BMW 3 Series Service Manual (E46)

General 

http://ebahn.bentleypublishers.com/BMW/3/E46/Repair%20Manuals/0... 

1 of 5 2/25/2009 10:07 PM 

How to Use This Manual 

WARNING! 

010-2 

Your common sense and good 

judgment are crucial to safe and 

successful service work. Read 

procedures through before starting 

them. Think about whether the 

condition of your car, your level of 

mechanical skill, or your level of 

reading comprehension might result 

in or contribute in some way to an 

occurrence that 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 

6 ELECTRICAL SYSTEM 

7 EQUIPMENT AND 

ACCESSORIES

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ELE ELECTRICAL WIRING 

DIAGRAMS 

OBD ON BOARD DIAGNOSTICS 

0 GENERAL DATA AND 

MAINTENANCE covers general vehicle 

information (Repair Group 010) as well 

as the recommended maintenance 

schedules and service procedures to 

perform BMW scheduled maintenance 

work (Repair Group 020). 

The next seven sections (Repair 

Groups 1 through 7) are repair based 

and organized by three digit repair 

groups. Most major sections begin with 

a General repair group, e.g. 100 

Engine–General. These “00” (double 

zero) groups are mostly descriptive in 

nature, covering topics such as theory 

of operation 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 are many 

passages with the headings 

WARNING, CAUTION, or NOTE. These 

very important headings have different 

meanings. 

WARNING! 

The text under this heading warns of 

unsafe practices that are very likely 

to cause injury, either by direct 

threat to the person(s) performing

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the work or by increased risk of 

accident or mechanical failure while 

driving. 

CAUTION! 

A caution calls attention to important 

precautions to be observed during 

the repair work that will help prevent 

accidentally damaging the car or its 

parts. 

Note: 

A note contains helpful information, tips 

that will help in doing a better job and 

completing it more easily. 

Please read every WARNING, 

CAUTION, and NOTE at the front of 

the manual and as they appear in 

repair procedures. They are very 

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 can result 

from these things being caught 

in rotating parts. 

Remove rings, watches, and 

bracelets. Aside from the 

dangers of moving parts, 

metallic jewelry conducts 

electricity and may cause

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shorts, sparks, burns, or 

damage to the electrical system 

when accidentally contacting 

the battery or other electrical 

terminals. 

Disconnect the battery negative 

(–) cable whenever working on 

or near the fuel system or 

anything that is electrically 

powered. Accidental electrical 

contact may damage the 

electrical system or cause a fire. 

Fuel is highly flammable. When 

working around fuel, do not 

smoke or work near heaters or 

other fire hazards. Keep an 

approved fire extinguisher 

handy. 

The fuel system 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 

using a light with a normal 

incandescent bulb, use rough 

service bulbs to avoid breakage. 

The hot filament of an 

accidentally broken bulb can 

ignite spilled fuel or oil. 

Keep sparks, lighted matches,

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and any open flame away from 

the top of the battery. Hydrogen 

gas emitted by the battery is 

highly flammable. Any nearby 

source of ignition may cause the 

battery to explode. 

Copyright © 2006 Robert Bentley, Inc. All rights reserved. 

Never lay tools or parts in 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.

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Getting Started 

010-3 

Most of the necessary maintenance 

and minor repair that an automobile will 

need can be done with ordinary tools. 

Below is some important information on 

how to work safely, a discussion of 

what tools will be needed and how to 

use them. 

Safety 

Although an automobile presents many 

hazards, common sense and good 

equipment can help ensure safety. 

Many accidents happen because of 

carelessness. Pay attention and stick 

to safety rules in this manual. 

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 jack or a hydraulic lift, 

carefully position the jack pad to 

prevent damaging the car body. 

Plastic pads are provided for 

this purpose by the 

manufacturer at the jacking

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points. 

Watch the jack closely. Make 

sure it stays stable and does not 

shift or tilt. As the car is raised, 

it may roll slightly and the jack 

may shift. 

