 78: ...ng and Wheel Alignment for a more detailed discussion of alignment requirements and specifications Copyright 2006 Robert Bentley Inc All rights reserved Maintenance http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 0 15 of 15 2 25 2009 10 03 PM ...

Page 79: ... minimum as the alcohol in the de icer will wash the grease out of the lock assemblies and may cause the locks to corrode internally or become difficult to operate Exterior washing The longer dirt is left on the paint the greater the risk of damaging the glossy finish either by scratching or by the chemical effect dirt particles may have on the painted surface Do not wash the car in direct sunligh...

Page 80: ...th The idea is to get rid of the dirt in the creases and pores that can cause brittleness and premature aging On heavily soiled areas use a mild detergent such as Woolite or other specially formulated leather cleaners Use two tablespoons to one quart of cold water Dry the trim and upholstery completely using a soft cloth Regular use of a good quality leather conditioner will reduce drying and crac...

Page 81: ... information Special cleaning Tar spots can be removed with a bug and tar remover Never use gasoline kerosene nail polish remover or other unsuitable solvents Insect spots also respond to tar remover A bit of baking soda dissolved in the wash water will facilitate their removal This method can also be used to remove spotting from tree sap Washing chassis Periodic washing of the underside of the ca...

Page 82: ...ommon problems with the windshield wipers include streaking or sheeting water drops after wiping and blade chatter Streaking is usually caused when wiper blades are coated with road film or car wash wax 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 T...

Page 83: ...pressure along the blade and so that the blade is perpendicular to the windshield at rest Lubricate the wiper linkage with a light oil The linkage is located under the hood on the driver s side If the problem persists the blades are excessively aged or worn and should be replaced Note See 611 Wipers and Washers for more information Copyright 2006 Robert Bentley Inc All rights reserved Maintenance ...

Page 84: ...heir entire life Each emission influencing component is checked by a diagnostic routine to verify that it is functioning properly If a problem or malfunction is detected the OBD II system illuminates a warning light on the instrument panel to alert the driver This malfunction indicator light MIL will display the phrase Check Engine or Service Engine Soon The OBD II system also stores important inf...

Page 85: ...mance monitoring devices Standardized 16 pin OBD II connector under the dash Upgraded components for the federally required 100 000 mile or 10 year reliability mandate Malfunction Indicator Light MIL The OBD II system is designed to illuminate the Malfunction Indicator Light MIL when emission levels exceed 1 5 times the Federal standards Note On model year 1999 and 2000 cars the MIL is labeled Che...

Page 86: ... input signal is generated Misfire faults occur A leak is detected in evaporative system The oxygen sensors observe no purge flow from purge valve evaporative system The engine control module ECM fails to enter closed loop operation within specified time The engine control module ECM or automatic transmission control module TCM enters limp home operation mode Key is in ignition on position before ...

Page 87: ...MIL is illuminated if the function is checked and the fault is still present Once the MIL is illuminated it will remain illuminated unless the specific function has been checked without fault through three complete consecutive drive cycles The fault code will be cleared from memory automatically if the specific function is checked through 40 consecutive drive cycles without the fault being detecte...

Page 88: ...artment Data from the OBD II DLC may be limited depending on scan tool and vehicle OBD II standards mandate that the 16 pin DLC must be located within three 3 feet of the driver and must not require any tools to be exposed The communication protocol used by BMW is ISO 9141 Starting with June 2000 production the 20 pin BMW diagnostic port Data Link Connector or DLC which was previously located in t...

Page 89: ... nonetheless powerful diagnostic tools These tools read live data streams and freeze frame data as well as a host of other valuable diagnostic data For the do it yourself owner simple aftermarket DTC readers are also available These inexpensive BMW only tools are capable of checking for DTCs as well as turning off the illuminated MIL and resetting the service indicator lights Diagnostic monitors A...

Page 90: ...ion control systems For example a vehicle may not be equipped with secondary air injection so naturally no secondary air readiness function code would be present OBD lI requires monitoring of the following Oxygen sensor monitoring Catalyst monitoring Misfire monitoring Evaporative system monitoring Secondary air monitoring Fuel system monitoring Monitoring these emissions related functions is done...

Page 91: ... strategy monitors the two heated oxygen sensors per bank of cylinders It compares the oxygen content going into the catalytic converter to the oxygen leaving the converter The diagnostic executive knows that most of the oxygen should be used up during the oxidation phase and if it sees higher than programmed values a fault will be set and the MIL will illuminate Misfire detection This strategy mo...

Page 92: ...old By injecting oxygen into the exhaust manifold catalyst warm up time is reduced System components Electric air injection motor pump Electric motor pump relay Non return valve Vacuum vent valve Stainless steel air injection pipes Vacuum reservoir The secondary air system is monitored via the use of the pre catalyst oxygen sensors Once the air pump is active and air is injected into the system th...

Page 93: ...time Fuel system monitoring monitors the calculated injection time ti in relation to engine speed load and the pre catalytic converter oxygen sensor s signals as a result of residual oxygen in the exhaust stream The diagnostic executive uses the precatalyst oxygen sensor signal as a correction factor for adjusting and optimizing the mixture pilot control under all engine operating conditions Evapo...

Page 94: ...ï F and at least 40ï F above its original starting temperature Once the drive cycle is completed the system status or inspection maintenance I M readiness codes are set to Yes System status codes will be set to No in the following cases The battery or ECM is disconnected The ECM s DTCs have been erased after completion of repairs and a drive cycle has not be completed A scan tool can be used to de...

Page 95: ...ermine if ignition actually occurred 3 Ignition coil cyl 6 Input analog timing 100 mV DME initiates secondary ignition for each cylinder then looks for feedback through shunt resistor in harness to determine if ignition actually occurred 5 P0202 Injector circuit cyl 2 Output digital pulse width active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disc...

Page 96: ...heck of phase shift from camshaft sensor should change during every crankshaft revolution Phase shift occurs due to 2 1 relationship between camshafts 19 P1529 VANOS solenoid activation exhaust Output digital pulse width active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 21 P1525 VANOS sol...

Page 97: ...s 27 P1550 Idle control valve closing coil Output digital pulse width active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 29 Ignition coil cyl 1 Input analog timing 100 mV DME initiates secondary ignition for each cylinder then looks for feedback through shunt resistor in harness to determi...

Page 98: ...d DME internal values such as load and engine speed 39 Brake light switch and brake light plausibility test Input digital 0 12V When brake light switch is active brake light test switch must be also active If not fault is stored 40 Brake light switch pedal sensor plausibility test Input digital analog 0 12V 0 5V If pedal sensor is showing angle greater than limp home angle and additionally brake l...

Page 99: ...43 ECU internal test DME HW test 52 Rear exhaust valve flap Output digital steady active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 53 P1509 Idle control valve opening coil Output digital pulse width active low DME final stage will set flag whenever a short to ground a short to battery vo...

Page 100: ...stor and component exists 62 P0412 Secondary air injection system switching valve Output digital on off active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 65 P0340 Intake cam position sensor malfunction Input analog phase shift 0 5V DME final stage will set flag whenever a short to ground ...

Page 101: ...nternal values logical Internal hardware test of RAM ROM and Flash Prom 103 P1519 VANOS faulty reference value intake DME internal values logical Maximum VANOS adjustment angle checked at every engine start must be within a specified limit 104 P1520 VANOS faulty reference value exhaust DME internal values logical Maximum VANOS adjustment angle checked at every engine start must be within a specifi...

Page 102: ...r throttle valve final stage DME internal test Final stage inside DME special H bridge will set internal flag whenever a short to ground a short to battery voltage or a disconnection occurs MS 43 A second pedal sensor range check failure is determined DME internal values logical If pedal sensor malfunction is determined followed by a second malfunction a signal is sent 115 P1623 MS 42 Output volta...

Page 103: ...ck sensor 1 to mass air flow meter DME internal values Signal range is checked against predetermined diagnostic limits Rationality check with mass air flow meter 120 P1542 MS 42 Pedal sensor motor throttle valve potentiometer not plausible DME internal values logical motor Signal from motor throttle valve potentiometer must be equal signal from pedal sensor potentiometer plus any adaptive values M...

Page 104: ...voltage or a disconnection between output transistor and component exists MS 43 DMTL valve Output digital on off active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 127 Fuel pump Output digital on off active low DME final stage will set flag whenever a short to ground a short to battery vol...

Page 105: ...e fault is set 140 P1475 LDP reed switch not closed Input digital on off 0 12V With shut off valve open and no pressure on system reed contact should be closed showing a high signal If not the case in beginning of every diagnostics check a signal is sent 140 MS 43 DMTL pump final stage Output digital on off active low DME final stage will set flag whenever a short to ground a short to battery volt...

Page 106: ...r and air mass sensor signal not plausible Input analog 0 5V Signal from motor throttle valve potentiometer must be suitable to signal from air mass sensor A fault is set if difference exceeds specified limit 150 P0130 Oxygen sensor pre cat Bank 1 short to battery volt Input analog 0 5V Oxygen sensor signal range is checked to determine if electrical shorts exist on input line Voltage signal has t...

Page 107: ... 0 5V Oxygen sensor signal range is checked to determine if electrical shorts exist on input line Voltage signal must be within a predetermined range 0 1V 1V or fault will set 157 P0136 Oxygen sensor Post Cat Bank 1 short to ground Input analog 0 5V Oxygen sensor signal range is checked to determine if electrical shorts exist on input line Voltage signal must be within a predetermined range 0 1V 1...

Page 108: ...1542 Pedal sensor potentiometer short between two potentiometer paths DME internal check 5 volts for potentiometers are switched on within a specific time pattern 173 P0120 Motor throttle valve potentiometer contact short Rationality check Motor throttle valve potentiometer 174 P0120 Motor throttle valve potentiometer adaptation of idle end position Input analog 0 5V Signal for idle position must ...

Page 109: ...E internal analog input 202 P0170 Fuel trim Bank 1 O2 control limit DME internal values logical Controller for lambda is too long beyond a min or a max 203 P0173 Fuel Trim Bank 2 O2 control limit DME internal values logical Controller for lambda is too long beyond a min or a max 204 P0505 Idle control system idle speed not plausible DME internal values logical Functional check between actual engin...

Page 110: ...nection exist on input line 216 P0136 Oxygen sensor post cat Bank 2 disconnection Input analog 0 5V Oxygen sensor signal range is checked to determine if electrical disconnection exist on input line 217 P0505 CAN time out EGS1 Input digital binary information 0 12V CAN message between DME EGS was not received within expected time 219 CAN chip bus off Input digital binary information 0 12V Hardware...

Page 111: ... Input analog 0 5V Rationality check for O2 control adaptation with post catalyst sensor bank 2 227 P0188 Fuel trim Bank 1 O2 control adaptation limit DME internal values logical Range control of adaptation values 228 P0189 Fuel trim Bank 2 O2 control adaptation limit DME internal values logical Range control of adaptation values 229 P0133 Oxygen sensor pre cat Bank 1 slow response time Input anal...

Page 112: ...xygen storage capability efficiency of catalytic converter Post cat oxygen sensor must be relatively lean 235 P1190 Pre cat sensor Bank 1 trim control Input analog high is rich 0 1V Rationality check for O2 control adaptation with pre cat sensor bank 1 236 P1191 Pre cat sensor Bank 2 trim control Input analog high is rich 0 1V Rationality check for O2 control adaptation with pre cat sensor bank 2 ...

Page 113: ...sfire detected DME internal values logical Crankshaft speed acceleration is monitored by crank sensor Time for each cylinder combustion is compared against avg of others If time for cylinder 5 is longer fault will set 243 P0306 Cyl 6 misfire detected DME internal values logical Crankshaft speed acceleration is monitored by crank sensor Time for each cylinder combustion is compared against avg of o...

Page 114: ...nmetered airflow generated by secondary air pump operation Oxygen sensor must sense lean condition or fault will set 248 P1184 Post cat sensor signal after decel phase not plausible Bank 1 Input analog 0 5V Signal is checked for a lean signal in decel and a transition between lean to rich after decel 249 P1185 Post cat sensor signal after decel phase not plausible Bank 2 Input analog 0 5V Signal i...

Page 115: ...l and Installation 116 Cylinder Head and Valvetrain 117 Camshaft Timing Chains 119 Lubrication System 120 Ignition System 130 Fuel Injection 170 Radiator and Cooling System Engine M52 TU 6 cylinder engine is a technical update hence the designation TU of the earlier 2 8 liter M52 engine The main technical update for M52 TU was the addition of double VANOS In model year 2001 the M54 2 5 and Engine ...

Page 116: ...ement cc cu in Bore stroke Compression ratio Torque lb ft rpm Horsepower Hp rpm 323i 1999 2000 M52 TU B25 6 2494 152 2 84 mm 3 307 in 75 mm 2 953 in 10 5 1 181 3 500 170 5 500 325i Ci xi 2001 M54 B25 6 2494 152 2 84 mm 3 307 in 75 mm 2 953 in 10 5 1 175 3 500 184 6 000 328i Ci 1999 2000 M52 TU B28 6 2793 170 4 84 mm 3 307 in 84 mm 3 307 in 10 2 1 206 3 500 193 5 500 330i Ci xi 2001 M54 B30 6 2979 ...

Page 117: ...placement cc cu in Bore stroke Compression ratio Torque lb ft rpm Horsepower Hp rpm in Torque power graphs M52 TU 2 5 liter M52 TU 2 8 liter Engine General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 3 of 19 2 25 2009 9 58 PM ...

Page 118: ...M54 2 5 liter M54 3 0 liter Engine General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 4 of 19 2 25 2009 9 58 PM ...

Page 119: ...lways drilled into the crankshaft provide bearing lubrication Oil seals pressed into alloy seal housings are installed at both ends of the crankshaft The 2 5 liter crankshaft is cast iron The 2 8 and 3 0 liter engines use a forged steel crankshaft to accommodate the higher torque The crankshaft for the 3 0 liter engine is adapted from the S52 M3 engine Engine General http ebahn bentleypublishers c...

Page 120: ... optimum coolant circulation allowing the head to operate at lower temperatures than the cylinder block The aluminum cylinder head uses chain driven double overhead camshafts and four valves per cylinder The cylinder head employs a crossflow design for greater power and efficiency Intake air enters the combustion chamber from one side while exhaust gasses exit from the other Oilways in the head pr...

Page 121: ...ve The coolant passages in the cylinder block are only connected to the coolant supply through the holes in the head gasket A reduced volume of the coolant flows through the cylinder block All models are equipped with a DME controlled electric cooling fan On some models a supplemental cooling fan is used See 170 Radiator and Cooling System for specific configuration and application information An ...

Page 122: ...The oil pump draws oil through a pickup in the bottom of the oil pan then forces it through a replaceable oil filter and into the engine oil passages The chain driven oil pump is bolted to the bottom of the cylinder block inside the oil pan A pressure relief valve limits the maximum system pressure A bypass valve prevents the oil filter from bursting and insures engine lubrication should the filte...

Page 123: ...ntake air to be drawn through both resonance tubes providing the air volume necessary for additional power at the upper rpm range Note The rpm for resonance valve activation may vary slightly depending on temperature In addition when the valve is closed a dynamic effect is produced For example as intake air is flowing into cylinder 1 the intake valves will close This blocks the onrushing air The c...

Page 124: ...both the M52 TU and the M54 engines VANOS is fully variable and operates independently on both intake and exhaust sides When the VANOS solenoid is actuated engine oil pressure is applied to the front side of the gear cup piston This forces the gear cup into the camshaft helical gears to change camshaft timing In addition to offering increased power the double VANOS system offers the following adva...

Page 125: ... diagnostics OBD II standards See OBD On Board Diagnostics at the back of this manual for additional information Table b Engine management systems Year Engine DME system 1999 2000 M52 TU B25 M52 TU B28 Siemens MS 42 0 2001 M54 B25 M54 B30 Siemens MS 43 0 Engine control module ECM The engine control module ECM is mounted in the electronics box E box next to the brake master cylinder The ECM is flas...

Page 126: ...tors intake air with no moving parts Pre and post catalytic converter oxygen sensors monitor engine emissions and catalyst efficiency MS 42 0 Static Hall effect sensors are used to detect camshaft position as soon as the ignition is turned ON before the engine is started Dynamic Hall effect crankshaft position sensor is mounted at the flywheel end of the engine block and is integral to misfire det...

Page 127: ...or EDK in MS 43 0 Idle speed control valve MS 42 0 Resonance valve in the intake manifold ECM outputs cont MS 42 0 Fuel pressure via 3 2 way valve monitors running losses evaporative losses during engine operation Secondary air injection if applicable to reduce HC and CO Multiple spark ignition system Maximum vehicle speed and cruise control Brake booster vacuum pump Engine General http ebahn bent...

Page 128: ...ay pattern Air intake Air entering the engine passes through a pleated paper air filter in the air cleaner Intake air mass is then measured by a mass air flow MAF sensor A reference current is used to heat a thin film in the sensor when the engine is running The current needed to hold the temperature of the film constant is the basis of the electronically converted voltage measurement correspondin...

Page 129: ...ivation Drive gear selected auto transmission During passenger compartment heating During different cooling fan speeds If the ECM detects a fault in the idle control valve it will increase or decrease air flow depending on the nature of the fault If the fault causes decreased air flow idle control valve closed the electronic throttle control MDK or EDK will compensate to maintain idle The EML lamp...

Page 130: ...hrottle assembly for the MS 42 0 system is referred to as the MDK Motor Driven Throttle Valve The MDK is identified as follows A throttle cable is used to actuate the accelerator pedal position potentiometers and also serves as a backup to open the throttle plate full control when the MDK system is in the failsafe mode The throttle assembly for the MS 43 0 system is referred to as the EDK Electron...

Page 131: ... knock sensors function like microphones and are able to convert mechanical vibration knock into electrical signals The ECM is programmed to react to frequencies that are characteristic of engine knock and adapt the ignition timing point accordingly See 120 Ignition System for further details Note M52 TU and M54 engines are designed to operate best with fuel octane of at least 91 anti knock index ...

Page 132: ...Siemens DME MS 43 0 Engine General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 18 of 19 2 25 2009 9 58 PM ...

Page 134: ...ents See OBD On Board Diagnostics at the back of this manual Two of the most common causes of driveability problems are system voltage levels and poor grounds System voltage The DME system requires that the system battery voltage be maintained within a narrow range Voltage levels outside the operating range can cause havoc When troubleshooting an illuminated MIL make sure the battery is fully char...

Page 135: ...uctions on conducting a voltage drop test and other general electrical troubleshooting information see 600 Electrical System General The DME system operates at low voltage and current levels making it sensitive to small increases in resistance The electrical system is routinely subjected to corrosion vibration and wear so faults or corrosion in the wiring harness and connectors are not uncommon Vi...

Page 136: ...ions on conducting a voltage drop test and other general electrical troubleshooting information see 600 Electrical System General Below is a listing of the main grounds for the fuel and ignition circuits of the DME system Main ground arrow for engine management system in left rear of engine compartment on bulkhead behind E box Main grounds for ignition coils arrows Main chassis ground harness conn...

Page 137: ... headlight assembly shown removed Main fuel pump ground arrow behind right rear seat back rest Copyright 2006 Robert Bentley Inc All rights reserved Engine General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 4 of 4 2 25 2009 9 59 PM ...

Page 138: ...in service position See 410 Fenders Engine Hood Note It is not necessary to remove the engine hood but it is helpful and will make engine removal and installation easier Intake manifold removing and installing Note The intake manifold must be removed to facilitate engine assembly removal Disconnect negative battery cable in luggage compartment CAUTION Prior to disconnecting the battery read the ba...

Page 139: ...arrows Remove cover hold down bolts and lift off cover Working above engine detach the following A Positive engine lead at B terminal B Manifold vacuum line C Oxygen sensor connectors D Electrical harness connector for intake air temperature sensor E Positive lead hold down bracket F Resonance valve electrical connector CAUTION Engine Removal and Installation http ebahn bentleypublishers com BMW 3...

Page 140: ...m engine compartment Separate brake booster vacuum hose at one way valve A Plug hose ends Detach engine vent hose from cylinder head cover by squeezing sides of spring clip arrows Detach VANOS solenoid electrical harness connector A Detach fuel injector electrical connectors from injectors Use small screwdriver to pry one corner of wire lock clip on fuel injector 1 connector Repeat for all injecto...

Page 141: ...omplete 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 rubber air duct Loosen clamps 2 and 8 and remove mass air flow sensor and air ducts 1 Throttle assembly 2 Hose clamp 77 84 mm 3 Y duct 4 Air duct 5 Hose clamp 83 90 mm 6 Mass air flow sensor 7 Idle control valve Engine Removal and Install...

Page 142: ...do not use a throttle cable mounted to throttle housing Remove nuts and bolt arrows retaining wiring harness conduit to throttle body Working at throttle housing Turn harness plug arrow counterclockwise and remove Disconnect electrical harness connector at idle speed control valve arrow Engine Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 5 of 16 2 25 2009 ...

Page 143: ...e B Remove lower guide tube mounting bolt C Pull out dip stick guide tube Remove schræder valve cap arrow from air connection on fuel rail Using a tire chuck blow fuel back through feed line using a brief burst of compressed air maximum of 3 bar or 43 5 psi WARNING Fuel in fuel line is under Engine Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 6 of 16 2 25 ...

Page 144: ...ise car and support in a safe manner 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 A floor jack is not adequate support Remove protective engine splash guard Working beneath car on left side under driver seat remove fuel filter cover and clamp fuel hose s Detach fuel hose s from fuel line s arrows usin...

Page 145: ...erneath car remove lower intake manifold support mounting bolt arrow located adjacent to left engine mount Remove fuel rail mounting bolts arrows Carefully pry fuel rail off manifold 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 manifold mounting nuts arrows Engine Removal and Installation http ...

Page 146: ...fuel injector seals 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 nothing CAUTION When reattaching throttle assembly harness connector connector is fully tightened when arrows on connector and plug line up Tightening torques Intake manifold to cylinder ...

Page 147: ...ses Remove expansion tank cap on radiator Place a 3 gallon pail beneath engine to capture coolant Remove coolant drain plug located on exhaust side of cylinder 2 of engine block arrow Drain radiator into a 3 gallon pail by removing plastic drain plug completely arrow WARNING Use extreme caution when draining and disposing of engine coolant Coolant is poisonous and lethal to Engine Removal and Inst...

Page 148: ...om thermostat housing by releasing locks arrows On vehicles equipped with automatic transmissions Remove radiator cooling fan and radiator as described in 170 Radiator and Cooling System CAUTION 32 mm radiator fan mounting nut has left hand threads Detach coolant hose at rear left side of engine above starter by releasing lock arrow Engine Removal and Installation http ebahn bentleypublishers com ...

Page 149: ...bed drive belts Mark belt direction of rotation if belts will be reused See 020 Maintenance All wheel drive models Remove front axle differential and output shaft bearing pedestal See 311 Front Axle Final Drive Remove transmission from car See 230 Manual Transmission or 240 Automatic Transmission Note Detach automatic transmission cooler lines from radiator remove brackets holding lines to side of...

Page 150: ... windshield and headlight washer reservoir 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 Remove secondary air pump Remove hose at one way valve A Remove bolts at support bracket on strut tower arrows Disconnect electr...

Page 151: ...nstall 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 Carefully raise engine out of car checking for any wiring fuel lines or mechanical parts that might become snagged as engine is removed Engine Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20...

Page 152: ...ke 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 harness connector connector is fully tightened when arrows on connector and plug line up Check that engine drive belts properly engage pulley grooves Install exhaust manifolds using ne...

Page 153: ...M7 or M8 20 Nm 15 ft lb Intake manifold to cylinder head M7 15 Nm 11 ft lb M8 22 Nm 16 ft lb Radiator cooling fan to coolant pump 40 Nm 30 ft lb Radiator drain screw to radiator 2 5 Nm 22 in lb Copyright 2006 Robert Bentley Inc All rights reserved Engine Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 16 of 16 2 25 2009 9 36 PM ...

Page 154: ...te If a head gasket problem is suspected a compression test or leak down test will usually detect the fault 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 to remove the VANOS control unit the camshaft...

Page 155: ...ng tool BMW special tool 11 2 300 Camshaft locking tool BMW special tool 11 3 240 Camshaft locking tool bracket BMW special tool 11 3 244 Lifter retaining suction cup BMW special tool 11 3 250 Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 2 of 4 2 25 2009 9 48 PM ...

Page 156: ...BMW special tool 11 4 220 VANOS adjustment plate BMW special tool 11 6 150 Secondary sprocket setup tool BMW special tool 11 6 180 Air line adapter BMW special tool 11 3 450 Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 3 of 4 2 25 2009 9 48 PM ...

Page 157: ...sioner lock pin BMW special tool 11 3 292 Copyright 2006 Robert Bentley Inc All rights reserved Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 4 of 4 2 25 2009 9 48 PM ...

Page 158: ...tion label all components wires and hoses before removing them Do not reuse gaskets O rings or seals during reassembly To assist the technician in this repair the procedure has been organized into discrete jobs Please be advised that these individual jobs must be accomplished in the order in which they appear Intake manifold removing Cylinder head cover removing VANOS control unit removing Camshaf...

Page 159: ...es 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 Unfasten screws B and remove lower microfilter housing Remove intake manifold cover Remove plastic trim covers arrows Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Man...

Page 160: ...itive lead hold down bracket F Intake manifold resonance valve electrical connector Working at left rear of engine compartment Peel rubber edge seal off top of panel Separate brake booster vacuum hose at intake jet pump A Plug hose ends Twist plastic panel retainers arrows 90 and pull out to remove Disengage panel from hoses and wiring harnesses and remove from engine compartment Cylinder Head Rem...

Page 161: ...epeat for all injectors Lift off connector loom and lay aside Remove complete air filter housing 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 connection E and lift complete air filter housing out of engine compartment Cylinder Head Removal an...

Page 162: ...m 6 Mass air flow sensor 7 Idle control valve 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 Note Models with M54 engines do not use a throttle cable Remove nuts and bolt arrows retaining wiring harness conduit to throttle body Cylinder Head Removal and Installation http ebahn b...

Page 163: ...l valve arrow directly above throttle housing Working under front corner of intake manifold disconnect electrical harness connector at fuel tank venting valve A Disconnect vent hose at quick disconnect fitting arrow Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 6 of 25 2 25 2009 9 39 PM ...

Page 164: ...si and 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 Catch and dispose of escaped fuel Plug all open fuel lines Always unscrew fuel tank cap to release pressure in the tank before working on the tank or lines Raise car and support in a sa...

Page 165: ...il use only a single supply line 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 Remove fuel rail mounting bolts arrows Carefully pry fuel rail of...

Page 166: ...ead while carefully checking for any remaining electrical connections or hoses CAUTION Stuff clean lint free rags into open intake ports to prevent any foreign matter from falling into the ports Drain engine coolant from engine block Remove expansion tank cap on radiator Place 3 gallon pail beneath engine to capture coolant Remove coolant drain plug located on exhaust side of cylinder Cylinder Hea...

Page 167: ...housing by releasing locks arrows Disconnect electrical harness at thermostat housing Remove radiator cooling fan and shroud as described in 170 Radiator and Cooling System CAUTION On cars with viscous clutch cooling fan radiator fan mounting nut 32 mm has left hand threads Remove fasteners arrows from heater bypass tube and set tube to side leaving heater hose connected Unbolt power steering flui...

Page 168: ...e at one way valve A Remove bolts at support bracket on strut tower arrows Lift up pump and disconnect electrical harness from bottom of pump Remove pump Unbolt and remove pump bracket from strut tower Cylinder head cover removing Remove cylinder head top cover Remove plastic trim covers arrows Remove cover hold down nuts and lift off cover Cylinder Head Removal and Installation http ebahn bentley...

Page 169: ...t insulators and gaskets should be reinstalled in their original locations The three grounds mount to the first second and fourth central studs Make note of their arrangement during removal Remove spark plugs CAUTION Stuff clean lint free rags into open intake ports to prevent any foreign matter from falling into the ports Remove oil baffle cover from above intake camshaft Cylinder Head Removal an...

Page 170: ... 5 mm 5 Splined shaft 6 Torx screw 7 Exhaust secondary sprocket 8 Secondary timing chain 9 Splined sleeve 10 Primary sprocket 11 Threaded locating stud 12 Secondary chain tensioner 13 Secondary chain lower guide Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 13 of 25 2 25 2009 9 39 PM ...

Page 171: ... sprocket 23 Primary chain tensioner 24 Primary chain 25 Locating stud 26 Guide rail 27 Locating stud 28 Woodruff key VANOS control unit removing Disconnect electrical connections at exhaust camshaft position sensor and exhaust camshaft VANOS control valve arrows Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 14 of 25 2 25 2009 9 39 PM ...

Page 172: ... air line connected rotate engine in direction of rotation clockwise until cylinder 1 intake and exhaust camshaft lobes face each other arrows in the top dead center TDC position for cylinder 1 Rotate engine at least twice leaving the cylinder 1 intake and exhaust camshaft lobes facing each other as shown CAUTION Do not rotate engine counterclockwise to reach the top dead center position Instead c...

Page 173: ... 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 CAUTION Oil will drain from pressure line Have a drain container and rags ready Do not allow oil to run onto drive belts Unscrew sealing plugs arrows from VANOS unit Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW ...

Page 174: ...NOS unit Remove set screws left hand thread on ends of intake and exhaust camshafts CAUTION Set screws have left hand threads Remove in clockwise motion Remove VANOS unit Remove engine support eye fasteners from side of VANOS unit Remove VANOS mounting nuts arrows from cylinder head and pull VANOS unit and metal gasket off CAUTION Cylinder Head Removal and Installation http ebahn bentleypublishers...

Page 175: ...the VANOS adjustment unit is replaced or if operations are completed that may change the timing of the camshafts the camshaft timing must be checked as described later in this chapter Camshafts and valvetrain removing Remove primary camshaft chain tensioner cylinder arrow CAUTION Primary camshaft chain tensioning piston is under spring pressure Press down on secondary chain tensioner and lock into...

Page 176: ...spring plate A Remove intake camshaft sprocket mounting nuts arrows and remove spring plate labelled FRONT Remove torx screws from exhaust camshaft sprocket arrows Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 19 of 25 2 25 2009 9 39 PM ...

Page 177: ...and exhaust camshafts Remove and mark used splined shafts in order and reinstall in original locations Remove exhaust camshaft splined sleeve A and shaft B Remove secondary chain tensioner mounting bolts arrows Remove tensioner from between camshafts while keeping retaining pin in place Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 20 of 25 2 ...

Page 178: ...shaft Remove sprocket from chain Place timing chain on end of exhaust camshaft Remove locating studs arrows from intake camshaft Lift off intake camshaft thrust spacer A and impulse wheel B Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 21 of 25 2 25 2009 9 39 PM ...

Page 179: ...rotate engine against direction of rotation counterclockwise approximately 30 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 CAUTION Intake camshaft bearing cap 1 is Cylinder Head Removal and Installation...

Page 180: ...ning bearing caps Release tension on eccentric shaft and remove BMW special tools 11 3 260 and 11 3 270 Remove bearing caps and set aside in order Remove camshaft and store safely Repeat procedure for exhaust camshaft Secure hydraulic lifters in lifter bores using BMW special tool 11 3 250 or remove lifters using a magnetic pick up tool With lifters secure or removed lift out camshaft bearing carr...

Page 181: ...n sensor arrow from side of cylinder head Remove secondary chain lower guide bolts arrows Remove chain guide The bolt on the intake camshaft side is a long bolt that extends into the lower timing chain cover Remove screws arrows holding lower timing chain cover to cylinder head Photo shows camshafts in place Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 2...

Page 182: ...with an extended reach The cylinder head bolts are recessed into the head below the camshaft towers with little working space Lift off cylinder head Refer to 116 Cylinder Head and Valvetrain to evaluate the head Copyright 2006 Robert Bentley Inc All rights reserved Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 25 of 25 2 25 2009 9 39 PM ...

Page 183: ...d as shown in 116 Cylinder Head and Valvetrain Note 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 Lubricate camshafts camshaft carriers bearing caps hydraulic lifters friction washers splined shaft...

Page 184: ...ged Apply permanently elastic sealing compound 3 Bond 1209 to joints with timing belt cover Place new cylinder head gasket on cylinder block Note The word OBEN printed on the gasket should face up The cylinder head gasket will fit correctly in only one orientation Set cylinder head in position guiding primary chain through cylinder head opening CAUTION Make sure the crankshaft which had been rotat...

Page 185: ...he head bolts are in place before installing the bolts Some of the washers may be staked to the cylinder head Tighten cylinder head bolts in correct sequence 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 Secure cylinder head bolts by...

Page 186: ...olt on the intake camshaft side is long and extends into the engine block Tightening torque Secondary chain guide to cylinder head 10 Nm 89 in lb Install and tighten cylinder head to lower timing chain cover bolts arrows Photo shows camshafts in place Camshafts and valvetrain installing CAUTION Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 4 o...

Page 187: ...erference Before installing camshaft carriers examine bearing points arrows on hydraulic lifter bores for signs of wear Install camshaft carriers with hydraulic lifters into cylinder head Note marks on carriers E for intake side and A for exhaust side Center camshaft carrier on pins arrows at bearing positions 2 and 7 Lift timing chain and place exhaust camshaft onto exhaust camshaft carrier Place...

Page 188: ...shaft and screw long bolts arrows into spark plug threads CAUTION Do not overtighten bolts into spark plug holes Turn eccentric shaft of special tool to pretension bearing caps Install and torque nuts on intake camshaft bearing caps Tightening torque Camshaft bearing cap to cylinder head M7 14 Nm 10 ft lb Release tension on eccentric shaft and remove BMW special tool 11 3 260 270 Cylinder Head Rem...

Page 189: ...ng times 68 F 20 C and higher 4 minutes 50 68 F 10 20 C 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 Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 7 of 21 2 25 2009 9 42 PM ...

Page 190: ...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 Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 8 of 21 2 25 2009 9 42 PM ...

Page 191: ... into timing chain tensioning piston bore and bring adjustment screw into contact with tensioning rail but do not pretension timing chain 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 Reposition sprocket if necessary Insert and tighten down threaded...

Page 192: ...lines aligns with corresponding gap in camshaft splines arrows Slide splined shaft onto exhaust camshaft Be sure that locating tooth of shaft arrow fits into spline gaps of camshaft and splined sleeve Slide splined shaft in further until three small slots on splined sleeve are centered on three threaded holes in primary chain sprocket Cylinder Head Removal and Installation http ebahn bentleypublis...

Page 193: ...n of sprockets with respect to chain when removing from special tool 11 6 180 Slide splined shaft onto intake camshaft until approx 1 mm 0 04 in of splines arrows are visible Confirm that locating tooth of shaft fits into spline gaps on camshaft and sprocket Install intake camshaft spring plate so that FRONT mark is visible Install mounting nuts arrows finger tight Insert sprocket mounting bolts a...

Page 194: ...ark is visible Note If F mark is no longer visible install spring plate so that convex side points forward toward front of car Install exhaust camshaft impulse wheel aligning pointer B with top edge of cylinder head A Install mounting nuts arrows finger tight Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 12 of 21 2 25 2009 9 42 PM ...

Page 195: ...Nm 6 in lb 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 CAUTION Cylinder Head Removal and Installation http ebahn ben...

Page 196: ...rque down mounting screws A and nuts B to final specifications Tightening torques Sprocket assembly to camshaft initial torque 5 Nm 44 in lb Sprocket assembly wheel to camshaft M7 Torx screws A 20 Nm 15 ft lb M6 mounting nut B 10 Nm 8 ft lb Remove flywheel locking tool from transmission bellhousing so that crankshaft is no longer secured Remove camshaft locking tools from cylinder head Turn engine...

Page 197: ... correctly the intake side of special tool 11 3 240 B may be up to 1 mm 0 04 in above the surface of the cylinder head This is normal Reassemble engine Otherwise reset camshaft timing as described in 117 Camshaft Timing Chains Remove BMW special tool 11 6 150 from front of cylinder head VANOS control unit installing Clean contact edges of cylinder head face and VANOS unit and apply a thin coat of ...

Page 198: ...it is being replaced be sure to check and adjust camshaft timing as described in 117 Camshaft Timing Chains Reinstall engine support hook Tightening torque VANOS unit to cylinder head M6 nut 10 Nm 89int lb M7 nut 14 Nm 10 ft lb Reconnect electrical harness connectors to camshaft position sensors and VANOS solenoid valves Insert and tighten down VANOS hydraulic piston set screws arrows in splined s...

Page 199: ... sealing plugs arrows with new sealing O rings Tightening torque Sealing plug to VANOS unit 50 Nm 37 ft lb Install coolant pipe fasteners at base of cylinder head and tighten fasteners arrows Note Use new sealing O ring on coolant pipe Install VANOS oil line banjo bolt with new seals Attach oil line to VANOS unit Tightening torque Cylinder Head Removal and Installation http ebahn bentleypublishers...

Page 200: ...emove camshaft locking tools from cylinder head Cylinder head cover manifolds cooling system installing Install intake camshaft cover and cylinder head cover Check for correct seating of half moon seals A in back of cylinder head cover Use a small amount of 3 Bond 1209 or equivalent sealant at corners B of half moon cutouts Seat gasket and seal corners in front of cylinder head at VANOS unit Cylin...

Page 201: ...sor before installing intake manifold Intake manifold Installation is reverse of removal 1 Manifold mounting nuts tighten to 15 Nm 11 ft lb 2 Fuel pipe bracket 3 Fuel pipe bracket 4 Vacuum pump bracket 5 Manifold mounting bracket 6 Tank venting valve bracket 7 Mounting bracket to manifold bolt M6 tighten to 10 Nm 7 ft lb 8 Mounting bracket to cylinder block nut M10 tighten to 47 Nm 33 ft lb Use ne...

Page 202: ...ntake manifold to cylinder head M7 15 Nm 11 ft lb M8 22 Nm 16 ft lb Mounting bracket to cylinder block M10 47 Nm 33 ft lb Mounting bracket to intake manifold M6 10 Nm 7 ft lb Installation of remaining parts is reverse of removal noting the following Refill cooling system as described in 170 Radiator and Cooling System Change engine oil and filter as described in 020 Maintenance If necessary adjust...

Page 203: ...ques Coolant drain plug to cylinder block 25 Nm 18 ft lb Radiator cooling fan to coolant pump 40 Nm 30 ft lb Radiator drain screw to radiator 2 5 Nm 22 in lb Spark plug to cylinder head 25 Nm 18 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Cylinder Head Removal and Installation http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 21 of 21 2 25 2009 9 42 PM ...

Page 204: ...ent aftermarket scan tool Disconnecting the battery will not erase the fault memory nor turn out the light Disable ignition system by removing DME main relay arrow from the electronics box E box in left rear of engine compartment WARNING The ignition system produces high voltages that can be fatal Avoid contact with exposed terminals and use extreme caution when working on a car with the ignition ...

Page 205: ... oil filler cap Remove engine cover over ignition coils Replace oil filler cap Remove ignition coils Pull up on spring clips to disconnect ignition coil harness connectors Remove coil grounding straps Remove coils Remove spark plugs Note Check the spark plugs for oil deposits that may indicate poor cylinder sealing then set them aside in order Used spark plugs should be reinstalled in the same cyl...

Page 206: ...cylinders should reach maximum compression in the same number of strokes If a cylinder needs significantly more strokes to reach maximum compression there is a problem Release pressure at compression gauge valve then remove gauge from spark plug hole Repeat test for each cylinder and compare results with values given below Compression pressures Minimum 10 11 bar 142 156 psi Maximum difference betw...

Page 207: ...ls Note Used spark plugs should be reinstalled in the same cylinder from which they were removed Remainder of installation is reverse of removal Be sure to reinstall all wires disconnected during test especially ground wires at coils and cylinder head cover where applicable Tightening torque Spark plug to cylinder head 25 Nm 18 ft lb Wet compression test To further help analyze the source of poor ...

Page 208: ...eakage probably from valves Cylinder leak down test The most conclusive diagnosis of low compression symptoms requires a cylinder leak down test Using a special tester and compressed air each cylinder in turn is pressurized The rate at which the air leaks out of the cylinder as well as where the air leaks out can accurately pinpoint the magnitude and location of the leakage Before attempting any r...

Page 209: ...ized BMW dealer The information given in this repair group is organized according to engine code 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 the special tools are not available have the cyli...

Page 210: ...d BMW repair facility or an ASE certified machinist 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 Cylinder Head and Valvetrain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 2 of 3 2 25 2009 9 47 PM ...

Page 211: ...em seal guide BMW special tool 11 1 960 Copyright 2006 Robert Bentley Inc All rights reserved Cylinder Head and Valvetrain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 3 of 3 2 25 2009 9 47 PM ...

Page 212: ...aler or an ASE certified machinist A cracked cylinder head must be replaced Note When disassembling and inspecting the cylinder head on an engine be sure to check the camshaft carrier bearing surfaces for warpage A warped cylinder head can be machined provided no more than 0 3 mm 0 012 in of material is removed If further machining is required the head should be replaced Removing more than this am...

Page 213: ...ith a thin non flammable liquid such as a parts cleaning fluid After fifteen minutes check the level of the fluid If the fluid level in any cylinder drops that cylinder is not sealing properly Camshaft Camshaft wear is usually caused by insufficient lubrication Visually inspect camshaft lobes and journals for wear Camshaft wear specifications are given in Table b Table b Camshaft wear specificatio...

Page 214: ...ers may become noisy Hydraulic lifter noise is usually a high pitched tapping or chattering noise In most instances this is considered normal as long as the noise goes away in a few minutes maximum 20 minutes If the noise does not go away either the lifter is faulty or the oil pressure to the lifter is low Hydraulic lifter replacement requires that the camshaft first be removed Note Before checkin...

Page 215: ...tors and lay harness aside Remove coil grounding straps Remove coils Remove spark plugs Remove cylinder head cover mounting fasteners and remove cylinder head cover Note The cylinder head cover mounting bolt insulators and gaskets should be reinstalled in their original locations Make note of their arrangement during removal Remove oil baffle cover from above intake camshaft Cylinder Head and Valv...

Page 216: ... a hydraulic lifter remove appropriate camshaft Refer to camshaft removal procedures given in 113 Cylinder Head Removal and Installation Once camshaft is removed withdraw faulty lifter and replace with new one Inspect lifter bores for wear and scoring Camshaft timing chain and cylinder head cover reassembly is reverse of disassembly Copyright 2006 Robert Bentley Inc All rights reserved Cylinder He...

Page 217: ... upright position If necessary use a magnetic tool to aid in removal of the lifters Remove valves using a valve spring compressor CAUTION Label each valve assembly as it is removed so it can be installed in its original position Remove and discard valve stem oil seals from valve guides See Valve stem oil seals later in this section Valve installation is reverse of removal Valve specifications are ...

Page 218: ...1 299 in Exhaust 30 5 mm 1 201 in Valve stem dia Standard Intake 6 0 0 015 mm 0 2362 0 0006 in Exhaust 6 0 0 015 mm 0 2362 0 0006 in Oversize 1 Intake 6 1 0 025 mm 0 2401 0 0010 in Exhaust 6 1 0 040 mm 0 2401 0 0016 in Oversize 2 Intake 6 2 0 025 mm 0 2441 0 0010 in Cylinder Head and Valvetrain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 2 of 6 2 25 2009 9 48 PM ...

Page 219: ...inspect the cylinder head to ensure that it can be reused before reworking the guides Note International Organization for Standardization ISO tolerance classes are listed in Table c ISO allowances are based on nominal sizes and should be used to determine proper fit Most machine shops should have this information available Replacement valve guides may be available through aftermarket suppliers Val...

Page 220: ...Oversize 2 6 2 mm 0 244 in Valve stem oil seals The purpose of the valve stem oil seal is to prevent excess oil from entering the combustion chamber The sign of faulty valve stem oil seals is excessive oil consumption and smoke from the exhaust immediately after starting and during deceleration Note Valve stem oil seals should not be reused If valves are removed new valve stem oil seals should be ...

Page 221: ...led Cutters are required to resurface the seats Always check the valves for leaks after reconditioning a valve seat as described above Table e lists valve seat dimensions Note Standard size replacement valve seats are not available from BMW Replacement valve seats are only available from BMW in 0 4 mm oversize oversized in both height and diameter The manufacturer does not provide specifications f...

Page 222: ... Valve springs The valve springs should be checked for fatigue To quickly check the springs line them up in a row Place a straight edge across the top of the springs 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 Cylinder Head an...

Page 223: ...e the timing chain the VANOS control unit the camshafts and the valvetrain Many of these tools are expensive and only available through an authorized BMW dealer Be sure to read each procedure thoroughly before starting a job to determine which special tools will be necessary In addition VANOS system diagnosis can only be carried out by using BMW specific electronic scan tools such as BMW DIS or Mo...

Page 224: ... 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 Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 2 of 4 2 25 2009 9 50 PM ...

Page 225: ...3 450 Primary chain tensioner tool BMW 11 4 220 VANOS setup bracket BMW 11 6 150 Secondary sprocket tool BMW 11 6 180 Crankshaft hub locking tool BMW 11 8 190 11 8 200 Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 3 of 4 2 25 2009 9 50 PM ...

Page 226: ...Puller for crankshaft hub BMW 11 8 210 Copyright 2006 Robert Bentley Inc All rights reserved Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 4 of 4 2 25 2009 9 50 PM ...

Page 227: ... 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 Check for fault codes using special BMW diagnostic equipment Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Remove drive belts Use long handled wrench...

Page 228: ...t Use only the special tools specified or equivalent hub holding tool Note The crankshaft hub center bolt is tightened to a torque of 410 Nm 300 ft lb On cars built up to 1 2000 2 piece vibration damper assembly remove vibration damper mounting bolts and remove vibration damper and pulley from hub Remove crankshaft hub up to 1 2000 production or vibration damper 1 2000 and later production Note If...

Page 229: ...l To install new seal coat with oil and use special tool 11 3 280 and crankshaft center bolt to draw seal in flush with timing case cover Install crankshaft hub up to 1 2000 or vibration damper from 1 2000 to crankshaft Install new crankshaft center bolt finger tight Torque crankshaft hub center bolt using special tools 11 2 150 11 2 410 up to 1 2000 or 11 8 190 11 8 200 from 1 2000 nothing Tighte...

Page 230: ...e special tools specified or equivalent hub holding tool Install vibration damper mounting bolts where applicable Note hub locating dowel arrow Tightening torque Vibration damper to crankshaft hub M8 22 Nm 16 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 4 of 4 2 25 2009 9 50 PM ...

Page 231: ... assure proper timing of the valvetrain Precise marks to set the timing on the camshafts are not provided for reassembly Read the procedures through before beginning the job nothing CAUTION If the camshafts are not properly timed the pistons can contact the valves Disconnect negative cable from battery CAUTION Disconnecting the battery may erase fault code s stored in control module memory Check f...