Raising car safely 

- Park car on flat, level surface. 

- If changing a tire, loosen lug bolts 

before rasing car. See 

Changing a tire. 

Place jack into position. Make sure jack 

is resting on flat, solid ground. Use a 

board or other support to provide a firm 

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 that is 

supported only by a jack. Use 

jack stands that are designed to 

support the car. See Tools.

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Working under car safely 

- Disconnect negative (–) cable from 

battery so that no one can start 

car. Let others know what you will 

be doing. 

CAUTION! 

Prior to disconnecting the battery, 

read the battery disconnection 

cautions given at the front of this 

manual on page viii. 

- Raise car slowly as described 

above. 

- Use at least two jack stands to 

support car. Use jack stands 

designed for the 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. If necessary, use a flat 

board or similar solid object to 

provide a firm footing.

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- 

Lower car slowly until its weight is 

fully supported by jack stands. 

Watch to make sure that the jack 

stands do not tip or lean as the 

car settles on them. 


- Observe all jacking precautions 

again when raising car to remove 

jack stands.

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Advice for the Beginner 

010-4 

The tips in the paragraphs that follow are 

general advice to help any do-it-yourself 

BMW owner perform repairs and 

maintenance tasks more easily and more 

professionally. 

Planning ahead 

To prevent getting in too deep, know what 

the whole job requires before starting. Read 

the procedure thoroughly, from beginning to 

end, in order to know just what to expect and 

what parts will have to be replaced. 

Cleanliness 

Keeping things organized, neat, and clean is 

essential to doing a good job. When working 

under the hood, fender covers will protect 

the finish from 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 the cleaner will evaporate completely. 

WARNING! 

Most solvents used for cleaning parts are 

highly flammable as well as toxic, 

especially in aerosol form. Use with 

extreme care. Do not smoke. Do not use 

these products indoors or near any source 

of heat, sparks or flame. 

Non-reusable fasteners

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Many fasteners used on the cars covered by 

this manual must be replaced with new ones 

once they are removed. These include but 

are not limited to: bolts, nuts (self-locking, 

nylock, etc.), cotter pins, studs, brake 

fittings, roll pins, clips and washers. Genuine 

BMW parts should be the only replacement 

parts used for this purpose. 

Some bolts are designed to stretch during 

assembly and are permanently altered 

rendering them unreliable once removed. 

These are known as torque-to-yield 

fasteners. Always replace fasteners where 

instructed to do so. Failure to replace these 

fasteners could cause vehicle damage and 

personal injury. See an authorized BMW 

dealer for applications and ordering 

information. 

Tightening fasteners 

When tightening the bolts 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 

sequence until all the bolts are evenly 

tightened to the proper specification. 

For some repairs a specific tightening 

sequence is necessary, or a particular order 

of assembly is required. Such special 

conditions are noted in the text, and the 

necessary sequence is described or 

illustrated. Where no specific torque is 

listed, Table a can be used as a general 

guide for tightening fasteners. 

WARNING! 

Table a is a general reference only. The

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values listed in the table are not intended 

to be used as a substitute for torques 

specifically called out in the text. 

Note: 

Metric bolt classes or grades are 

marked on the bolt head. 

Do not confuse wrench size with bolt 

diameter. For a listing of the common 

wrenches used on various bolt 

diameters, see Basic tool 

requirements. 

Table a. General bolt tightening torques 

in Nm (max. permissible) 

Bolt 

diameter 

Bolt Class (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 of making as good a seal 

as when new, and is much more likely to 

leak. For this reason, gaskets should not be 

reused.

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Some gaskets—such as head gaskets—are 

directional. Make sure that these are 

installed correctly. This same logic applies to 

any part used for sealing, including rubber 

O-rings and copper sealing washers. 

In places where a shaft must pass through a 

housing, flexible lip seals are used to keep 

the lubricating oil or grease from leaking out 

past the rotating shaft. Seals should never 

be reused once they have been removed. 