Page 232: ...ter housing Release mass air flow sensor clips A Remove filter housing mounting screws B Disconnect air duct connections C and lift complete air filter housing out of engine compartment pulling it forward away from mass air flow sensor Note Mass air flow sensor remains attached to air duct in above step Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 2 of 16 2 2...

Page 233: ...low engine to cool before opening or draining cooling system Use caution when draining and disposing of engine coolant Coolant is poisonous and lethal to humans and pets Pets are attracted to coolant because of its sweet smell and taste Consult a veterinarian immediately if ingested by an animal Drain radiator into 3 gallon pail by removing plastic drain plug at lower left corner of radiator Camsh...

Page 234: ...locking clips and pull hoses from thermostat housing arrows Unbolt and remove thermostat houses Remove drive belts Use long handled wrench to turn A C belt tensioner hex A clockwise against spring tension Remove A C belt Similarly turn main engine drive belt tensioner hex B clockwise and remove belt Remove coolant pump pulley Remove alternator cooling duct at radiator support Camshaft Timing Chain...

Page 235: ...n 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 Note The crankshaft hub center bolt is tightened to a torque of 410 Nm 300 ft lb BMW special tools 11 2 150 and 11 2 410 up to 1 2000 models...

Page 236: ...coil mounting studs Remove all ignition coils Remove spark plugs Remove cylinder head cover mounting fasteners and remove cylinder head cover Note The cylinder head cover mounting bolt insulators gaskets and coil grounds should be reinstalled in their original locations Remove oil baffle cover from intake camshaft Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 ...

Page 237: ... VANOS unit arrow with shop towel to capture oil which will spray when compressed air line is connected Connect compressed air line to air fitting Apply air pressure set to 2 8 bar 30 110 psi With compressed air line connected rotate engine in direction of rotation clockwise at least two full rotations leaving cylinder 1 intake and exhaust camshaft lobes facing each other as shown arrows CAUTION D...

Page 238: ...hreaded 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 Note Oil will drain from pressure line Have a container and rags ready Unscrew sealing plugs from VANOS unit arrows Note Oil will drain from sealing plug bores Camshaft Timing Chain http ebahn b...

Page 239: ...N Set screws have left hand threads Remove with a clockwise motion Remove VANOS unit Remove fasteners from engine support eye Remove VANOS mounting nuts arrows from cylinder head Slide VANOS unit and metal gasket off CAUTION Do not crank or turn over engine with VANOS unit removed Piston valve interference is possible Note The VANOS unit will contain Camshaft Timing Chain http ebahn bentleypublish...

Page 240: ...Remove primary camshaft chain tensioner arrow from timing chain cover 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 rod Remove exhaust camshaft impulse wheel mounting nuts arrows Remove impulse wheel A Camshaft Timing Chain http ebahn bentleypublishers com BMW 3...

Page 241: ...camshaft sprocket arrows Lift off exhaust and intake sprockets together with secondary chain thrust spacer A and splined shaft B CAUTION Splined shafts for both intake and exhaust camshafts share the same part number Remove and mark used Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 11 of 16 2 25 2009 9 51 PM ...

Page 242: ...sioner mounting bolts arrows Remove tensioner while keeping locking pin in place Remove primary chain sprocket mounting studs arrows on exhaust camshaft Lift primary chain sprocket off exhaust camshaft Remove sprocket from chain Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 12 of 16 2 25 2009 9 51 PM ...

Page 243: ...move chain guide Note Bolt on intake camshaft side is long and extends into timing chain cover Remove crankshaft hub center bolt and remove crankshaft hub to 1 2000 models or vibration damper models from 1 2000 CAUTION The crankshaft must not be allowed Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 13 of 16 2 25 2009 9 51 PM ...

Page 244: ...he cylinder head gasket If the cover is stuck use a sharp knife to separate it from the head gasket Note The chain cover can be removed with the coolant pump installed Use care when removing the cover from the coolant pipe at rear Push primary chain tensioner guide rail aside and remove chain Double VANOS components M52 TU M54 engine 1 Impulse wheel mounting nut 2 Camshaft impulse wheel exh 3 Spri...

Page 245: ... stud 13 Secondary chain tensioner 14 Sprocket mounting nut 15 Spring plate 16 Splined shaft 17 Intake camshaft sprocket 18 Secondary chain lower guide 19 Thrust spacer 20 Camshaft impulse wheel intake 21 Chain tensioner rail 22 Crankshaft sprocket Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 15 of 16 2 25 2009 9 51 PM ...

Page 246: ...ain 25 Threaded stud 26 Guide rail 27 Threaded stud 28 Woodruff key Copyright 2006 Robert Bentley Inc All rights reserved Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 16 of 16 2 25 2009 9 51 PM ...

Page 247: ...in tensioner 2 Chain tensioner rail 3 Crankshaft sprocket 4 Exhaust camshaft sprocket 5 Primary chain 6 Anchor bolt 7 Guide rail 8 Anchor bolt 9 Woodruff key Note If any sprockets are being replaced due to wear the chain should also be replaced If the crankshaft sprocket requires replacement the oil pump drive sprocket and chain must be removed See 119 Lubrication System for oil pump removal infor...

Page 248: ... small bead of silicon sealer 3 Bond 1209 or equivalent to corners of cylinder head where timing cover meets cylinder head and engine block Tap cover into position to engage dowels Install all bolts hand tight including two Torx bolts from above Install secondary chain lower guide Drive dowels in flush to front of cover Tighten cover mounting bolts alternately and in stages Tightening torques Cams...

Page 249: ...ars built up to January 2000 are fitted with a 2 piece vibration damper and hub assembly 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 22 Nm 16 ft lb Fit top sprocket to primary timing chain and ins...

Page 250: ...ocket is still lined up with upper edge of cylinder head Reposition sprocket if necessary Install and tighten down threaded locating studs arrows in end of exhaust camshaft Tightening torques Exhaust camshaft locating stud 20 Nm 15 ft lb Install secondary chain tensioner on cylinder head Make sure tensioner is locked in compressed position as described earlier Camshaft Timing Chain http ebahn bent...

Page 251: ...ecial tool 11 6 180 Position spline gap on intake sprocket arrow as shown and place secondary chain on sprockets Carefully remove chain and sprockets from tool and slide onto camshafts Align gap in intake sprocket splines with corresponding gap in camshaft splines arrow CAUTION Do not alter position of sprockets with respect to chain when removing from special tool 11 6 180 Slide splined shaft ont...

Page 252: ...t Working at exhaust side insert sprocket mounting Torx screws into threaded holes arrows Initially tighten screws to approx 5 Nm 44 in lb Back off half a turn Fit thrust spacer A on exhaust camshaft Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 6 of 11 2 25 2009 9 51 PM ...

Page 253: ...se wheel aligning mark B with top edge of cylinder head A Install mounting nuts arrows finger tight 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 Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1...

Page 254: ...uniformly until special tool is firmly contacting cylinder head CAUTION 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 Secure camshaft sprockets and impulse wheels Tighten mounting screws A on exhaust camshaft impulse wheel to approx 5 Nm 44 i...

Page 255: ...ger secured Remove camshaft locking tools from rear of camshafts Crank engine over by hand twice in direction of rotation until cylinder 1 intake and exhaust camshaft lobes 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 If the exhaust side of the t...

Page 256: ...m front of cylinder head Install VANOS unit See VANOS control unit given later Install intake camshaft oil baffle Install cylinder head cover Check for correct seating of half moon seals A in back of cylinder head cover Use a small amount of 3 Bond 1209 or equivalent sealant at corners B of half moon cutouts Seal corners in front of cylinder head at VANOS unit Tightening torque Cylinder head cover...

Page 257: ...all coolant hoses thermostat housing engine coolant drains Reinstall engine oil drain plug Refill engine oil and coolant before running engine Check for leaks Tightening torques Coolant drain plug to cylinder block 25 Nm 18 ft lb Radiator cooling fan viscous clutch to coolant pump 40 Nm 30 ft lb Radiator drain screw to radiator 2 5 Nm 22 in lb Vibration damper hub to crankshaft 410 Nm 302 ft lb Us...

Page 258: ...haft position sensors Camshaft position is varied based on engine rpm throttle position signal intake air and coolant temperature When engine is started camshafts are in deactivated position Intake camshaft is held in RETARDED position by oil pressure Exhaust camshaft is held in ADVANCED position by preload spring and oil pressure Within 2 5 seconds 50 engine revolutions the ECM begins monitoring ...

Page 259: ...e 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 Diagnostic Trouble Codes DTCs pertaining to the VANOS system are listed in Table a See also OBD On Board Diagnostics at the back of this manual Elevated oil temperatures can cause VANOS to deactivate Oil that is too thick hi...

Page 260: ...enoid valve activation intake 103 P1519 VANOS faulty reference value intake 104 P1520 VANOS faulty reference value exhaust 105 P1522 VANOS stuck Bank 1 intake 106 P1523 VANOS stuck Bank 2 exhaust Double VANOS components Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 3 of 19 2 25 2009 9 52 PM ...

Page 261: ...plug tighten to 50 Nm 37 ft lb 5 Camshaft seal cap 6 VANOS hydraulic piston set screw CAUTION left hand thread tighten to 10 Nm 89 in lb 7 Nut M7 tighten to 14 Nm 10 ft lb 8 Engine lifting hook Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 4 of 19 2 25 2009 9 52 PM ...

Page 262: ... 32 Nm 24 ft lb VANOS control unit removing Note If the Double VANOS control unit is being replaced camshaft timing must be checked as described later in this group This procedure requires multiple special tools Be sure to read the procedures through before beginning the repair Working inside trunk disconnect Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 5 of ...

Page 263: ...ier in 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 Do not allow oil to run onto drive belts Cover top of VANOS unit with lint free shop cloth Compressed air will force oil to spray out of oil bore o...

Page 264: ...der 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 Note Oil will drain from fittings when air line is removed Have a container and rags ready Do not allow oil to run onto drive belts Unscrew sealing plugs arrows from VANOS unit Note Oil will drain from plugs when removed Have a con...

Page 265: ...s have left hand threads Remove with a clockwise motion Disconnect electrical harness connectors from camshaft position sensors and solenoid valves on both exhaust and intake sides of VANOS unit Remove VANOS unit Remove fasteners from engine support eye Remove VANOS mounting nuts arrows from cylinder head Slide VANOS unit and metal gasket off CAUTION Camshaft Timing Chain http ebahn bentleypublish...

Page 266: ...face the camshaft timing will be incorrect Check locating dowel A and dowel sleeve B at top of cylinder head for damage or incorrect installation Note If the Double VANOS control unit is being replaced be sure to check and adjust camshaft timing as described later in this group If work being carried out has no effect on camshaft timing it is not necessary to recheck the timing It is recommended ho...

Page 267: ...kwise Tightening torque 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 using new sealing O rings Tightening torque Sealing plug to VANOS unit 50 Nm 37 ft lb Remove compressed air fitting from VANOS unit Camshaft Timing Chain http ebahn bentley...

Page 268: ...dust guard Install intake camshaft plastic baffle and then install cylinder head cover Check for correct seating of half moon seals A in back of cylinder head cover Use a small amount of 3 Bond 1209 or equivalent sealant at corners B of half moon cutouts Similarly seat gasket and seal corners in front of cylinder head at VANOS unit Tightening torque Cylinder head cover to cylinder head M6 10 Nm 89...

Page 269: ...g Chains Removing Also be sure the cooling fan behind the radiator and the spark plugs have been removed Remove primary camshaft chain tensioner cylinder arrow CAUTION Primary camshaft chain tensioning piston is under spring pressure 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...

Page 270: ... air line to air fitting Apply air pressure set to 2 8 bar 30 110 psi With compressed air line connected turn engine at least twice in direction of rotation until cylinder 1 intake and exhaust camshaft lobes arrows face each other CAUTION Do not rotate engine counterclockwise to reach the top dead center position Instead complete another two complete rotations Remove sealing plug from bore on lowe...

Page 271: ...1 3 240 B may be up to 1 mm 0 04 in above the surface of the cylinder head This is normal Reassemble engine Otherwise retime the engine as described below Remove Double VANOS unit as described earlier Press down on secondary chain tensioner and lock into place using BMW special tool 11 3 292 or equivalent Make sure primary chain tensioner dummy tool special tool 11 4 220 is installed in side of cy...

Page 272: ...e camshaft splined shaft until approx 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 Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 15 of 19 2 25 2009 9 52 PM ...

Page 273: ...d timing case Tighten nuts arrows by hand and then tighten down uniformly until special tool is in full contact with cylinder head CAUTION 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 Secure camshaft impulse sprockets and wheels Pretighten T...

Page 274: ...g tool from transmission bellhousing so that crankshaft is no longer locked Remove camshaft locking tools from rear of cylinder head Crank engine over twice by hand in direction of rotation until cylinder 1 intake and exhaust camshaft lobes face each other again 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 cyli...

Page 275: ...m rear of camshafts Remove BMW special tool 11 4 220 dummy primary chain tensioner Reinstall primary chain tensioner Tightening torque Primary chain tensioner cylinder to cylinder head 70 Nm 52 ft lb Remove flywheel locking tool from transmission bellhousing Reinstall sealing plug Remove VANOS setup bracket from front of cylinder head Install VANOS control unit as described earlier in this group R...

Page 276: ...assembly Tightening torques Radiator cooling fan viscous clutch to coolant pump 40 Nm 30 ft lb Cylinder head cover to cylinder head 10 Nm 89 in lb Spark plug to cylinder head 25 Nm 18 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Camshaft Timing Chain http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 19 of 19 2 25 2009 9 52 PM ...

Page 277: ...t available a device to support the weight of the engine from above would be suitable 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 replacement are covered in 020 Maintenance Engine support bracket BMW 00 0 200 00 0 208 Adapter for BMW oil pressure gauge BMW 11 4 0...

Page 278: ...e 7 5 liters 7 9 qt Troubleshooting The oil pressure warning system consists of an oil pressure switch mounted in the oil circuit and an instrument panel warning light Other safety features include Oil level warning system A filter bypass to provide lubrication should the oil filter become clogged An oil pump pressure relief valve to prevent excessive system pressure CAUTION If the red oil pressur...

Page 279: ...t a fault code DTC Note Thoroughly clean around the oil pressure switch before removing it Be prepared to catch leaking oil with a shop towel Component location Oil pressure switch base of oil filter housing Install pressure gauge in place of switch With gauge installed start engine and allow to reach operating temperature Check oil pressure both cold and hot Note For the most accurate test result...

Page 280: ...orn or faulty oil pump Worn or faulty engine bearings Severe engine wear All of these conditions indicate the need for major repairs Oil pressure warning system testing When the ignition is turned on the oil pressure warning light comes on When the engine is started and the oil pressure rises slightly the oil pressure switch opens and the warning light goes out Make sure the oil level is correct b...

Page 281: ...light does not light when ignition is on remove connector from oil pressure switch and use a jumper wire to ground connector terminal to a clean metal surface Note If the warning light comes on check the switch as described in the next step If the warning light does not come on the wiring to the instrument cluster or to the light itself is faulty To test switch connect an ohmmeter between terminal...

Page 282: ...ght remains on while the engine is running check the oil pressure as described earlier Do not drive the car until the problem is corrected The engine may be severely damaged Copyright 2006 Robert Bentley Inc All rights reserved Lubrication System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 6 of 6 2 25 2009 9 52 PM ...

Page 283: ... or jack stands designed for the purpose A floor jack is not adequate support Remove splash shield from under engine Drain engine oil as described in 020 Maintenance Remove air filter housing complete with mass air flow sensor Install engine lifting equipment at front engine lifting point and raise approximately 5 mm inch until engine weight is supported On cars with automatic transmission remove ...

Page 284: ...mes out with the tube Working underneath car remove bolts arrow and lower reinforcing brace between front suspension subframe and body Note Reinforcement consists of a triangulated bar for Sedan or Sport Wagon or a reinforced plate for Convertible or Coupe Separate steering column shaft from steering rack at universal joint CAUTION In order to avoid the need for front end realignment do not unbolt...

Page 285: ...ve 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 arrow at oil level sensor Loosen top engine mount fasteners arrow Note Lubrication System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 3 of 16 2 25 2009 9 53 PM ...

Page 286: ...front ride level sensor mounting bolt arrow and lay sensor aside Remove left and right front control arm bracket bolts arrows from frame rails Note Right side is shown in photo Left is similar Detach left and right stabilizer bar anchors from frame rails Lubrication System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 4 of 16 2 25 2009 9 53 PM ...

Page 287: ...bframe as far as possible Note Right side is shown in photo Left is similar Remove oil pan screws arrows at cylinder block and transmission bellhousing Lower oil pan forward 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 When installing oil pan Thoroughly clean all old gasket...

Page 288: ...rque Oil drain plug to oil pan M12 25 Nm 18 ft lb Oil pan to engine block M6 8 8 grade 10 Nm 89 in lb M6 10 9 grade 12 Nm 106 in lb Transmission bellhousing to oil pan M8 Allen 24 Nm 17 ft lb M8 Torx 21 Nm 15 ft lb Remainder of installation is reverse of removal Replace self locking nuts when reinstalling front suspension components Match up key ways while installing steering column shaft See 320 ...

Page 289: ...joint to suspension subframe 90 Nm 66 ft lb Front subframe to frame rails M12 use new bolts 8 8 grade 77 Nm 57 ft lb 10 9 grade 110 Nm 81 ft lb 12 9 grade 105 Nm 77 ft lb Front end reinforcement to frame rails or suspension subframe M10 use new bolts Initial torque 59 Nm 44 ft lb Torque angle 90 30 Stabilizer bar to frame rail M8 nut 22 Nm 16 ft lb Steering column universal joint clamping screw M8...

Page 290: ...in 020 Maintenance Remove air filter housing complete with mass air flow sensor Install engine lifting equipment at front engine lifting point and raise approximately 5 mm inch until engine weight is supported Remove fuel line clamping brackets from oil pan On cars with automatic transmission remove ATF cooler line brackets from oil pan and from transmission Note Place drain pan under lines to cat...

Page 291: ... that the O ring comes out with the tube Separate steering column shaft from steering rack at universal joint Point wheels straight ahead before disconnecting shaft from rack See 320 Steering and Wheel Alignment Remove power steering pump pulley Remove two mounting bolts from the front arrows Note Do not detach power steering fluid lines from pump Lubrication System http ebahn bentleypublishers co...

Page 292: ...l level sensor Remove lower engine mount fasteners If applicable remove front ride level sensor mounting bolt arrow and lay sensor aside Working at rear right corner of front subframe unhook heatshield from subframe arrow Detach stabilizer bar anchors from frame rails Lubrication System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 10 of 16 2 25 2009 9 53 PM ...

Page 293: ...inal Drive Support subframe while removing four mounting bolts arrows CAUTION Lower subframe as far as possible without damaging power steering lines Make sure it is adequately supported throughout the remainder of this procedure Remove oil pan Remove bellhousing bolts from oil pan Remove all oil pan periphery bolts Remove center oil pan bolts arrows Lubrication System http ebahn bentleypublishers...

Page 294: ...nt to oil pan gasket directly below joints for end cover and front timing case cover Apply a bead 3 mm wide by 2 mm high Tighten oil pan bolts to cylinder block evenly all around Tighten transmission bellhousing bolts last Tightening torque Oil drain plug to oil pan M12 25 Nm 18 ft lb 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 Tran...

Page 295: ...d front steering arms as described in 310 Front Suspension Note Be sure to replace seals on differential output flanges Replace self locking fasteners when reinstalling front suspension components Tightening torques Control arm ball joint bracket to subframe M12 bolt 77 Nm 57 ft lb Control arm mounting bracket to subframe M10 bolt always replace 59 Nm 44 ft lb When reattaching engine to subframe b...

Page 296: ...10 Nm 81 ft lb Remainder of installation is reverse of removal Match up key ways while installing steering column shaft See 320 Steering and Wheel Alignment for more specific procedures Use new oil dipstick tube sealing O ring Fill engine with oil as described in 020 Maintenance After adding engine oil start and run engine Raise engine speed to 2 500 rpm until oil pressure warning lamp goes out ab...

Page 297: ...eel drive oil pan front differential and front subframe assembly 1 Front subframe 1a Right engine mounting point 1b Left engine mounting point 2 Right axle inner bearing pedestal 3 Sealing O ring 4 Oil pan 5 Bolt M12 always replace 8 8 grade tighten to 77 Nm 57 ft lb 10 9 grade tighten to 110 Nm 81 ft lb Lubrication System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 15 of 16 2 25...

Page 298: ...e tighten to 59 Nm 44 ft lb 9 Bolt M12 tighten to 77 Nm 57 ft lb 10 Front control arm with ball joint and rear mounting bracket 11 Front differential 12 Bolt M10 tighten to 45 Nm 33 ft lb 13 Left front axle Copyright 2006 Robert Bentley Inc All rights reserved Lubrication System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 16 of 16 2 25 2009 9 53 PM ...

Page 299: ... torque Oil pressure switch to oil filter housing 27 Nm 20 ft lb Oil level warning switch The oil level warning switch is located at the bottom of the engine oil pan Note Anytime the oil level warning switch is removed be sure to replace the sealing O ring between switch and oil pan Oil pump removing and installing Note Lubrication System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals...

Page 300: ...her with drive chain Remove mounting bolts from oil pump 7 and oil pump pickup tube 12 Withdraw pump 1 Drive chain 2 Nut M10x1left hand thread tighten to 25 Nm 18 ft lb 3 Oil pump sprocket 4 Inner rotor 5 Outer rotor 6 Oil pressure relief valve assembly 7 Bolt M8 tighten to 22 Nm 16 ft lb 8 Oil pump housing 9 Locating dowels 10 Sealing O ring Lubrication System http ebahn bentleypublishers com BMW...

Page 301: ... pump and engine block Note positions of locating dowels Remove cover from oil pump and check for wear or scoring Spin oil pump shaft and check that gears turn smoothly Replace pump if gears spin with difficulty or any wear is present Installation is reverse of removal noting the following Align sprocket splines to oil pump shaft splines before tightening sprocket nut Tightening torques Oil drain ...

Page 302: ...d 25 Nm 18 ft lb Transmission bellhousing to oil pan M8 Allen 24 Nm 17 ft lb M8 Torx 21 Nm 15 ft lb Oil pump pressure relief valve The oil pump pressure relief valve is held in the side of the oil pump with a circlip 1 Control plunger 2 Spring 3 Sealing O ring 4 Sleeve 5 Circlip Copyright 2006 Robert Bentley Inc All rights reserved Lubrication System http ebahn bentleypublishers com BMW 3 E46 Repa...

Page 303: ...neral 130 Fuel Injection Electrical Wiring Diagrams at the rear of this manual OBD On Board Diagnostics at the rear of this manual Special tools Owing to the coil per cylinder configuration system diagnosis and testing requires special test equipment LED test light Baum 1115 Source Baum Tools Unlimited Automotive digital multimeter Fluke 87 Ignition System http ebahn bentleypublishers com BMW 3 E4...

Page 304: ...injection ignition and other engine control functions DME variants are listed in Table a Second generation On Board Diagnostics OBD II is incorporated into the engine management systems used on the cars covered by this manual Using a BMW specific electronic scan tool it is possible to access Diagnostic Trouble Codes DTCs that pinpoint ignition and other engine management problems Ignition System h...

Page 305: ...ess ignition system with individual ignition coils for each cylinder There is no distributor cap or ignition rotor Each coil can be controlled by the Engine Control Module ECM on a cylinder by cylinder basis Note Schematic diagram of ignition coil circuit is for MS 42 0 engine management system On MS 43 0 system ignition coil terminal 3 receives power from Fuse 1 30 amp See Electrical Wiring Diagr...

Page 306: ...lways disable the ignition Knock sensors arrows monitor the combustion chamber for engine damaging knock Two sensors monitor three cylinders each If engine knock is detected the ignition point is retarded by the ECM Note When knock is detected ignition timing will be retarded at the selective cylinder s by 3 increments If knock is no longer detected the timing will be advanced in 1 increments Igni...

Page 307: ...hould always begin with an interrogation of the On Board Diagnostics OBD II system The OBD II system detects engine management malfunctions When faults are detected the OBD II system stores a Diagnostic Trouble Code DTC in the Engine Control Module ECM along with other pertinent fault information In addition the Malfunction Indicator Light MIL will come on if an emissions related fault is detected...

Page 308: ... way to diagnose a faulty coil on a car that is running is to use an oscilloscope to analyze spark quality The illustrations show normal scope trace of spark at idle Table b lists common ignition coil voltage faults and related causes Note Note the length of sparking period and the up down voltage attenuations A short sparking period and or an irregular low voltage attenuation usually indicates a ...

Page 309: ...aulty Fuel air mixture too lean Misfire detection Engine misfire the result of inefficient combustion in one or more cylinders may be caused by a variety of malfunctions in various subsystems The OBD II system incorporated into the MS 42 0 and MS 43 0 engine management systems is designed to detect and warn of misfire faults during engine operation Misfire fault codes are listed in Table c Misfire...

Page 310: ...nk defective fuel pump running loss system fault leaking or blocked fuel injector s fuel pressure regulator fault evaporative system fault ECM sensor input fault Implausible sensor signal oxygen sensor s faulty ECM faulty P0302 239 Misfire cylinder 2 P0303 240 Misfire cylinder 3 P0304 241 Misfire cylinder 4 P0305 242 Misfire cylinder 5 P0306 243 Misfire cylinder 6 P1396 244 Crankshaft sensor adapt...

Page 311: ...nector pins Inspect ignition unloader relay Replace coils as necessary Warnings and cautions The engine management system contains sensitive electronic components To protect the system and for general safety the following warnings and cautions should be observed during ignition system troubleshooting maintenance or repair work WARNING Do not touch or disconnect any cables from the coils while the ...

Page 312: ...he coils from the spark plugs Connect or disconnect ignition system wires multiple wire connectors and ignition test equipment leads only while the ignition is off Switch multimeter functions or measurement ranges only with the test probes disconnected Do not disconnect the battery while the engine is running A high impedance digital multimeter should be used for all voltage and resistance tests A...

Page 313: ...described in this manual or as described by the instrument manufacturer Copyright 2006 Robert Bentley Inc All rights reserved Ignition System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 11 of 11 2 25 2009 9 54 PM ...

Page 314: ...o be switched on The engine management system can be disabled by removing the DME main relay arrow The relay is located in the electronics box E box in the left rear of the engine compartment CAUTION Relay locations may vary Use care when identifying relays The main relay has a large 4 mm 2 red wire at terminal 30 and a large 4 mm 2 red white wire at terminal 87 See 610 Electrical Component Locati...

Page 315: ...always If a coil is not operating the engine management system will electrically disable the fuel injector to that cylinder The key is to look for differences between cylinders Ignition coil assembly testing and replacing CAUTION Use a digital multimeter for the following tests Remove interior ventilation microfilter Remove housing for microfilter for interior ventilation Open wiring harness loom ...

Page 316: ...itch See Electrical Wiring Diagrams CAUTION The wiring to terminal 15 of the coil via the ignition switch is not fuse protected Use care when testing this circuit Turn ignition off Remove coil and inspect coil housing for hairline cracks or leaking casting material A leaky ignition coil may indicate a faulty Engine Control Module ECM Check ECM before installing a new coil CAUTION Note location of ...

Page 317: ...osch 1 k 20 Beru 1 8 k 20 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 Clip scope high pick up lead C around ignition lead Start engine Ignition System http ebahn bentleypublishers c...

Page 318: ... mounted to the end of the crankshaft If the Engine Control Module ECM does not receive a signal from the crankshaft speed sensor during cranking the engine will not start If the OBD II system misfire detection protocol detects a catalyst damaging fault due to a malfunction in crankshaft speed sensor components the Check Engine light Malfunction Indicator Light or MIL will be illuminated Note If t...

Page 319: ... wire tie securing crankshaft speed sensor harness connector arrow to sensor Disconnect harness connector Remove sensor mounting screw arrow and remove sensor from cylinder block Installation is reverse of removal noting the following Use a new O ring when installing sensor Be sure wiring is rerouted in same orientation Secure sensor using new wire ties Use scan tool to read out and clear Ignition...

Page 320: ...for interior ventilation as shown earlier Remove plastic cover from above fuel injectors by prying off bolt covers and removing cover mounting bolts Remove complete air filter housing Disconnect electrical harness connector on mass air flow sensor B Detach vacuum line at intake boot A Remove filter housing mounting screws D Loosen hose clamp at intake boot and detach air duct connections C Ignitio...

Page 321: ...oval attach a stiff piece of wire to the harness connector end to preserve proper routing of harness for reinstallation Installation is reverse of removal Use new O rings when installing sensor and solenoid Be sure wiring is rerouted in same orientation Use scan tool to read out and clear ECM fault memory Tightening torques Intake camshaft sensor to cylinder head 5 Nm 3 5 ft lb VANOS solenoid to V...

Page 322: ... same orientation Use scan tool to read out and clear ECM fault memory Tightening torque Exhaust camshaft sensor to cylinder head 5 Nm 3 5 ft lb Knock sensors replacing The knock sensors are bolted to the left side of the cylinder block under the intake manifold Remove intake manifold as described in 113 Cylinder Head Removal and Installation Disconnect knock sensor electrical harness connector ar...

Page 323: ...ue wrench when tightening the sensor mounting bolt Clean knock sensor contact surface on engine block and sensor arrows before installing knock sensor Tightening torque Knock sensor to cylinder block 20 Nm 15 ft lbs Use scan tool to read out and clear ECM fault memory Copyright 2006 Robert Bentley Inc All rights reserved Ignition System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1...

Page 324: ...essure testing and fuel pump repair information is covered in 160 Fuel Tank and Fuel Pump Table a Engine management systems Model Year Engine code DME system 1999 2000 M52 TU B25 M52 TU B28 Siemens MS 42 0 2001 M54 B25 M54 B30 Siemens MS 43 0 The Siemens systems are sophisticated self diagnosing OBD II systems These systems continuously monitor components and record and store valuable diagnostic i...

Page 325: ...gnostics at the back of this manual 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 1115a Source Baum Tools Unlimited Factory ...

Page 326: ...nal 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 Specialty Tools and the MT2500 from Snap on are three examples Fuel Injection http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 3 of 8 2 25 2009 9 55 PM ...

Page 327: ... available These inexpensive BMW only tools are capable of checking for DTCs as well as turning off the illuminated MIL and resetting the service indicator lights See 020 Maintenance for specialty tool manufacturer contact information Principle of operation The DME fuel injection system is completely electronic in operation Intake air engine coolant temperature crank and camshaft positions engine ...

Page 328: ...page shows the MS 42 0 ECM inputs and outputs The MS 43 0 system is similar in operation with the main difference being the fully electronic drive by wire throttle valve Additional system operational information can be found in 100 Engine General DME MS 42 0 Fuel Injection http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 5 of 8 2 25 2009 9 55 PM ...

Page 329: ...d repairing fuel system problems Have a fire extinguisher available in case of an emergency When working on an open fuel system wear suitable hand protection as prolonged contact with fuel can cause illnesses and skin disorders The ignition system produces high voltages that can be fatal Avoid contact with exposed terminals Use extreme caution when working on a car with the ignition switched on or...

Page 330: ...le the ignition system as described in 120 Ignition System CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Do not connect any test equipment that delivers a 12 volt power supply to terminal 15 of the ignition coil The current flow may damage the ECM In general connect test equipment only as specified by BMW or the eq...

Page 331: ...e the control module Cleanliness is essential when working on an open fuel system Thoroughly clean fuel line connections and surrounding areas before loosening Avoid moving the car Only install clean parts 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 ...

Page 332: ... On Board Diagnostics at the back of this manual Only use a digital multimeter for electrical tests Relay positions can vary Be sure to confirm relay position by identifying the wiring in the socket using the wiring diagrams found at the rear of this manual DME main relay testing The DME main relay is energized via the engine control module ECM and supplies battery positive B power to many of the ...

Page 333: ...derside of relay socket and check for ground at terminal 4 85 brown white wire If ground is present continue testing If ground is not present signal from ECM connector X60002 pin 23 is missing Check wire between ECM and relay With ignition on and relay installed check for battery voltage at terminal 2 87 red white wire If battery voltage is present relay has energized and is functioning correctly ...

Page 334: ...ocated behind glove compartment Remove glove compartment See 513 Interior Trim Remove fuel pump relay from socket With ignition in START position check for battery voltage at relay connector X10156 terminals 6 and 8 red violet andred white wires CAUTION Ensure that manual transmission vehicles are not in gear and automatic transmission vehicles are in Park or Neutral prior to operating ignition in...

Page 335: ...d Fuel Pump CAUTION The jumper wire should be 1 5 mm2 14 ga and include an in line fuse holder with a 15 amp fuse To avoid fuse relay panel damage from repeated connecting and disconnecting also include a toggle switch Fuel delivery and fuel pressure Checking fuel delivery volume and fuel pressure is a fundamental part of troubleshooting and diagnosing the engine management system Fuel pressure di...

Page 336: ... is highly flammable and its vapors are explosive Do not smoke or work on a car near heaters or other fire hazards when diagnosing and repairing fuel system problems Have a fire extinguisher available in case of an emergency When working on an open fuel system wear suitable hand protection Prolonged contact with fuel can cause illnesses and skin disorders Remove interior ventilation microfilter ho...

Page 337: ... 3 5 bar or 45 75 psi and 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 Catch and dispose of escaped fuel Plug all open fuel lines Always unscrew fuel tank cap to release pressure in the tank before working on the tank or lines Copyright ...

Page 338: ...connect negative battery cable CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Remove housing for microfilter for interior ventilation Remove upper cover and microfilter Open wiring harness loom A and remove wires Unfasten screws B and remove lower microfilter housing Remove fuel rail cover by prying off nut covers a...

Page 339: ...Disconnect fuel injector electrical connectors from injectors Use small screwdriver to pry one corner of wire lock clip on fuel injector 1 connector Repeat for all injectors Lift off connector loom and set aside 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 blow fuel back thr...

Page 340: ...ted at all times Use a professional automotive lift or jack stands designed for the purpose A floor jack is not adequate support Remove protective engine splash guard Working beneath car on left side under driver seat remove fuel filter cover and clamp off fuel hose s Note MS 42 0 vehicle shown Fuel line arrangement on MS 43 0 vehicles varies from that shown The MS 43 0 system uses a non return fu...

Page 341: ...fuel line support bracket at rear of intake manifold Guide fuel line s out of rear of engine compartment while lifting fuel rail out Remove individual injectors Pry retaining clip from injector 1 Pull injector from rail 2 Installation is reverse of removal Fit new O rings when installing injectors For ease of installation lightly lubricate all fuel system O rings with assembly lubricant Check that...

Page 342: ...0 under left side of car in fuel filter On models with DME MS 43 0 the fuel pressure regulator arrow is an integral part of the fuel filter Fuel filter replacement procedure is covered in 020 Maintenance DME MS 42 0 Working under car below driver s seat remove protective cover from below fuel pressure regulator arrow Disconnect vacuum hose A from fuel pressure regulator Fuel Injection http ebahn b...

Page 343: ...m components Loosen hose clamp A and pull intake air duct from mass air flow MAF sensor Disconnect electrical harness connector B and unclip fasteners C Remove sensor Inspect protective screen in sensor housing Replace sensor if screen is damaged Inspect air intake ducting for damage and cracks Replace rubber parts as necessary Installation is reverse of removal Replace sealing O ring between sens...

Page 344: ...ntake manifold as described in 110 Engine Removal and Installation WARNING Due to risk of personal injury be sure the engine is cold before beginning the removal procedure Working at rear of cylinder head disconnect harness connector arrow from ECT sensor Remove sensor Catch any coolant that leaks out with shop rags Installation is reverse of removal Use a new copper sealing washer when installing...

Page 345: ...ed on varying intake air temperatures Remove housing for microfilter for interior ventilation Remove upper cover and microfilter Open wiring harness loom A and remove wires Unfasten screws B and remove lower microfilter housing Remove fuel rail cover by prying off plastic covers arrows and removing nuts Remove electrical harness connector arrow from IAT sensor CAUTION Be sure the ignition is OFF F...

Page 346: ... reset ECM adaptations after throttle assembly replacement CAUTION After replacement of the throttle valve assembly and or on MS 43 0 systems the pedal position sensor an adaption procedure must be performed using the factory scan tool or equivalent The vehicle will not start unless this adaption procedure is carried out Disconnect battery negative cable in luggage compartment CAUTION Prior to dis...

Page 347: ...rward 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 ducts 1 Throttle assembly 2 Hose clamp 77 84 mm 3 Y duct 4 Air duct 5 Hose clamp 83 90 mm 6 Mass air flow sensor 7 Idle control valve 8 Hose clamp 28 33 mm 9 Hose clamp 77 84 mm On MS 42 0 vehicles Pull throttle cable Fuel Inj...

Page 348: ... conduit to throttle body Working at throttle housing Turn harness plug arrow counterclockwise and remove Working at side of intake manifold disconnect electrical harness connectors Idle control valve A Intake manifold resonance valve B Fuel Injection http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 11 of 19 2 25 2009 9 55 PM ...

Page 349: ...ng bolt C Pull out dipstick guide tube If necessary disconnect electrical harness connector at fuel tank venting valve A Disconnect hose at quick disconnect fitting arrow Remove throttle assembly mounting screws at all corners and pull assembly off manifold Installation is reverse of removal Replace sealing ring between throttle assembly and intake manifold Fuel Injection http ebahn bentleypublish...

Page 350: ... is disconnected or replaced This procedure requires the factory scan tool or an equivalent to read and adjust throttle angle It is recommended that procedure be done by an authorized BMW dealer service department Basic adjustment Ensure that at idle accelerator pedal in rest position throttle cable has detectable play at throttle lever attaching point Play must not exceed maximum allowable Adjust...

Page 351: ...th ignition key on press accelerator until pedal touches kickdown stop Check throttle angle Press accelerator pedal down beyond kickdown stop pressure point Check throttle angle Adjust kickdown stop if necessary recheck Press accelerator down fully against stop Check throttle angle Use scan tool diagnostic program or road test vehicle to confirm transmission downshifts when kickdown is actuated Th...

Page 352: ... is first removed Intake manifold removal is described in 113 Cylinder Head Removal and Installation Disconnect battery negative cable in trunk CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Remove complete air filter housing Disconnect vacuum line at intake boot A Disconnect electrical harness connector on mass air...

Page 353: ...duct Loosen clamps 2 and 8 and remove mass air flow sensor and air ducts 1 Throttle assembly 2 Hose clamp 77 84 mm 3 Y duct 4 Air duct 5 Hose clamp 83 90 mm 6 Mass air flow sensor 7 Idle control valve 8 Hose clamp 28 33 mm 9 Hose clamp 77 84 mm DME MS 42 0 Pull throttle cable upwards out of rubber retainer A but leave attached to throttle actuator B Fuel Injection http ebahn bentleypublishers com ...

Page 354: ...nd throttle assembly Pull control valve from rubber retainer Installation is reverse of removal Use new gaskets and O ring seals when installing Use assembly lubricant to facilitate reassembly Install idle control valve rubber seal in intake manifold first then insert control valve Similarly install mass air flow sensor into intake duct then install to throttle assembly Engine control module ECM r...

Page 355: ...e battery disconnection cautions given at the front of this manual on page viii Remove E box cover at left rear of engine compartment Cover is retained with four captive screws ECM arrow is located in right rear of E box as identified with five electrical harness connectors Disconnect ECM harness connectors by releasing lock on each plug and pivoting lever Pull all five connector up and off ECM Re...

Page 356: ... Installation is reverse of removal Copyright 2006 Robert Bentley Inc All rights reserved Fuel Injection http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 19 of 19 2 25 2009 9 55 PM ...

Page 357: ...sults are still incorrect check the component itself For engine management system electrical schematics see Electrical Wiring Diagrams CAUTION Always wait at least three minutes after turning off the ignition before removing the connector from the engine control module ECM If the connector is removed before this time residual power in the system relay may damage the ECM Always connect or disconnec...

Page 358: ...Fuse 2 Fuse carrier engine electronics 9 Input Voltage supply Fuse carrier engine electronics Connector X60002 24 pin black Pin Signal Component function Notes 1 Input Heater precatalyst oxygen sensor 1 Heated oxygen sensor 1 in front of catalytic converter 2 not used 3 Input output CAN bus signal low Transmission control module 4 Input output CAN bus signal high Transmission control module 5 not ...

Page 359: ... sensor 2 Heated oxygen sensor 2 behind catalytic converter 19 Input Heater post catalyst oxygen sensor 2 Heated oxygen sensor 2 behind catalytic converter 20 Ground Ground precatalyst oxygen sensor 1 Heated oxygen sensor 1 in front of catalytic converter 21 Ground Ground precatalyst oxygen sensor 2 Heated oxygen sensor 2 in front of catalytic converter 22 Ground Ground post catalyst oxygen sensor...

Page 360: ...dal position sensor 2 MS 42 0 Throttle valve MS 42 0 10 Input Signal throttle position potentiometer 2 Throttle valve 11 not used 12 Input Feedback signal engine start Starter 13 Input Signal battery charge indicator lamp Generator Alternator 14 Ground Ground throttle position sensor MS 42 0 Throttle valve MS 42 0 15 Ground Ground exhaust camshaft sensor 1 Camshaft position sensor II 16 Input Sign...

Page 361: ...essure Oil pressure switch 27 Output Signal engine oil temperature Oil temperature sensor 28 Ground Ground engine oil temperature sensor Oil temperature sensor 29 Output Signal knock sensor Knock sensor 30 Output Signal knock sensor Knock sensor 31 Output Signal knock sensor Knock sensor 32 Output Signal knock sensor Knock sensor 33 Input Signal cylinder 1 fuel injector Cylinder 1 fuel injector 34...

Page 362: ...e coolant thermostat Engine coolant thermostat map controlled 46 Input Signal close idle speed control valve Idle speed control valve 47 Input Signal open idle speed control valve Idle speed control valve 48 Ground Signal shield knock sensor Shield knock sensor 49 Input Signal resonance valve intake system Resonance valve intake system 50 not used 51 not used 52 Input Signal secondary air injectio...

Page 363: ...sor PWG MS 43 0 Pedal position sensor PWG MS 43 0 10 Input Signal fuel pump relay 1 Fuel pump relay 1 11 Input Signal oil pressure switch Instrument cluster control module 12 Pedal position sensor PWG MS 43 0 Pedal position sensor PWG MS 43 0 13 Signal pedal position sensor PWG MS 43 0 Pedal position sensor PWG MS 43 0 14 Pedal position sensor PWG MS 43 0 Pedal position sensor PWG MS 43 0 15 not u...

Page 364: ...unction steering wheel Volute spring 28 Input Signal brake light switch Brake light switch 29 Input Signal relay A C compressor A C compressor relay 30 Signal leakage diagnosis pump MS 42 0 Signal diagnostic module MS43 0 Leakage diagnosis pumpLeak detection MS 43 0 31 not used 32 Input output Transmit diagnosis line TXD data link signal Data link connector MS 42 0 OBD II connector MS 43 0 33 Inpu...

Page 365: ...n Notes 1 Input Signal ignition coil 3 Ignition coil 3 2 Input Signal ignition coil 2 Ignition coil 2 3 Input Signal ignition coil 1 Ignition coil 1 4 not used 5 Ground Ground Ground connector 6 Ground Ground Ground connector 7 Input Signal ignition coil 6 Ignition coil 6 8 Input Signal ignition coil 5 Ignition coil 5 9 Input Signal ignition coil 4 Ignition coil 4 Copyright 2006 Robert Bentley Inc...

Page 366: ...rmostat are controlled and monitored by the DME engine management system Therefore cooling system faults can be diagnosed using an appropriate scan tool 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 Radiator and ...

Page 367: ...Expansion tank cap test adapter BMW 17 0 007 Cooling system DME MS 42 0 Radiator and Cooling System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 2 of 6 2 25 2009 9 56 PM ...

Page 368: ...ature electronically results in improved emissions and performance Problems with the heated thermostat can be diagnosed using a compatible scan tool Radiator and expansion tank The radiator is a crossflow design An expansion tank provides for coolant expansion at higher temperatures and easy monitoring of the coolant level On cars with automatic transmission ATF is circulated through an additional...

Page 369: ...tput final stage On both configurations the output final stage is mounted on the fan housing next to the fan motor The fan is operated using a pulse width modulated PWM signal and is protected by a 50 amp fuse Electric fan activation is based on the following inputs to the ECM Radiator outlet temperature Catalyst temperature calculated temperature Vehicle speed Battery voltage A C pressure calcula...

Page 370: ...lowing warnings and cautions should be observed when working on the cooling system WARNING At normal operating temperature the cooling system is pressurized Allow the system to cool as long as possible before opening a minimum of an hour then release the cap slowly to allow safe release of pressure Releasing the cooling system pressure lowers the coolant boiling point and the coolant may boil sudd...

Page 371: ...e 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 BMW recommends removal of the radiator and expansion tank to flush When working on the cooling system cover the alternator to protect it against coolant drips Prior to disconnecting t...

Page 372: ...g fan faults Electrical electronic faults Be sure to check the condition and tension of the coolant pump drive belt Check hoses for cracks or softness Check clamps for looseness Check the coolant level and check for evidence of coolant leaks from the engine Check that the radiator fins are not blocked with dirt or debris Clean the radiator using low pressure water or compressed air Blow outward fr...

Page 373: ... the coolant to boil at a lower temperature If visual evidence is inconclusive a cooling system pressure test can help to pinpoint hard to find leaks If the cooling system is full of coolant and holds pressure the next most probable causes of overheating are Faulty radiator fan or DME control circuit Use an appropriate scan tool to interrogate the DME control module for faults Loose or worn drive ...

Page 374: ... 17 0 002 17 0 005 or equivalent to expansion tank Pressurize system to specification listed in Table a Pressure should not drop more than 0 1 bar 1 45 psi for at least two minutes If pressure drops rapidly and there is no sign of external leakage cylinder head gasket may be faulty Perform compression and leak down tests as described in 100 Engine General Also test expansion tank cap using pressur...

Page 375: ... from the coolant at the expansion tank CAUTION Use an extension tube above the reservoir neck to maintain distance between the top of the coolant and the gas analyzer nozzle The gas analyzer is easily damaged if it is allowed to inhale liquid coolant While running engine to check for causes of overheating observe coolant temperature carefully in order to avoid engine damage Thermostat checking If...

Page 376: ... Cooling system fault codes BMW fault code Explanation Possible cause s 10 Engine coolant temperature out of predefined range Faulty thermostat or cooling fan Faulty wiring to cooling fan or thermostat 222 Insufficient coolant temperature signal to permit closed loop operation Faulty thermostat Faulty thermostat electrical circuit Copyright 2006 Robert Bentley Inc All rights reserved Radiator and ...

Page 377: ...omotive lift or jack stands designed for the purpose A floor jack is not adequate support Remove splash shield from under engine Loosen radiator bleed screw at top radiator fitting arrow Remove cap from radiator expansion tank Set temperature controls to full warm Place 3 gallon pail underneath radiator Remove drain plug arrow on bottom of radiator WARNING Radiator and Cooling System http ebahn be...

Page 378: ...tor and engine block drain plugs using new sealing washers Before refilling radiator Switch ignition to ON Set temperature controls to full warm Set blower control to low Using a coolant mixture of 50 antifreeze and 50 distilled water fill expansion tank slowly Continue until coolant emerges from bleed screw Cooling system capacity is listed in Table c Note Be sure radiator bleed screw is loose wh...

Page 379: ...m 18 ft lb Radiator drain plug to radiator 2 3 Nm 18 27 in lb Cooling system bleeding Air may become trapped in the system during cooling system service Trapped air can prevent proper coolant circulation Whenever the coolant is drained and filled the system should be bled of trapped air Loosen bleed screw arrow on radiator expansion tank Set temperature controls in passenger compartment to full wa...

Page 380: ...ivalent to avoid the formation of harmful clogging deposits in the cooling system Use of other antifreeze solutions may be harmful to the cooling system Tightening torque Radiator bleed screw 2 5 Nm 22 in lb Viscous clutch cooling fan replacing models with automatic transmission To gain access to viscous clutch fan or electric fan at front of the engine Remove expansion rivets arrows and remove in...

Page 381: ...rom front of car to loosen Spin fan off coolant pump 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 To replace fan clutch remove fan mounting bolts and separate viscous clutch from fan Installation is reverse of removal Tigh...

Page 382: ...ansion rivet arrows holding fan shroud to radiator Unclip or disconnect electrical connector s from right side of shroud Lift fan assembly straight up and off radiator If necessary push center top area of fan shroud toward engine to unhook shroud from radiator crossmember Fan can be separated from shroud on bench CAUTION Do not carry fan by the blades it may disturb the balance Installation is rev...

Page 383: ...pers Disconnect fan electrical connector arrow on right side of radiator shroud Pull out plastic expansion rivets arrows and remove cover from front of fan Remove fan mounting nuts arrows and lift out fan Installation is reverse of removal Install front bumper See 510 Exterior Trim Bumpers Thermostat replacing Radiator and Cooling System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals ...

Page 384: ...aining and filling WARNING Allow cooling system to cool before opening or draining the system Remove air intake duct cooling fan and fan shroud as described earlier Disconnect electrical harness connector from thermostat housing Lever out retaining clips arrows and pull hose fittings off housing Unbolt and remove thermostat housing from front of engine Loosen nut at top of engine lifting eye to fa...

Page 385: ...ed in the front of the engine in the timing chain cover 1 Bolt M6 tighten to 10 Nm 89 in lb 2 Drive pulley 3 Coolant pump 4 O ring seal 5 Nut M6 tighten to 10 Nm 89 in lb Drain cooling system as described earlier WARNING Allow cooling system to cool before opening or draining system Remove air intake duct cooling fan and fan shroud as described earlier Radiator and Cooling System http ebahn bentle...

Page 386: ...ws in tapped bores and tighten uniformly until pump is free from timing chain cover Thermostat and hoses have been removed for visual access Installation is reverse of removal noting the following Be sure to replace sealing O ring and gaskets Coat O ring with lubricant during installation Tightening torques Coolant pump to timing chain cover 10 Nm 89 in lb Coolant pump pulley to coolant pump 10 Nm...

Page 387: ...e splash shield from under engine Drain radiator and engine block as described earlier WARNING Allow cooling system to cool before opening or draining system Remove complete air filter housing Remove air intake duct cooling fan and fan shroud as described earlier Working on left side of radiator lever out hose retaining clips and disconnect coolant hose fittings from radiator A and radiator expans...

Page 388: ...e applicable disconnect automatic transmission fluid ATF cooler lines from ATF cooler at quick disconnect unions arrows as follows Push hose toward oil cooler Press black locking ring into hose fitting while pulling hose off cooler CAUTION Be sure to have a drain pan ready to catch spilled ATF Radiator and Cooling System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 12 of 16 2 25 2...

Page 389: ... described under Coolant draining and filling Check ATF level and if necessary top up See 240 Automatic Transmission Tightening torques Engine block drain plug to block 25 Nm 18 ft lb Radiator drain plug to radiator 2 3 Nm 18 27 in lb Coolant expansion tank 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 profes...

Page 390: ...intake filter housing Working at front of engine compartment remove expansion rivets arrows retaining air intake duct to radiator support and remove intake duct Release hose retaining clips and disconnect coolant hose fittings A and B from expansion tank Working underneath radiator disconnect harness connector from coolant level sensor Radiator and Cooling System http ebahn bentleypublishers com B...

Page 391: ...l sensor 10 Locking clip Pull out expansion tank by detaching from radiator at top Then pull up from mounting bracket at bottom Installation is reverse of removal Do not coat O rings with anti seize paste Fill radiator and cooling system as described under Coolant draining and filling Tightening torques Engine block drain plug to block 25 Nm 18 ft lb Radiator and Cooling System http ebahn bentleyp...

Page 392: ...Radiator drain plug to radiator 2 3 Nm 18 27 in lb Copyright 2006 Robert Bentley Inc All rights reserved Radiator and Cooling System http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 1 16 of 16 2 25 2009 9 57 PM ...

Page 393: ...al drive On all wheel drive models a transfer case is mounted to the rear of the transmission with drive shafts leading to front and rear final drive assemblies Individual drive axles with integrated constant velocity joints transfer rotational power from the final drive units to the drive wheels Manual transmission Due to different power characteristics and performance requirements three differen...

Page 394: ...001 M54 ZF S5D 280Z Automatic transmission Two different automatic transmissions are used depending on model and model year and or production date All of the automatic transmissions are electrohydraulically controlled with five forward speeds Automatic transmission applications are given in Table b Automatic transmission applications For automatic transmission repair information see 240 Automatic ...

Page 395: ...ed transmissions have the ID tags mounted on the left side of the rear of the transmissions just above the automatic transmission pan arrow Table b Automatic transmission applications Model Year Engine Transmission 323i Ci 328i Ci 1999 2000 2000 2001 M52TU GM A5S 360R ZF A5S 325 Z 325i Ci 330i Ci 2000 2001 M54 ZF A5S 325 Z 325xi 330xi 2000 2001 M54 GM A5S 390R Transmission lubricants Copyright 200...

Page 396: ...ting clutch for manual transmission cars BMW suggests some specific tools for fitting and removing the self adjusting clutch SAC assembly These tools are required for aligning and assembling the clutch disk as well as locking the flywheel in place and aligning the SAC assembly to the dual mass flywheel Flywheel locking tool BMW 11 2 170 Pilot bearing removal tool BMW 11 2 340 Pilot bearing install...

Page 397: ...h centering mandrel BMW 21 2 142 SAC clutch lock tool BMW 21 2 150 Clutch diaphragm tensioning too BMW 21 2 160 SAC tensioning tool BMW 21 2 170 Clutch http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 2 of 3 2 25 2009 10 15 PM ...

Page 399: ...of the hydraulic parts Note The clutch hydraulic system shares the fluid reservoir and fluid with the brake hydraulic system Clutch hydraulic system bleeding and flushing If the clutch brake fluid is murky or muddy or has not been changed within the last two years the system should be flushed Flushing the old fluid from the clutch lines is done using a brake system pressure bleeder Raise and safel...

Page 400: ...ater 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 hydraulic systems and will also lower the brake fluid s boiling point Dispose of brake fluid properly Connect a length of hose from clutch slave cylinder bleeder valve arrow to a container Open bleeder valve and al...

Page 401: ...s withdraw pushrod completely Press slave cylinder pushrod all the way in If brake fluid appears without air bubbles close bleeder valve and slowly release pushrod Repeat procedure until fluid runs out clear and without bubbles Disconnect bleeder hose Install slave cylinder to transmission Add clean brake fluid to reservoir as necessary Check clutch operation Tightening torque Clutch slave cylinde...

Page 402: ...h guard if applicable Remove brake fluid reservoir cap Using a clean syringe remove brake fluid from reservoir Disconnect fluid supply hose from brake master cylinder Place a pan under hose to catch any excess fluid Working in engine compartment disconnect fluid line fitting from master cylinder Working at left rear of engine compartment Peel rubber edge seal off top of panel Twist plastic panel r...

Page 403: ...w retaining hydraulic line to master cylinder Be prepared to catch any excess brake fluid remaining in hydraulic line Note Wrap clutch master cylinder with shop rags when removing hydraulic fluid lines from master cylinder to prevent brake fluid spill Pull hydraulic line from master cylinder Remove master cylinder with supply hose Installation is reverse of removal Fill fluid reservoir with clean ...

Page 404: ...ine clamp tool Remove transmission splash guard if applicable Disconnect fluid hose from slave cylinder Place a pan under hose to catch any excess fluid Remove mounting nuts arrows from slave cylinder on left side of transmission Installation is reverse of removal noting the following Check for wear on slave cylinder Any other wear except on tip is caused by misalignment of clutch components Light...

Page 405: ...n fluid Bleed clutch hydraulics as described earlier Tightening torques Clutch slave cylinder to transmission 22 Nm 16 ft lb Fluid line to slave cylinder 20 5 Nm 15 4 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Clutch http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 7 of 7 2 25 2009 10 15 PM ...

Page 406: ...ressure plate of the SAC clutch uses a wedge ring which rotates against the diaphragm springs to accommodate for clutch disc wear The wedge ring adjusts by means of spring tension so special tools must be used to apply and relieve spring tension as the clutch pressure plate is removed and installed For special tools needed for clutch replacement procedures refer to the Special tools Table a Clutch...

Page 407: ...ial 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 CAUTION Self adjusting clutch tool feet must engage in the openings for adjusting springs to safely remove the SAC pressure plate Clutch http ebahn bentleypublishers com BMW 3 E46 Repai...

Page 408: ...om perimeter of pressure plate Remove self adjusting clutch unit and clutch disk Clutch assembly and hydraulics Clutch inspecting Inspect clutch disc for wear cracks loose rivets contamination or Clutch http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 3 of 8 2 25 2009 10 15 PM ...

Page 409: ...lts during installation The old stretch type bolts should not be reused Inspect transmission pilot bearing in end of crankshaft The bearing should rotate smoothly without play If necessary replace as described later Inspect and clean release bearing lever Apply a thin coat of grease to release bearing lever lubrication points arrows Also lightly lubricate clutch disc splines and transmission input...

Page 410: ...e proper direction Install self adjusting clutch pressure plate onto dowel pins at flywheel Tighten each bolt one turn at a time until pressure plate is fully seated and then torque to specification Tightening torque Clutch to flywheel M8 8 8 grade 24 Nm 18 ft lb M8 10 9 grade 34 Nm 25 ft lb Using a 14 mm allen wrench carefully screw out locking plate in a clockwise direction Remove BMW special to...

Page 411: ... special tool 21 2 180 must engage in openings of SAC pressure plate Place self adjusting clutch pressure plate on clean work surface Install special tool 21 2 180 onto pressure plate Squeeze handles of 21 2 180 together Tighten down knurled knobs of 21 2 180 SAC adjustment ring is now in installation position Install special tool 21 2 170 over 2 12 180 on SAC pressure plate Screw in handle of 21 ...

Page 412: ...then torque to specification Tightening torque Clutch to flywheel M8 8 8 grade 24 Nm 17 ft lb M8 10 9 grade 34 Nm 25 ft lb Unscrew handle of special tool until load is removed from diaphragm Remove BMW special tool 21 2 180 from pressure plate Remove clutch alignment tool from disk Clean and inspect release bearing guide sleeve on transmission Install release lever and release bearing Make sure be...

Page 413: ...as described earlier Remove transmission pilot bearing from end of crankshaft using 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 Clutch http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 8 of 8 2 25 2009 10 15 PM ...

Page 414: ...s 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 If these tools are unavailable equivalent tools may be substituted Seal puller BMW 00 5 010 Engine support bracket lower BMW 11 8 022 Input shaft seal puller slide hammer BMW 23 0 490 Manual Transmission htt...

Page 415: ...s Note Do not rely on forged casting numbers for transmission code identification Table a Manual transmission gear ratios Transmission Getrag S5D 250G ZF S5D 280Z ZF S5D 320Z Gear Ratios 1st 4 23 4 21 4 21 2nd 2 52 2 49 2 49 3rd 1 66 1 66 1 66 4th 1 22 1 24 1 24 5th 1 00 1 00 1 00 reverse 4 04 3 85 3 85 Copyright 2006 Robert Bentley Inc All rights reserved Manual Transmission http ebahn bentleypub...

Page 416: ... a finger into the hole to check the fluid level If the fluid level is up to the bottom of the fill hole finger is wetted by transmission fluid the level is correct Transmission fluid replacing Drive vehicle for a few miles to warm transmission Raise and safely support vehicle to access drain plug CAUTION Make sure the car is stable and well supported at all times Use a professional automotive lif...

Page 417: ...nd torque fluid fill plug nothing Fluid capacity Getrag transmission 1 0 liter 1 1 US qts ZF transmission 1 2 liters 1 3 US qts Tightening torque Transmission drain or fill plug 50 Nm 37 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Manual Transmission http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 2 of 2 2 25 2009 10 16 PM ...

Page 418: ...switch on ZF transmission is in the right front of the transmission Install new switch Tightening torque Back up light switch to transmission 20 Nm 15 ft lb Check transmission fluid level before lowering vehicle Selector shaft seal replacing transmission installed Raise and safely support vehicle Support transmission with transmission jack On rear wheel drive cars Manual Transmission http ebahn be...

Page 419: ... See 270 Transfer Case CAUTION Tilting the engine to lower the transmission can lead to damage to various components due to lack of clearance Working at rear of selector shaft pry snap ring A out of groove with a small screwdriver Push snap ring towards gear selector rod joint and drive out pin B Carefully pry out selector shaft oil seal with a narrow seal remover or small screwdriver Manual Trans...

Page 420: ... nuts Check transmission oil level topping up as necessary Tightening torques Center bearing driveshaft to body 21 Nm 15 ft lb Clamping sleeve driveshaft 10 Nm 89 in lb Driveshaft to final drive flange With U joint M10 ribbed nut 80 Nm 59 ft lb With U joint M10 compressed nut 64 Nm 47 ft lb Flex disc to driveshaft or transmission flange M10 8 8 grade 48 Nm 35 ft lb Manual Transmission http ebahn b...

Page 421: ...rt transmission with transmission jack On rear wheel drive cars Remove driveshaft See 260 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 See 260 Driveshaft Remove transfer case crossmember bolts arrows and remove transfer case See 270 Transfer Case Manual Transmission ...

Page 422: ...e to prevent it from turning Remove output flange If necessary use a puller 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 Note Manual Transmission http ebahn bentleypublisher...

Page 423: ...alling the flange collar nut to prevent oil from leaking past the threads Installation is reverse of removal noting the following Install driveshaft using new nuts See 260 Driveshaft Check transmission and transfer case fluid level if applicable topping up as necessary Tightening torque Transmission crossmember to chassis M8 21 Nm 15 ft lb Transmission output flange to output shaft Stage I 190 Nm ...

Page 424: ... inside bell housing Locate two indents arrows in seal Thread a slide hammer seal puller at indents pull seal and remove seal Use care not to scratch or damage input shaft Use a protective sleeve or tape the shaft when removing and installing the seal Lubricate new seal with transmission oil and drive into place using an appropriate drift Thoroughly clean guide sleeve mounting bolts sealing surfac...

Page 425: ...e Guide sleeve to transmission M6x12 bolt 10 Nm 89 in lb Copyright 2006 Robert Bentley Inc All rights reserved Manual Transmission http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 8 of 8 2 25 2009 10 17 PM ...

Page 426: ...es Use a professional automotive lift or jack stands designed for the purpose A floor jack is not adequate support The removal of the transmission may upset the balance of the vehicle on a lift Transmission removing and installing 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 427: ...nd slide trim panel from mounting lip Remove heater bulkhead cover mounting screws B and lift cover up and out from firewall Raise and safely support vehicle Remove engine splashguard from underside of vehicle Remove front suspension reinforcement bolts arrows Remove reinforcement coupe shown and front axle subframe Note Tubular style front end reinforcements are used in rear Manual Transmission h...

Page 428: ...ten knurled screws until tool makes contact with engine oil pan Support transmission with transmission jack Remove reinforcing cross brace from below engine transmission Disconnect harness connector from back up light switch on transmission Remove exhaust system and heat shield See 180 Exhaust System Remove driveshaft See 260 Driveshaft On all wheel drive vehicles Remove transfer case See 270 Tran...

Page 429: ...onnections CAUTION Tilting the engine to lower the transmission can lead to damage to various components due to lack of clearance at rear of engine Remove brake fluid reservoir if necessary Remove transmission mounting Torx head bolts arrows Note length and location of bolts Remove transmission by pulling backward until the transmission input shaft clears the clutch disc splines then pull downward...

Page 430: ...cles equipped with the plate style reinforcement Note Torx head mounting bolts should always be used with washers to prevent difficult removal in the future Install driveshaft and preload center bearing bracket Use new nuts when mounting driveshaft to transmission flex disc and final drive See 260 Driveshaft Refill transmission with appropriate lubricant before starting or towing the car See Trans...

Page 431: ...ion 22 Nm 16 ft lb Transmission crossmember to chassis M8 21 Nm 15 ft lb Transmission to engine Torx head M8 22 Nm 16 ft lb M10 43 Nm 32 ft lb M12 72 Nm 53 ft lb Transmission drain fill plug 50 Nm 37 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Manual Transmission http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 6 of 6 2 25 2009 10 17 PM ...

Page 432: ... towing an automatic transmission vehicle use a flat bed truck or raise the rear wheels off the ground All wheel drive vehicles equipped with automatic transmissions must be towed using a flat bed truck only The electronic transmission control module TCM monitors transmission operation for faults and alerts the driver by illuminating the transmission fault indicator on the instrument panel On boar...

Page 433: ...rque converter socket BMW 24 1 100 Spline bore alignment tool BMW 24 2 300 Torque converter clamp BMW 24 4 131 135 Internal repairs to the automatic transmission require special service equipment and knowledge If it is determined that internal service is required consult an authorized BMW Automatic Transmission http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 2 of 3 2 25 2009 10 17 PM...

Page 434: ...ped with the A5S 325Z transmission Table a Automatic transmission applications Model Year Engine Transmission 323i Ci 328i Ci 1999 2000 2000 2001 M52TU GM A5S 360R ZF A5S 325 Z 325i Ci 330i Ci 2000 2001 M54 ZF A5S 325 Z 325xi 330xi 2000 2001 M54 GM A5S 390R Copyright 2006 Robert Bentley Inc All rights reserved Automatic Transmission http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 3 o...

Page 435: ...ing 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 ATF level checking The automatic transmission is not equipped with a dipstick Checking the ATF level requires measuring and maintaining a specified ATF temperature within a narrow range during t...

Page 436: ...ata 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 Remove ATF fill plug arrow Place transmission in neutral and restart engine A5S 360R transmission shown Note Make sure ATF temperature is greater then 30 C before releasing fill plug With ATF between 30 50 C 85 120 F add fluid until it spills from...

Page 437: ...e includes removal and installation of the ATF fluid strainer filter Remove ATF drain plug arrow and drain fluid into container A5S 360R transmission shown WARNING The ATF must not be hot when draining Do not drain the ATF if the engine and or transmission is hot Hot ATF can scald Wear eye protection protective clothing and gloves Remove transmission pan mounting bolts and remove pan Remove pan ga...

Page 438: ...ssion with approved fluid 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 with torque converter 9 liters 9 5 qt without torque converter 4 liters 4 2 qt A5S 325Z 2 5 liter wi...

Page 439: ...plug to ATF sump A5S 360R A5S 390R M14 18 Nm 14 ft lb A5S 325Z 35 Nm 26 ft lb ATF fill plug to ATF sump A5S 360R A5S 390R M14 18 Nm 14 ft lb A5S 325Z 30 Nm 23 ft lb ATF sump to transmission A5S 360R A5S 390R M14 10 Nm 7 ft lb A5S 325Z 6 Nm 4 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Automatic Transmission http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 5 of 5 2 25 2...

Page 440: ...lift Tilting the engine to remove the transmission can lead to damage to various components due to lack of clearance On cars with AST remove throttle body Remove brake fluid reservoir if necessary Torx head bolts are used to mount the transmission to the bellhousing Be sure to have appropriate tools on hand before starting the job Transmission removing and installing Disconnect negative cable from...

Page 441: ...ove 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 Remove heater bulkhead cover mounting screws B and lift cover up and out from firewall Install engine support across engine bay Rais...

Page 442: ...bframe Drain ATF from transmission as described earlier Remove exhaust system and exhaust heat shield See 180 Exhaust System Remove driveshaft s See 260 Driveshaft On all wheel drive equipped vehicles Remove transfer case See 270 Transfer Case With selector lever in Park disconnect shift selector lever cable from lever and remove cable bracket Hold linkage clamping bolt A stationary when loosening...

Page 443: ...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 Tighten knurled screws of BMW special tool 11 8 022 until tool supports engine oil pan securely Remove access plug in cover p...

Page 444: ... Lower jack to allow transmission to clear vehicle Installation is reverse of removal noting the following Blow out oil cooler lines with low pressure compressed air and flush cooler with clean ATF twice before reattaching lines to transmission CAUTION Wear safety glasses when working with compressed air Do not reuse ATF after flushing Install new sealing washers on hollow bolts Automatic Transmis...

Page 445: ...wel to line up bolt holes if necessary Fill transmission with clean ATF until oil level is even with fill hole Then check fluid level as described earlier Adjust gearshift mechanism See 270 Transfer Case Note Torx head mounting bolts should always be used with washers to prevent difficult removal in the future Tightening torques ATF drain plug to ATF sump A5S 325Z 35 Nm 26 ft lb A5S 360R 20 Nm 15 ...

Page 446: ... lb Transmission support crossmember to chassis 23 Nm 17 ft lb Transmission to engine Torx head with washer M8 21 Nm 15 ft lb M10 42 Nm 31 ft lb M12 72 Nm 53 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Automatic Transmission http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 7 of 7 2 25 2009 10 18 PM ...

Page 447: ... the gear shift lever for manual transmission equipped vehicles Pin wrench BMW 25 1 110 To gain access to the complete gearshift mechanism it is necessary to remove the exhaust system and the driveshaft as described in 180 Exhaust System and 260 Driveshaft Copyright 2006 Robert Bentley Inc All rights reserved Gearshift Linkage http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 1 of 1 2 ...

Page 448: ...m bearing 4 Shift arm 5 Shift lever 6 Selector rod 7 Spacer ring 8 Circlip 9 Dowel pin 10 Lock ring 11 Washer 12 Gear selector rod joint 13 Bearing bolt 14 Bearing bushing Gearshift lever removing manual transmission Gearshift Linkage http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 1 of 4 2 25 2009 10 19 PM ...

Page 449: ...NG 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 Remove complete exhaust system See 180 Exhaust System Remove driveshaft s See 260 Driveshaft Support transmission with transmission jack Remove crossmember arrow from rear of transmission Lower rear of transmission to access ...

Page 450: ...se transmission and temporarily install transmission crossmember Lower vehicle Working from inside passenger compartment pull up on gearshift lever to remove it together with retaining ring and rubber grommet Gearshift lever installing manual transmission Install shift lever aligning locking tabs with openings in shift console arrows Press down on retaining ring until it clicks into place Install ...

Page 451: ...ll shift boot cover Push shift knob onto lever Tightening torques Rear driveshaft to final drive flange With U joint M10 ribbed nut 80 Nm 59 ft lb With U joint M10 compressed nut 64 Nm 47 ft lb 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 Front driveshaft to final drive flange with U joint M10 70 Nm 52 ft l...

Page 452: ...orted at all times Use a professional automotive lift or jack stands designed for the purpose Loosen selector clamping nut A Counterhold clamping bolt when loosening nut Push shift lever of transmission forward toward engine Park position while applying light pressure on cable end Tighten cable clamping nut Note Do not overtighten the nut so that it twists the cable Tightening torque Shift cable c...

Page 453: ...ents drive gear selection until the brake pedal is depressed With engine running and car stopped place selector lever in Park or Neutral Without depressing brake pedal check that selector lever is locked in position Park or Neutral Depress brake pedal firmly Solenoid should be heard to energize Check that selector lever can now be moved out of Park or Neutral Note The next test should be performed...

Page 454: ...transmission control module TCM See 610 Electrical Component Locations and Electrical Wiring Diagrams Note The solenoid is controlled via the TCM using brake pedal position engine speed and road speed as controlling inputs Automatic transmission gearshift mechanism Gearshift Linkage http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 3 of 4 2 25 2009 10 19 PM ...

Page 455: ...cannot be shifted out of Park position Note It must only be possible to remove ignition key with selector lever in Park position Shift interlock cable must not be kinked Turn ignition key on and depress brake pedal Check that selector lever moves freely from gear to gear With selector lever in a gear position other than Park attempt to turn key to off position and remove Key should not go into off...

Page 456: ...n the center by a sliding splined coupling This coupling compensates for fore and aft movement of the drive line The driveshaft is connected to the transmission by a rubber flex disc and to the rear final drive by a universal joint It is supported in the middle by a center support bearing The bearing is mounted in rubber to isolate vibration All wheel drive models incorporate two driveshafts The r...

Page 457: ...ial directly using no flexible rubber disk Rear wheel drive driveshaft assembly All wheel drive driveshaft assemblies 1 Front driveshaft assembly 2 Torx screw M10 tighten to 70 Nm 52 ft lb 3 Transfer case 4 Flex disc 5 Bolt M12 Driveshafts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 2 of 7 2 25 2009 10 20 PM ...

Page 458: ... Final Drive Driveshaft noise or vibration may be caused by worn or damaged components 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 At the rear driveshaft check the...

Page 459: ...le Transmission transfer case output flange axial play 0 10 mm 0 004 in radial play 0 07 mm 0 003 in Final drive input flange radial play measured at driveshaft centering lip 0 07 mm 0 003 in Spin the rear driveshaft center bearing and check for smooth operation without play Check that the splines of the sliding coupling move freely Clean and lubricate the splines with molybdenum disulfide grease ...

Page 460: ...driveshaft at the final drive and repositioning it 90 180 or 270 in relation to the final drive input flange Table a Driveshaft troubleshooting Symptom Probable cause Corrective action Vibration when starting off forward or reverse Incorrect preload of center bearing Check preload of center bearing Readjust preload Center bearing rubber deteriorated Inspect center bearing and rubber Replace if nec...

Page 461: ...o 50 km h Front centering guide worn or driveshaft mounting flanges out of round or damaged Check front centering guide and replace if necessary Check runout of driveshaft mounting flanges Universal joints worn or seized Check universal joint play and movement Replace driveshaft if necessary Flex disc damaged or worn Inspect flex disc Replace if necessary Center bearing rubber deteriorated Inspect...

Page 462: ...place driveshaft if necessary Sliding coupling seized Remove driveshaft and check movement of sliding coupling Clean coupling splines or replace parts as necessary Incorrect preload of center bearing Check preload of center bearing Readjust if necessary Center bearing faulty Replace center bearing Final drive rubber mount faulty Inspect final drive rubber mount and replace if necessary Driveshaft ...

Page 463: ...er bearing support 12 Lock ring The driveshaft is balanced to close tolerances Whenever it is to be removed or disassembled the mounting flanges and driveshaft sections should be marked with paint or a punch before proceeding with work This will ensure that the driveshaft can be reassembled or installed in exactly the original orientation Rear driveshaft aligning The alignment of the driveshaft do...

Page 464: ...xactly centered in driveshaft tunnel The second important driveshaft alignment check is more complicated It checks the amount the driveshaft is angled vertically at the joints This angle is known as driveshaft deflection In general there should be little deflection in the driveshaft between the engine the center bearing and the final drive Precise checks require the use of a large protractor or so...

Page 465: ...king nuts These nuts are designed to be used only once and should be replaced during reassembly Remove complete exhaust system See 180 Exhaust System Remove exhaust heat shields Matchmark front and rear driveshaft connections at transmission and final drive Remove driveshaft mounting bolts Discard old nuts Note open end wrench arrow being used to counterhold bolt at transmission flex disc Support ...

Page 466: ...gn driveshaft matchmarks at final drive and then at transmission flange Centerlines of universal joints arrows must be parallel or at 90 to each other Position center support bearing and start attaching nuts Use new self locking nuts Tighten flange nuts while preventing bolts from twisting in coupling Tighten final drive flange first then tighten coupling at transmission Preload center support bea...

Page 467: ...igned to be used only once Avoid stressing the flex disc when torquing the bolts Do this by holding the bolts steady and turning the nuts on the flange side Tightening torques Center bearing to body 21 Nm 15 ft lb Clamping sleeve 10 Nm 89 in lb Drive axle to differential flange M10 Torx bolt 83 Nm 61 ft lb M10 with locking teeth replace bolts 96 Nm 71 ft lb M10 with ribbed teeth black 100 Nm 74 ft...

Page 468: ...e of the transmission or transfer case should be checked for cracks tears missing pieces or distortion Check for worn bolt hole bores in the flange Remove driveshaft as described earlier Note It is possible to only partially remove the driveshaft leaving it connected to the final drive The driveshaft can be tilted down in the center and slid off the transmission flange once the clamping sleeve is ...

Page 469: ...ier Note Torque only the nuts while holding the bolt heads This will prevent damaging or fatiguing the rubber Tightening torques Center bearing to body 21 Nm 15 ft lb Clamping sleeve 10 Nm 89 in lb Drive axle to differential flange M10 Torx bolt 83 Nm 61 ft lb M10 with locking teeth replace bolts 96 Nm 71 ft lb M10 with ribbed teeth black 100 Nm 74 ft lb M10 with ribbed teeth silver ZNS replace bo...

Page 470: ...nt section of the driveshaft and secured by a circlip Remove rear driveshaft See Rear driveshaft removing Match mark front and rear driveshaft sections before separating Loosen clamping sleeve fully and pull driveshaft sections apart Remove rubber bushing washer and clamping sleeve from front section Inspect condition of rubber bushing for splined coupling Replace worn or damaged parts Remove cent...

Page 471: ...ssemble driveshaft Note Do not retighten clamping sleeve until driveshaft is installed Install driveshaft as described earlier Tighten clamping sleeve Tightening torque Clamping sleeve 10 Nm 7 5 ft lb Front centering guide replacing The front centering guide centers the driveshaft in relation to the transmission or transfer case The guide is press fit into a cavity in the front of the driveshaft a...

Page 472: ...mm approximately in diameter mandrel or metal rod into guide Strike guide with hammer to force centering guide out Note The mandrel should fit snugly in the centering guide so that the grease cannot escape around the sides of the mandrel Remove old grease from driveshaft lubricate new centering guide with molybdenum disulfide grease Molykote Longterm 2 or equivalent and drive it into driveshaft Wh...

Page 473: ... Install driveshaft as described earlier Copyright 2006 Robert Bentley Inc All rights reserved Driveshafts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 11 of 11 2 25 2009 10 20 PM ...

Page 474: ...the car using a floor jack or a hydraulic lift carefully position the jack pad to prevent damaging the car body A suitable liner wood rubber etc should be placed between the jack and the car to prevent body damage Watch the jack closely Make sure it stays stable and does not shift or tilt As the car is raised the car may roll slightly and the jack may shift Remove underbody splash guard Remove bol...

Page 475: ...f removal Tightening torques Driveshaft to drive flange M10 70 Nm 52 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Driveshafts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 2 of 2 2 25 2009 10 21 PM ...

Page 476: ...s used in all wheel drive models to direct power from the transmission to both the front and rear differentials via driveshafts This transfer case is unique in that it delivers 38 of the transmission s torque output to the front differential and 62 of the torque to the rear Unlike the transfer cases used in many four wheel drive trucks the transfer case used is a single range unit permanently enga...

Page 477: ...car to prevent body damage Watch the jack closely Make sure it stays stable and does not shift or tilt As the car is raised the car may roll slightly and the jack may shift Remove engine splash guard from underside of vehicle Remove exhaust system See 180 Exhaust System Remove exhaust system heat shields arrows Remove front drive shaft See 260 Driveshaft Support transmission with transmission jack...

Page 478: ...bearing and release mounting nuts Lower rear driveshaft at center bearing and remove from transmission output flange at flexible disk Support from vehicle body using stiff wire Remove bolts retaining transfer case to transmission and remove transfer case Installation is reverse of removal noting the following Replace dowel pins in transfer case mounting surface if damaged Coat dowel pins with anti...

Page 479: ...ghtening torques Transmission crossmember to body M8 21 Nm 15 ft lb Transfer case to transmission M10 41 Nm 30 ft lb Transfer case filler plug M18 33 Nm 24 ft lb Fluid capacities Transfer case oil change 0 16 liter 0 16 qt New transfer case fill 0 24 liter 0 25 qt Copyright 2006 Robert Bentley Inc All rights reserved Transfer Case http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 2 3 of ...

Page 480: ...ems rear wheel drive Front suspension In rear wheel drive cars the control arm on each side connects the steering arm A to mounting points on the subframe B and the body frame rail C On all wheel drive cars the rear mounting of the control arm is to the subframe Suspension Steering and Brakes General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 1 of 7 2 25 2009 10 23 PM ...

Page 481: ...ion is unequal from side to side Front suspension rear wheel drive cars The control arms are constructed of forged aluminum This design lowers the overall weight of the car and reduces the amount of unsprung mass By reducing unsprung mass softer more comfortable springs can be used and accurate handling is maintained The three point mounting of each L shaped control arm precisely controls the fron...

Page 482: ...ox 100 kg 220 lbs to the weight of the car Weight distribution is largely unaffected at 52 7 front 47 3 rear The front suspension for all wheel drive vehicles has been redesigned to provide clearance for the front axle differential and drive shafts All suspension components are constructed of steel The front subframe consists of two square frame sections welded to two tubes to form a box structure...

Page 483: ...the outboard end and a triple roller bearing CV joint at the inboard end The right inner joint shaft is supported by a bearing pedestal bolted to the oil pan The shaft extends through the engine oil pan into the front differential The front axle differential bolted to the left side of the engine oil pan is driven by a 40 mm 1 57 in single piece driveshaft Universal joints are located at both ends ...

Page 484: ...turning radius of the all wheel drive vehicle is 35 8 feet 1 4 feet greater than the rear wheel drive vehicle Rear suspension The rear suspension subframe final drive carrier is the main mounting point for the differential housing and rear suspension components It is bolted to the vehicle undercarriage using four large rubber bushings arrows Trailing arms locate the rear wheels and anchor the spri...

Page 485: ...port suspension n a on awd 24 0 mm 0 945 in 19 mm 0 748 in Brakes E46 cars are equipped with power disc brakes with integral antilock brakes ABS The parking brake is a dual drum system integrated with the rear brake rotors Power assist is provided by a vacuum booster when the engine is running The brake pedal pushrod is connected directly to the master cylinder so failure of the vacuum booster doe...

Page 486: ...ket wheels should be selected with care Improperly fitted wheels can contact and damage suspension brake or body components and may adversely affect vehicle stability Table b Rim and tire sizes Model Standard Option Rim size Tire size Rim size Tire size 323i 15 x 6 5 195 65R 15 16 x 7 205 55R 16 323Ci 325i Ci 328i 16 x 7 205 55R 16 17 x 8 225 45R 17 328Ci 16 x 7 205 55R 16 17 x 7 5 8 5 225 45R 17 ...

Page 487: ...tems as ABS ASC or DSC will be specified when necessary See the accompanying illustrations for individual system identification E46 Electronic braking and stability control systems ASC 1999 2000 Automatic Stability Control Teves MK 20 ASC 1 Brake master cylinder and fluid reservoir left rear of engine compartment 2 ASC control module and hydraulic unit left rear of engine compartment under master ...

Page 488: ...ing arm 6 Steering angle sensor at base of upper steering column 7 Lateral acceleration sensor behind driver s kickpanel 8 Rotational acceleration yaw sensor under driver s seat underneath rug 2001 rear wheel drive Dynamic Stability Control Teves MK 60 DSC 1 Brake fluid reservoir and master cylinder left rear of engine compartment 2 DSC control module and hydraulic unit left rear of engine compart...

Page 489: ...sensor right rear of engine compartment 2 Brake fluid reservoir and master cylinder left rear of engine compartment 3 DSC precharge pump left rear of engine compartment under brake master cylinder 4 Rear wheel speed sensor at each rear wheel hub 5 Front wheel speed sensor at each front steering arm 6 Steering angle sensor at base of upper steering column 7 Lateral acceleration sensor and rotationa...

Page 490: ...wheel is nearing a lock up condition the module signals the hydraulic unit to maintain or reduce pressure at the appropriate wheel s Pressure is modulated by electrically operated solenoid valves in the hydraulic unit Automatic Stability Control ASC The Automatic Stability Control ASC system works in conjunction with the Antilock Brake System ABS and the engine management system to enhance vehicle...

Page 491: ...on to replace the limited slip differential available in previous models Even with the ASC system turned off if the ASC control module senses a difference in wheel speed one wheel spinning the control module will apply modulated braking force to the slipping wheel until traction is regained but will not override fuel injection function Traction control also comes into operation during deceleration...

Page 492: ...eel speed sensor 2 Wheel speed pulse wheel 3 Brake disk 4 Brake caliper 5 ABS ASC hydraulic unit 6 Brake master cylinder 7 Throttle valve 8 Engine control module 9 Accelerator pedal 10 ABS ASC control module Table c ASC indicator lamp function Indicator lamp Condition Action Use Light on Normal ASC start up Automatic ASC self test Suspension Steering and Brakes General http ebahn bentleypublishers...

Page 493: ...components of the ASC traction control system DSC is active throughout the driving experience unlike ASC which is only active during acceleration and braking DSC helps stabilize the vehicle in cornering and avoidance maneuvers by adjusting engine controls such as throttle ignition fuel injection and the application of brake pressure to the wheels individually The DSC control module uses various in...

Page 494: ...tem 8 Ignition spark 9 Fuel injection 10 Throttle valve The DSC system can be toggled on and off by a switch mounted on the center console Turning off the DSC system does not disable ABS or ASC functions Vehicle stability parameters Suspension Steering and Brakes General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 8 of 24 2 25 2009 10 24 PM ...

Page 495: ...e proportioning EBV The Teves MK 20 ASC system functions as a basic ABS system but adds additional system functions Brake intervention ADB Drag torque reduction MSR All of the dynamic stability control systems are based on the ABS ASC system but add DSC system functions Dynamic brake control DBC Maximum brake control MBC Cornering brake control CBC Cornering brake control reduces brake pressure bu...

Page 496: ...heel deceleration rates as the brakes are applied If the difference in wheel speeds exceeds the programmed threshold values EBV is activated EBV activation modulates inlet valves to the rear wheels to regulate braking force Brake intervention ADB Brake intervention is applied to the individual drive wheel which is losing traction by activating the rear brake calipers in three phases Pressure build...

Page 497: ...id to wheel without traction Pressure hold and pressure release cycles are run by cycling inlet and outlet valve to rear brake caliper without traction Drive torque reduction In low traction conditions the ABS control module request is sent to the engine control module ECM via the CAN bus The ECM accomplishes torque reduction by implementing the following measures Reducing throttle opening angle R...

Page 498: ...ction provides increased braking pressure up to ABS threshold during emergency braking situations The DSC control unit will implement DBC function when brake pressure builds rapidly with application of the brake pedal DBC triggering conditions Brake light switch on Brake pressure in master cylinder above ABS threshold Brake pressure build up speed above threshold Vehicle road speed above 3 mph Pre...

Page 499: ... when the brakes are applied too slowly to reach DBC threshold MBC triggering conditions Both front wheels in ABS regulation Vehicle speed above 3 mph DBC and pressure sensor self test completed and OK Vehicle travelling forward Rear wheels not under ABS regulation MBC will activate the return pump to increase rear wheel pressure build up The function will be terminated under the following conditi...

Page 500: ...threshold Vehicle road speed drops below 3 mph Teves MK 20 ASC diagram Suspension Steering and Brakes General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 14 of 24 2 25 2009 10 24 PM ...

Page 501: ...Teves MK 20 DSC Diagram Suspension Steering and Brakes General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 15 of 24 2 25 2009 10 24 PM ...

Page 502: ... CAN bus Engine control module ECM provides current engine torque to ABS control module ABS control module provides wheel speed sensor signals vehicle speed to other modules ABS control module signals ECM to increase reduce torque ECM adjusts motor driven throttle MDK EDK ABS control module commands transmission control module AGS to suppress shifts during ASC DSC regulation DSC receives yaw later...

Page 503: ...the vehicle s engine control module ECM and transmission control module AGS if applicable by the CAN bus network Wheel speed sensors Wheel speed sensors are a crucial component in every ABS system Control modules use these sensor inputs to determine overall vehicle speed and individual wheel speed for both ABS braking and stability control functions Three different types of wheel speed sensor are ...

Page 504: ...rt 7 Evaluation module 8 Sensor element 9 Magnet 10 Pick up surface CAUTION The magnetoresistive and the Hall effect sensor for the rear wheel are physically interchangeable However the electronic properties are not the same and they must not be interchanged Suspension Steering and Brakes General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 18 of 24 2 25 2009 10 24 PM ...

Page 505: ...ence voltage the sensor will return an output voltage that ranges between 0 5 and 4 5 volts to the DSC control module with 1 8 volts as a standing voltage This input along with other DSC inputs determines the amount of DSC regulation needed to maintain vehicle stability Teves MK 60 DSC diagram Suspension Steering and Brakes General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 19 o...

Page 506: ...Bosch DSC III 5 7 diagram Suspension Steering and Brakes General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 20 of 24 2 25 2009 10 24 PM ...

Page 507: ...l activate a DSC regulation cycle to increase vehicle stability while cornering In case of failure the sensor will send a constant voltage to the DSC control unit DSC steering angle sensor Using two potentiometers the steering angle sensor determines the steering angle and the rate of steering change The sensor processes the two potentiometer outputs and provides a digital signal to the DSC contro...

Page 508: ...harge pump The DSC precharge pump is used in the Teves MK 20 DSC and Bosch DSC III 5 7 systems 1999 2000 DSC and 2001 all wheel drive equipped vehicles The DSC precharge pump provides the hydraulic unit with the necessary supply of hydraulic brake fluid When the DSC system is activated the precharge pump delivers brake fluid from the reservoir to the hydraulic unit at 10 bar 150 psi Switches and i...

Page 509: ...The pressure sensor must not detect more than 5 bar when the brake light switch is not actuated Parking brake switch The switch for the parking brake warning lamp is used to signal the control module if the parking brake is engaged This signal is used in stability control system logic to cancel system functions Brake fluid level switch The reed type brake fluid level switch monitors the level of b...

Page 510: ...hydraulic fluid level is low 3 Antilock brake system ABS warning light Indicates that the ABS system has been deactivated or when there is an ABS system malfunction 4 Brake pad wear warning light Indicates worn brake pads WARNING If the brake warning lamp ABS warning lamp and ASC DSC warning lamp are all illuminated at the same time there is an ABS and stability control system failure Do not drive...

Page 511: ...eshootinglists the symptoms of common suspension and steering problems and their probable causes and suggests corrective actions Bold type indicates the repair groups where applicable test and repair procedures can be found Table d Suspension and steering troubleshooting Symptom Probable cause Repairs Breaking away while braking Worn struts or shock absorbers Replace struts or shock absorbers 310 ...

Page 512: ...spension bottoms out easily Worn struts or shock absorbers Replace struts or shock absorbers 310 330 Rear end hop with hard braking Rear trailing arm busing worn or damaged Replace trailing arm bushing 330 Steering heavy poor return to center Worn upper strut mounts Replace strut mounts 310 Incorrect tire pressure Check and correct tire pressures 020 steering system faulty Check power steering flu...

Page 513: ...onents Inspect repair replace as necessary 310 330 Sagging coil springs Replace springs as necessary 310 330 Unsteady in curves self steering poor rear end stability Rear subframe bushings worn or damaged Replace rear suspension bushings as necessary 330 Differential bushings worn or damaged Replace rear suspension bushings as necessary 330 Rear shock absorbers worn Replace rear shock absorbers 33...

Page 514: ...and diagnosis for the electronic braking and stability control systems must be made using an electronic scan tool 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 If no visual faults can be found and the ABS light remains...

Page 515: ... specifications measurement A lists rear suspension ride height specifications These specifications apply to a car in a normally loaded position When checking ride height or installing suspension components that require the car to be normally loaded load the car as follows Normal loaded position Each front seat 68 Kg 150 lbs Rear seat center 68 Kg 150 lbs Trunk 21 Kg 46 lbs Fuel tank full Table e ...

Page 516: ...urement A Wheel size Standard suspension Sport suspension Rough road suspension All wheel drive suspension 15 inch 542 mm 21 33 in 526 mm 20 70 in 562 mm 22 12 in 16 inch 555 mm 21 85 in 539 mm 21 22 in 575 mm 22 64 in 572 mm 22 52 in 17 inch 570 mm 22 44 in 554 mm 21 81 in 590 mm 23 22 in 587 mm 23 11 in 18 inch 583 mm 22 95 in 567 mm 22 32 in 603 mm 23 74 in 600 mm 23 62 in Maximum variation bet...

Page 517: ...cial service tools are required for most of the work described in this repair group In addition to the tools depicted in the illustrations a variety of press tools are necessary for control arm bushing replacement 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 Front ...

Page 518: ...ing compressor BMW 31 3 120 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 Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 2 of 5 2 25 2009 10 25 PM ...

Page 519: ...sprung mass for better handling However the aluminum construction prevents removal or replacement of the pressed in ball joints WARNING Physical safety could be impaired if procedures described here are undertaken without the proper service tools and equipment Be sure to have the right tools on hand before beginning any job Do not reuse self locking nuts or bolts They are designed to be used only ...

Page 520: ... the control arms great care must be taken when working on and around the front suspension When replacing any damaged front end components always check the condition of the control arms Do not clean control arms with wire brushes made of brass or iron Only use brushes made of stainless steel Do not expose control arms to temperatures exceeding 80 C 176 F sparks created by grinding battery acid or ...

Page 521: ...rol arm bushing and mount 6 Tie rod 7 Steering rack 8 Front stabilizer bar 9 Front suspension subframe 10 Steering arm 11 Stabilizer bar link Copyright 2006 Robert Bentley Inc All rights reserved Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 5 of 5 2 25 2009 10 25 PM ...

Page 522: ...t mount or spring replacement is a two step procedure Removal of strut assembly from vehicle Disassembly and replacement of components on workbench Strut assembly removing and installing Raise car and remove front 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 s...