When removing a seal, be careful not to 

damage the metal surfaces. 

The key to seal installation is to get the seal 

in straight without damaging it. Use a seal 

driver that is the same diameter as the seal 

housing to gently and evenly install into 

place. If a proper size seal driver is not 

available, a socket of the right size will do. 

Some seals are directional and special 

installation 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 in 

the car requires a complete circuit including 

a voltage source and a path to ground. The 

positive (+) side of the battery is the original 

voltage source, and ground is any return 

path to the negative (–) side of the battery, 

whether through the wiring harness or the 

car body. Except for portions of the charging 

system, all electrical current in the car is 

direct current (DC) and flows from positive 

(+) to negative (–). 

Switches are used to turn components on or 

off by completing or interrupting the circuit. A

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switch is “open” when the circuit is 

interrupted, and “closed” when the circuit is 

completed. See 600 Electrical System– 

General for electrical troubleshooting. 

Wire repairs 

Repairs to a wiring harness require special 

care to make the repair permanent. The wire 

ends must be clean. If frayed or otherwise 

damaged, cut off the end. If the wire is too 

short, splice in a new piece of wire of the 

same size and make two connections. 

Use connectors that are designed for the 

purpose. Crimped-on or soldered-on 

connectors are best. Crimp connectors and 

special crimping pliers are widely available. If 

soldering, use needlenose pliers to hold the 

wire near the solder joint and create a “heat 

dam”. This keeps the heat and the 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 that can be placed onto the wire 

before connecting, slid over the finished 

joint, and shrunk to a tight fit with a heat gun 

or hair dryer. The next best alternative is 

electrical tape. Make sure the wire is clean 

and free of solder flux or other 

contamination. Wrap the joint tightly to seal 

out moisture. See 600 Electrical System– 

General for more information.

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Buying Parts 

010-5 

Many of the maintenance and repair 

tasks in this manual call for the 

installation of new parts, or the use of 

new gaskets and other materials when 

reinstalling parts. Most often, the parts 

that will be needed should be on hand 

before beginning the job. Read the 

introductory text and the complete 

procedure to determine which parts will 

be needed. 

Note: 

For some bigger jobs, partial 

disassembly and inspection are 

required to determine a complete parts 

list. Read the procedure carefully and, if 

necessary, make other arrangements to 

get the necessary parts while your car 

is disassembled. 

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 make 

a point of using genuine BMW parts, 

even though they may at times be 

more expensive. They know the value 

of doing the job right with the right 

parts. Parts from other sources can be 

as good, particularly if manufactured 

by one of BMWs original equipment 

suppliers, but it is often difficult to 

know.

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BMW is constantly updating and 

improving their cars, often making 

improvements during a given model 

year. BMW may recommend a newer, 

improved part as a replacement, and 

your authorized dealer’s parts 

department will know about it and 

provide it. The BMW parts organization 

is best equipped to deal with any BMW 

parts needs. 

Non-returnable parts 

Some parts cannot be returned, even 

for credit. The best example is 

electrical parts, which are almost 

universally considered non-returnable. 

Buy electrical parts carefully, and be as 

sure as possible that a replacement is 

needed, especially for expensive parts 

such as electronic control units. It may 

be wise 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 year. This is not necessarily the 

same as date of manufacture or date of 

sale. A 1999 model may have been 

manufactured in late 1998, and 

perhaps not sold until early 2000. It is 

still a 1999 model. Model years covered 

by this manual are 1999 to 2001. 

Date of manufacture. This information 

is necessary when ordering 

replacement parts or determining if any

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of the warranty recalls are applicable to 

your car. The label on the driver’s door 

below the door latch will specify the 

month and year that the car was built. 

Vehicle Identification Number (VIN). 

This is a combination of letters and 

numbers that identify the particular car. 

The VIN appears on the state 

registration document, and on the car 

itself. One location is on the right front 

strut tower in the engine compartment 

(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 transmissionrelated 

parts. For information on 

transmission codes and applications, 

see 200 Transmission–General.