Page 523: ...de sensor out of steering arm and lay aside Note Rear wheel drive vehicle shown in illustration On cars equipped with xenon headlights Remove headlight vertical aim sensor link bracket mounting nuts arrows from right control arm Loosen and remove stabilizer bar link mounting nut arrow from strut Detach link from strut housing Note Use a thin wrench to counterhold shaft Front Suspension http ebahn ...

Page 524: ...rt steering arm from below Loosen pinch bolt arrow at top of steering arm Spread clamping collar at slot A if necessary to slide steering arm off strut assembly Support strut assembly from below Working in engine compartment at strut tower remove three strut mounting nuts A on strut tower If factory alignment locating pin B is missing be sure to mark location of strut mounting studs in Front Suspe...

Page 525: ... to strut assembly insert positioning pin arrow of strut into slot of steering arm clamping collar To ensure proper alignment specifications slide steering arm up on strut until stop is reached Remainder of installation is reverse of removal Be sure to use new self locking nuts and bolts Use new steering arm mounting bolts or clean bolts and use Loctite 270 or equivalent thread locking compound Wh...

Page 526: ...l arm 65 Nm 48 ft lb Steering arm pinch bolt at strut housing 81 Nm 60 ft lb Strut assembly to strut tower self locking nuts 24 Nm 18 ft lb Upper strut mount to strut tower self locking M8 flanged nut 18 mm flange 24 Nm 18 ft lb 21 mm flange 34 Nm 25 ft lb Front spring and upper strut mount assembly 1 Cap 2 Upper strut self locking nut M14 tighten to 64 Nm 47 ft lb Front Suspension http ebahn bent...

Page 527: ... 24 Nm 18 ft lb 18 mm flange 34 Nm 25 ft lb 21 mm flange 6 Spacer plate all wheel drive or rough road package only 7 Upper strut bearing 8 Sealing ring 9 Flat washer 10 Upper spring seat 11 Upper spring pad 12 Rubber stop 13 Dust seal 14 Spring 15 Lower spring Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 6 of 10 2 25 2009 10 25 PM ...

Page 528: ...compress spring until spring force on upper mount is relieved WARNING Do not attempt to disassemble the struts without a spring compressor designed specifically for this job 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 Counter...

Page 529: ...uipped with a spacer plate above the upper strut mount Make sure the strut mount locating pin fits in the corresponding bore of the spacer plate Note If there is no locating bore in the strut tower for the pin in the replacement upper strut mount to fit drive out the pin before installing the new mount Replace springs in pairs only The part number A is stamped near the large end of the spring Fron...

Page 530: ...and lower spring seats Release spring compressor carefully and evenly allowing spring to expand slowly Have car professionally aligned when job is complete 1 Self locking nut M8 tighten to 24 Nm 18 ft lb 18 mm flange 34 Nm 25 ft lb 21 mm flange 2 Strut tower 3 Upper strut mount 4 Upper strut self locking nut M14 tighten to 64 Nm 47 ft lb 5 Upper strut bearing 6 Sealing ring 7 Rubber bump stop 8 Du...

Page 531: ... spring seat 16 Spring 17 Lower spring seat Tightening torque Upper strut mount to strut shaft M14 self locking nut 64 Nm 47 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 10 of 10 2 25 2009 10 25 PM ...

Page 532: ...Sport Wagon models manufactured until production date 12 2000 Coupe models manufactured until production date 11 1999 The aluminum plate type front end reinforcement is installed in the following cars All Convertible models Coupe models manufactured from production date 11 1999 Rear wheel drive Sedan and Sport Wagon models manufactured from production date 12 2000 CAUTION After 2 2001 the front re...

Page 533: ... bolts 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 subframe or body frame rails M10 bolt Aor B always replace Stage 1 59 Nm 43 ft lb Stage 2 torque angle 90 30 Copyright 2006 Robert Bentley Inc All rights reserved Fron...

Page 534: ...rame can be removed from below CAUTION Removal or replacement of the subframe may affect suspension and steering geometry including front wheel alignment Make appropriate matching marks during removal and have the front end aligned once repairs are complete Front subframe removing and installing rear wheel drive models Using engine support equipment raise engine until weight of engine is supported...

Page 535: ...xenon headlights Remove front ride level sensor mounting fastener arrow and lay sensor aside Remove right front control arm bracket bolts arrows from frame rail Repeat for left side Remove right inner control arm ball joint mounting nut arrow at subframe Drive ball joint shaft out of subframe using soft hammer Push control arm aside Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repai...

Page 536: ...on left side Support suspension subframe from below using appropriate jacking equipment Remove subframe mounting bolts arrows Remove subframe Note Right side is shown in photo Left is similar Installation is reverse of removal noting the following Make sure all bolts bolt holes Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 3 of 24 2 25 2009 10 26 PM ...

Page 537: ... mounting bolt See torque table 4 Control arm Tightening torques Control arm ball joint to subframe M14 self locking nut always replace 90 Nm 66 ft lb Control arm bushing carrier to body M10 bolt always replace 59 Nm 43 ft lb Front end reinforcement to front subframe or body frame rails M10 bolt always replace Stage 1 59 Nm 43 ft lb Stage 2 torque angle 90 30 Steering rack to subframe M10 bolt 42 ...

Page 538: ...RNING 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 Remove splash shield under engine compartment On cars equipped with xenon headlights Remove front ride level sensor mounting fastener arrow and lay sensor aside Front Suspension http ebahn bentleypublishers...

Page 539: ... of subframe detach power steering lines Remove stabilizer bar anchor fasteners arrows from front corners of subframe Suspend stabilizer bar from chassis using stiff wire Working at left rear corner of subframe remove control arm rear bracket mounting bolts arrows Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 6 of 24 2 25 2009 10 26 PM ...

Page 540: ...g arm ball joint This can damage the ball joint Working underneath subframe remove steering rack mounting bolts arrows Suspend rack with stiff wire Support subframe from below Remove subframe mounting bolts arrows Slowly lower subframe making sure heat shields wiring harnesses and other underbody components are clear during removal Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair...

Page 541: ... mounts before tightening engine mount fasteners When the job is completed have front end professionally aligned Tightening torques Control arm rear bracket to subframe M10 bolt always replace 59 Nm 44 ft lb Engine mount to subframe M10 self locking nut 45 Nm 33 ft lb Inner ball joint to control arm M14 self locking nut always replace 80 Nm 59 ft lb Inner ball joint mount to subframe M12 bolt 77 N...

Page 542: ... 9 bolt 105 Nm 77 ft lb Subframe rear to adapter M12 bolt always replace 110 Nm 81 ft lb All wheel drive front subframe 1 Front subframe 2 Blind rivet nut 3 Engine mounting flange 4 Steering rack mounting flange 5 Stabilizer bar mounting 6 Subframe to body adapter 7 Bolt M10 always replace tighten to 59 Nm 44 ft lb Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 9 of...

Page 543: ...me mounting bolt M12 see torque table 13 Control arm inner ball joint 14 Bolt M12 tighten to 77 Nm 57 ft lb 15 Self locking nut M14 always replace tighten to 80 Nm 59 ft lb Control Arms In all models each front control arm has three attachment points Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 10 of 24 2 25 2009 10 26 PM ...

Page 544: ...all wheel drive models the outer steering arm ball joint is pressed in Because of the aluminum construction of the control arm pressed in ball joints are not removable In case of pressed in ball joint wear or damage the complete control arm must be replaced 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 contr...

Page 545: ... chassis point Do not place jack stands under suspension parts Remove splash shield under engine compartment Remove front end reinforcement On cars equipped with xenon headlights 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 contro...

Page 546: ...l Remove control arm Inspect rear bracket rubber bushing for wear Check ball joints for damage looseness or torn boots Replace control arm if ball joints are damaged CAUTION If a control arm is deformed due to an accident inspect the inner ball joint mounting bore in the subframe for damage or eccentricity Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 13 of 24 2 25...

Page 547: ... checked after assembly nothing WARNING Do not reuse self locking nuts or bolts They are designed to be used only once and may fail if reused Tightening torques Control arm rear bracket to frame rails M10 bolt always replace 59 Nm 44 ft lb Front end reinforcement to front subframe or body frame rails M10 bolt always replace Stage 1 59 Nm 44 ft lb Stage 2 torque angle 90 30 Inner ball joint to subf...

Page 548: ...Place the jack stands beneath a structural chassis point Do not place jack stands under suspension parts Remove splash shield under engine compartment On cars equipped with xenon headlights 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 fr...

Page 549: ...ve control arm Inspect rear bracket rubber bushing for wear Check ball joints for damage looseness or torn boots Replace control arm if outer steering arm ball joint is damaged CAUTION If a control arm rear rubber bushing is damaged both bushings must be replaced Note Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 16 of 24 2 25 2009 10 26 PM ...

Page 550: ... locking nuts or bolts They are designed to be used only once and may fail if reused Tightening torques Control arm rear bracket to subframe M10 bolt always replace 59 Nm 44 ft lb Inner ball joint mount to subframe M12 bolt 77 Nm 57 ft lb Outer ball joint to steering arm M12 self locking nut always replace 65 Nm 48 ft lb Road wheel to hub 100 10 N 74 7 ft lb Inner ball joint replacing all wheel dr...

Page 551: ... subframe 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 Use new self locking nuts or bolts Tightening torques Inner ball joint mount to subframe M12 bolt 77 Nm 57 ft lb Front Sus...

Page 552: ...shing applications on E46 cars Control arm bushings should always be replaced in pairs The two bushings and bushing carriers should have the same markings indicating same manufacturer To gain access to bushing remove control arm as described earlier Use puller to remove rear bracket and bushing from control arm Inspect pin rubber bushing end of control arm Replace control arm with end A Note Contr...

Page 553: ...ine up marks on new bushing with boss on bracket Depending on manufacturer mark on bushing may consist of Extra buffer on inner part of bushing A Arrow on rubber webbing of bushing B Indent on outer casing of bushing C New bushing must be pressed in so that it protrudes the correct distance from edges of bracket See Table a Table a Control arm bushing Front Suspension http ebahn bentleypublishers ...

Page 554: ...shing to facilitate assembly Make sure dimension A distance from inner ball joint to edge of control arm bushing is correct after assembly See Table b Table b rear wheel drive models Bushing diameter or model Bushing distance A 60 mm 289 1 mm 11 38 0 04 in 66 mm 290 9 1 mm 11 45 0 04 in Be sure to reinstall bushing bracket to frame rail correctly with larger centering bores facing up toward body T...

Page 555: ... cars Control arm bushings should always be replaced in pairs The two bushings and bushing carriers should have the same markings indicating same manufacturer To gain access to bushing remove control arm as described earlier Use puller to remove rear bracket and bushing from control arm Use press tools to remove old bushing and press in new Align bushing with bracket as shown in accompanying illus...

Page 556: ...g tool when measuring installation distance Rubber bushing must be allowed to relax for measurement to be accurate Table c Control arm bracket installation distance all wheel drive models Measurement A 170 1 mm 6 69 0 04 in Bolt bracket and control arm to front subframe and steering arm immediately after pressing on bushing Be sure to reinstall bushing bracket to subframe correctly with larger cen...

Page 557: ...he lubricant used to slide on the bushing will have evaporated and the control arm will be correctly seated in the rubber Serious handling problems could result if these instructions are not carried out Copyright 2006 Robert Bentley Inc All rights reserved Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 24 of 24 2 25 2009 10 26 PM ...

Page 558: ...tands beneath a structural chassis point Do not place jack stands under suspension parts Remove stabilizer bar connecting link mounting nut arrow from stabilizer bar on right side Counterhold ball joint with flat wrench Rear wheel drive model shown Repeat on left side Remove stabilizer bar bushing anchor nuts arrows on right side Repeat on left side Remove bar Front Suspension http ebahn bentleypu...

Page 559: ...unterhold ball joints on link while tightening nut Installation of stabilizer bar is easiest with car level front wheels at the same height and as near to normal ride height as possible Tightening torques Stabilizer bar bushing brackets to subframe 22 Nm 16 ft lb Stabilizer bar link to stabilizer bar M10 self locking nut always replace 65 Nm 48 ft lb Stabilizer bar link to strut M10 self locking n...

Page 560: ...front wheel bearing is pressed into the steering arm The wheel hub is pressed into the bearing and the outer CV joint stub axle is pressed into the hub The ABS front pulse wheel in all wheel drive models is the inner ridged seal of the front wheel bearing Special press tools are required to replace the front wheel bearings Read the procedures through before beginning the job Front wheel bearing re...

Page 561: ...d to a torque of 290 Nm 214 ft lb Make sure the car is firmly on the ground Raise car and remove wheel Remove ABS wheel speed sensor arrow Remove brake caliper assembly and brake rotor as described in 340 Brakes Leave brake hose connected to caliper Suspend caliper assembly from chassis using stiff wire Remove wheel hub collar nut Remove wheel hub with integral wheel bearing from steering arm usin...

Page 562: ...l race off stub axle Install splash guard and new dust shield behind bearing Press new wheel hub bearing assembly on stub axle using BMW special tool 31 2 110 or equivalent CAUTION The BMW special tool insures that only the inner bearing race is used to press on the hub and bearing assembly The bearing is damaged if it is not pressed on using the inner race Install new collar nut Do not tighten nu...

Page 563: ...0 Nm 214 ft lb Raise car and remove wheel Stake axle nut and caulk threads of stub axle Install a new grease cap using Loctite 638 sealant or equivalent Install wheel and lower car Install ABS pulse sensor Tightening torques ABS pulse sensor to steering arm 8 Nm 71 in lb Front wheel bearing replacing all wheel drive models Removal and installation of the all wheel drive front wheel bearing is best...

Page 564: ...t arrow Remount wheel and lug bolts Lower car to ground With an assistant applying brakes loosen collar nut Do not remove completely CAUTION The wheel hub collar nut is tightened to a torque of 420 Nm 310 ft lb Make sure the car is firmly on the ground Raise car and remove front wheel Remove ABS wheel speed sensor arrow Remove brake caliper assembly and brake rotor as described in 340 Brakes Leave...

Page 565: ... Support steering arm from below Loosen pinch bolt arrow at top of steering arm Spread clamping collar at slot A if necessary to slide steering arm off strut assembly Working at bench clamp steering arm in a vise CAUTION Use a vise with aluminum jaws or protect steering arm from damage when clamping in vise Remove wheel hub with integral wheel bearing from steering arm using a slide hammer puller ...

Page 566: ... bearing Press in bearing using a press with appropriate adapters Note When installing the front wheel bearing into the steering arm be sure that the ridged bearing seal ABS impulse wheel is facing inboard Start the bevelled edge of the bearing into the bore first Coat bearing seat in steering arm over 50 of its length with Loctite 648 Make sure press fit surfaces are clean and free of grease Fron...

Page 567: ...e following Replace control arm bracket bolts Torque stub axle collar nut with vehicle on the ground Stake nut and caulk stub axle threads Have vehicle professionally aligned Tightening torques Ball joint to steering arm 65 Nm 48 ft lb Brake caliper to steering arm 110 Nm 81 ft lb Brake rotor to wheel hub 16 Nm 12 ft lb Collar nut to wheel hub 420 Nm 310 ft lb Control arm bracket to subframe 59 Nm...

Page 568: ...sing 81 Nm 60 ft lb Road wheel to hub 100 10 Nm 74 7 ft lb Tie rod to steering arm 65 Nm 48 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Front Suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 9 of 9 2 25 2009 10 26 PM ...

Page 569: ... groups 260 Driveshaft 270 Transfer Case 310 Front Suspension 340 Brakes Procedures involving the internal repairs of the front differential are not included in this manual Special tools BMW recommends special tools for the removal of the drive axles as well as the installation of the front differential input drive flange seal Commonly available pullers and drifts can often be substituted for the ...

Page 570: ...int 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 The front differential and the right side Front Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 2 of 5 2 25 2009 10 27 PM ...

Page 571: ...nt subframe 1 Front subframe 2 Right axle bearing pedestal 3 Sealing O ring 4 Oil pan 5 Bolt M12 always replace 8 8 grade tighten to 77 Nm 57 ft lb 10 9 grade tighten to 110 Nm 81 ft lb 12 9 grade tighten to 105 Nm 77 ft lb 6 Bolt M12 always replace tighten to 110 Nm 81 ft lb 7 Bolt M10 always replace tighten to 59 Nm 44 ft lb Front Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repai...

Page 572: ...ting bracket 11 Front differential 12 Front differential drain plug tighten to 65 Nm 48 ft lb 13 Bolt M10 tighten to 45 Nm 33 ft lb 14 Drive axle radial seal 15 Drive axle 16 Front differential fill plug tighten to 65 Nm 48 ft lb Front Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 4 of 5 2 25 2009 10 27 PM ...

Page 574: ...o move in and out to compensate for suspension travel To replace a CV joint or dust boot the drive axle must be removed from the car Drive axle removing and installing Note If removing the drive axle for service it is a good idea to replace the drive axle radial seal while the axle is removed from the vehicle Carefully remove center cap from wheel Break free staked collar nut arrow at steering arm...

Page 575: ... suspend from body using stiff wire On vehicles equipped with Xenon lighting detach headlight vertical aim sensor from control arm 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...

Page 576: ...destal Installation is reverse of removal noting the following Replace drive axle radial seal before replacing drive axle Before installing drive axle replace inboard CV joint spring clip arrow When pressing drive axle into front axle differential or bearing pedestal be sure to press axle beyond resistance of spring clip Spring clip must snap audibly into place Replace bolts holding control arm bu...

Page 577: ...t bracket to front axle subframe 77 Nm 57 ft lb Road wheel to hub 100 10 Nm 74 7 ft lb Stabilizer link to stabilizer bar 65 Nm 48 ft lb Drive axle radial seal replacing Note If only replacing drive axle radial seal the axle does not need to be completely removed from the vehicle Only the inboard CV joint needs to be removed from either the front axle differential or the right axle bearing pedestal...

Page 578: ...at rear of subframe remove control arm rear bracket mounting bolts 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 Note Be prepared to catch oil drips from differential or right side bearing pedestal Pry radial seal out of differential housing or bearing pedestal using a fla...

Page 579: ...eal and save for use during drive axle installation 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 Drive radial seal into differential or bearing pedestal Inser...

Page 580: ...or bearing pedestal Installation is reverse of removal noting the following Make sure inboard end of drive axle audibly snaps into place Replace control arm bracket bolts Top up differential fluid See Front differential oil checking and filling Tightening torques Inner ball joint bracket to front axle subframe 77 Nm 57 ft lb Brake caliper to steering arm 110 Nm 81 ft lb Control arm bracket to fron...

Page 581: ... drive axle Using a flat blade screw driver pry spring clip off drive axle splines Clean all old lubricant off axle splines Note To inspect a CV joint clean away grease and look for galling pitting and other signs of wear or physical damage Polished surfaces or visible ball tracks alone are not necessarily cause for replacement Discoloration due to overheating indicates lack of lubrication Place n...

Page 582: ...osition tightly sealing large end of boot against CV joint Note Before installing each small boot clamp be sure to burp boot by flexing CV joint as far over as it will go A small screw driver inserted between boot and axle shaft will help the process With outer CV boot full of grease and any air eliminated from boot secure small end of CV boot onto CV joint by securing clamp with pliers Installati...

Page 583: ...subframe 59 Nm 44 ft lb Drive flange collar nut to front hub 420 Nm 310 ft lb Inner CV joint boot replacing Note When replacing CV joint boots use complete boot repair kits 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 Release retain...

Page 584: ...ng clamp using clamp pliers tightly sealing small end of boot against drive axle Install triple roller bearing with flat edge of joint facing retaining circlip Replace inner CV joint housing shaft circlip Pack triple roller bearing and inner CV joint boot with fresh grease CV joint lubricant capacity Inner CV joint 85 gram 3 0 oz Insert triple roller bearing into inner CV joint housing Secure boot...

Page 585: ...op up differential fluid See Front differential oil checking and filling Tightening torques Ball joint bracket to front axle subframe 77 Nm 57 ft lb Brake caliper to steering arm 110 Nm 81 ft lb Control arm bracket to front axle subframe replace bolts 59 Nm 44 ft lb Drive flange collar nut to front hub 420 Nm 310 ft lb Inner CV joint assembly 1 Spring clip 2 Inner CV joint housing Front Axle Final...

Page 586: ...V joint boot adapter 6 Clamp 7 Inner CV joint boot 8 Drive axle shaft 9 Clamp Copyright 2006 Robert Bentley Inc All rights reserved Front Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 13 of 13 2 25 2009 10 27 PM ...

Page 587: ... the front differential Front differential drain plug and fill plug arrows Note Use an Allen bit socket to remove drain plug Alternatively cut approximately 30 mm 1 2 in from an Allen key and use a box end wrench on key stub Remove oil filler plug Note Differential fluid level is correct when fluid begins to spill from fill plug Fill differential with appropriate type and quantity of lubricant to ...

Page 588: ... disconnecting battery read battery disconnection cautions given at front of this manual on page viii Lift vehicle and support safely WARNING Make sure car is stable and well supported at all times Use a professional automotive lift or jack stands designed for purpose A floor jack is not adequate support Remove splash shield from below engine compartment Support engine using appropriate lifting de...

Page 589: ...ve front wheels Unbolt brake calipers and suspend from body using stiff wire See 340 Brakes Remove front driveshaft See 260 Driveshaft Remove left inner ball joint mounting bracket bolts arrows from subframe Repeat for right side Front Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 3 of 12 2 25 2009 10 28 PM ...

Page 590: ...re Repeat for right side Remove left ABS sensor arrow from steering arm Repeat for right side Unclip brake hoses and electrical harness wires from mounting brackets Swing control arms and steering arms out of the way Using BMW special tool 31 1 170 or equivalent pry bar pry inner CV joints out of front differential and bearing pedestal Front Axle Final Drive http ebahn bentleypublishers com BMW 3 ...

Page 591: ... lower steering column See 320 Steering and Wheel Alignment Remove stabilizer bar anchors from front subframe Working underneath car remove fluid line banjo bolts arrows from steering rack CAUTION Plug off power steering lines and connections to keep out contamination Remove front axle subframe and steering rack from frame rails See 310 Front Suspension Note Make sure heat shields wiring Front Axl...

Page 592: ...installed Assembly ring prevents damage when front axle differential is installed When front axle differential is installed 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 of differential before installing drive axles Top up differential fluid See Front differential oil check...

Page 593: ...14 banjo bolt 35 Nm 26 ft lb M16 banjo bolt 40 Nm 30 ft lb Inner ball joint to front suspension subframe 77 Nm 57 ft lb Stabilizer bar bushing brackets to subframe 22 Nm 16 ft lb Steering arm to lower ball joint 65 Nm 48 ft lb Steering arm clamping bolt at strut housing 81 Nm 60 ft lb Steering column to steering rack 22 Nm 16 ft lb Steering tie rod to steering arm 65 Nm 48 ft lb Subframe front to ...

Page 594: ...ssional automotive lift or jack stands designed for purpose A floor jack is not adequate support Remove right front wheel Release nut and remove tie rod end from right steering arm assembly Remove ABS sensor from steering arm Unclip brake hose from mounting bracket Unbolt brake caliper and suspend from body using stiff wire Remove inner ball joint mounting bracket bolts arrows from subframe Front ...

Page 595: ...ove grounding strap on bearing pedestal Remove four bolts retaining bearing pedestal to oil pan and remove pedestal Install new sealing ring coating inside edge with assembly lubricant Push assembly ring up to sealing ring Note Sealing and assembly rings between oil pan and differential must be replaced before differential is installed Assembly ring prevents damage when bearing pedestal is install...

Page 596: ... 33 ft lb Brake caliper to steering arm 110 Nm 81 ft lb Control arm bracket to front suspension subframe replace bolts 59 Nm 44 ft lb Inner ball joint to front suspension subframe 77 Nm 57 ft lb Steering arm to lower ball joint 65 Nm 48 ft lb Steering arm clamping bolt at strut housing 81 Nm 60 ft lb Steering tie rod to steering arm 65 Nm 48 ft lb Input flange radial seal replacing Lift vehicle an...

Page 597: ... 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 Using a seal puller or flat screwdriver pry radial seal out of differential housing Coat sealing edges of radial seal with transmission fluid and drive into differential housing using Front A...

Page 598: ...rque input flange retaining nut beyond matchmarks Over torquing can damage differential internals Do not replace input flange or input flange locking nut Installation is reverse of removal Tightening torque Input flange collar nut to differential until matchmarks align Copyright 2006 Robert Bentley Inc All rights reserved Front Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repair 20M...

Page 599: ...es including the ignition switch see 612 Switches Special tools Some special tools are necessary to carry out the repairs and adjustments required for steering service and wheel alignment Be sure to read the procedures through before starting work on the vehicle Inner tie rod removal tool BMW 32 2 110 Rear toe adjusting tool BMW 32 3 030 Steering and Wheel Alignment http ebahn bentleypublishers co...

Page 600: ... stability The power steering system varies assist based on engine speed Power assist is provided by a belt driven pump on the lower left front of the engine just below the alternator The steering rack is bolted to the front subframe underneath the engine The steering wheel connects to the rack via a telescoping column which incorporates a rubber coupling guibo to dampen vibration and noise The po...

Page 601: ...ersons unfamiliar with the BMW airbag system and its approved service procedures BMW specifies that all inspection and service should be performed by an authorized BMW dealer The BMW E46 is equipped with an airbag mounted in the steering wheel The airbag is an explosive device and should be treated with extreme caution Always follow the airbag removal procedure as outlined in 721 Airbag System SRS...

Page 602: ...installation or install new parts Do not attempt to weld or straighten any steering components Always replace damaged parts 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 Steering and Wheel Alignment ...

Page 603: ...21 Airbag System SRS Store airbag unit in a safe place WARNING Improper handling of the airbag could cause serious injury Store the airbag with the horn pad facing up If stored facing down accidental deployment could propel it violently into the air causing injury CAUTION Avoid damaging the variety of convenience switches such as radio and cruise controls installed in the steering wheel of some mo...

Page 604: ...Install steering column center bolt Do not over torque Tightening torque Steering wheel to steering shaft 63 Nm 46 ft lb Carefully install airbag See 721 Airbag System SRS Tightening torque Airbag to steering wheel 8 Nm 71 in lb Note The airbag in some models is attached to the steering wheel using spring clips instead of mounting screws Copyright 2006 Robert Bentley Inc All rights reserved Steeri...

Page 605: ...pper steering column 5 Lower steering column with universal joint 6 Torx bolt M8 x 33 tighten to 22 Nm 16 ft lb 7 Flexible joint guibo 8 Steering angle sensor 9 Steering angle sensor bracket 10 Column pivot bushing 11 Bolt M8 x 36 Steering and Wheel Alignment http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 1 of 8 2 25 2009 10 29 PM ...

Page 606: ...er 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 With ignition key in ON position 60 from LOCKED Insert a thin piece of stiff wire into opening arrow in lock cylinder and pull lock cylinder out Detach ring antenna harness connector Gently work ring antenna off key cylinder Steering and Wheel Al...

Page 607: ...el and remove ignition key Lift vehicle and support safely 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 Remove splash guard under engine Remove lower steering column flexible joint pinch bolt arrow Slide lower column up and pull flexible joint off steering rack sha...

Page 608: ...teering column to keyed upper steering column Align tab arrow on steering rack flange with lower steering column flexible joint Tightening torque Pinch bolts at steering columns joints 22 Nm 16 ft lb Upper steering column 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 upp...

Page 609: ...xible cover from upper trim Lift off trim Remove left footwell pedal cluster trim panel Remove screws A Remove fasteners B Disconnect electrical harness connectors at left footwell trim panel and remove panel Steering and Wheel Alignment http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 5 of 8 2 25 2009 10 29 PM ...

Page 610: ...vets arrows to release Pull down on trim Working at steering column Remove screws arrows Slide switch block out from steering column Disconnect electrical harness connectors at ignition switch wiper switch turn signal high beam switch and steering wheel functions airbag connector Remove switch block Slide lower section of upper steering column into upper section arrow Steering and Wheel Alignment ...

Page 611: ...ut steering column mounting shear bolt A and remove mounting bolt B Remove lower steering column mounting bolts arrows Remove upper steering column Installation is reverse of removal noting the following Replace shear bolt at steering column mounting bracket Tighten Steering and Wheel Alignment http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 7 of 8 2 25 2009 10 29 PM ...

Page 612: ...rim panel push expansion rivet pin into rivet until pin head is flush with rivet head Tightening torques Universal joint pinch bolt at steering column 22 Nm 16 ft lb Steering column to dashboard carrier 22 Nm 16 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Steering and Wheel Alignment http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 8 of 8 2 25 2009 10 29 PM ...

Page 613: ...r steering lines and connections to keep out contamination Power steering fluid Recommended fluid ATF automatic transmission fluid Power steering system 1 Power steering fluid reservoir 2 Fluid supply line 3 Power steering pump 4 Copper sealing ring 5 Banjo bolt M14 tighten to 35 Nm 26 ft lb Steering and Wheel Alignment http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 1 of 11 2 25 200...

Page 614: ...ighten to 65 Nm 48 ft lb 13 Outer tie rod end 14 Clamp ring 15 Outer tie rod end lock nut tighten to 45 Nm 33 ft lb 16 Inner tie rod tighten to 100 10 Nm 74 7 ft lb Power steering system bleeding and filling With engine off fill power steering Steering and Wheel Alignment http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 2 of 11 2 25 2009 10 29 PM ...

Page 615: ...emove splash shield from under engine Remove drive belt from power steering pump See 020 Maintenance 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 Remove power steering pump drive pulley Remove fluid hoses from pump Plug openings in pump and hose ends Rem...

Page 616: ...Use new sealing washers when reattaching power steering pressure lines Make sure hoses have adequate clearance from chassis Do not over torque banjo bolts Fill and bleed power steering system as described earlier Tightening torques Hydraulic hoses to power steering pump M14 banjo bolt 35 Nm 26 ft lb M16 banjo bolt 40 Nm 30 ft lb Power steering pump to bracket M8 self locking nuts 22 Nm 16 ft lb Po...

Page 617: ...reference to the tie rod will help approximate correct wheel alignment when new parts are installed Note correct placement of inner taper on locking ring Repeat for right side Loosen left outer tie rod end lock nut arrow Unscrew left tie rod end from steering rack by turning inner tie rod shaft CAUTION Grip end of rack boot to keep it from twisting as the tie rod shaft is unscrewed Repeat for righ...

Page 618: ...ack shaft Move steering wheel to straight ahead position and remove ignition key to lock steering On all wheel drive vehicles Support front subframe with a shop hoist or appropriate jack Detach subframe from engine and lower approx 20 mm in See 310 Front Suspension Remove steering rack mounting bolts arrows Remove steering rack from subframe by pulling it forward Installation is reverse of removal...

Page 619: ...ts Use tie rod measurement previously made measurement A to temporarily set toe Fill and bleed power steering system as described earlier Have car professionally aligned Tightening torques Outer tie rod end to steering arm replace self locking nut 65 Nm 48 ft lb Outer tie rod end lock nut 45 Nm 33 ft lb Steering column flexible joint to steering rack shaft 22 Nm 16 ft lb Steering rack to subframe ...

Page 620: ... stands under suspension parts 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 Note Accurate measurement of the tie rod end with reference to the tie rod will help approximate correct wheel alignment when new parts are installed Steering and...

Page 621: ...ble Use tie rod measurement A to set toe Have car professionally aligned Tightening torques Outer tie rod end to steering arm replace self locking nut 65 Nm 48 ft lb Outer tie rod end lock nut 45 Nm 33 ft lb Tie rod or rack boot replacing Raise front of car Remove splash shield from under engine WARNING Make sure the car is firmly supported on jack stands designed for the Steering and Wheel Alignm...

Page 622: ...ate correct wheel alignment when new parts are installed Note correct placement of inner taper on locking ring Cut rack boot band clamp and slide bellows back Inspect boot for any sign of damage 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 t...

Page 623: ...Replace self locking nuts Install outer tie rod end to new tie rod using reference measurement A recorded earlier Have car professionally aligned Tightening torques Outer tie rod end to steering arm 65 Nm 48 ft lb Outer tie rod end lock nut 45 Nm 33 ft lb Inner tie rod to steering rack 100 10 Nm 74 7 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Steering and Wheel Alignment http ebah...

Page 624: ...under the following conditions Correct wheels and tires are installed in good condition and are at the correct inflation pressures All steering and suspension parts and bushings are undamaged and show no signs of abnormal wear Wheel bearings are in good condition Ride height is in accordance with specifications See 300 Suspension Steering and Brakes General Car is in normal loaded position See Tab...

Page 625: ... Rough road suspension Toe angle total 0 14 8 Camber difference between left right max 30 track differential angle with 20 lock on inside wheel 20 20 1 34 30 20 20 53 30 43 20 1 34 30 8 20 1 34 30 Caster difference between left right max 30 with 10 wheel lock with 20 wheel lock 5 26 30 5 37 30 5 27 30 5 37 30 5 36 30 5 47 30 5 17 30 5 27 30 Front wheel displacement 0 15 Table b Rear wheel alignmen...

Page 626: ...e Front wheel camber adjustment can be made by driving out factory strut alignment pin 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 Upper strut mount to body 24 Nm 17 ft lb Front wheel toe Front wheel toe is adjusted at tie rod ends Loosen tie rod lock nut A Adjust tie ...

Page 627: ...45 Nm 33 ft lb Rear wheel camber Rear wheel camber is adjusted at outer end of rear lower control arm using camber adjusting bolt Make sure bolt remains between two alignment lugs arrows on end of control arm Check toe setting as described below Tightening torque Rear lower control arm to rear trailing arm 77 Nm 57 ft lb Rear wheel toe Loosen trailing arm bracket mounting bolts arrows Steering and...

Page 628: ... bracket Remove tool and tighten trailing arm bracket mounting bolts Tightening torque Rear trailing arm bracket to body 77 Nm 57 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Steering and Wheel Alignment http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 5 of 5 2 25 2009 10 29 PM ...

Page 629: ...g repair groups 310 Front Suspension 311 Front Axle Final Drive 331 Rear Axle Final Drive Alignment information can be found in 320 Steering and Wheel Alignment Special tools Special service tools are required for some of the work described in this repair group Most of these tools are specialized presses and pullers that might be replaced by standard pullers of various sizes Read the procedures th...

Page 630: ...ion description BMW uses an independent rear suspension consisting of an upper and a lower control arm and a trailing arm on each side The weight of the car is supported by coil springs There is a rear stabilizer bar attached to the upper control arms Gas pressure shock absorbers round out the rear Rear suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 2 of 3 2 25 2009 10 30...

Page 631: ...railing arm The trailing arms contain the wheel bearings for the rear drive hubs The rear brake calipers are bolted to the trailing arms E46 Rear suspension 1 Shock absorber 2 Differential housing 3 Rear subframe final drive carrier 4 Upper control arm 5 Trailing arm 6 Trailing arm bracket 7 Coil spring 8 Lower control arm 9 Stabilizer bar Copyright 2006 Robert Bentley Inc All rights reserved Rear...

Page 632: ...below using an adjustable jackstand Remove shock absorber lower mounting bolt arrow CAUTION The shock absorber prevents the drive axle from dropping too far Support the trailing arm before removing the lower shock absorber bolt to avoid damage to drive axle CV joints On Sedan or Coupe models Working in trunk pry out luggage compartment liner retaining clips Peel back liner to gain access to upper ...

Page 633: ...ew shock absorber 1 Self locking nut M10 tighten to 14 Nm 10 ft lb 2 Upper support plate 3 Top mount 4 Body seal 5 Lower support plate 6 Spacer ring 7 Rubber bump stop 8 Self locking nut M8 tighten to 24 Nm 17 ft lb Installation on car is reverse of removal noting the following Make sure all threaded bolts nuts and mating surfaces are clean Install shock absorber into shock tower using a new upper...

Page 634: ... Nm 74 ft lb Shock absorber to upper mount 14 Nm 10 ft lb Shock absorber upper mount to body M8 self locking nuts 28 Nm 21 ft lb Coil spring removing and installing Raise car and remove rear wheel Remove drive axle to final drive mounting bolts arrows Detach drive axle from final drive Suspend drive axle from chassis using stiff wire Remove fuel tank protective panel Detach stabilizer bar from rea...

Page 635: ...w Lower trailing arm slowly and carefully until the compressed coil spring is fully unloaded Remove spring If spring is to be reused Inspect spring for any surface damage or corrosion Inspect top and bottom spring seat rubber pads for signs of damage Replace any parts showing evidence of wear or damage Note In the rough road package the top spring seat pad is 14 5 mm 0 57 in thick Rear suspension ...

Page 636: ...bolt is between bolt head and shock absorber rubber Tighten lower shock absorber bolt to its final torque once car is on ground Remainder of installation is reverse of removal Tightening torques 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 replace 80 Nm 59 ft lb Road wheel to hub 100 10 Nm 74 7 ft lb Shock abs...

Page 637: ...Tightening torques position Copyright 2006 Robert Bentley Inc All rights reserved Rear suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 6 of 6 2 25 2009 10 30 PM ...

Page 638: ...m Bending or heating may weaken the original part If the suspension arm shows any signs of damage or excessive corrosion it must be replaced Note If a rear brake line is disconnected to remove a trailing arm the complete braking system must be bled as part of the reinstallation procedure Rear suspension arms assembly 1 Rear subframe 2 Upper control arm inner bolt self locking M12 nut tighten to 77...

Page 639: ...ng M12 nut tighten to 110 Nm 81 ft lb 7 Trailing arm front bolt self locking M12 nut tighten to 110 Nm 81 ft lb 8 Trailing arm front bracket 9 Bracket mounting bolt tighten to 77 Nm 57 ft lb 10 Drive axle 11 Lower control arm 12 Lower control arm plastic shield Rear suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 2 of 19 2 25 2009 10 30 PM ...

Page 640: ...uspension parts Remove drive axle as described in 331 Rear Axle Final Drive Right side Detach brake pad sensor connector at brake caliper Remove brake rotor and caliper as described in 340 Brakes Do not remove brake line from caliper Suspend caliper from body using stiff wire Remove parking brake cable from brake shoe expander See 340 Brakes Remove rear brake line bracket mounting bolt arrow Detac...

Page 641: ...nsor if applicable harnesses from control arm and lay aside Support trailing arm from below using an adjustable jackstand Remove shock absorber lower mounting bolt arrow Slowly lower suspension until coil spring can be safely removed Mark position arrows of lower control arm eccentric mounting bolt Rear suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 4 of 19 2 25 2009 10 3...

Page 642: ...ket from arm When reinstalling preload trailing arm front bracket bushing Install bolt A through bracket and arm and install nut finger tight Using 16 mm bar stock as shown in illustration align base of bracket so that it is parallel with center of wheel bearing bore on trailing arm Torque bracket bolt A Tightening torque Trailing arm to front bracket 110 Nm 81 ft lb Remainder of installation is r...

Page 643: ...m bushings installed A new wheel bearing will have to be installed Tightening torques Drive axle collar nut to drive flange M24 250 Nm 184 ft lb M27 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 replace 80 Nm 59 ft lb Road wheel to hub 100 10 Nm 74 7 ft lb Shock absorber to trailing arm car in ...

Page 644: ...k stands designed for the purpose Place the jack stands beneath a structural chassis point Do not place jack stands under suspension parts Remove coil spring as described earlier Remove stabilizer bar link bolts A at upper control arm Remove stabilizer bar anchor bolts B Carefully push stabilizer bar aside Note Do not twist stabilizer bar link bushing on end of bar See Rear Stabilizer Bar later in...

Page 645: ...me Installation is reverse of removal noting the following Insert mounting bolts in direction previously marked Always use new self locking nuts Have car professionally aligned when job is complete Tightening torques Drive axle collar nut to drive flange M24 250 Nm 184 ft lb M27 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 l...

Page 646: ...e rear wheel Support trailing arm from below using an adjustable jackstand Mark position arrows of lower control arm eccentric mounting bolt Remove lower control arm plastic shield Remove both lower control arm mounting bolts Note direction of bolt insertion Note For clearance reasons it may be necessary to unbolt the differential from the subframe and push it toward the rear of the car in order t...

Page 647: ...ar professionally aligned when job is complete Tightening torque Lower control arm to rear subframe M12 bolt 110 Nm 81 ft lb Lower control arm to trailing arm M12 eccentric bolt 110 Nm 81 ft lb Rear subframe In case of damage to the subframe or if a pressed in bushing is worn remove subframe Convertible models Remove rear body reinforcing brace Remove exhaust system See 180 Exhaust System Rear sus...

Page 648: ...eplace stud In case of damage to subframe mounting stud threads in body repair using Helicoil thread insert M12 x 1 5 x 18 Tightening torques Differential to subframe front bolt M12 110 Nm 81 ft lb Differential to subframe rear bolt M14 174 Nm 128 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 replace 80 N...

Page 649: ...rol arm to subframe M12 77 Nm 57 ft lb Rear subframe assembly 1 Rear subframe final drive carrier 2 M12 mounting stud tighten to 90 Nm 66 ft lb 3 Bushing 4 Bushing 5 M12 bolt with washer tighten to 110 Nm 81 ft lb 6 Rear suspension reinforcement 7 M12 self locking collar nut Rear suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 12 of 19 2 25 2009 10 30 PM ...

Page 650: ...12 Bushing 13 Stop washer 14 M12 reduced shaft bolt tighten to 77 Nm 57 ft lb 15 Heat shield 16 M6 self tapping screw Rear suspension bushings When replacing any bushing in a rear suspension component be sure to measure and record orientation and protrusion of old bushing from its boss Rear suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 13 of 19 2 25 2009 10 30 PM ...

Page 651: ...racket on body to facilitate resetting of rear toe Using appropriate press tools Press bushing out of trailing arm Clean all grease from eye of trailing arm Draw new bushing into trailing arm Line up slot in bushing with mark A on eye of trailing arm Fully pressed in cylindrical bushing must protrude from trailing arm eye by measurement B 2 5 mm 0 1 in Have car professionally aligned when job is c...

Page 652: ...detaching lower control arm from trailing arm be sure to mark position of eccentric mounting bolt to facilitate resetting of rear camber Note direction of bolt insertion To replace bushing Measure and record protrusion A of old bushing from trailing arm boss Press old bushing out and install new bushing using protrusion A as a reference Have car professionally aligned when job is complete Tighteni...

Page 653: ...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 Upper control arm to trailing arm M12 bolt 110 Nm 81 ft lb Upper control arm inner bushing Remove upper control arm as described earlier Press old bushing out using appropriate press tools Press new bushing starting at inner bevelled end arrow of contro...

Page 654: ...1 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 replace 80 Nm 59 ft lb 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 Upper control arm to trailing arm M12 bolt 110 Nm 81 ft lb R...

Page 655: ... Coat new bushing with Circolight or equivalent rubber bonding agent Bushing position and orientation Right front bushing has elongated hole arrow Orient all bushings with triangular arrow heads pointing front aft on car Have car professionally aligned when job is complete Tightening torque Drive axle collar nut to drive flange M24 250 Nm 184 ft lb M27 300 Nm 221 ft lb Drive axle to final drive fl...

Page 656: ...k absorber to trailing arm car in normal loaded position 100 Nm 74 ft lb Subframe to body M12 77 Nm 57 ft lb Upper control arm to rear subframe M12 bolt 77 Nm 57 ft lb Upper control arm to trailing arm M12 bolt 110 Nm 81 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Rear suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 19 of 19 2 25 2009 10 30 PM ...

Page 657: ...f locking nut 11 M8 Stabilizer link When installing new stabilizer link Clean rubber seating surface at end of stabilizer bar Moisten end of bar and inside rubber mount in link end with Circolight or equivalent rubber bonding agent Push bar into rubber mount and position as shown in illustration Once rubber bond has set stabilizer link can no longer be rotated Copyright 2006 Robert Bentley Inc All...

Page 658: ...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 Right side Detach brake pad sensor connector at brake caliper Remove brake caliper assembly and rotor as described in 340 Brakes Leave brake hose connected to caliper Suspend caliper assembly from chassis...

Page 659: ... separate inner bearing race from drive flange Remove bearing retaining circlip from bearing housing in trailing arm Using appropriate bearing extraction tools BMW special tools 33 3 261 262 263 or equivalent pull bearing assembly out of trailing arm bearing housing Inspect bearing housing for any damage or contamination Clean housing bore thoroughly before installing new bearing Rear suspension h...

Page 660: ...eated in its groove Always use a new retaining circlip Draw drive flange into bearing using appropriate press tools 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 Install brak...

Page 661: ... 184 ft lb M27 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 replace 80 Nm 59 ft lb Road wheel to hub 100 10 Nm 74 7 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Rear suspension http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 4 of 4 2 25 2009 10 31 PM ...

Page 662: ... not covered in this manual Special tools BMW recommends some special tools for the removal of the drive axles as well as the installation of rear differential input and output drive flange seals 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 Rear Axle Final Drive http ebahn...

Page 663: ... drift BMW 33 3 400 Input flange seal drift BMW 33 3 430 Copyright 2006 Robert Bentley Inc All rights reserved Rear Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 2 of 2 2 25 2009 10 32 PM ...

Page 664: ...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 The shorter of the two shafts is located on the left side the longer shaft on the right Rear drive axle removing and installing With an assistant applying brakes break free staked collar nut arrow at center of rear wheel...

Page 665: ...on left axle Detach rear of exhaust system and tilt down Support rear muffler securely Remove drive axle to differential mounting bolts arrows Detach drive axle from drive flange Suspend drive axle from chassis using stiff wire Press drive axle from wheel bearing housing using an appropriate puller Installation is reverse of removal Apply a light coating of oil to contact face of collar nut and in...

Page 666: ...nut to drive flange M24 250 Nm 184 ft lb M27 300 Nm 221 ft lb 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 Road wheel to hub 100 10 Nm 74 7 ft lb Rear drive axle assembly Rear Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 3 of 7 2 25 2009 10 32 PM ...

Page 667: ... it is necessary to remove the inner joint and boot first If the CV joints are worn or defective a complete rebuilt axle shaft is available from an authorized BMW dealer parts department Working with axle shaft at bench cut off old boot clamps and remove boots Clean old grease off joints and shafts Use new grease from CV joint boot kit Ball cage CV joint boot Lift off dust cover from inner CV join...

Page 668: ...original positions Note To inspect a CV joint clean away the grease and look for galling pitting and other signs of wear or physical damage Polished surfaces or visible ball tracks alone are not necessarily cause for replacement Discoloration due to overheating indicates lack of lubrication Apply Loctite 270 or an equivalent heavy duty locking compound to drive axle splines Position new CV joint o...

Page 669: ...sure to burp the boot by flexing the 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 Differential end 85 gram 3 0 oz Use sealing gel to seal dust cover to CV joint prior to reinstallation ...

Page 670: ... boot clamp Make sure sealing lip of joint and boot are free of grease The boot could otherwise slide off when boot clamp is tightened Slip sleeve joint boot lengths Inner boot 65 mm 2 6 in Outer boot 55 mm 2 2 in Note On the differential end CV joint position large boot clamp so that crimp in clamp faces rivet on CV joint flange Install large clamps of inner and outer CV joints so that the crimps...

Page 671: ...ng 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 Note Use a 14 mm Allen socket to remove the fill or drain plug Alternatively cut approximately 30 mm 1 2 in from an Allen key and use a box end wrench on the key stub If necessary fi...

Page 672: ...lug 70 Nm 52 ft lb Rear differential removing and installing Raise rear end of car and support it securely on jack stands 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 Remove rear drive axles If necessary drain differential oil Remove rear suspension...

Page 673: ...nge and suspend See 260 Driveshaft CAUTION Suspend the detached drive axle from the car body with a stiff wire hook to prevent damage to the outer CV joint Remove rear stabilizer bar Support differential with transmission jack Remove rear A and front B mounting bolts at subframe Slowly lower differential unit and remove toward rear Installation is reverse of removal In order to prevent excess vibr...

Page 674: ...0 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 Driveshaft to differential flange M10 compression nut 64 Nm 47 ft lb M10 Torx bolt 85 Nm 63 ft lb Rear suspension reinforcement to undercarriage M12 self locking nut 77 Nm 57 ft lb M8 bolt 8 8 grade 21 Nm 15 ft lb M8 bolt 10 9 grade 30 Nm 22 ft lb Be sure to refill differential Re...

Page 675: ... subframe Working at subframe use bushing press tools to remove old bushings and install new ones Carefully note installation marks arrows on new bushings 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 Rear Axle Final Dr...

Page 676: ...cing seals Output drive flange oil seal replacing Raise car and support safely 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 If working on left side Detach rear of exhaust system and tilt down Support rear muffler securely Detach stabilizer bar from ...

Page 677: ...l 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 Dip new seal in differential lubricant and drive into place until fully seated Replace locking circlip arrow on output flange Install flange by pressing it in by hand until snap ring engages It may be necessary to turn flange slightly while pushi...

Page 678: ...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 Support exhaust system securely Remove driveshaft from differential input shaft flange See 260 Driveshaft Tie end of driveshaft to Rear Axle ...

Page 679: ...t seal puller CAUTION Be careful not to mar the differential housing when removing the seal Dip new seal in differential lubricant and drive it into position Lightly lubricate input shaft and press input flange back on Install collar nut and slowly tighten until matching marks line up Install a new lock plate and refill differential with lubricant CAUTION If the flange collar nut is tightened past...

Page 680: ...der of assembly is reverse of disassembly Tightening torques Driveshaft to differential flange M10 compression nut 64 Nm 47 ft lb M10 Torx bolt 85 Nm 63 ft lb Differential drain or fill plug 70 Nm 52 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Rear Axle Final Drive http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 5 of 5 2 25 2009 10 33 PM ...

Page 681: ...ons are covered in 300 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 Pedal prop Brake caliper piston tool BMW 34 1 050 Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 1 of 9 2 25 20...

Page 682: ... vented front and rear rotors A brake pad wear sensor for each axle indicates when brake pads need replacement The dual drum type parking brake system is integrated with the rear brake rotors Electronic braking and stability control E46 models were introduced with Automatic Stability Control ASC ASC is a computer controlled traction control system that uses the ABS system in Brakes http ebahn bent...

Page 683: ...braking and stability control systems For ABS system and component descriptions see 300 Suspension Steering and Brakes General WARNING A car with electronic stability control is still subject to normal physical laws Avoid excessive speeds for the road conditions encountered Table a E46 Electronic braking and stability control systems Year model System manufacturer Identifiers ASC 1999 2000 Automat...

Page 684: ...ressure Condition of friction components Air in the brake fluid will make the brake pedal feel spongy during braking or will increase the brake pedal force required to stop Fluid contaminated by moisture or dirt can corrode the system Inspect the brake fluid inside the reservoir If it is dirty or murky or is more then two years old the fluid should be replaced Visually check the hydraulic system s...

Page 685: ... vacuum Switch engine off Press brake pedal to set partial vacuum of no more than 0 8 bar 11 6 psi Wait for vacuum value to stabilize When pedal is released partial vacuum should not drop by more then 0 06 bar 0 8 psi over 1 hour If vacuum values are not reached Check connections of vacuum hoses Replace vacuum non return valve B Check seal between brake booster and master cylinder If values still ...

Page 686: ... corrective actions 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 these cars must not be bled without the use of a factory diagnostic computer Semi metallic and metallic brake friction materials in brak...

Page 687: ...rking brake shoes or brake parts Check component installation Check replace anti rattle springs Brake pad carriers dirty or corroded Remove brake pads and clean calipers Brake pads heat glazed or oil soaked Replace brake pads Clean rotors Replace leaking calipers as required Wheel bearings worn noise most pronounced when turning Replace worn bearings See 310 Front Suspension or 330 Rear Suspension...

Page 688: ...Warped brake rotors Resurface or replace rotors Brake pads worn Replace brake pads Brake pads heat glazed or oil soaked Replace brake pads Clean rotors Replace leaking calipers Uneven braking car pulls to one side rear brakes lock Incorrect tire pressures or worn tires Inspect tire condition Check and correct tire pressures Brake pads on one side of car heat glazed or fluid soaked Replace brake pa...

Page 690: ... 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 When bleeding the brakes start at the wheel farthest from the master cylinder and progress in the following order right...

Page 691: ... reservoir Attach bleed hose and fluid receptacle to bleeder screw arrow Open bleeder screw Allow DIS bleeding procedure to cycle hydraulic control module valves with bleed screw open After bleeding procedure is completed slowly depress brake pedal 12 times on ABS ASC vehicles 5 times on ABS DSC vehicles with bleeder screw open holding pedal down on the last pump When escaping fluid is free of air...

Page 692: ...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 Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 3 of 3 2 25 2009 10 34 PM ...

Page 693: ...ious page and the detail notes below during replacement procedures WARNING Although semi metallic and metallic brake friction materials in brake pads or shoes no longer contain asbestos they produce dangerous dust Treat all brake dust as a hazardous material Do not create dust by grinding sanding or cleaning brake friction surfaces with compressed air Brake pads calipers and rotors assembly 1 Brak...

Page 694: ...nsor 4 Brake pad anti rattle clip See Brake pad anti rattle clip 5 Brake pads Replacement warning at 3 0 mm 0 11 in See Brake pads 6 Front brake rotor retaining screw Torque to 16 Nm 12 ft lb 7 Front brake rotor Make sure contact surfaces are clean Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 2 of 9 2 25 2009 10 34 PM ...

Page 695: ...clean and free from grease Parking brake drum dia 160 mm 6 3 in See Rear brake rotor For brake rotor specifications see Table c and Table d 10 Parking brake shoes with hardware Min lining thickness 1 5 mm 0 06 in 11 Rear brake dust shield 12 Brake pad carrier Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 3 of 9 2 25 2009 10 34 PM ...

Page 696: ...e Caliper removal Remove plastic caps from caliper mounting bolts and remove caliper mounting bolts arrows Remove caliper from pad carrier Brake caliper hydraulic line only needs to be removed when replacing brake caliper with a new unit If removing brake caliper to service brake pads or rotors leave hydraulic line connected If there is a ridge on rotor edge Brakes http ebahn bentleypublishers com...

Page 697: ...e caliper hang from brake hose Suspend it from chassis using stiff wire Inspect brake caliper for signs of leakage Check that caliper piston slides smoothly into caliper Replace caliper if any faults are found Thoroughly clean all contact points on caliper and brake pad carrier Clean guide bolts and make sure they slide freely Do not lubricate guide bolts Bleed brake system if hydraulic line to ca...

Page 698: ...cator light illuminated prior to brake pad replacement replace wear sensor Route pad wear sensor wiring through caliper opening and bleeder dust cap Brake pad anti rattle clip Remove anti rattle clip by unhooking at top and bottom Use screwdriver as an aid arrow Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 6 of 9 2 25 2009 10 34 PM ...

Page 699: ... if thickness is 3 0 mm 0 12 in or less Brake rotor removal Remove brake rotor mounting screw arrow Inspect rotor for cracksm signs of overheating and scoring On original equipment rotors the minimum allowable thickness is stamped on rotor hub Measure rotor braking surface with a micrometer at eight to ten different points and use the smallest measurement recorded Table c If rotor does not pass mi...

Page 700: ...stamped on rotor shell and identified with MIN TH Table d Brake rotor sizes Model Front brake rotor Rear brake rotor 323 i Ci 286 x 22 mm 11 3 x 0 9 in 276 x 19 mm 10 8 x 0 7 in 325 i Ci xi 328 i Ci 300 x 22 mm 11 8 x 0 9 in 294 x 19 mm 11 6 x 0 7 in 330 i Ci xi 325 x 25 mm 12 8 x 1 0 in 320 x 22 mm 12 6 x 0 9 in Brake rotors should always be replaced in pairs Clean rotor with brake cleaner Brakes...

Page 701: ...d carrier removal Remove brake pad carrier mounting bolts arrows and remove pad carrier from steering arm or trailing arm Tightening torques Pad carrier to front steering arm 110 Nm 81 ft lb Pad carrier to rear trailing arm 65 Nm 48 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 9 of 9 2 25 2009 10 34 PM ...

Page 702: ...zed BMW repair facility This procedure is necessary for the braking and stability controls to function properly Master cylinder removing and installing 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...

Page 703: ...s Working at brake master cylinder Disconnect brake fluid level sensor connector A from fluid reservoir Disconnect hydraulic clutch system supply line B if applicable Plug open brake fluid ducts to prevent fluid leakage or contamination CAUTION Keep clutch supply line supported and above clutch master cylinder to prevent any air bubbles from reaching the clutch hydraulic system If DSC precharge pu...

Page 704: ...s if replacing master cylinder Unscrew mounting nuts and remove master cylinder from brake booster Plug open brake lines to prevent contamination Make sure all nuts fluid couplings thread bores and mating surfaces are clean Mount master cylinder to brake booster using a new O ring and new self locking nuts Tightening torque Brake master cylinder to brake booster 26 Nm 19 ft lb CAUTION Be sure to a...

Page 705: ...in flexible brake lines between master cylinder and hydraulic unit Carefully reinstall fluid reservoir using new sealing grommets Reconnect supply hose of brake system precharge pump to brake fluid reservoir if applicable Connect hydraulic clutch hose to brake fluid reservoir if applicable Remainder of installation is reverse of removal Bleed entire brake system as described earlier Copyright 2006...

Page 706: ...TION 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 safety reasons the brake system on cars with electronic stability control must be bled using the procedures described in this repair group Do not mix up the f...

Page 707: ...angerous to the environment Dispose of it properly Remove brake master cylinder as described earlier Make sure to plug openings at brake fluid lines Disconnect engine vacuum hose from brake booster Remove hydraulic unit or precharge pump below master cylinder as described later in this repair group Working in interior remove left footwell pedal cluster trim panel Remove screws A Remove fasteners B...

Page 708: ...partment carefully separate brake booster from engine compartment bulkhead CAUTION Do not use force on booster when separating from bulkhead This can damage booster and pushrod Remove booster by tilting brake booster out in direction of engine Lift booster up and out from engine compartment Installation is reverse of removal noting the following Make sure all nuts fluid couplings thread bores and ...

Page 709: ...e master cylinder to brake booster 26 Nm 19 ft lb Brake booster to bulkhead 22 Nm 16 ft lb Brake fluid line to master cylinder or hydraulic unit 18 Nm 13 ft lb Note When replacing the brake booster one way valve or vacuum hose install the valve so that the molded arrow is pointing toward the intake manifold Use new hose clamps Copyright 2006 Robert Bentley Inc All rights reserved Brakes http ebahn...

Page 710: ...ssive stroke of parking brake handle required for actuation more then 10 notches Replacement of adjustment unit or parking brake cables Parking brake shoes adjusting Lift parking brake lever boot out of console While holding cables stationary loosen parking brake cable nuts A until cables are completely slack Raise rear of car WARNING Make sure the car is firmly supported on jack stands designed f...

Page 711: ...k adjuster off Repeat procedure on other rear wheel Parking brake adjusting initial Back off adjuster through wheel lug bolt hole 10 notches Working inside car set parking brake several times to seat cable Then pull parking brake lever up two notches Tighten cable adjusting nuts until it is just possible to turn rear wheels with slight resistance Release lever and make sure rear wheels turn freely...

Page 712: ... from trailing arms Remove rear brake rotors See Brake Pads Calipers and Rotors CAUTION Do not let the brake caliper assembly hang from the brake hose Support caliper from chassis with strong wire 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...

Page 713: ...he complete exhaust system and lower the exhaust system heat shield to access the front end of the parking brake cable housing Working inside car gain access to base of parking brake handle by removing center console storage tray and center armrest as necessary 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 Ra...

Page 714: ...g bolt from rear wheel Turn wheel until lug bolt hole is approx 20 below horizontal to access end of parking brake cable Disconnect cable from parking brake actuator Push free parking brake handle end of cable into housing to create slack inside brake drum Poke thin screwdriver through lug bolt hole and pry end of parking brake cable downward arrow Brakes http ebahn bentleypublishers com BMW 3 E46...

Page 715: ... end of cable snaps audibly into holder inside brake drum Reroute new cable under car attaching to brackets arrows Remainder of installation is reverse of removal noting the following Adjust parking brake as described earlier Copyright 2006 Robert Bentley Inc All rights reserved Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 6 of 6 2 25 2009 10 35 PM ...

Page 716: ...ing 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 This manual will refer to these systems as ABS ASC or DSC will be specified when necessary For ABS system and component descriptions see 300 Suspension Steering and Brakes General Wheel speed sensor replacing CAUTION Magnetoresistive...

Page 717: ...at steering arm arrow Rear sensor Remove sensor from its bore arrow in the rear trailing arm Note ABS wheel speed sensor application may vary depending on traction control system installed Disconnect and remove impulse sensor electrical harness arrow from retaining mounts Left front wheel shown During installation apply thin coat Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3...

Page 718: ...odels Impulse wheel is integral with front wheel bearing hub All wheel drive models Impulse wheel is integral with inner seal of front wheel bearing See 310 Front Suspension for front wheel bearing replacement procedure Note When installing the front wheel bearing on an all wheel drive car be sure that the ridged bearing seal ABS impulse wheel is facing inboard Rear impulse wheel All models Impuls...

Page 719: ...er the driver s seat in front of the left seat rail See DSC rotational rate yaw sensor replacing CAUTION After replacing the lateral accleration sensor perform sensor adjustment using either DiS or MoDiC under menu Service Functions Remove footwell trim on left side A pillar Fold foot trim panel and insulating mat to one side Disconnect electrical harness connector Remove mounting screw and nut Re...

Page 720: ...ole Move insulation forward to gain access to sensor Remove sensor bracket mounting screws Disconnect electrical harness connector at sensor Remove sensor to bracket mounting screws Lift sensor away from bracket Installation is reverse of removal CAUTION Be sure to tighten rotational rate sensor and mounting bracket to specified torques The sensor is vibration sensitive and subject to cause DSC ma...

Page 721: ...ce calibrated the sensor sends a confirmation ID code to the DSC control module to indicate proper calibration For steering column removal see 320 Steering and Wheel Alignment DSC pressure sensor Rear wheel drive cars Two DSC pressure sensors are used mounted in the brake master cylinder All wheel drive cars One DSC pressure sensor is used mounted on the hydraulic unit Tightening torques Pressure ...

Page 722: ...ting work perform the function test on control module using either DIS or MoDiC The procedure for removing the ABS ASC or ABS DSC hydraulic unit control module is similar for all models The location of the units varies On vehicles with hydraulic unit mounted beneath master cylinder remove master cylinder as described earlier Disconnect electrical harness connector at hydraulic unit control module ...

Page 723: ... to bend or kink brake lines while separating rubber grommet from retainer Remove mounting screws of hydraulic unit housing and remove hydraulic unit control module from engine bay If necessary separate hydraulic unit from control module Installation is reverse of removal noting the following Check rubber mount for hydraulic unit control module Replace if damaged Make sure all nuts fluid couplings...

Page 724: ...6 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 on cars with ABS must be bled using the procedures described in this repair group Note Before starting this procedure read any fault codes from control module memory and print out the diagnostic record Th...

Page 725: ...g Remove side trim panel from left rear of engine compartment Remove rubber strip A from top of trim panel at brake booster Remove vacuum line and positive battery cable with grommets B from trim panel Release locking clips C on edges of trim panel and remove panel by pulling upwards Working at precharge pump beneath brake master cylinder Remove brake fluid feed line arrow from brake fluid reservo...

Page 726: ... noting the following Be sure to replace rubber pump mounts if damaged or worn When installing vacuum hose and battery cable at trim panel make sure isolating grommets are securely seated Bleed brakes as described earlier Copyright 2006 Robert Bentley Inc All rights reserved Brakes http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 3 11 of 11 2 25 2009 10 35 PM ...

Page 727: ...ons 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 Body General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 1 of 1 2 25 2009 10 37 PM ...

Page 728: ...e 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 E46 Sedan E46 Sport Wagon Body General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 1 of 8 2 25 2009 10 37 PM ...

Page 729: ...E46 convertible E46 Coupe Body General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 2 of 8 2 25 2009 10 37 PM ...

Page 730: ...ng torsional rigidity For good handling purposes the more rigid the structure the more precisely the suspension can operate High strength steels now account for 50 of the body shell weight The body shell s resistance to twisting forces has been almost doubled over the previous 3 series models To help insure long lasting strength 85 of the body in surface area is made of galvanized steel This resis...

Page 731: ...f cooling air into the engine compartment provide a good coefficient of drag Cd E46 cars have been designed for balanced aerodynamics but not necessarily an extremely low Cd A low coefficient of lift Cl promotes stability at high speeds The current design has a front Cl of 0 08 and a rear Cl of 0 10 Windshield wipers are designed for effectiveness at speeds up to and beyond 200 kph 124 mph Body wi...

Page 732: ...mpers and hydraulic dampeners are designed This helps avoid expensive damage to the body at impact speeds up to 14 kph 9 mph Coupe models The E46 Coupe is similar to the 4 door Sedan but has a more stretched and sleeker appearance Thus with the same wheelbase and identical length it looks different but still familiar The 2 door Coupe differs from the 4 door 2 wheel drive Sedan by a longer front en...

Page 733: ... to the rear undercarriage Note The aluminum reinforcement plate is used in all rear wheel drive E46 models produced from December 2000 Transverse seat support reinforcements in the floor pan accommodates the new seat integrated seat belts SGS The windshield frame is reinforced with stepped reinforcing tubes which allow it to act as roll over protection The windshield is bonded into its frame Ther...

Page 734: ...echanisms can be found 541 Convertible Top Sport Wagon Introduced in 2000 the E46 Sport Wagon is identical to the E46 Sedan from the front bumper to the B pillar middle door post From the B pillar back the Sport Wagon features Remodelled rear doors Tail gate and hinge mechanism Rear tail gate window that flips up to open independent from the tailgate held open by compact torsional coil springs New...

Page 735: ...t Rear seat backrest folded down 1345 liters 47 5 cu ft Load capacity In cargo compartment 540 Kg 1191 lb On roof 75 Kg 165 lb Copyright 2006 Robert Bentley Inc All rights reserved Body General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 8 of 8 2 25 2009 10 37 PM ...

Page 736: ...ced with a diagonal aluminum bar with a metal hook at the rear edge Upon severe side impact the hook locks into a recessed notch in the B or C pillar thus providing unitized protection against buckling of the door The body side holds together as a unit offering significantly greater strength After most impacts the door springs back and unhooks from the notch It can then be opened again Door locks ...

Page 737: ...s Seat belts In the Sedan Coupe and Sport Wagon models each front seat belt assembly has a height adjustable anchor at the B pillar An automatic pyrotechnic explosive charge tensioner tightens the front belt at the buckle upon impact snugging up lap and shoulder segments of the belt The tensioners are designed to automatically tension the belts by about 2 inches 55 mm in the event of a collision A...

Page 738: ...f the Sedan and Sport Wagon models protecting passengers against side impacts Coupe and Convertible models are equipped with door installed airbags as well Head Protection System HPS airbags stretch diagonally across the tops of the front doors Airbag deployment automatically triggers fuel shut off turns on the hazard and interior lights and unlocks the doors WARNING Airbags are inflated by an exp...

Page 739: ...e controlled by the Multiple Restraint System MRS II control module Security Electronic immobilization EWS 3 3 All E46 vehicles incorporate an electronic immobilization system known as EWS 3 3 This system uses a wireless communication link between a transponder chip in the ignition key and the ring antenna surrounding the ignition switch The EWS control module blocks the starting of the vehicle un...

Page 740: ...detector is installed in the center of the headliner of Sedan Coupe and Sport Wagon models The DWA alarm is triggered if motion is detected inside the car Short distance radar SDR is the interior motion detector system used in Convertible models The SDR emitter is located on the driveshaft tunnel under the center console next to the parking brake For further information about anti theft systems se...

Page 741: ... are reading lights at four seating positions Noise reduction To reduce interior noise certain body cavities are sealed with shaped parts installed during the manufacturing process The body is heated to approx 180 C 356 F and kept at that temperature for approx 20 minutes during which interval the shaped parts expand to fit the shapes of the cavities Seats Anatomically correct seats are constructe...

Page 742: ...at control switches are along the outside edge of the seat Heated seats are an option in all models In cars equipped with seat position memory three different seat configurations can be memorized by the seat control module s Seat memory coordinates with outside mirror memory In Convertible models When a rear passenger presses the seat back switch forward the comfort entry aid system moves the seat...

Page 743: ... been arranged ergonomically and are fully integrated into the overall design of the vehicle The following features are optional in some models Tilt telescopic steering wheel has 30 mm 1 2 in of vertical and longitudinal adjustment Multi function steering wheel contains two key pads containing controls for the sound system telephone and cruise control Padded dashboard houses the instrument cluster...

Page 744: ... optional system which uses ultra sonic sensors in the rear bumper trim to warn the driver of approaching too close to obstacles when parking Central Body Electronics ZKE V E46 cars are equipped with a sophisticated centralized body electric electronics plan Central Body Electronics ZKE V is self diagnostic and incorporates many functions into a single control module The consolidation of several s...

Page 745: ...l Other functions not directly controlled by ZKE V but interconnected Rain sensor AIC Sunroof operation See 540 Sunroof Seat memory See 520 Seats Outside rear view mirror control and heating Windshield washer jet heating ZKE V Diagnostic Trouble Codes DTCs are accessible electronically through the data link connector DLC See 610 Electrical Component Locations Body General http ebahn bentleypublish...

Page 746: ...cluster under a cover Heating and air conditioning IHKA The integrated heating and air conditioning IHKA system uses an extra large infinitely variable radial blower motor for good distribution of air Fresh air enters through the grille below the engine hood and into the passenger compartment via the dashboard and footwell vents Repair information for the heating and air conditioning system is cov...

Page 747: ...behind the rear seat Storage There are extra storage compartments on the left and right sides in the rear These house the rear window washer fluid reservoir and sound system components Power socket A 12 volt power socket is in the left side of the cargo area behind the rear seat backrest Copyright 2006 Robert Bentley Inc All rights reserved Body General http ebahn bentleypublishers com BMW 3 E46 R...

Page 748: ...tal Paint all exposed metal once the work is complete Special tools Most body repairs can be performed using regular automotive service tools Some BMW special tools are required to set body pieces into the service positions Service position hood props BMW 51 2 160 Copyright 2006 Robert Bentley Inc All rights reserved Fenders Engine Hood http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4...

Page 749: ...table and does not shift or tilt As the car is raised the car may roll slightly and the jack may shift Remove front wheel Remove inner plastic liner from wheel housing Remove front turn signal lens assembly from applicable front corner Carefully pry out side directional from fender and disconnect See 630 Lights Remove body colored trim panel underneath headlight assembly Working at cowl feed corne...

Page 750: ...ching 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 Fenders Engine Hood http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 2 of 3 2 25 2009 10 39 PM ...

Page 751: ...loosely install all mounting bolts Align fender with door pillar and inner fender then tighten bolts Repair any paint damage and paint any exposed metal Reseal and apply protective coating to mounting surfaces Clearance specification Fender to front hood or to door 4 25 0 75 mm 0 167 0 03 in Copyright 2006 Robert Bentley Inc All rights reserved Fenders Engine Hood http ebahn bentleypublishers com ...

Page 752: ...Open hood fully With the help of a partner support hood and remove retaining clips 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 Raise hood Disconnect washer fluid hose A from washer nozzles Where applicable disc...

Page 753: ...amage and paint any exposed metal Check hood alignment as described next Note The hood was fitted and attached to an unfinished body at the factory Unfinished surfaces exposed by this procedure must be touched up with paint Hood aligning When installing the hood align the hinges as close to the original painted surface as possible Movement of the hood on its attaching hardware may require touch up...

Page 754: ...oosen lower hinge bolts arrows and reposition as necessary Plastic coating on top of hinge stop screw must not be damaged or missing Stop disk for front of hood arrow is eccentric and is marked 0 10 Initial setting is with the 0 setting forward for Fenders Engine Hood http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 3 of 6 2 25 2009 10 40 PM ...

Page 755: ...right locks Loosen hood spring pin bolts A and retaining hook bolts B at hood on left and right sides only enough to allow movement Turn rubber stop buffers over headlights inwards to provide clearance Lower but do not fully latch hood several times so pins on hood center themselves in lower locks CAUTION Do not let hood lock with latch bolts loose Tighten hood spring pin bolts and latch bolts whe...

Page 756: ...es not spring open lengthen spring pins To lengthen spring pin loosen locknut arrow with wrench inserted through spring then turn pin counterclockwise Hood latch components assembly 1 Hood hinge 2 Hood release lever 3 Torx bolt 4 Bowden cable main 5 Hex bolt 6 Gas pressurized strut 7 Ball pin Fenders Engine Hood http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 5 of 6 2 25 2009 10 40 P...

Page 757: ...cer 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 Fenders Engine Hood http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 6 of 6 2 25 2009 10 40 PM ...

Page 758: ...BMW 328 2000 2 5L L6 M52 Logout Welcome tethoma gmail com http ebahn bentleypublishers com header jsp 1 of 1 2 25 2009 10 40 PM ...

Page 759: ...rior front door trim panels rear door trim panels of Sedans and Sport Wagons and rear trim panels of Coupes and Convertibles For information on the power door windows and door glass replacement see 512 Door Windows For information on the power door locking system see 515 Central Locking and Anti theft Subscription Status FAQs Contact Us Help Copyright 2008 All http ebahn bentleypublishers com main...

Page 760: ...irbag system Front or rear door removing and installing If working on a door with side impact airbag disconnect negative battery cable CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Remove harness connector mounting bolt arrow at door pillar Pull up on locking clip and separate connector Doors http ebahn bentleypubl...

Page 761: ... body surfaces Make sure no load is placed on wiring harness Installation is reverse of removal Keep in mind the following On 4 door models mount and align rear doors first followed by the front doors Align door so that panel gaps are equal on either side as described later If necessary adjust door hinges as described later Doors http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 2 of 6...

Page 762: ... 512 Door Windows must be carried out after installation to prevent damaging the glass Door adjustment Front fender to front door gap approx 4 25 mm 0 25 mm 0 17 0 01 in Front door to rear door gap approx 4 5 mm 0 25 mm 0 18 0 01 in Rear door to rear fender approx 4 0 mm 0 25 mm 0 16 0 01 in Permissible deviation from parallel 1 0 mm 0 04 in Tightening torque Door hinge to door 20 Nm 15 ft lb Door...

Page 763: ... CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Remove interior door panel as described later Where applicable remove side impact airbag from door See 721 Airbag System SRS Remove door vapor barrier Remove door check mounting bolt arrow Remove rubber cover A and bolts B from door check lockplate on door Remove door ...

Page 764: ...or out of parallel shims can be used to correct its position The shims are placed behind the hinge plate and are available in two different thicknesses 0 5 mm and 1 0 mm 1 Door 2 Protective cap 3 Spacer plate 4 Hex bolt 5 Lower door hinge 6 Hex nut with plate 7 Door check gasket 8 Torx bolt with washer 9 Door check 10 Torx bolt 11 Upper door hinge Front and rear doors are similar Doors http ebahn ...

Page 765: ...Tightening torques Door hinge to door 20 Nm 15 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Doors http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 6 of 6 2 25 2009 10 40 PM ...

Page 766: ...ns and procedures relating to the airbag system Door trim panel removing and installing Disconnect negative battery cable CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Gently pry off door panel trim strip Carefully pry out mirror adjustment switch and disconnect harness connector from switch Doors http ebahn bentle...

Page 767: ...ing 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 Doors http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 2 of 6 2 25 2009 10 41 PM ...

Page 768: ...he following Replace any damaged plastic parts or clips Renew vapor barrier if it is damaged Use new mounting bolts when reinstalling side impact airbag to door When installing door panel align metal retainers on window sill with openings on top of door panel Check door lock mechanism and window for ease of movement Doors http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 3 of 6 2 25 20...

Page 769: ... armrest Remove panel mounting screws Gently pry off panel using trim tool Disconnect electrical harness connectors as necessary Remove side panel by lifting up and toward interior Installation is reverse of removal Replace any damaged plastic parts or clips Rear side trim panels removing and installing Convertible model Remove rear seat cushion Remove rear backrest side section See 520 Seats Lowe...

Page 770: ...p upwards from weather stripping Unhook spring from linkage at convertible top Remove retaining screws from lower edge of upper panel Gently pull weather stripping from rear edge of upper panel as necessary Pry up on upper panel and remove Remove lower side trim panel Gently pry lower side trim panel from body Make sure to feed lower front corner of side trim panel out from door threshold trim Doo...

Page 771: ...n is reverse of removal Make sure to replace any broken trim clips Copyright 2006 Robert Bentley Inc All rights reserved Doors http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 6 of 6 2 25 2009 10 41 PM ...

Page 772: ...t hold the trunk lid or tailgate in the open position Note The body is painted at the factory after assembly Realignment of body panels may expose unpainted metal Paint all exposed metal once the work is complete Copyright 2006 Robert Bentley Inc All rights reserved Trunk Lid Tailgate http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 1 of 1 2 25 2009 10 41 PM ...

Page 773: ...k liner Disconnect electrical harness connectors from components and remove wiring harness from trunk lid While supporting trunk lid loosen top hinge screws arrows and remove lower screws from left and right sides Note Before loosening hinge bolts mark hinge and hinge bolt locations for reinstallation Installation is reverse of removal If necessary align trunk lid to body as described next Trunk L...

Page 774: ...and replace if necessary Remove protective caps at trunk lower trim panel and loosen screws of trunk lock until it can be moved Check stop screw at trunk lid hinge If stop screw has a round plastic head cut or grind off bolt head If head is removed replace round headed stop screw with flat head Trunk Lid Tailgate http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 2 of 6 2 25 2009 10 41 ...

Page 775: ...k lid arrows until trunk lid is just able to move If range of adjustment is insufficient loosen lower bolts on trunk hinge Once trunk lid gap is within specification tighten trunk hinge to lid bolts Trunk lid gap specification Trunk lid gap at rear fender 4 25 0 75 mm 0 17 0 03 in CAUTION Before closing truck lid be sure that trunk lid and body are not damaged Trunk Lid Tailgate http ebahn bentley...

Page 776: ...nel Check adjustment of trunk lid and lock repeat adjustment process if necessary Screw in trunk lid detent buffers until left and right sides of lid rest on buffers with trunk lid closed CAUTION Top surface of trunk lid must not protrude above top lip of fenders or height adjustment can be distorted Gently twist detent buffer ejector clockwise with screwdriver to unlock buffer and release ejector...

Page 777: ... if necessary CAUTION Excessive force should not be needed to close trunk lid Set gap measurements as listed below Trunk position gap adjustment Trunk lid trunk panel A 5 1 5 mm 0 2 0 06 in Trunk lid rear fender B 4 25 0 75 mm 0 17 0 03 in Trunk lid support strut removing and installing WARNING Make sure to support trunk lid before removing strut Open trunk lid and support in open position Remove ...

Page 778: ...lation is reverse of removal Replace retaining clips damaged during removal Copyright 2006 Robert Bentley Inc All rights reserved Trunk Lid Tailgate http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 6 of 6 2 25 2009 10 41 PM ...

Page 779: ...istance to properly support both sides prior to removal of the hinge bolts Installation is the reverse of removal Follow alignment procedures as shown below Tightening torques Tailgate to tailgate hinge M8 20 Nm 15 ft lb Tailgate emergency release The tailgate of the E46 Sport Wagon has no key cylinder An emergency release mechanism is incorporated into the tailgate latch This allows mechanical op...

Page 780: ... clips arrow on upper end of pressurized lifting struts CAUTION The tailgate is very heavy and will close without both pressurized lifting struts installed Properly support tailgate prior to removal of the lifting struts Pull struts off tailgate Remove spring retainer from lower end of support strut and remove strut Installation is reverse of removal Replace retaining clips if damaged during remov...

Page 781: ...own in place Installation is the reverse of removal Replace any waterproofing sheeting disturbed during removal Adjust spoiler as shown later in this section Rear window removing and installing Remove rear spoiler as detailed above Working at top outside of window remove waterproofing sheeting over antenna amplifier and disconnect wiring connections Release tape retaining wiring harnesses Release ...

Page 782: ...oofing sheeting where disturbed Align window as described below Tightening torques Hatchback window to hinge M8 16 Nm 12 ft lb Alignment of spoiler rear window and tailgate Alignment procedures involve adjusting tailgate window and spoiler to have equal space between left and right sides and to be flush with body Measurement locations and specific dimensions are shown If alignment has been disturb...

Page 783: ...tical alignment is adjusted using hinge bolts for window and tailgate Fine adjustment of the tailgate to the body is made using rubber stop buffers and latch assembly Tailgate and rear window position gap adjustment Rear spoiler side panel A 3 75 1 3 mm 0 15 0 05 in Rear window side panel B 3 5 1 4 mm 0 14 0 06 in Tailgate side panel C 3 6 0 75 mm 0 14 0 03 in Tailgate side panel height D flush to...

Page 784: ...cation gap on left and right When gap is correct tighten screws To prevent damage or poor operation adjustments must be made to the rear window f the vertical adjustment of the tailgate is changed Window hinge must be parallel to the tailgate hinge Stop buffers arrows are adjustable and set height between tailgate and body at sides To adjust buffers remove inner trim panel and loosen lock nut Init...

Page 785: ... must not touch lock housing Tighten striker mounting bolts then check tailgate to body gaps as shown below Note Do not lubricate lock or lock striker with grease Inspect plastic guides arrows on lock assembly for damage or wear and replace if necessary Trim panel is removed for clarity The rear window lock striker height is adjusted by loosening lock nut A then turning striker in or out Trunk Lid...

Page 786: ...unting 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 Copyright 2006 Robert Bentley Inc All rights reserved Trunk Lid Tailgate http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 4 8 of 8 2 25 2009 10 41 PM ...

Page 787: ...or the outside rear view mirror front and rear bumpers and the easily removable exterior trim parts Copyright 2006 Robert Bentley Inc All rights reserved Exterior Trim Bumpers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 1 of 1 2 25 2009 10 43 PM ...

Page 788: ...pe wrapped screwdriver between bottom mirror edge and mirror housing and carefully pry out mirror glass from housing Prying mirror glass out of mirror housing Note screwdriver shaft wrapped with tape Heated mirror remove heating element harness connectors from back of mirror glass Install new glass into position by pressing firmly until it snaps into place Outside mirror housing removing and insta...

Page 789: ...d by either three or four clips depending on model Installation is reverse of removal Check mirror function before installing covering parts Outside mirror removing and installing Remove front door panel trim See 411 Doors Working at door hinge remove door inner trim panel retaining pins arrows Exterior Trim Bumpers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of 4 2 25 2009 10 ...

Page 790: ...pped Remove inner door panel trim On sedan models trim strip extends around window to door latch area Support mirror and speaker if equipped and remove mounting bolts arrows Lift speaker and mirror off door and feed out cable Installation is reverse of removal Exterior Trim Bumpers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 3 of 4 2 25 2009 10 43 PM ...

Page 791: ...g covering parts Tightening torque Outside mirror to door M6 6 Nm 4 5 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Exterior Trim Bumpers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 4 of 4 2 25 2009 10 43 PM ...

Page 792: ...bolt tighten to 41 Nm 30 ft lb 6 Protective rubber strip 7 License plate bracket 8 Tow eye cover 9 Bumper cover 10 Carrier bumper 11 Grill 12 ASA bolt tighten to 41 Nm 30 ft lb 13 Mounting sleeve Exterior Trim Bumpers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 1 of 8 2 25 2009 10 44 PM ...

Page 793: ...eft and right side corner trim then remove trim Remove bumper cover retaining screws arrows Remove screws arrows retaining bumper bar to impact absorbers on left and right sides Slide bumper assembly out a few inches and disconnect the following connections if applicable Electrical harness connectors at fog light assemblies Electrical harness connector at signal horn Electrical harness connectors ...

Page 794: ...ecessary See Bumper height adjusting Tightening torque Bumper to impact absorber M10 41 Nm 30 ft lb Front bumper impact absorber replacing The bumper mounting bracket and impact absorber mounting hardware are accessible with the front bumper removed as described above Front bumper impact absorber mounting nuts A and drill out pop rivets B Note Install the bumper bracket bolt with thread locking co...

Page 795: ...rip 8 Bumper cover 9 Lower part cover 10 Tow eye cover 11 ASA bolt tighten to 41 Nm 30 ft lb 12 Bumper bracket bolt tighten to 41 Nm 30 ft lb Rear bumper removing and installing Raise and properly support vehicle Exterior Trim Bumpers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 4 of 8 2 25 2009 10 44 PM ...

Page 796: ... rear of left and right rear wheel wells Remove expansion pin from lower rear wheel well 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 Installation is reverse of removal Note Ex...

Page 797: ...uggage compartment floor covering Remove battery and battery tray on right side and trunk trim panel on left side Remove trim caps arrow at rear of frame rails Release nuts on inside on vehicle trunk and remove absorber Installation is reverse of removal Replace body seal and protective cap if necessary Make sure to check bumper height See Exterior Trim Bumpers http ebahn bentleypublishers com BMW...

Page 798: ...port 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 Front bumper Remove bumper as described earlier Remove bumper bracket bolt Rear bumper Remove lower bumper panel as described in Rear bumper removing and installing Remove bumper bracket moun...

Page 799: ...d check bumper height Refit front bumper Tightening torques Front bumper to bumper bracket M8 nut 22 Nm 16 ft lb Front bumper bracket to impact absorber M10 bolt 55 Nm 41 ft lb Rear bumper bracket to impact absorber M10 bolt 42 Nm 31 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Exterior Trim Bumpers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 8 of 8 2 25 2009 10 44...

Page 800: ...Protect hood paint by covering area around emblem with tape Carefully pry out emblem Pry up emblem carefully on either side arrows Note tape on screwdriver tips Installation is reverse of removal Replace plastic inserts in body if damaged If emblem fits loosely use a small amount of body molding tape or adhesive on rear of emblem before installing Body side molding replacing To remove body side mo...

Page 801: ... hood lever on driver s side grill Once grill is removed pry remaining tabs B to separate inner grill from chrome trim ring Before installation assemble chrome trim ring and grill insert securely Replace components if tabs or catches are broken or missing To install align grill and trim ring in appropriate location in hood Press on trim ring until grill snaps into place Exterior Trim Bumpers http ...

Page 802: ...e 611 Wipers and Washers Unclip inner tab at radiator support Press pane downward out of retaining brackets Feed out retaining hook at fender Installation is reverse of removal Copyright 2006 Robert Bentley Inc All rights reserved Exterior Trim Bumpers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 3 of 3 2 25 2009 10 44 PM ...

Page 803: ...cement is covered in 612 Switches The windshield rear window fixed rear door glass and cargo compartment glass Sport Wagon only are bonded using special adhesives and tools It is recommended that bonded glass replacement be done by an authorized BMW service facility or an automotive glass installer Special tools Some window repair operations require the use of special tools 2 door window adjustmen...

Page 804: ...sitive finger guard The window switch is pulled up to raise the window and pushed down to lower 4 door models Each rear door has a single window switch located in the door handle trim The rear window switches can be deactivated by pressing the child lock out switch in the center console Convenience closing opening of the windows from the driver s lock cylinder or convenience opening only from the ...

Page 805: ...r until 16 minutes has elapsed The GM V bases window motor end position on current draw load There is a maximum window motor run time of 8 seconds The motor is then switched off even if the end position load sensor fails Power window electronics GM V Sedan and Sport Wagon Door Windows http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 3 of 8 2 25 2009 10 44 PM ...

Page 806: ...ovides an additional ground signal on the second wire requesting one touch mode The GM V lowers the window automatically until it reaches the end position The switch functions in the same manner for window closing but the ground signal sequence is reversed Note In Coupe models the rear windows switches are used for operating the rear swing out vent windows Electric window switch replacement is cov...

Page 807: ...e window motor control circuit consists of two wires for operating the motor in both directions The motors are activated by relays in the GM V The relays provide either power or ground depending on the direction of window travel The GM V controls the polarity based on a request to run the window from a window switch or a convenience opening closing signal Convenience opening closing The GM V provi...

Page 808: ...sor finger guard has a resistance of 3 K and it is monitored for open circuit When pressed the monitored resistance changes to 1K If anti trap protection becomes faulty the one touch window closing will not function Window anti trap protection is only active in the one touch and convenience close modes of operation If the window switch is pulled and held anti trap protection will not function Wind...

Page 809: ...plied with window anti trap protection Therefore only the driver s window allows one touch closing When the convertible top is opened the power windows are lowered for approx 1 5 seconds to ensure clearance for the top Once the top is stored in the storage compartment the windows will close again if the top switch is held in the open position WARNING Always wear hand and eye protection when workin...

Page 810: ...ways be disconnected to prevent pinching fingers in the moving window mechanism Copyright 2006 Robert Bentley Inc All rights reserved Door Windows http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 8 of 8 2 25 2009 10 44 PM ...

Page 811: ...ble See 721 Airbag System SRS for cautions and procedures relating to the airbag system Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Window anti trap strip testing To test function of anti trap strip on any window With key ON and window down pull up window switch to second detent thus activating one touch close operation ...

Page 812: ...anel and vapor barrier as described in 411 Doors Detach window frame molding strip and peel toward inside of vehicle Separate anti trap electrical harness connector arrow at top front of door Note Wire colors for anti trap strip are black white If replacing molding with new one transfer mounting clips and foam insulation as necessary Door Windows http ebahn bentleypublishers com BMW 3 E46 Repair 2...

Page 813: ...arrows Do not tear strip in area A Detach electrical harness connector at top front of door just below window Note Wire colors for anti trap strip are black white After installation recheck anti trap protection Front door window adjusting 4 door models Whenever the front window or window regulator is removed window adjustment should be checked The glass should contact the top of the window squarel...

Page 814: ...read the battery disconnection cautions given at the front of this manual on page viii Partially detach rear of vapor barrier sound insulation from door and fold forward Hold in place using adhesive tape Loosen window guide rail mounting nuts arrows but do not remove Reconnect battery Open window fully Tighten guide rail nuts Tightening torque Window regulator guide rail to door 9 Nm 80 in lb Fron...

Page 815: ...ach battery Move window to approx 140 mm 5 5 in from bottom Remove window retaining screws insets at window regulator rails WARNING Once the window is positioned correctly disconnect harness connector from power window motor to prevent accidental operation of the window Detach plastic window retainers from glass Push expander nut 1 out of plastic retainer Squeeze retainer tabs 2 and remove from gl...

Page 816: ... torque Side impact airbag to door 8 5 Nm 75 in lb Window to regulator guide 8 Nm 71 in lb Rear door window removing and installing 4 door models Remove rear door panel and vapor barrier See 411 Doors In model with rear side impact airbag Disconnect negative cable from battery Then remove airbag unit from door See 721 Airbag System SRS Detach window from window regulator rail If applicable reattac...

Page 817: ...r 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 Installation is reverse of removal Replace plastic window retainer once glass is inside door If applicable use new mounting bolts when reinstalling side impact airbag to door Rear window does not ne...

Page 818: ...ct airbag to door 8 5 Nm 75 in lb Window to regulator guide 8 Nm 71 in lb Copyright 2006 Robert Bentley Inc All rights reserved Door Windows http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 8 of 8 2 25 2009 10 45 PM ...

Page 819: ...battery cable See 721 Airbag System SRS for cautions and procedures relating to the airbag system Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Front door window adjusting 2 door models The close with door shut feature of 2 door cars with frameless windows makes window adjustment critical CAUTION There is risk of window gl...

Page 820: ... feature insures low wind noise and water leakage past windows With the door closed the window must jam a predetermined amount up into the seal When the door is opened the window must lower immediately to clear the seal With door open close window To simulate closed door use screwdriver or finger to push door lock rotary latch in direction of arrow Window must rise to its full closed position Door...

Page 821: ...riangle in A pillar Use door handle to open rotary latch Window should lower a small amount Close door Window should raise a small amount Reopen door Window should lower a small amount and clear rubber seal If window gets stuck in rubber seal Lower glass Adjust retraction depth as described later Longitudinal adjustment Door Windows http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 3 o...

Page 822: ... 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 Coupe models When fully closed rear edge of window must protrude by distance A from edge Door Windows http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 4 of 13 2 25 2009 10 45 PM ...

Page 823: ...to side window trim Gap A is measured from edge of door window to rear of side window seal Window longitudinal adjustment Door window rear edge to side window seal Convertible 25 mm 1 in Tighten longitudinal adjustment screws Tightening torque Window to guide 8 Nm 71 in lb Pretension Note Window pretension can also be thought of as the inward rake of the window Door Windows http ebahn bentleypubli...

Page 824: ...ow adjustment Torx screw A 180 counterclockwise Turn slider adjustment nut B until it is hard to move Continue loosening window adjustment Torx screw and tightening slider adjustment nut see previous step until correct window rake is reached Tighten window adjustment screw Tightening torque Window to guide 8 Nm 71 in lb Vertical adjustments Note Door Windows http ebahn bentleypublishers com BMW 3 ...

Page 825: ...epth 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 line arrows 3 4 mm 0 12 0 16 in Window protrusion When all the way down measure door window glass protrusion above top edge of door Window protrusion Door window above top of door max 2 mm 0 08 in To adjust Lower door glass Doo...

Page 826: ...ling 2 door models Remove interior door panel See 411 Doors Disconnect negative cable from battery Then remove airbag unit and vapor barrier from door See 721 Airbag System SRS WARNING Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Detach door corner rubber seal mounting clips arrows Remove seal by pulling up in direction o...

Page 827: ...orarily reconnect battery cable WARNING Once the window is lowered disconnect harness connector from power window motor to prevent accidental operation of the window Remove window mounting screws from window regulator rails Note Window mounting screws have left hand thread Door Windows http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 9 of 13 2 25 2009 10 45 PM ...

Page 828: ...al Install window rear mounting screw with adjusting sleeve through guide rail and threaded sleeve in glass Note Window mounting screws have left hand thread Use new mounting bolts when reinstalling side impact airbag to door Adjust window as described earlier Tightening torque Side impact airbag to door 8 5 Nm 75 in lb Window to guide 8 Nm 71 in lb Rear vent window or vent latch Coupe models Door...

Page 829: ...es remove B pillar door pillar trim When reinstalling make sure window seals completely Note gap clearances below Vent window clearances Front trim strip to rear edge of front window up to 6 mm 0 24 in Rear of window to water drain up to 1 8 mm 0 07 in Top of window to water drain 1 mm 0 04 in Tightening torques Vent window to body M6 nut 6 2 Nm 55 in lb Rear side window Convertible Door Windows h...

Page 830: ...w adjusting Convertible models The Convertible rear side window shares a version of close with door shut feature of the front window It retracts slightly when the top is raised or lowered then rises to seal against the folding top once the top is locked in place The procedure for setting Convertible rear side window adjustment while similar in principle to front window adjustment also depends on c...

Page 831: ...djustment screws To set side window depth in relation to door window D rear interior side trim panel must be removed to access adjustment screws Convertible rear side window adjustments A 23 25 mm 0 9 1 0 in B Window must run into convertible top seal when top is closed With top open glass must rest firmly against window seal C With convertible top open window must be centered in channel D up to 1...

Page 832: ...or to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Window regulator motor Note Because window operation is electronically controlled a window motor does not have mechanical end positions For this reason it can be removed and installed with the window in any position and does not need reinitialization To remove motor Remove inner d...

Page 833: ...ot travelled fully downward Manipulate spring loaded window control cable C to engage motor teeth to regulator gears Window regulators and motors 4 door models assembly 1 Front window motor 2 Front window regulator 3 Rear window motor 4 Rear window regulator Door Windows http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of 6 2 25 2009 10 45 PM ...

Page 834: ...ble and remove side impact air bag if applicable See 721 Airbag System SRS 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 See 721 Airbag System SRS for cautions and procedures relating to the airbag system Pr...

Page 835: ...hrough opening in bottom of door checking for any wiring harnesses that might become snagged during removal Installation is reverse of removal Be sure to route wiring harnesses to keep them away from moving window mechanism Use new wire ties as necessary Adjust front window as described earlier Tightening torques Window motor to regulator 5 Nm 4 ft lb Window regulator to door 9 Nm 7 ft lb Window t...

Page 836: ...rrectly disconnect harness connector from power window motor to prevent accidental operation of the mechanism Detach window regulator from door 1 Window motor 2 Front window rail 3 Window regulator mechanism 4 Rear window rail Disconnect electrical harness connector to power window motor Remove regulator mounting nuts Remove window regulator through opening in bottom of door checking for any wirin...

Page 837: ...ss See Front door window removing and installing 2 door models Tighten upper nut of front rail Lower window glass fully Tighten front rail lower nuts Adjust window See Front door window adjusting 2 door models Tightening torques Window motor to regulator 5 Nm 4 ft lb Window regulator to door 9 Nm 7 ft lb Window to guide 8 Nm 71 in lb Copyright 2006 Robert Bentley Inc All rights reserved Door Windo...

Page 838: ...or door panels 612 Switches 620 Instruments 640 Heating and Air Conditioning IHKA control panel 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 Interior Trim http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 1 of 3 2 25 2009 10 46 PM ...

Page 839: ... SRS WARNING Special precautions must be observed when servicing the BMW Supplemental Restraint System SRS Serious injury may result if system service is attempted by persons unfamiliar with the BMW SRS and its approved service procedures BMW specifies that all inspection and service should be performed by an authorized BMW dealer Before performing any work involving airbags disconnect the negativ...

Page 840: ...sconnection cautions given at the front of this manual on page viii To prevent marring the trim when working on interior components work with plastic prying tools or wrap the tips of screwdrivers and pliers with tape before prying out switches or electrical accessories Copyright 2006 Robert Bentley Inc All rights reserved Interior Trim http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 ...

Page 841: ... ashtray down Depress cover fully to pop ashtray out of console Remove ashtray Remove retaining screws and bracket Remove ashtray cover and housing Disconnect electrical harness connector for ashtray courtesy light Remove screws at base of ashtray compartment in console Unclip trim boot for parking brake lever and pull boot and handle forward off brake lever Gently pry up boot or trim at transmiss...

Page 842: ...connector press catch A and slide lock B forward Disconnect antenna connection On vehicles with center armrest Tilt armrest upright Lift parking brake lever upwards Feed center console panel out over armrest and brake lever Installation is reverse of removal Make sure to securely fasten all electrical harness connectors during reassembly Copyright 2006 Robert Bentley Inc All rights reserved Interi...

Page 843: ...dow control switches Dashboard removal is a complex operation Read the procedures through before starting work Dashboard assembly 1 Dashboard 2 Passenger knee protector 3 Reinforcement 4 Damper piston 5 Glove compartment 6 Glove compartment door 7 Latch 8 Right top footwell trim panel 9 Storage compartment 10 Glove compartment door strap Interior Trim http ebahn bentleypublishers com BMW 3 E46 Rep...

Page 844: ...ight cover 18 Footwell light socket 19 Left knee protector Glove compartment and right footwell trim panel removing and installing Open glove compartment door Snap out glove compartment light fixture and detach electrical harness connector To detach glove compartment Pull out retaining pin arrow for Interior Trim http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of 10 2 25 2009 10 46...

Page 845: ...rrows If necessary release mounting pin A at right side of housing Pull glove compartment housing down Note Detach glove compartment electrical harness from guides while removing housing Remove right footwell trim panel arrow by pulling backward to detach from mounting points Note Detach electrical harness connector s from panel while removing Interior Trim http ebahn bentleypublishers com BMW 3 E...

Page 846: ...s of upper trim cover arrow 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 See Steering column trim removing and installing To remove steering column lower trim drive pins into expansion rivets arrows Interior Trim http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 ...

Page 847: ...et must be rotated 90 to remove If equipped detach electrical harness connectors from footwell light and warning chime Release OBD II socket from panel and pull out 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 chime C Interior...

Page 848: ...oard trim CAUTION To avoid marring interior trim work with a plastic prying tool Note Left side shown Center and right trim are similar To remove center trim right trim must be removed first Remove steering wheel See 320 Steering and Wheel Alignment Remove left footwell trim panel as described earlier Remove upper and lower steering column trim Detach steering column stalk switch electrical connec...

Page 849: ...f switch carrier and detach electrical harness connectors to window switches Remove glove compartment as described earlier To remove storage compartment below IHKA control panel Open compartment door Push upward on tabs arrows then pull out Remove A pillar windshield pillar trim on left and right sides by prying out finishing strip CAUTION The Head Protection Airbag is behind the A pillar Do not u...

Page 850: ...anel opening and disconnect solar sensor harness connector Remove radio See 650 Radio Remove front passenger airbag See 721 Airbag System SRS Remove glove compartment as described earlier Remove right footwell trim panel arrow by pulling backward to detach from mounting points Note Detach electrical harness connector s from panel while removing Remove dashboard mounting screw or expansion rivet ar...

Page 851: ...ully Push seats fully back Lift instrument panel off carefully making sure all harness connectors and wiring are disconnected Remove through passenger door When installing fit dashboard guide pin into locator slot at base of windshield in center Install center console with dashboard mounting nuts loose Align and center parts before Interior Trim http ebahn bentleypublishers com BMW 3 E46 Repair 20...

Page 853: ... be diagnosed using the BMW service tester DIS or MoDiC or equivalent An advanced diagnostic scan tool can usually pinpoint electrical faults quickly and safely Consult an authorized BMW dealer Note Additional general electrical information can be found in 610 Electrical Component Locations and Electrical Wiring Diagrams Special tools A few special tools may be necessary for repairs in this sectio...

Page 855: ...e automatic locking feature can activates the door lock actuators when a road speed signal of 2 5 MPH is detected via the K Bus The factory default coding for this feature is OFF but can be coded ON for individual users with the Key Memory function See Car Memory Key Memory later in this section The driver s door lock location is the only point outside of the vehicle where the key can mechanically...

Page 856: ...s are double locked Continuous locking unlocking will initiate a timed arrest of the locking system The GM V counts each time the locks are actuated After approximately 12 cycles the timed arrest is active The timed arrest is deactivated one actuator cycle for every 8 seconds until the counter is reset to 0 The timed arrest is overridden if a crash signal is received from the multiple restraint sy...

Page 857: ...ocks each door and the trunk The fuel filler flap remains unlocked for refueling purposes If a door is manually unlocked and opened while centrally locked the remaining doors stay locked The opened door can be re locked when closed by manually locking or pushing the central switch twice This allows the locks of the remaining doors to be resynchronized Central Locking and Anti Theft http ebahn bent...

Page 858: ... entry FZV system In this case the double lock motor is activated simultaneously with the single lock motor The function of the double lock motor is to mechanically offset an internal rod in the lock actuator disabling it from unlocking the vehicle from the interior This prevents the doors from being unlocked by any means except from an unlock request at the driver s door or via the FZV remote key...

Page 859: ...ground signal to the GM V signifying a CLOSED trunk This contact also serves as the trunk light switch when the trunk is OPEN The actuator motor only operates in one direction to release the latch mechanism The latch mechanism can also be manually unlocked with the key Located on the trunk lock are two additional microswitches for key position status signalling to the GM V Valet position switch Wi...

Page 860: ...ver s door DWA disarmed interior lights on Press twice total unlocking Hold convenience opening 2 Press once lock DWA armed interior lights ON when vehicle is locked Press twice within 10 seconds deactivate interior and tilt monitoring 3 Press momentarily trunk lid opens Press and hold Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 6 of 14 2 25 2009 10...

Page 861: ...ior lighting activation search mode Panic mode alarm activation if equipped Automatic correction for up to 1000 erroneous activation signals Low transmitter battery fault code storage in the GM V 3 volt lithium battery commercially available CR 2016 used as power supply for key transmitters An EEPROM to stores key data Data is no longer lost when key battery is replaced reinitialization is not req...

Page 862: ...mory Key Memory is covered later in this section Starting with 2000 models the battery in the FZV ignition key is recharged while the key is in the ignition switch Therefore there is no need to replace the key battery The remote key receiver is part of the antenna amplifier and is installed in the left C pillar The receiver produces a digital signal based on the transmitter command and sends it to...

Page 863: ...e 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 The functions that can be set using Car Memory include Alarm system DWA features such as arming disarming with keyless entry FZV activation of tilt sensor or interior sensor...

Page 864: ...gramming 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 Available Key Memory functions vary based on vehicle equipment The functions that can be set include Automatic locking after start off Selective locking Heating A C blower speed heated or cooled air distribution automati...

Page 865: ...ization is only possible with the vehicle unlocked Close all doors and have all keys available Using key number 1 turn the ignition switch to KL R accessory position then switch off within 5 seconds and remove the first key Within 30 seconds of turning the ignition switch to OFF Press and hold button 2 While holding button 2 press and release tap button 1 three times within 10 seconds Release both...

Page 866: ...on The trunk can only be opened with either the remote FZV key or the wallet key Also the trunk is locked whenever the top storage compartment is unlocked while the top is raised or lowered The top storage cover motor Hall sensor signals the GM V whenever the cover is unlocked The Convertible Top Module CVM II receives a signal from the GM V over the K bus to lock out convertible top operation whe...

Page 867: ...o switch on the interior lights with a tailgate unlock request The rear window is opened with the release switch on the rear wiper arm cover Pressing the switch signals the GM V to activate the rear window release relay Sport Wagon tailgate and rear window lock controls Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 13 of 14 2 25 2009 10 53 PM ...

Page 869: ...der Rotary latch adjustments CAUTION Do not close the door before resetting rotary latch adjustment The door may lock and be unopenable from outside Rotary latch adjustments CAUTION Carry out rotary latch checks and adjustments with the door open If the door is closed with the incorrect latch setting it may not be possible to open the door without destroying the inner door panel Door lock and hand...

Page 870: ...Door handle inner mechanism 6 Inner handle mounting bolt 7 Key cylinder mounting bolt Torx 8 Gasket 9 Door lock with rotary latch 10 Plug 11 Bolt M6 always replace tighten to 9 Nm 80 in lb 12 Gasket 13 Outer door handle 14 Driver s door Door lock Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of 22 2 25 2009 10 59 PM ...

Page 871: ...ing resetting With door open close rotary latch Lock car with key or lock button Unlock car Open rotary latch using outside handle If latch unlocks adjustment is correct If latch fails to unlock Remove latch adjuster access hole cover Use 4 mm Allen wrench to loosen Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 3 of 22 2 25 2009 10 59 PM ...

Page 872: ...andle Measure additional distance A handle can travel once rotary latch releases If measurement A is obtained rotary latch adjustment is correct If measurement A is not obtained readjust rotary latch through access hole as described above and check handle overtravel again If measurement A is still not obtained replace door lock Outside door handle overtravel Measurement A min 2 mm 0 08 in Central ...

Page 873: ... window from window regulator rails Reattach battery Move window to approx 140 mm 5 5 in from bottom Remove window retaining screws insets at window regulator rails WARNING Once the window is positioned correctly disconnect harness connector from power window motor to prevent accidental operation of the window Note Be prepared to retrieve the captured nut corresponding to the retaining screw on th...

Page 874: ...gative battery terminal See 721 Airbag System SRS for cautions and procedures relating to the airbag system Driver s door Remove door lock cylinder as described later Models produced from 9 2000 Carefully pry outside door handle Bowden cable off lock assembly Remove lock mounting bolts arrows from rear edge of door Support lock to prevent it from falling into bottom of door Disconnect harness conn...

Page 875: ...bolts when reinstalling side impact airbag to door where applicable Secure wire harnesses with wire ties as applicable Be sure to check unlocking of rotary latch and outside door handle overtravel as described above under Rotary latch adjustments Check function of window mechanism before reinstalling vapor barrier and inner door panel Tightening torques Airbag to door replace screws 8 5 Nm 75 in l...

Page 876: ...ng Coupe or Convertible at lock cylinder mounting bolt access hole in upper rear door edge Note On Sedan or Sport Wagon Remove inner plug by prying with screwdriver then peel off outer oval plastic trim Remove lock cylinder mounting screw arrow Pull out lock cylinder Note Use key in cylinder to help pull cylinder out Use a small screw driver to pry cylinder cover locking tabs arrows Slide cover of...

Page 877: ...tly approx 4 mm 0 16 in Remove door handle from door by angling out of door cavity Note Make sure the lock release pawl at the rear of the handle and the mounting guide at the front of the handle are intact Before reinstalling insert screwdriver through access hole in edge of door to push lock release lever arrow outward Insert outside handle and snap forward until a click is heard Be sure to chec...

Page 878: ...on Lock is now in installation position Remove special tool 00 9 322 Tightening torque Outside handle to lock left hand thread 2 0 0 4 Nm 18 3 5 lb in Pull outside door handle outward and unhook from front guide Note Make sure the lock release bore at the rear of the handle and the mounting guide at the front of the handle are intact Before reinstalling handle make sure lock mechanism is in instal...

Page 879: ...ck unlocking of rotary latch and outside door handle overtravel as described above under Rotary latch adjustments Door handle inner mechanism removing and installing to production date 9 2000 Remove door lock and outside door handle as described earlier Remove front door tim panel air bag and vapor barrier as described in 411 Doors and 721 Airbag System SRS Remove outside handle base seals Loosen ...

Page 880: ...move front door tim panel air bag and vapor barrier as described in 411 Doors and 721 Airbag System SRS Lever out Bowden cable from door handle with screwdriver On Sedan or Sport Wagon Slide Bowden cable out of guide Note Foam insulation on bowden cable must be placed in original position during reinstallation On Coupe or Convertible Remove inner door guide plastic to gain access to Bowden cable N...

Page 881: ...riker replacing Remove striker plastic cover Remove striker top mounting bolt A Screw M8 stud into top bolt hole to keep striker backing plate from falling down into B pillar cavity Remove lower bolt B Remove and reinstall striker and gasket while holding on to stud Install striker mounting bolts finger tight Position striker bar approx 90 to inside edge of door frame Leave striker mounting bolts ...

Page 882: ...Coupe or Convertible No deviation is allowed at measurement B When door is closed striker must not contact lock housing With door closed there must be no in out movement of door Torque striker bolts Recheck door alignment Reinstall plastic cover Door striker position Deviation from parallelism of closed door A max 1 mm 0 04 in Deviation from flush at door shoulder B 0 Tightening torque Striker pla...

Page 883: ...cylinder gasket 10 Self threading screw 11 Lock cylinder The trunk can be unlocked by using Central locking button Left door key FZV remote entry system Trunk lock cylinder in the trunk lid right side taillight assembly Trunk release in the driver s footwell if equipped Microswitch in the center of the Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 15 ...

Page 884: ...ng tool kit to trunk lid white arrows Unclip retaining strap at trunk lid and remove tool kit Remove insulating liner expansion rivets black arrows and remove trunk liner Expansion rivets are released by pry upper portion out inset Lift off trim panel To remove trunk lock cylinder Remove right taillight socket from trunk lid See 630 Lights Remove right tail lens mounting nut A and detach tail lens...

Page 885: ...e trunk lock striker When reinstalling or to adjust trunk lid alignment adjust position of trunk lock striker with mounting bolts finger tight Set gap measurements as listed below Check trunk lid lock operation with lid open Also see 412 Trunk Lid Tailgate Trunk position gap adjustment Trunk lid trunk panel A 5 1 5 mm 0 2 0 06 in Trunk lid rear fender B 4 25 0 75 mm 0 17 0 03 in Central Locking an...

Page 886: ...ock cylinder in the tailgate In case of electrical failure there is an emergency tailgate lock release The release is located in the rear cargo area along the lower edge of the rear apron behind a small access cover Remove access cover and push release in direction of arrow to open tailgate Tailgate and rear window locking mechanism Tailgate lock assembly 1 Torx bolt M6 2 Rear window lock 3 Rear w...

Page 887: ...ness connector from strip Separate microswitch from strip To remove tailgate lock Open tailgate and remove tailgate rear panel trim Mark position of lock on rear panel Remove lock mounting bolts arrows Detach lock mechanism electrical harness contractor Electric lock actuator and emergency release lever can now be separated from tailgate lock mechanism Central Locking and Anti Theft http ebahn ben...

Page 888: ...ng bolts To adjust striker position Close tailgate slowly allowing striker to center itself on lock Striker must not touch lock housing Tighten striker mounting bolts then check tailgate to body gaps as shown below Note Do not lubricate lock or lock striker with grease To remove rear window lock striker Adjust striker height by loosening lock nut A then turning striker in or out Retighten lock nut...

Page 889: ...on Close window slowly allowing lock to center itself on striker Tighten striker mounting bolts then check rear window to body gaps as shown below Tighten lock mounting bolts When reinstalling or to adjust tailgate or rear window alignment adjust position of tailgate striker or window lock with mounting bolts finger tight Set gap measurements as listed below Also see 412 Trunk Lid Tailgate Central...

Page 890: ...e side panel height flush to 2 mm 0 08 in lower Tailgate light corner light D 4 25 0 75 mm 0 17 0 03 in Tailgate rear bumper E 5 1 mm 0 2 0 04 in Rear window tailgate F 4 1 mm 0 16 0 04 in Rear window tailgate G 5 4 1 mm 0 21 0 04 in Copyright 2006 Robert Bentley Inc All rights reserved Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 22 of 22 2 25 2009 ...

Page 891: ...ircuitry A damaged key will not start the engine In the EWS system the ignition key is embedded with a computer chip and permanently coded The key communicates with the vehicle using a transponder in the key and a ring antenna surrounding the steering lock cylinder A primary code is programmed into the key and into the vehicle itself A secondary code is changed every time the vehicle is started If...

Page 892: ...y is recharged while the key is in the ignition switch Therefore there is no need to replace the key battery EWS control module replacing 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 Lower left footwell pedal cluster trim panel Remove screws A Remove fasteners B Central Locki...

Page 893: ... be identified with 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 With ignition key in ON position 60 from LOCKED insert a thin piece of stiff wire into opening arrow in lock cylinder and pull lock cylinde...

Page 894: ... work ring antenna off key cylinder Copyright 2006 Robert Bentley Inc All rights reserved Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 4 of 4 2 25 2009 11 00 PM ...

Page 895: ... to recognize the installed components and carry out DWA functions The GM V utilizes existing components and or circuits as part of the DWA system Door lock hall effect sensor contacts Trunk lid switch contact Trunk lock key position switch Hood switch DWA status LED The DWA accessory kit includes the following Tilt sensor in right trunk area UIS interior monitoring sensor in center of headliner S...

Page 896: ...rror flashes as an acknowledgment along with flashing exterior lights and a momentary chirp from the siren The GM V monitors all required input signals for CLOSED status door closed trunk closed etc The inputs must be in CLOSED status for a minimum of 3 seconds for the GM V to include them as Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of 11 2 25 ...

Page 897: ...ctivating This feature is customizable under the Car Memory function If opened with the key at the trunk lock cylinder the trunk key position switch signals the GM V and in the same manner prevents the alarm from activating In either case when the trunk is returned to the CLOSED position it will no longer activate the alarm Alarm operation When the alarm is triggered the siren will sound for 30 se...

Page 898: ...und signal to the GM V signifying a CLOSED trunk With the DWA armed the GM V will activate the siren if it receives a trunk OPEN signal Trunk lock key position switches There are two switches mounted in one block arrow on the trunk lock cylinder Valet position switch With the key lock in the valet position this switch provides a ground signal to the GM V The GM V locks out the interior trunk relea...

Page 899: ...agnosing the DWA system DWA LED The DWA indicator is located in the rear view mirror All E46 vehicles are equipped with the LED It is not part of the retailer installed accessory DWA system The LED is provided with constant battery voltage KL 30 The GM V provides a switched ground signal providing the various blinking signals used to convey DWA status to the vehicle operator DWA LED status is summ...

Page 900: ...ilt sensor monitors the vehicle parked angle when DWA is armed The sensor requires three signal wires to perform its function KL 30 Constant battery voltage STDWA signal Switched ground input signal provided by the GM V indicating DWA armed disarmed status The tilt sensor is used as a splice location for the STDWA signal to the siren and interior protection sensor NG signal Switched ground output ...

Page 901: ... in the center of the headliner panel even with the door B pillar Due to the design of the vehicles interior the sensor is unidirectional and must be installed in the proper direction to ensure proper operation of the system trim cover ensures directional installation Every time the DWA system is armed STDWA signal the sensor adapts to whatever objects are stationary in the interior The sensor emi...

Page 902: ...el under the center console next to the parking brake handle The central position allows the most effective monitoring of the vehicle interior The SDR detector consists of two printed circuit boards one being the transmitter receiver and the other the processing electronics The module housing is highly conductive material for high frequency transmission The SDR sensor transmits an electromagnetic ...

Page 903: ... a sensor shadow effect in the interior As with the tilt sensor and the UIS the SDR sensor can be switched OFF by activating the central locking system twice within 10 seconds Alarm siren The DWA siren is installed in the right rear engine compartment This location provides a secure position with loud acoustic output The siren contains electronic circuitry for producing the warning tone when the a...

Page 904: ...ched to a 50 duty cycle at the GM V The control circuitry in the siren activates the siren If the DWA is armed and the battery is disconnected the siren circuitry recognizes the normally high NG signal as suddenly going low In this case the siren is also activated Panic mode operation When the trunk button on an FZV key is pressed and held the GM V activates the siren for the panic mode The panic ...

Page 905: ... V to unlock the doors and to deactivate the DWA Copyright 2006 Robert Bentley Inc All rights reserved Central Locking and Anti Theft http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 11 of 11 2 25 2009 11 00 PM ...

Page 906: ...of these seats Convertible front seats are unique to those models in that they incorporate the seat belts This is called the Seat Integrated Seatbelt SGS system Vinyl is the most common upholstery and leather is an available option The leather appears not only on the seats but on the door panels and other areas as well Front seatback nets are standard Seat adjustments Regardless of level of trim E...

Page 907: ...M V and instrument cluster The driver seat module stores three seat positions for recall The information is stored in non volatile memory preventing loss of memory in case of electrical power failure or battery disconnection The seat adjusting switch block in the driver s seat communicates with the seat cushion control module over dedicated lines The output stages for seat motor movement are in th...

Page 908: ...ule memorizes the position of the seat and headrest when the entry aid feature is activated The seat will return to its previous set position when the entry aid button is pressed rearward or the seat backrest is locked The passenger s seat on four door models uses a simplified control system within the switch block and does not include a memory module No on board diagnostics are incorporated into ...

Page 909: ...Passenger seat memory module Seats http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 4 of 5 2 25 2009 11 03 PM ...

Page 910: ... 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 Copyright 2006 Robert Bentley Inc All rights reserved Seats http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 5 of 5 2 25 2009 11 03 PM ...

Page 911: ...re powerful devices and should be handled with extreme care Incorrect handling can trigger off the tensioner and cause injury 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 Pyrotechnic devices cannot be repaired Always re...

Page 912: ...ging of the new components During body straightening and welding with an electric arc welder always disconnect the battery and the connection to the pyrotechnic gas generators 4 door models raise seat and move to its forward position Working at base of seat near doors remove seat belt mounting bolt arrow Remove headrests not convertible Remove two mounting bolts arrows at rear of seat rails Move s...

Page 913: ...release and disconnect Cut or untwist wire ties as necessary Remove seat from car The headrests may be removed to provide additional clearance Note Use a blanket to protect door sill from scuffing by seat rail during seat removal Installation is reverse of removal Use wire ties or equivalent means to keep seat harness wiring from fraying Tightening torque Front seat to floor 45 Nm 33 ft lb Seat be...

Page 915: ...tainers Pull entire backrest up B to detach from bottom hooks Slide backrest to side to clear seat belts Note If the car is equipped with heated rear seats detach electrical harness connector s as you remove the seat components When reinstalling be sure to pull seat belts and buckles up through appropriate slots in seat cushion Rear seat cushion and backrest removing and installing fold down seat ...

Page 916: ... side section by pulling out A and up B Working between two sections of backrest remove backrest center mount screws Remove outer backrest mounting screws Raise backrests in middle slightly and separate left and right backrest guide Lift backrest s out through back door s Copyright 2006 Robert Bentley Inc All rights reserved Seats http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of ...

Page 917: ...ectronic controls initializing Initialize the sunroof in the following situations Malfunctions such as lack of one touch function lack of comfort opening closing or lack of safety anti trapping features If sunroof motor has been removed and reinstalled If power supply to the sunroof has been interrupted If repairs have been performed on the slide tilt mechanism Normalization During normalization t...

Page 918: ...ic 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 Disconnect the electrical connections and lay switch panel aside Sunroof http ebahn bentleypublishers com BMW...

Page 919: ...s in front corners of sunroof carrier if water is entering car through headliner The sunroof is controlled by a set of cables that move the sunroof panel along guide rails when the motor is operated The sunroof can be adjusted without removing it from the car The sunroof panel should be adjusted under the following circumstances Sunroof misaligned with roof Sunroof does not close squarely Wind noi...

Page 920: ...ll around edge of sunroof Note Use a credit card to measure the gap The card should insert through the gap with equal resistance all around the perimeter Front of sunroof must be flush to 1 mm 0 04 in below surface of roof Rear of sunroof must be flush to 1 mm 0 04 above surface of roof To adjust sunroof height shut sunroof fully Slide sunroof liner back into roof cavity until approx 90 mm 3 5 in ...

Page 921: ...orrect height is achieved Tighten screws Recheck height Check sunroof function nothing Sunroof height adjustment specifications Rear flush 1 mm higher than roof top Front flush 1 mm lower than roof top Tightening torque Sunroof panel to roof Torx 4 5 Nm 40 in lb Copyright 2006 Robert Bentley Inc All rights reserved Sunroof http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 5 of 5 2 25 2...

Page 922: ...nt procedures given earlier Sunroof assembly 1 Torx bolt M5 2 Slider 3 Glass sunroof panel 4 Sunroof panel gasket 5 Velour ceiling panel 6 Synthetic strip 7 Slider 8 Gasket 9 Wind deflector 10 Deflector spring 11 Sunroof motor 12 Felt 13 Frame gasket 14 Sunroof frame 15 Torx bolt M5 tighten to 3 5 Nm Sunroof http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 1 of 4 2 25 2009 11 04 PM ...

Page 923: ...nd remove wind blocker by removing Torx screw arrow on each side Close sunroof and slide sunroof liner back into roof cavity until approximately 90 mm 3 5 in is exposed Remove three Torx screws arrows on each side and lift panel out Installation is reverse of removal Sunroof http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of 4 2 25 2009 11 04 PM ...

Page 924: ...rting at back center of panel install new seal taking care to not pull seal too tightly around four corners of panel Installation is reverse of removal Adjust sunroof height and gap as shown earlier in this repair group Tightening torque Wind blocker to roof Torx 1 Nm 9 in lb Sunroof panel to roof Torx 4 5 Nm 40 in lb Sunroof motor replacing Remove access panel from below sunroof motor by gently p...

Page 925: ... 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 Sunroof http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 4 of 4 2 25 2009 11 04 PM ...

Page 926: ... top control module CVM II is located behind the left rear side trim panel For the location of other convertible top electric components see 610 Electrical Component Locations The glass rear window in the Convertible is not replaceable separately Convertible top controls Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 1 of 11 2 25 2009 11 05 PM ...

Page 927: ...nvertible top operation The automatic E46 Convertible top system completely opens and closes the top using hydraulic cylinders and electric motors The convertible top system features Convertible Top Module CVM II with fault memory storage Electro hydraulic operation Convenience opening using FZV remote key or door lock cylinder Convenience closing using door lock cylinder Glass rear window Convert...

Page 928: ...gh access hole in motor assembly cover Unlock top cover and open Switch off ignition Hydraulic pressure will be released in steps after approximately 10 seconds until all pressure is drained from cylinders Manually raise or lower top Use handcrank to lock or unlock top at windshield top frame Hydraulic fluid level checking or filling Note Make sure top is lowered into storage compartment and stora...

Page 929: ... To fill Detach hydraulic unit and pull out without disconnecting fluid lines Lay unit on its side and fill through fill plug Turn unit upright and recheck level Install new fill plug seal To drain Detach hydraulic unit and pull out without disconnecting fluid lines Lay unit on its side and allow to drain through fill plug Turn unit upright and recheck level Install new fill plug seal Convertible ...

Page 930: ...ible Top Module CVM II Two LEDs are positioned in the center of the switch assembly The top LED will flash whenever the top is being operated and not locked to the windshield or stored completely in the storage compartment The lower LED will illuminate if the top switch is pushed open top signal and the storage compartment floor is in the folded up position See Top storage compartment floor later ...

Page 931: ...with the General Module GM V over the K bus for operation of top storage cover and windows 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 Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals...

Page 932: ...d on more than 20 seconds after the top is completely raised or lowered a fault code will be set CVM II assumes a fault to ground in the switch or electrical harness The ignition switch must then be cycled OFF ON to clear the fault before the top will function again The fault will remain in memory until cleared with a scan tool DIS MoDiC or equivalent All sequenced movements of the convertible top...

Page 933: ... is possible from either the driver door or remotely using the FZV key Windshield frame lock The windshield frame lock assembly consists of the top lock motor positioned in the center of the top frame and two lock drive mechanisms positions on either side of the top frame The lock motor and drive mechanism unlock the top from the windshield and raise the front of the top past the tension point Fle...

Page 934: ...t side top linkage by left main pillar hydraulic cylinder The CVM uses input signal from main pillar angle sensor for top frame positioning Top storage compartment cover Top storage compartment cover position is detected and signalled to CVM II by a Hall sensor on left side storage cover hydraulic cylinder in trunk The sensor provides a high signal when storage cover is fully open The CVM II uses ...

Page 935: ...e time GM V will signal CVM II to continue top operation There are two storage compartment cover lock Hall sensors one mounted on each storage cover latch The switches receive power and ground from CVM II Each switch input provides a high signal when cover is unlocked and raised far enough by cover hydraulic cylinders to clear latches When cover is completely lowered by hydraulic cylinders the Hal...

Page 936: ...es and locks floor into position A dampening piston on right side maintains position of variable floor The lower dampening piston hinge switches a microswitch on right side of variable floor when floor is in folded raised position This signal to CVM II locks out operation of top Copyright 2006 Robert Bentley Inc All rights reserved Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair ...

Page 937: ... Fabric outer layer Middle fleece liner Inner liner Refer to the accompanying illustration for mechanical component locations Convertible top mechanical components 1 Folding top 2 Folding top frame 3 Base plate 4 Windshield frame lock microswitch 5 Windshield frame lock drive motor 6 Windshield Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 1 of 8 2 25 2009 11 05 PM ...

Page 938: ...h left side Hydraulic system repairs CAUTION When working on hydraulic system system must be at zero pressure Disconnect supply and return lines a with convertible top stowed and in untensioned state Once hydraulic system has been opened a function test must be carried out after work has been completed Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of 8 2 25 2009 1...

Page 939: ...lings are protected against damage The hydraulic system cannot build up high pressure and convertible top can be moved manually Hydraulic system compontents and electronics are shown in the accompanying illustrations Terms and definitions used in diagnosing and repairing the convertible top hydraulic system are listed in Table a Definition of hydraulic system terms Basic repair procedures for hydr...

Page 940: ...ght tension bow cylinder routed under top fabric along tension bow 2 Main pillar hydraulic cylinders Actuate soft top frame Located on two sides of top frame linkage Angle hall sensor detects position of main top linkage Hydraulic lines for right main pillar cylinder routed under top fabric along tension bow Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 4 of 8 2 25 ...

Page 941: ...er 4 Solenoid valve block on left side of top frame Solenoid V1 controls operation of main pillar hydraulic cylinder Solenoid V2 controls tension bow cylinders for raising top Solenoid V3 controls tension bow cylinders for lowering top 5 Quick disconnect in trunk 6 Hydraulic pump unit Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 5 of 8 2 25 2009 11 05 PM ...

Page 942: ...c motor and pump Storage cover solenoid valve Drain solenoid valve Hydraulic fluid reservoir Hydraulic fluid temperature sensor Operates at pressures of up to 200 bar 2900 lb in2 Convertible top hydraulic electronics Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 6 of 8 2 25 2009 11 05 PM ...

Page 943: ...nstructions Short circuit Unfasten quick release coupling Connect supply and return lines to each other Hydraulic system cannot build up pressure Convertible top can be moved Table b Convertible top hydraulic system repair procedures Operation Procedures Mechanical manual operation of top Ignition must be turned off Hydraulic lines must be disconnected Reconnect when finished After repeated actuat...

Page 944: ...ydraulic fluid level checking or filling earlier in this group Fluid topping up or draining Copyright 2006 Robert Bentley Inc All rights reserved Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 8 of 8 2 25 2009 11 05 PM ...

Page 945: ...re during a crash The rollover sensor performs a self check every time the ignition is switched on The sensor is connected to the diagnostic link DLC for troubleshooting purposes If faults are detected the warning lamp in the instrument cluster will light up In case of a crash the system will attempt to trigger the rollover cassettes to deploy even if a fault code is stored in fault memory Note Di...

Page 946: ...N It is not possible to close convertible top with rollover bars extended If a hardtop is mounted be sure to install the protective rollover bar covers provided with hardtop to prevent damaging rear window in case of deployment Copyright 2006 Robert Bentley Inc All rights reserved Convertible Top http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 5 2 of 2 2 25 2009 11 05 PM ...

Page 947: ...needle may draw enough current to damage sensitive electronic components An LED test light is a safe inexpensive tool that can be used to perform many simple electrical tests that would otherwise require a digital multimeter The LED indicates when voltage is present between any two test points in a circuit The integrated safety comfort security and handling systems on E46 cars are designed with se...

Page 948: ... 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 Electrical System General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 2 2 25 2009 11 07 PM ...

Page 949: ... hand wiring harnesses now must be so complex that they become unmanageable In addition the finite number of pins on conventional connectors becomes a limiting factor in electronic control module development The solution has been found in the use of specialized vehicle compatible serial bus systems The E46 bus system is summarized in Table a Table a E46 busses Bus Circuits covered K bus Driver inf...

Page 950: ... components CAN bus Engine management system DME Transmission control AGS Antilock brakes ABS Traction control ASC Dynamic stability control DSC D bus Data link connector DLC OBD II connector Multiple restraint system MRS II 1999 E46 bus system diagram Electrical System General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 10 2 25 2009 11 07 PM ...

Page 951: ...r ground strap between the body and the battery negative terminal Wiring fuses and relays Electrical components connect using one of the following Heavy cables with lug type connectors battery and starter Electrical harnesses with keyed push on connectors that lock into place Busses with modular connectors With the exception of the starter and the charging system most electrical power is routed fr...

Page 952: ...Module GM V These functions are controlled directly by the GM V Windshield wiper washer system with optional Rain Sensor Interface See 611 Wipers and Washers Central locking power trunk release keyless entry FZV See 515 Central Locking and Anti theft Power window control See 512 Door Windows Car Memory Key Memory See 515 Central Locking and Anti theft Interior lighting See 612 Switches Alarm syste...

Page 953: ...mation is stored redundantly in the instrument cluster and the light switch module Vehicle identification number VIN Total mileage Service interval data This redundancy means that the instrument cluster or light module may be replaced without loss of stored data The data between the two units is compared each time the ignition is switched on KL 15 on If the data does not match the tamper warning d...

Page 954: ... details Electrical consumer sleep mode Central body electronics ZKE V is designed to bring the vehicle electrical consumers into sleep mode after 16 minutes of inactivity In order to test sleep mode Switch ignition off Close all doors trunk and hood Lock vehicle using central locking Wait 16 minutes If one of a number of inputs into the General Module GM V is activated before the vehicle is in sl...

Page 955: ... Tilt sensor Driver s door lock sensors Note If an interior light is accidentally left on the GM V will override the signal from it after 16 minutes and implement sleep mode Electrical system safety precautions Please read the warnings and cautions in this section before doing any work on your electrical system WARNING Electrical System General http ebahn bentleypublishers com BMW 3 E46 Repair 20M...

Page 956: ...m for additional ignition system warnings and cautions Keep hands clothing and other objects clear of the electric radiator cooling fan when working on a warm engine The fan may start at any time even when the ignition is switched off CAUTION Always turn off the engine and disconnect the negative cable from the battery before removing any electrical components Disconnecting the battery may erase f...

Page 957: ...a second time Do not use an analog meter Use only a digital multimeter Many of the solid state modules are static sensitive Static discharge will permanently damage them Always handle the modules using proper static prevention equipment and techniques To avoid damaging harness connectors or relay panel sockets use jumper wires with flat blade connectors that are the same size as the connector or r...

Page 958: ...ast 10 megaohm input impedance or an LED test light An analog meter swing needle or a test light with a normal incandescent bulb may draw enough current to damage sensitive electronic components An ohmmeter must not be used to measure resistance on solid state components such as control units or time delay relays Always disconnect the battery before making resistance ohm measurements on the circui...

Page 959: ...e wire with a red stripe Many electrical components connectors fuses and ground locations are identified using a unique number Each of these numbers corresponds to a particular part in the circuit commonly found in Electrical Wiring Diagrams Note Sometimes the color of an installed wire may be different than the one on the wiring diagram Don t be concerned Just be sure to confirm that the wire con...

Page 960: ...ghout the electrical system and identify certain types of circuits Some common circuit numbers are listed below in Table c Table c Terminal and circuit numbers Number Circuit description 1 Low voltage switched terminal of coil 4 High voltage center terminal of coil X Originates at ignition switch Supplies power when the ignition switch is in the PARK RUN or START position 15 Originates at ignition...

Page 961: ... switch is in the RUN position only 85 Ground side of relay coil 86 Power in side of relay coil 87 Relay actuated contact D Alternator warning light and field energizing circuit Additional abbreviations shown in the wiring diagrams are given below Table d Common E46 abbreviation Abbreviation Component or system Abbreviation Component or system ABS antilock brakes KL 50 ignition switch start positi...

Page 962: ...stics DLC diagnostic link connector ORVR on board refueling vapor recovery DME digital motor electronics PDC park distance control optional DMTL diagnosis module tank leakage DME MS 43 0 PWG pedal position sensor DSC III dynamic stability control RAM random access memory DTC diagnostic trouble code RDC tire pressure control optional DWA anti theft alarm system RPS rollover protection system E box ...

Page 963: ...r conditioning system TLEV transitional low emissions vehicle ITS head protection system TXD transmit data line KL 15 battery positive ignition switch on run UIS ultrasonic interior protection KL 30 battery positive hot all the time ULEV ultra low emissions vehicle KL 31 battery chassis ground ZKE central body electronics Copyright 2006 Robert Bentley Inc All rights reserved Electrical System Gene...

Page 964: ...ts can usually be located through a process of elimination When troubleshooting a complex circuit separate the circuit into smaller parts General tests outlined below may be helpful in finding electrical problems The information is most helpful when used with wiring diagrams Be sure to analyze the problem Use wiring diagrams to determine the most likely cause Get an understanding of how the circui...

Page 965: ...dim headlights to sluggish wipers Some common sources of voltage drops are corroded or dirty switches dirty or corroded connections or contacts and loose or corroded ground wires and ground connections A voltage drop test is a good test to make if current is flowing through the circuit but the circuit is not operating correctly A voltage drop test will help to pinpoint a corroded ground strap or a...

Page 966: ...tion on and then with the engine running to get exact measurements Voltage measuring Connect digital multimeter negative lead to a reliable ground point on car Note The negative battery terminal is always a good ground point Connect digital multimeter positive lead to point in circuit you wish to measure If a reading is obtained current is flowing through circuit Note The voltage reading should no...

Page 967: ...ed 1 volt Note The maximum voltage drop in an automotive circuit as recommended by the Society of Automotive Engineers SAE is as follows 0 volts for small wire connections 0 1 Volts for high current connections 0 2 volts for high current cables and 0 3 volts for switch or solenoid contacts On longer wires or cables the drop may be slightly higher In any case a voltage drop of more than 1 0 volt us...

Page 968: ...e light switch for continuity With brake pedal in rest position switch open there is no continuity infinite With pedal depressed switch closed there is continuity 0 Short circuits Short circuits are exactly what the name implies The circuit takes a shorter path than it was designed to take The most common short that causes problems is a short to ground where the insulation on a positive wire wears...

Page 969: ... replacing blown fuses use only fuses having the correct rating Always confirm the correct fuse rating printed on the fuse relay panel cover Short circuit testing with ohmmeter Remove blown fuse from circuit and disconnect cables from battery Disconnect harness connector from circuit load or consumer Using an ohmmeter connect one test lead to load side of fuse terminal terminal leading to circuit ...

Page 970: ...st fuses power more than one consumer Be sure all consumers are disconnected when checking for a short circuit Using a digital multimeter connect test leads across fuse terminals Make sure power is present in circuit If necessary turn key on If voltage is present at voltmeter there is a short to ground If voltage is not present work from wire harness nearest to fuse relay panel and move or wiggle ...

Page 971: ...y slice open harness cover or wire insulation for further inspection Repair any faults found Copyright 2006 Robert Bentley Inc All rights reserved Electrical System General http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 8 of 8 2 25 2009 11 08 PM ...

Page 972: ...ways an important first step in any kind of electrical diagnosis Investigating and correcting ground problems often clears mysterious and difficult to trace electrical problem This repair group covers the major ground locations on the vehicle Keep in mind that electrical equipment and accessories installed vary depending on model and model year Always confirm that the proper electrical component h...

Page 973: ...ange 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 position is to compare the wiring colors at the relay socket to the colors indicated on the wiring diagrams located at the rear of this manual Always switch the ignition off and remove the negative battery cable before removi...

Page 974: ...digital multimeter for electrical tests Copyright 2006 Robert Bentley Inc All rights reserved Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 3 of 3 2 25 2009 11 08 PM ...

Page 975: ... F5 in the E box fuse carrier is rated 30A and protects the unloader relay circuit in 1999 2000 models and fuel injector relay in 2001 models In a few cases a fuse may have two different amperage ratings depending on equipment in the vehicle In such cases the second rating is put in parenthesis in the fuse rating tables Main harness fuse Fig 1 Main harness fuse in trunk Working ahead of battery in...

Page 976: ... release fuse pack To remove an individual defective fuse inside fuse pack carrier slide cover off by prying gently while you use pin tool to squeeze lock tabs nothing CAUTION Once cover is off fuses can fall out easily Be sure to keep them in order while replacing defective fuse Table a E box fuse pack Fuse Rating Protected circuits 1 30A Not used 1999 2000 models DME main relay 2001 models Ignit...

Page 977: ...A C compressor clutch relay Camshaft position sensors Crankshaft position sensor DME main relay Fuel pump relay Leakage diagnosis pump fuel tank Mass air flow sensor Secondary air injection pump relay Thermostat 4 30A Changeover valve running losses 3 2 valve Oxygen sensors 5 30A Fuel injector relay 2001 models Unloader relay to ignition coils 1999 2000 models Electrical Component Locations http e...

Page 978: ...ar A small built in flashlight A is in the glove compartment next to the fuse box A red plastic fuse puller B is in the center of the fuse box The sheet of paper with the fuse assignments below the fuses can be slid out for reference Vertical fuses are active Horizontal fuses are spares Fuse locations in the main panel are detailed in Table c 1999 fuse positions and Table d 2000 2001 fuse position...

Page 979: ... panel Fuses F101 through F107 are mounted in this location Table b High amperage fuse positions Fuse Rating Protected circuits 101 50A Engine cooling fan 1999 2000 models 102 80A B terminal DME mail relay Engine control module Fuse 5 E box fuse pack Transmission control module TCM 103 80A not used 104 100A Preheater relay 105 50A Ignition switch DLC Electrical Component Locations http ebahn bentl...

Page 980: ...r control module Trailer module 108 200A Main harness fuse in trunk see Fig 1 E46 main fuse panel Table c 1999 fuse positions Fuse Rating Protected circuit 1 not used 2 3 4 5 5A Horn see also fuse 55 6 5A Make up mirror light Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 6 of 14 2 25 2009 11 09 PM ...

Page 981: ...ag Side impact airbag 12 7 5A Roller sun blind 13 not used 14 5A Electronic immobilizer EWS see also fuse 67 Starter interlock 15 5A Rain sensor 16 not used 17 18 19 20 21 22 23 24 5A Electrochromic rear view mirror see also fuse 67 Parking distance control 25 5A Heated outside mirror passenger Heated spray nozzles 26 5A Garage door opener Overheat JP 27 10A Back up lights Electrical Component Loc...

Page 982: ...wer see also fuse 28 38 10A 15A Front fog lights 39 5A Telephone see also fuse 7 40 5A ABS DSC see also fuses 33 53 56 61 Shift gate illumination 41 30A Navigation see also fuse 7 On board monitor see also fuse 7 Radio see also fuse 7 42 not used 43 5A Clock Instrument cluster see also fuses 10 34 OBD II system 44 20A Trailer module 45 not used 46 30A Sunroof 47 15A 20A Cigarette lighter power out...

Page 983: ... fuses 33 53 ABS DSC see also fuses 33 40 53 61 57 5A Outside mirror 58 not used 59 30A Windshield washer system see also fuses 49 52 60 25A Central locking see also fuse 49 61 30A ABS DSC see also fuses 33 40 53 56 62 7 5A A C see also fuses 28 63 63 7 5A A C see also fuses 28 62 64 20A Auxiliary heater diesel 65 30A Driver seat adjustment 66 not used 67 5A Anti theft see also fuse 49 Electrochro...

Page 984: ...use 41 Radio see also fuse 41 Telephone see also fuse 39 8 5A Sequential transmission M3 see also fuse 22 9 5A Brake light Light module see also fuse 32 On board computer Speed control 10 5A Instrument cluster see also fuses 34 43 11 5A Airbag Side impact airbag 12 7 5A ABS ASC see also fuses 33 42 53 56 ABS DSC see also fuses 33 40 42 53 56 61 ABS DSC all wheel drive see also fuses 33 35 40 42 53...

Page 985: ... 5A Electrochromic rear view mirror see also fuse 67 Park distance control 25 5A Heated outside mirror passenger Heated spray nozzles 26 5A Cigarette lighter Australia see also fuse 47 Garage door opener 27 10A Engine control see also fuses 29 30 Back up light 28 5A Air conditioner see also fuses 62 63 Blower see also fuse 50 Heater see also fuses 23 62 29 5A Engine control see also fuses 27 30 En...

Page 986: ... 53 56 61 ABS DSC all wheel drive see also fuses 12 33 35 42 53 Shift gate illumination 41 30A Navigation system see also fuse 7 On board monitor see also fuse 7 Radio see also fuse 7 42 30A ABS ASC see also fuses 12 33 53 56 ABS DSC see also fuses 12 33 40 53 56 61 ABS DSC all wheel drive see also fuses 12 33 35 40 53 Manual top Convertible see also fuses 12 46 Power top Convertible see also fuse...

Page 987: ...A Central locking system see also fuses 49 60 Sport Wagon see fuse 58 Glove compartment light Hand lamp Interior lights see also fuse 49 Passenger compartment trunk lighting Windshield washer system see also fuses 49 59 53 30A ABS ASC see also fuses 12 33 42 56 ABS DSC see also fuses 12 33 40 42 56 61 ABS DSC all wheel drive see also fuses 12 33 35 40 42 54 15A Fuel pump 55 15A Horn see also fuse ...

Page 988: ... not used 67 5A Anti theft DWA see also fuse 49 Electrochromic rear view mirror see also fuse 24 Electronic immobilizer EWS see also fuse 14 68 30A Heated rear window Convertible see also fuse 7 69 5A Tire pressure control see also fuses 12 31 42 70 30A Passenger seat adjustment 71 30A 10A Coupe Hinged window Coupe Window rear Copyright 2006 Robert Bentley Inc All rights reserved Electrical Compon...

Page 989: ...eptible to damage and corrosion Clean or renew them as necessary Fig 5 Left front engine compartment behind left headlight 1 Ground X165 Fig 6 Right front engine compartment behind right headlight 1 Ground X166 Fig 7 On bulkhead behind E box 1 Ground X6454 Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 1 of 3 2 25 2009 11 09 PM ...

Page 990: ...carpet 1 Ground connector X1108 2 Side impact airbag crash sensor Fig 10 Under right front carpet on door sill 1 Ground connector X490 Fig 11 Behind right rear seat backrest 1 Ground X494 Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 3 2 25 2009 11 09 PM ...

Page 991: ...1 Ground X498 Fig 13 Left side trunk behind trim 1 Ground X13016 Copyright 2006 Robert Bentley Inc All rights reserved Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 3 of 3 2 25 2009 11 09 PM ...

Page 992: ...e switch is also sometimes referred to as the gear position switch The EWS 3 3 system is also known as the driveaway protection system or the electronic immobilization system All Season Traction AST is a marketing term that refers to ABS ASC Main relay panel To access main relay panel located under right side of dashboard remove glove compartment as described in 513 Interior Trim Fig 14 Behind glo...

Page 993: ...eadlight cleaning relay 2 Secondary air pump relay 3 A C relay 4 Fuel pump relay 5 A C relay 6 Foglight relay 7 Horn relay Electronics box E box To access E box components Working in left rear of engine compartment remove M6 Allen head bolts arrows Lift off E box cover Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 40 2 25 2009 11 09 PM ...

Page 994: ...nced listing of electrical components in E46 vehicles Where available photos of components in this repair group are referred to in the fourth column Note Every attempt has been made in this repair manual to standardize component names Nevertheless in some cases the same component may appear with different names No E46 vehicle is equipped with all components illustrated Where necessary year and mod...

Page 995: ...le 1999 2001 Center of dashboard A C evaporator temperature sensor 1999 2001 Left side of IHKA housing below instrument cluster Fig 39 A C pressure sensor 1999 2001 Behind right headlight on top of receiver drier Fig 32 ABS wheel speed sensor connector front right left 1999 2001 In wheel housing right left Fig 62 ABS wheel speed sensor connector rear right left 1999 2001 Ahead of rear wheel housin...

Page 996: ...h rotational rate yaw sensor under driver side carpet ABS DSC precharge pump 1999 2001 Left rear engine compartment below brake master cylinder Fig 18 ABS DSC rotational rate yaw sensor 1999 2001 Under driver side carpet ABS DSC steering angle sensor 1999 2001 Base of upper steering column Fig 35 ABS DSC switch see ASC DSC switch Accelerator pedal sensor PWG 1999 2000 At throttle housing Accelerat...

Page 997: ...bottom of windshield pillar A pillar behind dashboard left right Fig 42 Airbag passenger side 1999 2001 Right side dashboard Fig 41 Airbag side impact left right front rear 1999 2001 Inside door left right front rear Alarm control module DWA 1999 2001 Above main fuse box behind glove box Alarm indicator LED DWA 1999 2001 Attached to rear view mirror Alarm siren DWA 1999 2001 Right side rear of eng...

Page 998: ...na diversity Sport Wagon Left rear side window Antenna FZV keyless entry Convertible Interior rear view mirror Antenna FZV keyless entry Sedan Coupe Rear window lower antenna grid Antenna FZV keyless entry Sport Wagon Center rear window combined with FM2 antenna Antenna main Convertible Mast on left rear fender Antenna main FM1 and FM2 Sport Wagon Rear window center and right Antenna telephone Con...

Page 999: ...range switch harness connector ZF trans Left side of transmission Fig 64 B jumper connector 1999 2001 Next to right front strut tower right rear engine compartment Fig 17 Fig 19 B supply E box Left side of E box Fig 16 Back up light switch automatic transmission see Automatic transmission range switch Back up light switch manual transmission 1999 2000 Top left side of transmission housing Back up ...

Page 1000: ...Brake pad wear sensor connector right rear 1999 2001 Ahead of right rear wheel housing Camshaft actuator VANOS see VANOS Camshaft position sensor exhaust 1999 2001 Right front of cylinder head Fig 29 Camshaft position sensor intake 1999 2001 Left front of cylinder head Fig 28 Carbon canister valve 1999 2000 Right side of spare tire well under floor pan CD changer 1999 2001 Left side of trunk Cente...

Page 1001: ... Convertible top main pillar Hall sensor Convertible Behind rear seat in C pillar position Fig 66 Convertible top solenoid valves Convertible Left and right rear main pillar behind quarter panel windows Fig 66 Convertible top storage compartment floor microswitch Convertible Right side storage compartment hinge in trunk Fig 66 Convertible top storage cover Hall sensor Convertible Left rear of conv...

Page 1002: ...sor 1999 2001 Left rear of engine block under starter motor Fig 22 Cruise control cut off switch 1999 2001 At pedal cluster Fig 37 Cruise controls steering wheel 1999 2001 Steering wheel right side keypad Data link connector 20 pin DLC 1999 2000 Right rear engine compartment see also OBD II connector Fig 17 Diagnosis module tank leakage DMTL 2001 see Fuel tank leakage diagnosis pump LDP or DMTL Di...

Page 1003: ... E box temperature sensor 1999 2001 Rear of E box Fig 16 ECT sensor see Engine coolant temperature ECT sensor Electric coolant thermostat see Coolant thermostat Electronic immobilizer see EWS entries Electronics box see E box entries Engine compartment light switch see Engine hood contact switch Engine control module ECM 1999 2001 Left rear engine compartment in E box Fig 16 Engine coolant tempera...

Page 1004: ...r module 1999 2001 In ignition key Exhaust camshaft position sensor 1999 2001 Right front of engine top Fig 29 Exhaust camshaft VANOS solenoid 1999 2001 Right front of engine top Fig 29 Fog light relay 1999 2001 Main relay panel behind glove compartment Fig 14 Fig 15 Footwell light left 1999 2001 In left footwell top trim pedal cluster trim Footwell light right 1999 2001 In right footwell top trim...

Page 1005: ...in harness F108 200 amp 1999 2001 Right wheel housing in trunk Fig 1 Fuse panel main 1999 2001 Above glove compartment Fig 14 Fig 15 Fuses additional high amperage 1999 2001 Above main fuse panel Fig 4 Fuses engine electronics 1999 2001 Left rear engine compartment in E box Fig 2 FZV antenna see Antenna FZV keyless entry Gas generator airbag see Airbag entries Gear position indicator light 1999 20...

Page 1006: ...tunnel carpet X490 1999 2001 Under right front seat carpet on door sill Fig 10 X494 1999 2001 Behind rear seat backrest Fig 11 X498 1999 2001 Right side trunk Fig 12 Fig 53 X6454 1999 2001 On bulkhead left rear engine compartment Fig 7 Hazard warning central locking switch 1999 2001 On center console behind shifter Head protection airbag HPS see Airbag listings Headlight dimmer relay 1999 2001 In ...

Page 1007: ...ide of left strut tower Fig 27 Heating A C see A C entries High beam switch see Turn signal headlight dimmer switch stalk switch Hood switch see Engine hood security switch Horn button 1999 2001 On steering wheel pad Horn relay 1999 2001 Main relay panel behind glove compartment Fig 14 Fig 15 Horn left right 1999 2001 Next to front bumper impact absorber left right Hot film mass air flow sensor se...

Page 1008: ...ake fan 1999 2001 In A C control module in center console Keyless entry antenna see Antenna FZV keyless entry Kickdown switch automatic transmission see Accelerator pedal sensor PWG Knock sensors 1999 2001 Under intake manifold Fig 24 Lateral acceleration sensor see ABS DSC lateral acceleration sensor entries LDP see Fuel tank leakage diagnosis pump LDP or DMTL Leakage diagnosis pump LDP see Fuel ...

Page 1009: ...hometer Multiple restraint system MRS module see Airbag control module Navigation computer 1999 2001 Left side of trunk Neutral safety switch see Automatic transmission range switch OBD II connector 16 pin DLC 1999 2001 In left footwell top trim under left side of instrument cluster see also Data link connector Oil pressure switch 1999 2001 Left front of engine at oil filter housing Fig 26 Oil tem...

Page 1010: ...001 Rear bumper trim strip Fig 67 Park distance control warning speaker 1999 2001 Right rear speaker rear parcel shelf Parking brake warning switch 1999 2001 Under center console rear of parking brake handle Fig 49 Pedal position sensor see Accelerator pedal sensor PWG Pinch protection window see Window anti trap strip Power socket 12 volt Sport Wagon Cargo compartment behind left rear seat Fig 57...

Page 1011: ...ort Wagon Right rear cargo area behind trim panel Rear window washer pump Sport Wagon Behind panel in right rear cargo area Fig 56 Relay panel main 1999 2001 Behind glove compartment Resonance valve intake manifold 1999 2001 Left of intake manifold Fig 17 Reversing light switch see Back up light entries Ride level sensor see Headlight vertical aim sensor entries Ring antenna EWS see EWS ring anten...

Page 1012: ...eat belt lock Seat belt tensioner pyrotechnic left right 1999 2001 Base of seat belt lock left right Secondary air injection pump 1999 2001 Right side engine compartment above exhaust manifold Fig 17 Fig 30 Secondary air injection pump relay 1999 2001 Main relay panel behind glove compartment Fig 14 Fig 15 Secondary air injection pump valve 1999 2001 Left front of engine Fig 30 Shift interlock cab...

Page 1013: ...3 Sunroof sunshade switch 1999 2001 In center console ahead of shifter Supplemental restraint system SRS see Airbag entries Tailgate lock central locking Sport Wagon In tailgate lock Tailgate emergency release actuator Sport Wagon Rear deck sill under trim panel integrated with lock mechanism Tailgate unlock switch exterior Sport Wagon Above license plate Tailgate unlock switch interior Sport Wago...

Page 1014: ... control module see Automatic transmission module Transmission range switch see Automatic transmission range switch Transverse acceleration sensor see ABS DSC lateral acceleration sensor entries Trunk lid microswitch Sedan Coupe Convertible In trunk lid lock Trunk light switch Sedan Coupe Convertible In trunk lid lock Trunk lock central locking Sedan Coupe Convertible In trunk lid lock Turn signal...

Page 1015: ...indow lock out switch rear Sedan Sport Wagon Left side shifter bezel Window motors 1999 2001 Inside doors Window switches 1999 2001 On shifter bezel Windshield washer nozzle heaters 1999 2001 In nozzles at rear of engine hood Windshield washer pump 1999 2001 At rear of washer tank right front engine compartment Windshield washer relay 1999 2001 Left rear engine compartment in E box Fig 16 Wiper mo...

Page 1016: ...valve 8 Mass air flow sensor 9 Brake fluid level sensor 10 Ground lug X6454 11 Electronics box E box 12 Air quality sensor AUC for automatic recirculation control 13 Intake camshaft VANOS solenoid 14 Engine cooling fan electric Fig 18 Left rear corner of engine compartment near E box 1 Brake fluid level sensor 2 DSC precharge pump Teves DSC MK 20 60 3 Brake fluid pressure sensor Electrical Compone...

Page 1017: ...artment behind bulkhead 1 Wiper assembly electrical harness connector Fig 21 Under rear of intake manifold 1 Engine coolant temperature ECT sensor Fig 22 Left rear of engine block under intake manifold 1 Starter motor terminal 50 2 Starter motor terminal 30 3 Crankshaft position sensor Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 26 of 40 2 25 2009 1...

Page 1018: ...or cylinder 4 6 Fig 25 Center top of engine under covers 1 Intake air temperature IAT sensor 2 Ignition coils 3 Post catalyst oxygen sensor connectors 4 Precatalyst oxygen sensor connectors 5 Precatalyst oxygen sensors Fig 26 Left front of engine at oil filter housing 1 Oil coolant temperature sensor 2 Oil pressure switch Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Re...

Page 1019: ...mshaft position sensor Fig 29 Right front of engine top 1 Exhaust camshaft position sensor 2 Exhaust camshaft VANOS solenoid 3 Air quality sensor AUC for automatic recirculation control Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 28 of 40 2 25 2009 11 09 PM ...

Page 1020: ...t position sensor 2 Coolant outlet temperature sensor Fig 32 Top of A C receiver drier right front engine compartment 1 A C pressure sensor Car interior electrical components Fig 33 Front door window frame 1 Door mounted tweeter Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 29 of 40 2 25 2009 11 09 PM ...

Page 1021: ... Fig 35 Left side of steering column below dashboard 1 Steering angle sensor Fig 36 At ignition switch 1 EWS electronic immobilizer ring antenna Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 30 of 40 2 25 2009 11 09 PM ...

Page 1022: ... 1 EWS control module Fig 39 Left side IHKA housing below instrument cluster 1 A C evaporator temperature sensor Fig 40 Right side IHKA housing below glove compartment 1 Blower motor resistor pack Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 31 of 40 2 25 2009 11 09 PM ...

Page 1023: ...airbag connector Fig 42 In windshield pillar A pillar 1 Head protection airbag HPS electrical connector Fig 43 In headliner 1 Sunroof motor Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 32 of 40 2 25 2009 11 09 PM ...

Page 1024: ...er console utility bin 1 Heater core temperature sensor Fig 46 Under shifter bezel 1 Shiftlock solenoid Fig 47 At shifter bezel 1 Gear position indicator light Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 33 of 40 2 25 2009 11 09 PM ...

Page 1025: ... handle 1 Parking brake warning switch Fig 50 Driver seat Convertible seat front view 1 Seat memory module 2 Seat control switch module 3 Seat tilt motor 4 Seat forward back motor Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 34 of 40 2 25 2009 11 09 PM ...

Page 1026: ...side Electric fuel pump and fuel level sender connector 2 Left side Fuel level sender connector Electrical components in luggage cargo compartment Fig 53 Right side trunk 1 Rear window defogger relay 2 F108 200 amp fuse in main harness 3 Battery safety terminal BST explosive charge Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 35 of 40 2 25 2009 11 09...

Page 1027: ... Trunk below parcel shelf 1 Telephone transceiver Fig 56 Right cargo area behind trim panel Sport Wagon 1 Rear window washer pump Fig 57 Left cargo area Sport Wagon Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 36 of 40 2 25 2009 11 09 PM ...

Page 1028: ...h right side of engine at lower end of front exhaust pipes 1 Post catalyst oxygen sensors Fig 59 At front subframe right side 1 Front ride level sensor Fig 60 Right front steering arm rear wheel drive model shown Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 37 of 40 2 25 2009 11 09 PM ...

Page 1029: ...s similar Fig 62 In left front wheel housing 1 ABS wheel speed sensor connector 2 pin grey 2 Brake pad wear sensor connector 2 pin black Note Right rear wheel speed sensor connector is similar The right front and left rear brake pads lack the wear sensor Fig 63 Rear of automatic transmission GM Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 38 of 40 2 ...

Page 1030: ...ght switch 3 Transmission control AGS harness connector Fig 65 Underneath trunk 1 LDP DMTL fuel tank diagnosis pump Convertible top electrical components Fig 66 Convertible 1 Visor latch hall sensors 2 Solenoid valves 3 Tension bow hall sensor 4 Main pillar hall sensor Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 39 of 40 2 25 2009 11 09 PM ...

Page 1031: ...ch 13 Convertible top switch 14 Cover lock motor hall sensor 15 Convertible top module CVM II 16 Storage cover and hard top lock hall sensor 17 Storage cover hall sensor Exterior electrical components Fig 67 Rear bumper 1 Park distance control PDC ultrasonic sensors Copyright 2006 Robert Bentley Inc All rights reserved Electrical Component Locations http ebahn bentleypublishers com BMW 3 E46 Repai...

Page 1032: ...and relays for the wiper washer system are covered in Electrical Wiring Diagrams Special tools Although most wiper system repairs can be carried out with normal shop tools a few special tools may be necessary as well Headlight washer nozzle aligning tool BMW 00 9 100 Rear wiper drive aligning tool BMW 61 1 330 Wiper arm removal tool BMW 61 6 060 Wipers and Washers http ebahn bentleypublishers com ...

Page 1033: ...ribed below Some functions or components are optional as indicated Wiper washer stalk switch The system has four wiper settings for the windshield at the steering column stalk switch The settings are A Single wipe hold stalk switch down B Off C Interval thumb wheel on stalk switch D Slow automatically switches to interval when car is stopped E Fast automatically switches to slow speed when car is ...

Page 1034: ... The infrared rain sensor and module switch on the windshield wipers automatically when water drops are detected on the windshield The rain sensor system is described more fully below Windshield headlight washer fluid tank is in right front of engine compartment Windshield washer pump is in rear portion of front washer tank arrow Headlight washer pump optional is in front portion of front washer t...

Page 1035: ...ed Rear window wiper assembly Sport Wagon is mounted to the tailgate and linked to the rear wiper shaft via a mechanical coupling Rear washer fluid tank and pump Sport Wagon is mounted in the right cargo compartment behind trim panel Fill reservoir through cap in right side rear deck pillar The rear window wiper washer system is described more fully below Table a Wiper interval seconds Thumb wheel...

Page 1036: ...Windshield wiper washer system Wipers and Washers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 5 of 11 2 25 2009 11 10 PM ...

Page 1037: ...dshield at a set angle The beam is reflected back and forth within the windshield until it is detected by the detector component of the rain sensor Rain drops or other impurities on the outside of the windshield cause some of the infrared to be dissipated outside the windshield As a result the detector sees less infrared intensity This is interpreted as a need for the wiper to be turned on System ...

Page 1038: ...rain sensor has a defect and operates the intermittent wipe function as a system not equipped with a rain sensor The wiper intermittent cycling is based solely on the knurled wheel setting The rain sensor continuously monitors the windshield for rain accumulation and signals the GM V to activate the wipers based on the knurled wheel position and how fast rain accumulates on the windshield The knur...

Page 1039: ... wheel setting is adjusted The wash function is activated The reasoning behind this switching strategy is to have the driver make a conscious decision to activate the system The rain sensor control module adapts to the optics system environment as follows Windshield aging As the vehicle ages windshield pitting in the rain sensor monitoring area may cause a loss of light in the optics system The co...

Page 1040: ...s which lengthens the time intervals on an intermittent wipe CAUTION On rain sensor equipped models make sure the wiper blades are in perfect condition Only use window cleaner to clean the windshield Note A dirty windshield can cause the rain sensor control module to set a fault due to approaching limits of its adaptation abilities Rain sensor system Wipers and Washers http ebahn bentleypublishers...

Page 1041: ...This is triggered by pressing the stalk switch forward to the first detent Full sweep and park position of the wiper arm are recognized by two hall sensors on the motor assembly If the wiper is switched OFF the wiper arm will return to the park position Programmed interval wipe Quickly switch rear wiper ON and OFF Wait the needed interval time Switch rear wiper ON again The OFF time will be the pr...

Page 1042: ...ash cycle 2 Washer pump ON for 0 5 second after 0 8 second delay Wiper continues Wash cycle 3 Washer pump ON for 0 5 second after 0 8 second delay Wiper ON for two wipe dry cycles Note After washing the rear wiper will remain in interval normal wiping mode until switched OFF Rear wiper washer system Copyright 2006 Robert Bentley Inc All rights reserved Wipers and Washers http ebahn bentleypublishe...

Page 1043: ...should be replaced BMW recommends replacing the wiper blades twice a year before and after the cold season Water drops that remain behind after wiping are usually caused by oil road film or diesel exhaust residue on the glass Use an alcohol or ammonia solution or a non abrasive cleaner such as Bon Ami to clean the windshield Chatter may be caused by dirty or worn blades or by wiper arms that are o...

Page 1044: ...o replace just the inserts every second time Wiper blades replacing To replace wiper blades Pivot wiper arm off windshield Position wiper blade approximately perpendicular to wiper arm Remove wiper blade from wiper arm by depressing retaining tab arrow and sliding blade out of arm Installation is reverse of removal Install wiper blade to wiper arm until retaining tab can be heard to click into pos...

Page 1045: ...to slots in new insert noting installation direction of cutouts in support strips Slide new insert through wiper blade guides Lock insert in place at end guides Note The notched cutouts in the retaining strips should engage the molded notches in the inserts Wiper arms removing and installing Note Wiper arm removal and installation on the Sport Wagon rear window is similar to the operation on the f...

Page 1046: ...sition remove both wiper blades Open hood Gently pry off caps covering wiper arm retaining nuts Remove each wiper arm retaining nut arrow Detach arm from shaft Note Use BMW special tool 61 6 060 or equivalent puller to remove arm If wiper arm sleeve arrow at shaft is loose it must be replaced Install arms and thread nuts on loosely Torque nuts after installing wiper blades Tightening torque Wipers...

Page 1047: ...of wiper arms from lower portion of window gasket with wiper blades installed before tightening to correct torque Wiper blade park position Front wiper blade tip distance from windshield gasket Right blade 24 mm 1 in Left blade 44 mm 1 7 in Rear wiper blade tip distance from rear window gasket 12 mm 1 2 in Copyright 2006 Robert Bentley Inc All rights reserved Wipers and Washers http ebahn bentleyp...

Page 1048: ...er 3 Damping ring 4 Motor and rod assembly 5 Rubber damper 6 Center mounting bolt tighten to 10 Nm 88 in lb Note BMW does not provide the windshield wiper motor as a separate component It may be necessary to raise the hood to the service position to access the wiper arm fasteners See 410 Fenders Engine Hood CAUTION Make sure wipers are parked stalk switch in OFF position and the ignition is also O...

Page 1049: ...nd 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 Remove heater bulkhead cover mounting screws B and lift cover up and out from firewall Detach wiper assembly inside cowl Remove assembly center mounting bolt A Disconnect electrical harness connecto...

Page 1050: ...sheet metal with thick tape to prevent damage during wiper assembly removal Installation is reverse of removal noting the following Fit center mounting rubber damper over pin A into wiper motor mounting arm B Install all fasteners finger tight first Once installed wiper motor should first be run to parked position and switched off Wipers and Washers http ebahn bentleypublishers com BMW 3 E46 Repai...

Page 1051: ...ly mount to cowl 10 Nm 88 in lb Wiper arm to wiper shaft 30 Nm 22 ft lb Wiper shaft nut at cowl 10 Nm 88 in lb Rear window wiper motor removing and installing Sport Wagon Remove rear deck interior trim panel Detach electrical harness connector s and remove screws mounting motor assembly to rear deck lid Remove motor assembly 1 Plastic trim 2 Rear wiper pivot assembly 3 Nut M6 tighten to 9 5 Nm 7 f...

Page 1052: ...1 1 330 on rear window wiper drive and close rear window With rear wiper vertical allow rear wiper shaft mechanical coupling to snap into special tool bore Tighten down wiper motor assembly Remove special tool Remainder of assembly is reverse of removal Tightening torque Wiper motor to rear deck Torx 9 5 Nm 7 ft lb Rear window wiper shaft removing and installing Sport Wipers and Washers http ebahn...

Page 1053: ... and bearing out of housing Installation is reverse of removal Adjust wiper arm position as described earlier Tightening torques Rear window button to rear window 9 5 Nm 7 ft lb Wiper arm to wiper shaft 9 5 Nm 7 ft lb Wiper shaft housing to rear window 9 5 Nm 7 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Wipers and Washers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals...

Page 1054: ...agon only consists of a washer tank and pump in the right side cargo compartment behind a trim panel and a spray nozzle at the top of the rear window frame Windshield spray nozzle removing and installing Working under open engine hood gently squeeze retaining clips arrows on nozzle sides to free nozzle from plastic intake grille Carefully disconnect hose from nozzle Disconnect harness connector fo...

Page 1055: ... on the underside Do not mix them up Prior to removal cover spray nozzle with shop rag Wash water drains out Gently pry out spray nozzle and pull out to stop Tug on nozzle to detach from washer fluid duct Transfer trim to new nozzle before installing Snap new nozzle on fluid duct by pushing into opening Check to make sure nozzle is fully snapped into place Using BMW special tool 00 9 100 or equiva...

Page 1056: ...eservoir and washer fluid pumps replacing Open hood and siphon washer fluid from reservoir Detach washer fluid level sensor harness connector A in front bottom of fluid reservoir Remove reservoir retaining screw arrow Lift reservoir Pry gently at retaining clip arrow on heat shield to disengage from reservoir Cut off wire tie to release washer pump harness from heat shield Lay heat shield aside Wi...

Page 1057: ...se of reservoir Transfer reservoir cover and strainer to new container Coat fluid pump sealing ring with anti friction agent On installation check that fluid hoses are not kinked Make sure reservoir heat shield is correctly engaged Replace wire tie Refill reservoir Front washer fluid level sensor replacing Remove front washer fluid reservoir Twist washer fluid level sensor Wipers and Washers http ...

Page 1058: ...e into rubber strip Adjust nozzle spray pattern using alignment specifications Rear window spray nozzle alignment specifications A 100 mm 3 9 in B 320 mm 12 6 in Rear window washer fluid reservoir replacing Sport Wagon Working in right rear cargo area remove side trim panel then remove sound insulation Siphon out washer fluid reservoir Wipers and Washers http ebahn bentleypublishers com BMW 3 E46 ...

Page 1059: ...eservoir To remove fluid pump Detach electrical harness connector B Pry pump gently outward and up to remove from tank When installing Coat pump sealing ring with anti friction agent Make sure hoses are not kinked Refill reservoir Copyright 2006 Robert Bentley Inc All rights reserved Wipers and Washers http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 6 of 6 2 25 2009 11 11 PM ...

Page 1060: ... 250 Gearshift Linkage for information about the gearshift lever 515 Central Locking and Anti theft for information about the electronic immobilization system EWS 3 3 520 Seats for information about power seat controls 540 Sunroof 541 Convertible Top 610 Electrical Component Locations 630 Lights Electrical Wiring Diagrams Special tools A few special tools are necessary for Switches http ebahn bent...

Page 1061: ... accidental reconnection Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii To prevent marring the trim when working on interior components work with plastic prying tools or wrap the tips of screwdrivers and pliers with tape before prying out switches or electrical accessories Copyright 2006 Robert Bentley Inc All rights reserv...

Page 1062: ...the airbag could cause serious injury Store the airbag with the horn pad facing up If stored facing down accidental deployment could propel it violently into the air causing injury CAUTION Special test equipment is required to retrieve SRS fault codes diagnose system faults and reset turn off the SRS indicator light The SRS indicator light will remain on until any problem has been corrected and th...

Page 1063: ...ight switch set Note BMW does not provide the horn contact switch as a separate part Sport steering wheel switches accessing Remove airbag Note There is a special procedure for detaching the airbag from the sport steering wheel See 721 Airbag System SRS Remove screws mounting switch carrier to steering wheel 1 Switch carrier 2 Steering wheel switch set electrical harness 3 Airbag 4 Lower cover Swi...

Page 1064: ...eel Remove electrical harness connector Separate bottom trim piece from switch carrier Note BMW does not provide the horn contact switch as a separate part Copyright 2006 Robert Bentley Inc All rights reserved Switches http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 3 of 3 2 25 2009 11 12 PM ...

Page 1065: ...the EWS 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 With ignition key in ON position 60 from LOCKED Insert a thin piece of stiff wire into opening arrow in lock cylinder and pull lock cylinder out Detach...

Page 1066: ...ve 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 Remove airbag unit from steering wheel See 721 Airbag System SRS Store airbag unit in a safe place with pad facing up WARNING Any work involving the SRS system should only be performed by an authorized BM...

Page 1067: ...ft before disassembly Remove steering column trim See 513 Interior Trim Detach EWS ring antenna electrical harness connector arrow Detach wiper washer switch electrical harness connector arrow Detach turn signal headlight dimmer switch electrical harness connector arrow Switches http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 3 of 5 2 25 2009 11 12 PM ...

Page 1068: ...center position before installing Ensure that self cancelling cams on turn signal switch are not damaged during installation Tightening torque Steering wheel to steering column spindle shaft 63 Nm 46 ft lb Turn signal headlight dimmer switch wiper switch removing and installing After removing steering column stalk switch assembly as Switches http ebahn bentleypublishers com BMW 3 E46 Repair 20Manu...

Page 1069: ... arrows on sides of switch and slide switch out of assembly holder Push in new switch until it positively snaps into switch housing Copyright 2006 Robert Bentley Inc All rights reserved Switches http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 5 of 5 2 25 2009 11 12 PM ...

Page 1070: ...rear of car Note The brake light switch is held in place via a serrated mounting Remove switch mounting from pedal cluster bracket Push brake pedal down install new switch then allow brake pedal to spring back slowly automatically adjusting switch position Cruise control clutch switch replacing Working at pedal cluster Push clutch pedal to floor and lock in position using a pedal stop Detach elect...

Page 1071: ...out of holder toward rear of car Install new switch then allow clutch pedal to spring back slowly automatically adjusting switch position Copyright 2006 Robert Bentley Inc All rights reserved Switches http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 2 2 25 2009 11 13 PM ...

Page 1072: ...out switch sedan and Sport Wagon models on the left side of the shifter The central locking switch and hazard warning switch are ganged into one unit behind the shifter mechanism Replacement of the above switches is covered below noting when each switch is accessible The left and right electric outside rear view mirrors are controlled by one switch on the driver door armrest Lower dashboard consol...

Page 1073: ...witches Shifter bezel Lift up by prying gently Shifter boot Unclip bottom of boot from center console trim by pushing forward Pull boot up around shifter but do not remove Unclip switch retainer A and pull out switches from under console trim Detach electrical harness connector B from switches Installation is reverse of removal Switches http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6...

Page 1074: ...pull out Remove retaining screws from storage compartment ash tray housing Slide housing out and disconnect electrical harness connectors Remove housing from lower dashboard With housing removed slide switches out of housing by gently pushing from behind Installation is reverse of removal Central locking hazard warning switches replacing Working at rear of center console press rolling cover of rea...

Page 1075: ...r console back from dash and lift up Disconnect electrical harness protector from hazard light central locking switch To remove switch from console depress retaining tabs on each side of switch and push switch out through surface of console trim Installation is reverse of removal Outside mirror switch replacing Carefully pry outside mirror switch from door arm rest Disconnect harness connector Swi...

Page 1076: ...from switch Installation is reverse of removal Copyright 2006 Robert Bentley Inc All rights reserved Switches http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 5 of 5 2 25 2009 11 13 PM ...

Page 1077: ...Stabilant 22A Electrical contact enhancer Experience has found that the use of an electrical contact enhancer will help prevent oxidation and intermittent circuit malfunctions at electrical harness connectors CAUTION When servicing the instrument cluster always disconnect the negative cable from the battery and insulate the cable end to prevent accidental reconnection Copyright 2006 Robert Bentley...

Page 1078: ...ts to engine management DME transmission control AGS and traction stability control ASC DSC D bus connects to 20 pin Diagnostic Link Connector DLC and or 16 pin OBD II diagnostic connector The instrument cluster stores and communicates Diagnostic Trouble Codes DTCs via the D bus diagnostic link If the vehicle is equipped with On Board Computer pushing the button at the end of the directional stalk...

Page 1079: ...ific vehicle information is stored redundantly in the instrument cluster and the light control module This information includes Vehicle identification number VIN Total vehicle mileage and Service interval data Instrument cluster layout The instrument cluster uses stepper motor driven analog gauges for display of engine and road speed engine temperature fuel level and economy 1 Fuel Gauge 2 Left di...

Page 1080: ...etc In addition three LCD blocks display Check Control pictographs Service interval and mileage On Board Computer Automatic transmission range program and failure display Warning indicators and lamps are arranged to the right and left of the LCD blocks The ASC DSC light charge indicator high beam and oil pressure lamps are located between the speedometer and tachometer The instrument cluster is a ...

Page 1081: ...E46 instrument cluster Instruments http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 4 of 9 2 25 2009 11 14 PM ...

Page 1082: ...ults There are a total of 21 test menus Table a Instrument cluster test functions lists instrument cluster test menus and submenus To scroll through numbered test menus Make sure ignition switch is OFF Press and hold left cluster button Turn ignition switch to radio Test 1 main menu will be displayed Do nothing and display will automatically scroll through Test 1 submenus Tap or press instrument c...

Page 1083: ... automatically scroll through 0 9 within each group 1s 10s 100s Table a Instrument cluster test functions Menu Submenu Sample output Meaning Test 1 Vehicle specific data see Note below 1 0 12345 Vehicle identification number VIN 1 1 4812 Body number 6_1 2 834762 Part number of cluster 1 3 010203 Coding diagnosis bus index 1 4 3499 Manufacturing date calendar week year 1 5 04_600 Hardware software ...

Page 1084: ...ensor input in liters 6 0 237415 Fuel level averaged Left side fuel sensor input 23 7 liters Right side fuel sensor input 41 5 liters 6 1 0652 Total tank level averaged 65 2 liters 1_6 2 0667 Indicated value and tank phase 1 Both sensors OK 2 One sensor faulty 3 Implausible input Test 7 Temperature and speed 7 0 032 Coolant temperature input 32 C 7 1 245 Outside temperature input 24 5 C 7 2 5283 E...

Page 1085: ...functions press cluster button immediately when it changes to L OFF Tests are automatically locked when exiting test functions 19 0 L OFF Test 20 Average fuel consumption correction factor see Note 20 0 XXX9 Press button when correct 1s position is attained 20 1 XX5X Press button when correct 10s position is attained 20 2 12XX Press button when correct 100s position is attained Test 21 Software re...

Page 1086: ... detach trim by unlocking plastic clips arrows and pushing through slots Installation is reverse of removal noting the following Instrument cluster harness connector locking levers must be in up position before installing connector Recode new or replacement cluster using BMW scan tools DISplus MoDiC or equivalent Copyright 2006 Robert Bentley Inc All rights reserved Instruments http ebahn bentleyp...

Page 1087: ...light fixtures Plastic trim prying tool BMW 00 9 321 Foglight headlight adjusting tool 4 mm 6 mm Allen Bulb applications For convenience the bulb applications for E46 cars are listed in Table a Table a E46 bulb applications Location Type rating Headlights High beam H7 12V 55W Low beam Halogen H7 12 V 55 W Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 1 of 6 2 25 2009 11 14 P...

Page 1088: ...D Turn signal front or rear 12V 21W Interior lights Footwell Softlite 5W Glove compartment Softlite 5 W Passenger compartment front or rear Softlite 5W Reading front or rear 6W Trunk or tailgate Softlite 10W Visor vanity Softlite 10W Light switch center LSZ The light switch center LSZ mounted in the left side of the dashboard consists of the following components Lights http ebahn bentleypublishers...

Page 1089: ...bulbs Emergency lighting function Short circuit protection Redundant storage of mileage and service interval data Automatic headlight adjustment LWR programmed control if equipped Bulb monitoring The light control module monitors the following bulbs in both hot and cold states High low beams Brake lights Turn signal lights Taillights Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manua...

Page 1090: ...ve the vehicle and enter their house The feature is switched on by activating the headlight flasher switch after the lights and ignition are switched OFF The feature is switched off after the coded time delay or by switching the ignition ON Redundant data storage The light control module serves as the redundant storage module in parallel with the instrument cluster This includes all data used for ...

Page 1091: ...sed WARNING When working on electrical systems remove the fuse protecting the circuit under repair See 610 Electrical Component Locations CAUTION The headlight and foglight assemblies use halogen bulbs To ensure the longevity of halogen bulbs the bulb glass should not be handled Dirt and skin oils may cause a bulb to fail prematurely If necessary wipe bulb using a clean cloth dampened with rubbing...

Page 1092: ...ing car paint or trim work with plastic prying tools or wrap the tips of tools with tape Copyright 2006 Robert Bentley Inc All rights reserved Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 6 of 6 2 25 2009 11 14 PM ...

Page 1093: ...aw from dashboard Note If the vehicle is equipped with a left side glove compartment remove the compartment for improved access to the back of the headlight switch and its electrical harness Remove the left side footwell trim above the pedals for better access to the headlight switch electrical harness See 513 Interior Trim To release harness connector latch Lights http ebahn bentleypublishers com...

Page 1094: ...emove light switch assembly as described earlier Press in on tabs arrows in light switch assembly to separate light switch from light control module Gently wiggle harness connector to remove from switch Copyright 2006 Robert Bentley Inc All rights reserved Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 2 2 25 2009 11 14 PM ...

Page 1095: ...adlight bulbs Cars equipped with Xenon headlights also feature automatic headlight adjustment control LWR for varying passenger and cargo loads Components of the headlight system can be purchased from BMW Use illustrations on the following pages to identify components Headlight aim adjusting Adjust headlight aim with correct tire pressures fuel tank full and weight of one person approx 75 Kg 200 l...

Page 1096: ...en headlight assembly 1 Mounting screw 2 Expanding nut 3 High beam cover 4 High beam bulb 5 High beam bulb socket 6 Low beam bulb socket 7 Low beam bulb 8 Low beam cover 9 Headlight housing 10 Sealing gasket 11 Cover 12 Cover lock strip Xenon headlight asembly Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 10 2 25 2009 11 15 PM ...

Page 1097: ...trol module bracket 7 High beam cover 8 High beam bulb 9 High beam bulb socket 10 Low beam cover 11 Xenon bulb ignition element 12 Supporting ring 13 Xenon low beam bulb 14 Headlight assembly carrier plate 15 Headlight housing 16 Sealing gasket 17 Cover Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 3 of 10 2 25 2009 11 15 PM ...

Page 1098: ...ight out of socket Replace bulb by pushing firmly into socket Headlight bulb applications are listed below Installation is reverse of removal Note To remove left side high beam bulb remove air filter housing cover See 020 Maintenance CAUTION Do not touch halogen bulbs with your bare hands If necessary wipe bulb using a clean cloth dampened with rubbing alcohol Headlight bulb Xenon Lights http ebah...

Page 1099: ...ed below CAUTION Do not touch bulbs with your bare hands If necessary wipe bulb using a clean cloth dampened with rubbing alcohol Headlight bulb application Low beam Halogen H7 12V 55W Low bean Xenon D2 S High beam H7 12V 55W Headlight assembly removing and installing CAUTION Following headlight assembly work headlight beam aim must be adjusted using special equipment Disconnect harness connectors...

Page 1100: ... group Use plastic prying tool to detach and remove trim piece below headlight assembly Remove headlight mounting screws arrows Lift headlight assembly forward and out of car During reassembly Install top mounting screws hand tight Pull headlight assembly toward front of car Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 6 of 10 2 25 2009 11 15 PM ...

Page 1101: ...sion A 5 0 1 0 mm 0 2 0 04 in Adjust headlight aim as described earlier Headlight lens removing and installing If necessary remove headlight washer spray nozzles See 611 Wipers and Washers Remove front turn signal assembly as described later in this repair group Use plastic prying tool to detach and remove trim piece below headlight assembly Lights http ebahn bentleypublishers com BMW 3 E46 Repair...

Page 1102: ...cles equipped with the optional Xenon low beam headlight bulbs also feature automatic headlight adjustment LWR This system automatically adjusts the vertical positioning of the headlights to maintain optimum headlight beam angle for maximum driving visibility and to prevent undue glare for oncoming motorists The system compensates for vehicle load Lights http ebahn bentleypublishers com BMW 3 E46 ...

Page 1103: ...of the headlight beams At each axle of the vehicle the LWR sensor A is mounted to a fixed point on the suspension subframe A lever B is connected to the moving suspension member The sensor output voltage changes as the suspension moves up and down All LWR diagnosis is accessed through the light control module Note LWR is not available with standard halogen headlights Headlight vertical aim system ...

Page 1104: ...r mounting bracket 9 Bolt M6 10 Rear ride height sensor 11 Self locking nut M6 12 Rear ride height sensor link 13 Extension 14 Bracket 15 Bolt M6 Copyright 2006 Robert Bentley Inc All rights reserved Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 10 of 10 2 25 2009 11 15 PM ...

Page 1105: ... outer edge of foglight Coupe or Convertible Use adjuster arrow on inside upper edge of foglight 2001 models Using plastic pry tool pry off foglight cover at slot arrow Adjust using 6 mm Allen on outside upper corner of foglight Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 1 of 3 2 25 2009 11 15 PM ...

Page 1106: ...ve lower bumper trim Working at foglight detach grille and loosen mounting screws Remove foglight assembly with grille attached Detach electrical harness connector Unclip grille from foglight 1 Grille 2 Foglight 3 Adjuster 4 Support with grommet 5 Foglight bulb 6 Body nut 7 Self tapping screw Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 3 2 25 2009 11 15 PM ...

Page 1107: ...ed earlier Twist and remove bulb from rear of foglight assembly CAUTION Do not touch halogen bulbs with your bare hands If necessary wipe bulb using a clean cloth dampened with rubbing alcohol Installation is reverse of removal Check electrical connector for corrosion Spray with contact cleaner if necessary Foglight application Front foglight bulb HB4 Copyright 2006 Robert Bentley Inc All rights r...

Page 1108: ...eadlight assembly frame Screwdriver must reach into fender hole a minimum of 3 in to reach the retaining tab Push turn signal forward Light slides straight out Detach electrical harness connector Twist and remove bulb from rear of turn signal assembly CAUTION Do not touch bulb with your bare hands If necessary wipe bulb using a clean cloth dampened with rubbing alcohol Note Lights http ebahn bentl...

Page 1109: ...ying tool to gently lever assembly out of fender Side turn signal Side light bulb 12V 5W Taillight assembly removing and installing Taillight assembly 1 Backup light bulb 12V 21W 2 Rear foglight bulb Euro only 12V 21W 3 Trunk lid tailgate bulb carrier 4 Trunk light bulb 12V 10W 5 Taillight brake light bulb 12V 21 4W 6 Turn signal bulb 12V 21W 7 Brake light bulb 12V 21W 8 Corner bulb carrier Lights...

Page 1110: ... only To access taillight bulbs carriers open trunk lid or tailgate To access corner bulbs Sport Wagon Remove cargo area side trim See 513 Interior Trim Unlatch bulb carrier retainer arrow then pull carrier off taillight assembly Detach electrical harness connector Replace bulbs as necessary CAUTION Do not touch bulb with your bare hands If necessary wipe bulb using Lights http ebahn bentleypublis...

Page 1111: ...er retainer arrow then pull carrier off Detach electrical harness connector Replace bulb s as necessary CAUTION Do not touch bulb with your bare hands If necessary wipe bulb using a clean cloth dampened with rubbing alcohol Installation of either bulb carrier is reverse of removal Taillight applications Backup light bulb 12V 21W Brake light bulb 12V 21W Brake light taillight bulb 12V 21 4W Rear fo...

Page 1112: ...er trunk lid trim adjacent to license plate light assembly Detach electrical harness connector Push center brake light out Sport Wagon Open rear window Carefully detach rear window hinge cover Remove rear spoiler mounting bolts arrows Detach electrical harness connector and rear washer hose from spoiler Remove mounting screws and remove third brake light assembly from spoiler When installing be su...

Page 1113: ...of license plate light assembly arrow Lift off lens CAUTION To avoid marring trim wrap the screwdriver tip with tape Remove bulb Note Inspect bulb contact springs for damage and corrosion Replace socket assembly if necessary License plate light application License plate bulb 12V 5W Installation is reverse of removal Copyright 2006 Robert Bentley Inc All rights reserved Lights http ebahn bentleypub...

Page 1114: ... A change in current flow informs the GM V when a door is opened or closed The overhead front seat interior map light unit contains a single main interior light The light is controlled by the GM V automatically or by momentarily pressing the interior light switch located on the light assembly The switch provides a momentary ground signal that the GM V recognizes as a request to either turn the lig...

Page 1115: ...depressing the corresponding switch The power supply for the map lights is supplied by the GM V There is a courtesy light in each front footwell These lights are only operated when the GM V provides power to the interior lighting circuit Interior lighting system Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 5 2 25 2009 11 15 PM ...

Page 1116: ...exterior lights on for minimum of 2 minutes when ignition switch is OFF Active crash signal from MRS II control module Lock button of FZV key pressed with vehicle already locked interior search function Immediately after ignition switch is turned to radio position with driver door closed When vehicle is locked single or double with door contacts closed When vehicle door contacts are closed Lights ...

Page 1117: ...or light fixture gently to remove Detach electrical harness connector Remove bulb and replace CAUTION When replacing bulbs do not touch glass of bulb with fingers Only touch bulb with clean cloth or bulb packaging Installation is reverse of removal Bulb types and specifications for various interior lamps are listed below Interior light applications Footwell light bulb Softlite 5W Glove compartment...

Page 1118: ...ights are integrated with the taillight assembly Pry trunk light cover arrow gently to remove from taillight corner bulb carrier Remove bulb and replace Installation is reverse of removal Trunk light application Trunk light bulb Softlite 10W Copyright 2006 Robert Bentley Inc All rights reserved Lights http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 5 of 5 2 25 2009 11 15 PM ...

Page 1119: ...ng System Special tools Some special tools are necessary for heating and A C repair procedures A variety of A C system evacuation and recharge equipment is available Follow the equipment manufacturer s recommendations and instructions Plastic tool for prying off interior trim BMW 00 9 321 IHKA control panel removal tools BMW 64 1 010 A C line plug kit BMW 64 5 100 Note A C system recharging proced...

Page 1120: ...emperature regulation Maximum heating and cooling for defroster functions Rear window defogger operation integrated into the heating cooling system Blower controlled through a final stage variable resistor Road speed dependent air distribution and fresh air volume Self calibrating air distribution stepper motors controlled via M bus Fresh air microfilter system Electronically regulated A C compres...

Page 1121: ...Heater control personalization via Car Memory Key Memory E46 IHKA control Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 3 of 22 2 25 2009 11 16 PM ...

Page 1122: ... 1 Manual air distribution control buttons 2 Interior temperature sensor intake outlet 3 LCD matrix 4 A C control snowflake 5 Windshield defrost control 6 Rear window defogger control 7 Recirculation control 8 Blower control 9 Temperature control 10 Automatic air distribution The IHKA control module integral with Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manu...

Page 1123: ...he control module is replaced it must be recoded using BMW scan tools DIS or MoDiC Heat regulation The E46 uses a single water valve and heater core to provide passenger compartment heat The water valve is electrically pulsed to control the flow of coolant through the heater core Temperature regulation is based on the following inputs Temperature control switch setting Interior temperature sensor ...

Page 1124: ... panel is the master switch for the entire system Rocking the switch to select slower and slower fan speeds eventually results in the following Blower motor turns off All air distribution valves are closed LED and LCD displays are switched off Rear window defroster is switched off A C compressor is switched off Even in the lowest setting the interior temperature sensor blower continues to operate ...

Page 1125: ... activate the compressor The IHKA control module sends the following signals to the ECM over the K bus and CAN bus via the instrument cluster Request for A C activation Load torque for switching the compressor Requested cooling fan speed The IHKA determines the load torque for compressor activation and required engine cooling fan speed from the pressure sensor mounted on the receiver dryer The pre...

Page 1126: ...e fan through a pulse modulated final stage control See 170 Radiator and Cooling System for further details Note Automatic transmission models The engine cooling fan is located in front of the radiator A belt driven fan and fan clutch assembly is installed at the rear of the radiator Standard transmission models The electric engine cooling fan is installed at the rear of the radiator A C system He...

Page 1127: ...Blower runs at maximum speed Rear window defroster is switched on Note When windshield defrosting is turned on the A C compressor does not run automatically although it can be turned on manually Air distribution control via M bus Five stepper motors control fresh heated and air conditioned air distribution 1 Face vent Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 2...

Page 1128: ...motor arrow allows ventilation air temperature to be controlled by the driver or passenger When fresh air is selected the fresh air inlet distribution flaps are positioned according to road speed and blower motor speed The motors close the air inlet flaps incrementally according to road speed but the motion is dampened to avoid closing and opening continually due to slight speed changes Heating an...

Page 1129: ...atic closing of footwell flaps with A C activation Automatic closing of defroster flaps with A C activation Adjustments to set temperature Automatic activation of compressor control when the ignition is switched on Auto program for blower control when the ignition is switched on These features are programmed using the coding programming function of the DIS MoDiC Note See 515 Central Locking and An...

Page 1130: ...ved for 15 minutes after which the IHKA system reverts to fresh air mode This feature can be over ridden using the Car Memory feature so that recirculating interior air is automatically selected on engine start up Fresh air micro filter system A fresh air micro filter system is used in all E46 models The filter is housed below the fresh air inlet at the rear of the engine compartment The filter ca...

Page 1131: ... 80 seconds off for 5 minutes The defogger element in the rear glass is integrated with the radio antenna The rear window defogger relay arrow is located in the right side of the luggage or cargo Sport Wagon compartment behind the trim Convertible heated rear window In the E46 Convertible both the soft top and the hard top are equipped with rear window defogger Power is supplied by two relays loca...

Page 1132: ...sound system to switch stereo sound ON when top is up stereo sound OFF when top is down Solar sensor The purpose of the solar sensor is to detect and relay information about the amount and intensity of solar heating to the IHKA control module The settings of the climate control system are changed to compensate for this additional influence The solar sensor consists of a photoresistor installed in ...

Page 1133: ...ing Blower The blower activation curve is changed Ventilation The opening angles of air distribution flaps are changed Troubleshooting of the solar sensor is carried out through the IHKA diagnostic program incorporated in DIS or MoDiC The IHKA control module may set codes indicating a short or an open circuit To access the solar sensor remove the trim in front of the main dashboard panel ahead of ...

Page 1134: ...ling System Refrigerant leak Use diagnostic equipment to pinpoint refrigerant leaks Replace leaky components or seals Note Diagnosis of A C system components is beyond the scope of this manual Follow the equipment manufacturer s instructions Odors MIldew in the IHKA housing and in the evaporator fins can cause strong odors Working under right side of dash remove blower fan resistor pack arrow as d...

Page 1135: ...n be stored in the EEPROM when the ignition is switched off The E46 IHKA module is connected to the Diagnostic Link Connector DLC via the K bus instrument cluster Use DIS MoDiC or other suitable scan tool to access DTCs When troubleshooting problems with the E46 IHKA it is important to note that because the Car Memory Key Memory feature can change the functionality of the system a review of memory...

Page 1136: ...cified temperature 16 to 32 C 61 to 90 F 22 C 72 F Note The substitute value for the evaporator temperature sensor is below the A C compressor cycling temperature 2 C 34 F If the evaporator temperature sensor signal is not plausible the substitute value will switch the A C OFF Table b lists resistance values and fault limits for IHKA temperature sensors Table b Temperature sensor resistance values...

Page 1137: ...ues Table c A C evaporator temperature sensor resistance values Temperature C F Resistance range k 5 23 11 7 11 9 0 32 8 8 9 2 5 41 6 8 7 2 10 50 5 3 5 6 15 59 4 2 4 5 20 68 3 3 3 6 25 77 2 6 2 9 30 86 2 1 2 3 35 95 1 7 1 9 Table d lists A C expansion valve pressure values Table d Expansion valve pressure values Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manua...

Page 1138: ...water for 15 minutes rush to a doctor or hospital do not attempt to treat yourself Work in a well ventilated area Switch on exhaust ventilation systems when working on the refrigerant system Do not expose any component of the A C system to high temperatures above 80C 176F or open flames Excessive heat causes a pressure increase which could burst the system Keep refrigerant away from open flames Po...

Page 1139: ...d and use approved refrigerant recycling equipment Technicians must complete an EPA approved recycling course to be certified It is recommended that all A C service be left to an authorized BMW dealer or other qualified A C service facility State and local governments may have additional requirements regarding air conditioning servicing Always comply with state and local laws Do not top off a part...

Page 1140: ... and lines that are identified with a green mark stripe or the lettering R 134a Immediately plug open connections on A C components and lines to prevent dirt and moisture contamination Do not steam clean A C condensers or evaporators Use only cold water or compressed air Copyright 2006 Robert Bentley Inc All rights reserved Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Re...

Page 1141: ...cautions must be observed prior to any work at or near the airbags See 721 Airbag System SRS CAUTION When working on interior trim removal work with plastic prying tools or wrap the tips of screwdrivers and pliers with tape Air distribution motors The five air distribution motors are installed under the dashboard They are made accessible by removing either the glove compartment and right footwell ...

Page 1142: ...irculation Defroster Ventilation flaps Right footwell vent Remove glove compartment and right footwell trim panel for access See 513 Interior Trim CAUTION Disassemble interior trim carefully to avoid damage Disconnect negative battery cable in trunk CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Heating and Air Cond...

Page 1143: ...stribution motor arrow Ventilation distribution motor arrow For access remove defroster air distribution motor Right footwell vent air distribution motor arrow For access remove passenger side airbag as described in 721 Airbag System SRS Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 3 of 6 2 25 2009 11 17 PM ...

Page 1144: ...position Working at trim panel remove fasteners Note locking clips A which must be rotated 90 to remove Remove mounting screws B Unhook retaining clip from steering column lower trim Detach electrical harness connectors from footwell light and speaker if equipped Release OBD II socket from panel and pull out Reach up above accelerator pedal to gain access to fresh air distribution motor arrow Heat...

Page 1145: ... locking clip arrow from heater evaporator housing Separate bottom of air duct from rear compartment duct Pull forward and down to remove Installation is reverse of removal Dashboard vent removing and installing Pry gently at dashboard trim to remove CAUTION To avoid marring interior trim work with a plastic prying tool Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair...

Page 1146: ...ard vent is similar To fully remove the center dashboard vent use pliers to detach control cable housing and remove from control lever Remove trim on right side prior to removing center trim Copyright 2006 Robert Bentley Inc All rights reserved Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 6 of 6 2 25 2009 11 17 PM ...

Page 1147: ...cial tools 64 1 010 are available slide them between IHKA control panel front bezel and dashboard then pull panel out Otherwise use the following procedure Remove utility compartment below IHKA control panel Open compartment door Push upward in center of compartment to release locking tabs arrows Pull out compartment Shifter bezel Lift up by prying gently Shifter boot Unclip bottom of boot from sh...

Page 1148: ... IHKA control module and panel out Detach electrical harness connectors Disassemble panel from module using an anti static mat as a working surface CAUTION Do not touch circuit boards with bare fingers Installation is reverse of removal On Board Monitor removing Remove dashboard center vent as described earlier Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manual...

Page 1149: ... earlier Reach through dashboard opening and detach heater core temperature sensor electrical harness connector arrow Pull sensor out of IHKA housing Installation is reverse of removal Evaporator temperature sensor To gain access to evaporator temperature sensor arrow Remove left footwell trim panel above pedals See 513 Interior Trim Sensor is installed in left side of IHKA housing above coolant H...

Page 1151: ... housing Remove heater bulkhead cover Remove engine compartment side trim panel Turn locking clips A and slide trim panel up Remove heater bulkhead cover mounting screws B and lift cover off bulkhead Remove intake manifold cover Remove plastic trim covers arrows Remove cover hold down bolts and lift off cover Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals ...

Page 1152: ...Pry off blower cover retaining clips A Remove screw B and lift off outer blower housing cover Remove blower cover retaining screws arrows Lift off cover Detach electrical harness connector arrow Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 2 of 4 2 25 2009 11 17 PM ...

Page 1153: ...ower motor resistor pack is also referred to as the final stage unit Remove right footwell air duct as described earlier Working under right side of dashboard at side of IHKA housing unhook linkage then remove air distribution motor arrow To remove blower resistor pack from IHKA housing Remove mounting screws Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals ...

Page 1154: ...switch Installation is reverse of removal Make sure electrical harness is routed as before Align guides and clips correctly Copyright 2006 Robert Bentley Inc All rights reserved Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 4 of 4 2 25 2009 11 17 PM ...

Page 1155: ...ard removal Before starting work disconnect the battery negative cable in the trunk Be sure to read the battery disconnection cautions on page viii and the airbag warnings in 721 Airbag System SRS Heater valve replacing Drain engine coolant See 170 Radiator and Cooling System WARNING Allow the cooling system to cool before opening or draining the cooling system Disconnect hoses A and electrical ha...

Page 1156: ...rofilter Remove upper cover and microfilter Open wiring harness loom A and remove wires Unfasten screws B and remove lower housing Remove center console and dashboard See 513 Interior Trim Drain engine coolant See 170 Radiator and Cooling System WARNING Allow the cooling system to cool before opening or draining the cooling system Heating and Air Conditioning http ebahn bentleypublishers com BMW 3...

Page 1157: ...housing Detach wiring harness A from housing Remove heater core temperature sensor B by pulling straight out Remove retaining clips C from housing cover Lift off front of cover then unhook tabs from housing at rear Remove coolant pipe retaining clamps mounting screws arrows To remove heater core from IHKA housing Remove coolant pipe retainers Heating and Air Conditioning http ebahn bentleypublishe...

Page 1158: ...ystem CAUTION Replace coolant flange O rings and tighten fasteners to specified torques Tightening torque Coolant hose clamp 32 48 mm 2 1 4 4 in 2 5 Nm 22 in lb IHKA housing removing and installing CAUTION Removing the IHKA housing requires evacuating the A C system DO NOT attempt this procedure without proper tools and training Any person who services a Heating and Air Conditioning http ebahn ben...

Page 1159: ... lower housing Remove heater bulkhead cover Remove engine compartment side trim panel Turn locking clips A and slide trim panel up Remove heater bulkhead cover mounting screws B and lift cover off bulkhead Drain engine coolant See 170 Radiator and Cooling System WARNING Allow the cooling system to cool before opening or draining the cooling system Working at rear engine compartment bulkhead loosen...

Page 1160: ... bulkhead Using BMW special tool 64 5 102 or equivalent detach and plug A C lines Working inside right side of cowl pull up on lever arrow and detach right air intake flap from blower housing Working in right front of IHKA housing detach double pipe A C line from expansion valve Lay double pipe aside Plug up open A C ports Remove IHKA housing mounting nuts arrows at bulkhead Remove center console ...

Page 1161: ...ection airbag 4 Steering column 5 Dashboard mounts 6 Center tunnel 7 Relay panel 8 Right A pillar Remove dashboard reinforcement fasteners Detach bulkhead brace 1 Detach left and right A pillar braces 2 and 8 Detach head protection airbag 3 Remove center tunnel mounting bolts 6 Detach heater housing electrical harness connectors Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E...

Page 1162: ...all electrical harnesses and hoses are free Installation is reverse of removal Note the following Make sure A C condensate drain is routed correctly Replace wire ties sealing O rings and hose clamps Use new shear bolt at steering column mounting Tighten bolt until head shears off Evacuate and recharge A C system using specialized equipment Fill and bleed cooling system See 170 Radiator and Cooling...

Page 1163: ... torques Coolant hose clamp 32 48 mm 2 1 4 4 in 2 5 Nm 22 in lb Steering column to dashboard reinforcement 22 Nm 16 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Heating and Air Conditioning http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 9 of 9 2 25 2009 11 17 PM ...

Page 1164: ... compartment The A C evaporator is located in the IHKA housing Removal of the IHKA housing involves dashboard removal Before starting work disconnect the battery negative cable in the trunk Be sure to read the battery disconnection cautions on page viii and the airbag warnings in 721 Airbag System SRS Note The air conditioning system is filled with R 134a refrigerant A C system components 1 High p...

Page 1165: ...charge system WARNING Do not discharge charge the A C system without proper equipment and training Damage to the vehicle and personal injury may result Remove splash shield from under engine Mark A C drive belt with direction of rotation Release tension on A C belt Use long handled wrench to turn tensioner pulley release lug A clockwise against spring tension Heating and Air Conditioning http ebah...

Page 1166: ... lower front stabilizer bar See 310 Front Suspension Support compressor while removing compressor mounting bolts arrows Remove compressor Installation is reverse of removal CAUTION Always replace O rings when reconnecting refrigerant lines When installing a new compressor always replace receiver drier unit Tightening torque A C line to A C compressor 20 Nm 15 ft lb Heating and Air Conditioning htt...

Page 1167: ...uctions connect an approved refrigerant recovery recycling recharging unit to A C system and discharge system WARNING Do not discharge charge the A C system without proper equipment and training Damage to the vehicle and personal injury may result Remove complete air filter housing Detach vacuum line at intake boot A Disconnect electrical harness connector on mass air flow sensor B Release mass ai...

Page 1168: ...fastener expansion rivet from top left corner of condenser Remove Torx screw from top right corner of condenser just below refrigerant line flange Lift up condenser to disengage from plastic bracket and remove from above Installation is reverse of removal CAUTION Always replace O rings when reconnecting refrigerant lines When installing a new condenser always replace receiver drier unit Recharge s...

Page 1169: ...overy recycling recharging unit to A C system and discharge system CAUTION The receiver drier must be replaced when There is dirt in the A C system The compressor has seized or has been replaced for any reason The condenser or evaporator are replaced for any reason The A C system is leaking and there is no more refrigerant The A C system was open for 24 hours or more Remove right headlight assembl...

Page 1170: ...removal CAUTION Always replace O rings when reconnecting refrigerant lines Recharge system following equipment manufacturer s instructions A C system fluid specifications Fluid Quantity R 134a refrigerant 740 25 g 2 lb 1 oz Refrigerant oil PAG oil A C expansion valve removing and installing Following manufacturer s instructions connect an approved refrigerant recovery recycling recharging unit to ...

Page 1171: ...ower housing To remove heater bulkhead cover Remove engine compartment side trim panel Turn locking clips A and slide trim panel up Remove heater bulkhead cover mounting screws B and lift cover off bulkhead Working in right rear of engine compartment detach A C lines Remove A C recharging port bracket mounting nut A Remove allen bolts B at bulkhead Release and plug open A C lines Heating and Air C...

Page 1172: ...AUTION Always replace O rings when reconnecting refrigerant lines Recharge system following equipment manufacturer s instructions A C system fluid specifications Fluid Quantity R 134a refrigerant 740 25 g 2 lb 1 oz Refrigerant oil PAG oil A C evaporator removing and installing Following manufacturer s instructions connect an approved refrigerant recovery recycling recharging unit to A C system and...

Page 1173: ...ing harness from housing Detach linkage from fresh air distribution motor Working on right side of IHKA housing Unclip and remove fresh air recirculation motor Remove evaporator cover mounting screw and remove cover Detach and remove microswitch at side of IHKA housing Working in front of IHKA housing Remove blower housing mounting screws Lift out blower housing Heating and Air Conditioning http e...

Page 1174: ...straighten with fin comb Installation is reverse of removal Make sure electrical harnesses are routed as before Align guides and clips correctly Recharge system following equipment manufacturer s instructions A C system fluid specifications Fluid Quantity R 134a refrigerant 740 25 g 2 lb 1 oz Refrigerant oil PAG oil Copyright 2006 Robert Bentley Inc All rights reserved Heating and Air Conditioning...

Page 1175: ...pecial tools Use BMW special tool 00 9 321 or equivalent plastic prying tool to pry out plastic interior parts without damage or marring Plastic prying tool BMW 00 9 321 General A tag on the bottom of the radio contains the serial number A and model number B Sound system Radio http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 1 of 3 2 25 2009 11 18 PM ...

Page 1176: ...ignal from the instrument cluster Other features of the sound system include Autostoring of stations Speed dependent volume Telephone muting Diversity antenna described later in this group is optional on some models and standard on the Convertible and Sport Wagon RDS Radio Data System RDS is a transmit and receive system operated in the FM band It is a data service offered by radio stations in whi...

Page 1177: ...tware version display Speed dependent volume control adjustment Station signal strength including FM frequency set signal strength and quality of signal received AM frequency set and signal strength The test also checks antenna functions Antenna signal strength F number indicates the quality of the signal received by the antenna The scale ranges from 0 to 15 with the optimum value being 15 If the ...

Page 1178: ...nt of the equipment s manufacturer Note On Board Monitor removal is covered in 640 Heating and Air Conditioning Prying gently remove right dashboard trim then center dashboard trim CAUTION To avoid marring interior trim work with a plastic prying tool Remove radio mounting screws arrows Pull radio out of instrument panel opening Detach electrical harness connector and antenna lead Installation is ...

Page 1179: ...und insulation Convertible Disconnect battery negative terminal Remove lower section of rear seat left side trim If necessary remove convertible top module See 541 Convertible Top Amplifier is attached to side wall CD changer The optional CD changer is located in the left side of the trunk behind the trim panel An access door allows loading of up to 6 CDs Copyright 2006 Robert Bentley Inc All righ...

Page 1180: ...n the left and right rear side trim panels Convertible The standard speaker set up consists of four speakers mounted in the rear side trim panels two on each side One speaker on each side is a 130 mm wide band and the other is a tweeter The Harman Kardon system incorporates an additional subwoofer installed in the trunk The amplification for this subwoofer comes from the main sound system amplifie...

Page 1181: ...ttery cable See 721 Airbag System SRS CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Remove interior door panel as described in 411 Doors Detach electrical harness connector A and remove speaker mounting screws B Remove speaker Rear side panel speaker removing Disconnect battery negative terminal CAUTION Radio http ...

Page 1182: ...removing and installing Working at rear parcel shelf pry speaker cover by inner edge and remove CAUTION To avoid marring interior trim work with a plastic prying tool Remove mounting screws lift up speaker and detach electrical harness connector When reinstalling make sure speaker and harness are seated as before Subwoofer removing Coupe Working in trunk under parcel shelf remove subwoofer mountin...

Page 1183: ...swing out subwoofer Squeeze plastic harness cover and remove Detach electrical harness connector Using plastic pry tool gently pry subwoofer at bottom left and pull out Copyright 2006 Robert Bentley Inc All rights reserved Radio http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 4 of 4 2 25 2009 11 19 PM ...

Page 1184: ...ain and the auxiliary antenna s receive radio signals and both signals are amplified in separate amplifiers The signals are then transmitted to the diversity switching module which locks onto the strongest signal and sends it to the radio receiver Sport Wagon antenna system The diversity antenna system on the E46 Sport Wagon consists of the following FM1 antenna in rear window right half FM2 anten...

Page 1185: ...will select the clearest signal from the three antennas and transmit that to the sound system The AM antenna is glued to the bottom of the rear spoiler Convertible antenna system The diversity antenna system on the E46 Convertible consists of the following Main antenna mast on left rear fender Auxiliary antenna in convertible top storage cover Main antenna amplifier mounted directly below the ante...

Page 1186: ...Convertible models Unscrew and remove antenna mast 1 Antenna mast 2 Antenna head 3 Antenna base 4 Nut M5 5 Antenna cable 6 Antenna FM amplifier 7 Antenna diversity amplifier 8 Nut M6 Detach and remove wheel housing trim liner in left side of trunk Through elongated hole of antenna retaining bracket unscrew M5 nut This releases antenna head from base Radio http ebahn bentleypublishers com BMW 3 E46...

Page 1187: ...fier Detach and remove wheel housing trim liner in left side of trunk Antenna amplifier is mounted below antenna bracket Convertible auxiliary antenna amplifier Open convertible top compartment lid Auxiliary amplifier is attached to left rear corner of lid Sedan or Coupe antenna amplifier Remove left roof pillar C pillar trim panel as described in 513 Interior Trim to access amplifier Radio http e...

Page 1188: ...left cargo compartment trim cover to gain access to module arrow Sport Wagon FM1 FM2 antenna amplifier Remove rear spoiler See 412 Trunk Lid Tailgate Amplifier is in center of rear window beneath spoiler Copyright 2006 Robert Bentley Inc All rights reserved Radio http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 6 5 of 5 2 25 2009 11 19 PM ...

Page 1189: ...n additional 3 point shoulder belt in the center of the rear seat Sedan and Coupe models are equipped with a lap belt in the center rear seat position Convertible models are equipped with seat integrated seat belt system SGS in the front seats Child safety anchors Sport Wagon models are equipped with three child safety harness anchors behind the rear seat in the cargo compartment floor Remove plas...

Page 1190: ...ween strap and seat cover A small remaining loop in belt strap when fully retracted is acceptable WARNING For maximum protection from injury seat belts should be replaced as a set including all hardware if they are subject to occupant loading in a collision Seat belts should not be modified or repaired The seat belt mounting points should not be changed or modified Do not bleach or dye seat belt w...

Page 1191: ...Seat belt mounting on seat runner Belt creased unraveled pinched cut or melted Seat belts aged or worn Replace complete automatic seat belt Belt buckle or belt lock plastic casing worn damaged or missing Seat belt buckle is not ejected with spring pressure when red button on seat belt lock is pressed Seat belt lock mechanism worn or damaged Replace seat belt lock Seat belt automatic reel does not ...

Page 1192: ...ia seat belt Replace front seat Seat back lock warning lamp on when seat back is locked or warning lamp lights up when seat back is shaken Seat back lock microswitch defective Replace microswitch Microswitch electrical harness connectors loose or defective Repair electrical leads Seat back lock is damaged If fault persists replace front seat Contact surface of inertia reel warped Accident damage R...

Page 1194: ...erful devices and should be handled with extreme care Incorrect handling can trigger the tensioner and cause injury 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 Pyrotechnic devices cannot be repaired Always replace them...

Page 1195: ...body straightening and welding with an electric arc welder always disconnect the battery and the connection to the pyrotechnic gas generators Detach battery negative cable in luggage compartment CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Remove front seat as described in 520 Seats Remove pyrotechnic belt tension...

Page 1196: ...o relieve tension on the pyrotechnic belt tensioner harness connector Make sure tensioner harness connector mounting bracket arrow is installed correctly Tightening torques Front seat to floor M10 fastener 45 Nm 33 ft lb Seat belt to seat 48 Nm 35 ft lb Tensioner mounting bracket to seat rail 24 Nm 18 ft lb Tensioner to mounting bracket 48 Nm 35 ft lb Front seat belt Seat Belts http ebahn bentleyp...

Page 1197: ...4 Seat belt stop button 5 Seat belt anchor bolt tighten to 48 Nm 35 ft lb 6 Seat belt reel assembly 6a Seat belt anchor end Sedan Sport Wagon models 7 Bolt M8 8 B pillar cross brace 9 Plastic cap 10 Bolt M10 tighten to 31 Nm 23 ft lb 11 Spring washer Seat Belts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 7 4 of 10 2 25 2009 11 20 PM ...

Page 1198: ... Detach battery negative cable in luggage compartment CAUTION Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page viii Remove front seat as described in 520 Seats Coupe models Working just inside door sill Pry off plastic protective cap over end of seat belt anchor bar Seat Belts http ebahn bentleypublishers com BMW 3 E46 Repair 20Ma...

Page 1199: ...illar door pillar plastic trim Pry gently along bottom of trim to disengage clips from pillar Slide trim down and out Coupe models Remove rear side panel as described in 411 Doors Note Partially peel rubber door seal s away from B pillar Remove upper B pillar door pillar plastic trim expansion rivets arrows Seat Belts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 7 6 of 10 2 25 2009 ...

Page 1200: ...nsulation at base of B pillar Then remove automatic seat belt reel mounting bolt C Lift out reel If it is necessary to remove sliding seat belt height adjuster unscrew mounting bolts from B pillar Installation is reverse of removal Install automatic reel housing to Seat Belts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 7 7 of 10 2 25 2009 11 20 PM ...

Page 1201: ...front seat occupant during a collision are channeled to the reinforced floor All belt fastening points move with the seat as it is adjusted This ensures the best possible body strapping regardless of seat position or occupant size With the shorter free belt length the occupant is held more reliably with vehicle deceleration The fixed anchor point and the seat belt lock tensioner are mounted on the...

Page 1202: ...arnings and cautions in the procedure for front seat belt tensioner removal and installation earlier in this group Note SGS seat belt removal can only be carried out with the seat out of the car See 520 Seats Once the seat has been removed the seat backrest must be partially disassembled The accompanying illustration provides information on SGS component locations and fastener torques Seat integra...

Page 1203: ... 5 Nm 40 in lb 9 Seat belt guide cover front 10 Seat belt guide cover rear 11 Connector 12 Clip 13 Seat belt button 14 Bushing 15 Bolt M10 self locking always replace tighten to 45 Nm 33 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Seat Belts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 7 10 of 10 2 25 2009 11 20 PM ...

Page 1204: ...mation on rear seat belt component locations and fastener torques When installing seat belt lock straps Install right lock strap which is shorter underneath middle lock strap Install left lock strap underneath middle lap belt strap Metal strap ends must rest against stop on floor underneath seat Rear seat belt assembly Sedan Coupe 1 Center shoulder belt reel assembly if Seat Belts http ebahn bentl...

Page 1205: ...if equipped 8 Bolt M12 tighten to 31 Nm 23 ft lb Rear seat belts Sport Wagon models Center shoulder belt Remove shoulder belt guide trim at top of seat backrest Feed belt out through slot in trim Working in cargo compartment partially remove backrest cover to access shoulder belt reel Seat Belts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 7 2 of 5 2 25 2009 11 20 PM ...

Page 1206: ...ccompanying illustration provides information on rear seat belt component locations and fastener torques 1 Bolt M10 tighten to 31 Nm 23 ft lb 2 Right shoulder belt reel assembly 3 Center belt lock 4 Right belt lock 5 Left belt lock 6 Center shoulder belt reel assembly 7 Left shoulder belt reel assembly 8 Bolt M12 tighten to 31 Nm 23 ft lb When installing seat belt lock straps Install right belt lo...

Page 1207: ... top guides Lift seat cushion up and forward to remove Remove lower backrest securing screws located below backrest Lift backrest straight up and unhook from tabs in back Remove rear head restraints by pulling straight up Remove cover of rollover protection bars for right and left side Open convertible top compartment cover Shoulder belt reels are bolted to convertible top storage compartment Seat...

Page 1208: ...ques 1 Bolt M10 tighten to 31 Nm 23 ft lb 2 Left shoulder belt reel assembly 3 Seat belt stop button 4 Left belt lock 5 Bolt M12 tighten to 31 Nm 23 ft lb Copyright 2006 Robert Bentley Inc All rights reserved Seat Belts http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 7 5 of 5 2 25 2009 11 20 PM ...

Page 1209: ... and reset turn off the airbag indicator light The indicator light will remain on until any problem has been corrected and the fault memory has been cleared Individual airbag system components can only be tested electronically when installed in the car BMW service testers DIS or MoDiC or equivalent must be used for diagnostic work Special tools Most airbag system repairs can be performed with norm...

Page 1210: ...front roof pillar A pillar As an option some cars may be equipped with Rear side impact airbags one in each rear door 4 door Sedan or Sport Wagon The airbags and seat belts are integrated into the Multiple Restraint System MRS The MRS control module is located on the center tunnel underneath the rug below the parking brake handle E46 Airbags 1 Driver air bag Airbag System SRS http ebahn bentleypub...

Page 1211: ... airbags are designed to provide soft deployment if the acceleration sensor detects a low speed impact with a hard deployment only in higher speed impacts Head protection airbags HPS This protective system covers a large area between the front roof pillar A pillar and the rear section of the roof A hollow flexible tube about 5 feet long and 1 5 inches in diameter is anchored inside the A pillar an...

Page 1212: ...encounters additional side impacts during the crash Rear side impact airbags Similar to the standard equipment front side impact airbags the rear airbags are built into the doors of sedan models These were offered as a special order option on certain models only They can be deactivated to protect infants or small children riding in the rear seat Activation and deactivation can be performed by usin...

Page 1213: ... threshold Only seat belt pyrotechnic tensioners are deployed Belts fastened high impact speed Higher deployment threshold Tensioners and front impact airbags are deployed Belts not fastened low or high impact speed Airbags are deployed Passenger seat not occupied Neither belt tensioner nor airbag is deployed on that side MRS Airbag System SRS http ebahn bentleypublishers com BMW 3 E46 Repair 20Ma...

Page 1214: ...on Indicator light comes on briefly goes out and lights up again The airbag indicator light also comes on if the seat belt pyrotechnic tensioners have been triggered Warnings When servicing airbag equipped cars the following precautions must be observed to prevent personal injury WARNING If the airbag indicator light is on there is a risk that the airbags will not be triggered in case of an accide...

Page 1215: ...dealer Always disconnect the battery and cover the negative battery terminal with an insulator before starting diagnostic troubleshooting or service work not associated with the airbags and before doing any welding on the car After disconnecting the battery wait 5 seconds before beginning work on airbag components If an airbag has been activated due to an accident BMW specifies that airbag compone...

Page 1216: ...eratures above 167F 75C When reconnecting the battery no person should be inside the vehicle Always place an airbag unit that has been removed from its packaging with the padded side facing upward Do not leave an airbag unit unattended If the airbag unit or airbag control module has been dropped from a height of meter 1 ft or more the airbag unit should not be installed Copyright 2006 Robert Bentl...

Page 1217: ...e or on intermediate plug Cut through one cable then the other and repair CAUTION Do not under any circumstances cut through both wires of an airbag harness at the same time Perform only one repair on an airbag harness wire If more than one spot is damaged replace the entire section of harness MRS control module replacing Disconnect negative cable from battery and cover negative terminal with insu...

Page 1218: ...electrical harness connector Installation is reverse of removal Be sure that MRS module ground cable is attached to the module mounting stud Side impact crash sensor removing and installing Make sure ignition key is OFF Remove front seat See 520 Seats Remove plastic door sill trim by lifting to release clips at one end then sliding off Fold up carpet towards rear seat floor If necessary remove flo...

Page 1219: ...ove sensor Note direction of sensor arrow before removing Installation is reverse of removal Note Arrow on sensor must point to door sill Copyright 2006 Robert Bentley Inc All rights reserved Airbag System SRS http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 7 3 of 3 2 25 2009 11 21 PM ...

Page 1220: ...ry read the battery disconnection cautions given at the front of this manual on page viii Multifunction MFL steering wheel Working behind steering wheel completely loosen Torx screws T30 while holding airbag in place Support airbag unit to prevent it from falling out Carefully lift airbag unit off steering wheel and disconnect harness connector arrow from rear of airbag unit Airbag System SRS http...

Page 1221: ...eployment could propel it violently into the air causing injury Once an airbag is removed the car must not be driven Do not connect the battery with the airbag disconnected A fault code will be stored setting off the airbag indicator light Special tools are needed to reset the fault memory Once the airbag unit is installed and all other service procedures have been completed start the engine and c...

Page 1222: ...y CAUTION Do not pinch airbag harness in center of steering wheel when installing airbag Tightening torque Airbag to steering wheel MFL 8 Nm 71 in lb Passenger airbag removing and installing Disconnect negative cable from battery and cover negative terminal with insulating material WARNING After disconnecting the battery wait 5 seconds before beginning work on airbag components CAUTION Prior to di...

Page 1223: ...dashboard CAUTION The plastic retainer at the right end of the cover may snap during removal Be sure to have extra retainers on hand for reassembly Remove airbag mounting bolts arrows Lift airbag and disconnect electrical harness connector Remove airbag WARNING Store the removed airbag unit with the soft pad facing up If stored facing down accidental deployment could propel it violently into the a...

Page 1224: ... lb Passenger air bag to dashboard M8 22 Nm 16 ft lb Door mounted side impact airbag removing and installing Disconnect negative cable from battery and cover negative 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 Remove inside door panel as described in 411 Doors Front door airbag ...

Page 1225: ...tallation is reverse of removal Route electrical harnesses as they were before Use new wire ties as necessary Use new self locking mounting bolts Tightening torque Side impact airbag to door 8 5 Nm 75 in lb Head protection airbag HPS components Replacement of a head protection airbag HPS is an extensive operation Replacement includes removal of the following components Airbag System SRS http ebahn...

Page 1226: ...ry read the battery disconnection cautions given at the front of this manual on page viii Tightening torque HPS airbag to body 11 Nm 8 ft lb HPS airbag mounting bracket to A or B pillar 2 5 Nm 22 in lb HPS gas generator to dashboard reinforcement M6 self tapping screw 4 Nm 35 in lb Head protection airbag HPS 1 B pillar deflection plate 2 Head protection airbag Airbag System SRS http ebahn bentleyp...

Page 1227: ...s generator 5 Self tapping screw M6 tighten to 4 Nm 35 in lb Copyright 2006 Robert Bentley Inc All rights reserved Airbag System SRS http ebahn bentleypublishers com BMW 3 E46 Repair 20Manuals 7 8 of 8 2 25 2009 11 21 PM ...

Page 1228: ...heir entire life Each emission influencing component is checked by a diagnostic routine to verify that it is functioning properly If a problem or malfunction is detected the OBD II system illuminates a warning light on the instrument panel to alert the driver This malfunction indicator light MIL will display the phrase Check Engine or Service Engine Soon The OBD II system also stores important inf...

Page 1229: ...mance monitoring devices Standardized 16 pin OBD II connector under the dash Upgraded components for the federally required 100 000 mile or 10 year reliability mandate Malfunction Indicator Light MIL The OBD II system is designed to illuminate the Malfunction Indicator Light MIL when emission levels exceed 1 5 times the Federal standards Note On model year 1999 and 2000 cars the MIL is labeled Che...

Page 1230: ... input signal is generated Misfire faults occur A leak is detected in evaporative system The oxygen sensors observe no purge flow from purge valve evaporative system The engine control module ECM fails to enter closed loop operation within specified time The engine control module ECM or automatic transmission control module TCM enters limp home operation mode Key is in ignition on position before ...

Page 1231: ...MIL is illuminated if the function is checked and the fault is still present Once the MIL is illuminated it will remain illuminated unless the specific function has been checked without fault through three complete consecutive drive cycles The fault code will be cleared from memory automatically if the specific function is checked through 40 consecutive drive cycles without the fault being detecte...

Page 1232: ...artment Data from the OBD II DLC may be limited depending on scan tool and vehicle OBD II standards mandate that the 16 pin DLC must be located within three 3 feet of the driver and must not require any tools to be exposed The communication protocol used by BMW is ISO 9141 Starting with June 2000 production the 20 pin BMW diagnostic port Data Link Connector or DLC which was previously located in t...

Page 1233: ... nonetheless powerful diagnostic tools These tools read live data streams and freeze frame data as well as a host of other valuable diagnostic data For the do it yourself owner simple aftermarket DTC readers are also available These inexpensive BMW only tools are capable of checking for DTCs as well as turning off the illuminated MIL and resetting the service indicator lights Diagnostic monitors A...

Page 1234: ...ion control systems For example a vehicle may not be equipped with secondary air injection so naturally no secondary air readiness function code would be present OBD lI requires monitoring of the following Oxygen sensor monitoring Catalyst monitoring Misfire monitoring Evaporative system monitoring Secondary air monitoring Fuel system monitoring Monitoring these emissions related functions is done...

Page 1235: ... strategy monitors the two heated oxygen sensors per bank of cylinders It compares the oxygen content going into the catalytic converter to the oxygen leaving the converter The diagnostic executive knows that most of the oxygen should be used up during the oxidation phase and if it sees higher than programmed values a fault will be set and the MIL will illuminate Misfire detection This strategy mo...

Page 1236: ...old By injecting oxygen into the exhaust manifold catalyst warm up time is reduced System components Electric air injection motor pump Electric motor pump relay Non return valve Vacuum vent valve Stainless steel air injection pipes Vacuum reservoir The secondary air system is monitored via the use of the pre catalyst oxygen sensors Once the air pump is active and air is injected into the system th...

Page 1237: ...time Fuel system monitoring monitors the calculated injection time ti in relation to engine speed load and the pre catalytic converter oxygen sensor s signals as a result of residual oxygen in the exhaust stream The diagnostic executive uses the precatalyst oxygen sensor signal as a correction factor for adjusting and optimizing the mixture pilot control under all engine operating conditions Evapo...

Page 1238: ...ï F and at least 40ï F above its original starting temperature Once the drive cycle is completed the system status or inspection maintenance I M readiness codes are set to Yes System status codes will be set to No in the following cases The battery or ECM is disconnected The ECM s DTCs have been erased after completion of repairs and a drive cycle has not be completed A scan tool can be used to de...

Page 1239: ...ermine if ignition actually occurred 3 Ignition coil cyl 6 Input analog timing 100 mV DME initiates secondary ignition for each cylinder then looks for feedback through shunt resistor in harness to determine if ignition actually occurred 5 P0202 Injector circuit cyl 2 Output digital pulse width active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disc...

Page 1240: ...heck of phase shift from camshaft sensor should change during every crankshaft revolution Phase shift occurs due to 2 1 relationship between camshafts 19 P1529 VANOS solenoid activation exhaust Output digital pulse width active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 21 P1525 VANOS sol...

Page 1241: ...s 27 P1550 Idle control valve closing coil Output digital pulse width active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 29 Ignition coil cyl 1 Input analog timing 100 mV DME initiates secondary ignition for each cylinder then looks for feedback through shunt resistor in harness to determi...

Page 1242: ...d DME internal values such as load and engine speed 39 Brake light switch and brake light plausibility test Input digital 0 12V When brake light switch is active brake light test switch must be also active If not fault is stored 40 Brake light switch pedal sensor plausibility test Input digital analog 0 12V 0 5V If pedal sensor is showing angle greater than limp home angle and additionally brake l...

Page 1243: ...43 ECU internal test DME HW test 52 Rear exhaust valve flap Output digital steady active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 53 P1509 Idle control valve opening coil Output digital pulse width active low DME final stage will set flag whenever a short to ground a short to battery vo...

Page 1244: ...stor and component exists 62 P0412 Secondary air injection system switching valve Output digital on off active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 65 P0340 Intake cam position sensor malfunction Input analog phase shift 0 5V DME final stage will set flag whenever a short to ground ...

Page 1245: ...nternal values logical Internal hardware test of RAM ROM and Flash Prom 103 P1519 VANOS faulty reference value intake DME internal values logical Maximum VANOS adjustment angle checked at every engine start must be within a specified limit 104 P1520 VANOS faulty reference value exhaust DME internal values logical Maximum VANOS adjustment angle checked at every engine start must be within a specifi...

Page 1246: ...r throttle valve final stage DME internal test Final stage inside DME special H bridge will set internal flag whenever a short to ground a short to battery voltage or a disconnection occurs MS 43 A second pedal sensor range check failure is determined DME internal values logical If pedal sensor malfunction is determined followed by a second malfunction a signal is sent 115 P1623 MS 42 Output volta...

Page 1247: ...ck sensor 1 to mass air flow meter DME internal values Signal range is checked against predetermined diagnostic limits Rationality check with mass air flow meter 120 P1542 MS 42 Pedal sensor motor throttle valve potentiometer not plausible DME internal values logical motor Signal from motor throttle valve potentiometer must be equal signal from pedal sensor potentiometer plus any adaptive values M...

Page 1248: ...voltage or a disconnection between output transistor and component exists MS 43 DMTL valve Output digital on off active low DME final stage will set flag whenever a short to ground a short to battery voltage or a disconnection between output transistor and component exists 127 Fuel pump Output digital on off active low DME final stage will set flag whenever a short to ground a short to battery vol...

Page 1249: ...e fault is set 140 P1475 LDP reed switch not closed Input digital on off 0 12V With shut off valve open and no pressure on system reed contact should be closed showing a high signal If not the case in beginning of every diagnostics check a signal is sent 140 MS 43 DMTL pump final stage Output digital on off active low DME final stage will set flag whenever a short to ground a short to battery volt...

Page 1250: ...r and air mass sensor signal not plausible Input analog 0 5V Signal from motor throttle valve potentiometer must be suitable to signal from air mass sensor A fault is set if difference exceeds specified limit 150 P0130 Oxygen sensor pre cat Bank 1 short to battery volt Input analog 0 5V Oxygen sensor signal range is checked to determine if electrical shorts exist on input line Voltage signal has t...

Page 1251: ... 0 5V Oxygen sensor signal range is checked to determine if electrical shorts exist on input line Voltage signal must be within a predetermined range 0 1V 1V or fault will set 157 P0136 Oxygen sensor Post Cat Bank 1 short to ground Input analog 0 5V Oxygen sensor signal range is checked to determine if electrical shorts exist on input line Voltage signal must be within a predetermined range 0 1V 1...

Page 1252: ...1542 Pedal sensor potentiometer short between two potentiometer paths DME internal check 5 volts for potentiometers are switched on within a specific time pattern 173 P0120 Motor throttle valve potentiometer contact short Rationality check Motor throttle valve potentiometer 174 P0120 Motor throttle valve potentiometer adaptation of idle end position Input analog 0 5V Signal for idle position must ...

Page 1253: ...E internal analog input 202 P0170 Fuel trim Bank 1 O2 control limit DME internal values logical Controller for lambda is too long beyond a min or a max 203 P0173 Fuel Trim Bank 2 O2 control limit DME internal values logical Controller for lambda is too long beyond a min or a max 204 P0505 Idle control system idle speed not plausible DME internal values logical Functional check between actual engin...

Page 1254: ...nection exist on input line 216 P0136 Oxygen sensor post cat Bank 2 disconnection Input analog 0 5V Oxygen sensor signal range is checked to determine if electrical disconnection exist on input line 217 P0505 CAN time out EGS1 Input digital binary information 0 12V CAN message between DME EGS was not received within expected time 219 CAN chip bus off Input digital binary information 0 12V Hardware...

Page 1255: ... Input analog 0 5V Rationality check for O2 control adaptation with post catalyst sensor bank 2 227 P0188 Fuel trim Bank 1 O2 control adaptation limit DME internal values logical Range control of adaptation values 228 P0189 Fuel trim Bank 2 O2 control adaptation limit DME internal values logical Range control of adaptation values 229 P0133 Oxygen sensor pre cat Bank 1 slow response time Input anal...

Page 1256: ...xygen storage capability efficiency of catalytic converter Post cat oxygen sensor must be relatively lean 235 P1190 Pre cat sensor Bank 1 trim control Input analog high is rich 0 1V Rationality check for O2 control adaptation with pre cat sensor bank 1 236 P1191 Pre cat sensor Bank 2 trim control Input analog high is rich 0 1V Rationality check for O2 control adaptation with pre cat sensor bank 2 ...

Page 1257: ...sfire detected DME internal values logical Crankshaft speed acceleration is monitored by crank sensor Time for each cylinder combustion is compared against avg of others If time for cylinder 5 is longer fault will set 243 P0306 Cyl 6 misfire detected DME internal values logical Crankshaft speed acceleration is monitored by crank sensor Time for each cylinder combustion is compared against avg of o...

Page 1258: ...nmetered airflow generated by secondary air pump operation Oxygen sensor must sense lean condition or fault will set 248 P1184 Post cat sensor signal after decel phase not plausible Bank 1 Input analog 0 5V Signal is checked for a lean signal in decel and a transition between lean to rich after decel 249 P1185 Post cat sensor signal after decel phase not plausible Bank 2 Input analog 0 5V Signal i...

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