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Tools 

010-7 

Most maintenance can be 

accomplished with a small selection of 

the right tools. Tools range in quality 

from inexpensive junk, which may 

break at first use, to very expensive 

and well-made tools for the 

professional. The best tools for most 

do-it-yourself BMW owners lie 

somewhere in between. 

Many reputable tool manufacturers 

offer good quality, moderately priced 

tools with a lifetime guarantee. These 

are your best buy. They cost a little 

more, but they are good quality tools 

that will do what is expected of them. 

Sears’ Craftsman® line is one such 

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: 

Assenmacher Specialty Tools 

6440 Odell Place, Boulder, CO 

80301 

303-530-2424 

http://www.asttool.com 

Baum Tools Unlimited, Inc. 

P.O. Box 5867, Sarasota, FL 

34277-5867 

800-848-6657 

http://www.baumtools.com 

Schley Products, Inc. 

5350 E. Hunter Ave., Anaheim Hills, 

CA 92807 

714-693-7666

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http://www.sptool.com 

Zelenda Machine and Tool Corp. 

65-60 Austin Street, Forest Hills, NY 

11374-4695 

718-896-2288 

http://www.zelenda.com 

Basic tool requirements 

The basic hand tools described below 

can be used to accomplish most of the 

simple maintenance and repair tasks. 

Screwdrivers. The common flat-blade 

type and the Phillips type will handle 

almost all screws used on BMWs. Two 

or three different sizes of each type will 

be required, since a screwdriver of the 

wrong size will damage the screw 

head. 

A complete set of screwdrivers should 

also include Torx® type screwdrivers. 

Wrenches. Wrenches come in different 

styles, including 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 

lines, a flare-nut wrench offers the 

advantages of a box-end wrench with a 

slot that allows it to fit over the line. 

The combination wrench is the most 

universal. It has one open-end and one 

box-end. 10 mm and 13 mm wrenches 

are the most common sizes needed. A 

more complete set of wrenches would 

include 6 mm through 19 mm sizes.

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Sockets. Sockets are used with a 

ratchet handle for speed and 

convenience and can be combined with 

extensions and universal joints 

(swivels) to reach fasteners more 

easily. The most common drive sizes 

are 1/4 in., 3/8 in., and 1/2 in. 

Sockets come in 6-point and 12-point 

styles. The 6-point offers a better grip 

on tight nuts and bolts. 6mm to 19mm 

sockets are the most needed sizes. 

Below is a list of typical bolt diameters 

and the corresponding wrench sizes. 

Common bolt diameters and 

wrench sizes 

M5 

M6 

M8 

M10 

M12 

M14 

8 mm 

10 mm 

12 mm or 13 mm 

17 mm 

19 mm 

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 pliers 

including snap-ring, needlenose, 

adjustable-joint, slip-joint 

(Channellock®), and locking (Vise- 

Grip®) most of which are used for

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holding irregular objects, bending, or 

crimping. Some have special 

applications. 

Needlenose pliers are used for gripping 

small and poorly accessible objects, 

and are useful for wiring and other 

electrical work. Locking pliers such as 

the Vise-Grip® are useful because of 

their tight grip. 

Snap-ring and circlip pliers with special 

tipped jaws are used to remove and 

install snap-rings or circlips. 

Channel-lock® or water pump pliers 

have adjustable jaws that can be 

quickly changed to match the size of 

the object being held to give greater 

leverage. 

An adjustable wrench can be a useful 

addition to a small tool kit. 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 length. 

Jack stands 

Strong jack stands are extremely 

important for any work that is done 

under the car. Use only jack stands 

that are designed for the purpose. 

Blocks of wood, concrete, bricks, etc. 

are not safe or suitable substitutes. 

WARNING! 

A jack should be used only to raise 

the vehicle and should not be used

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to support the car for a long period. 

Always use jack stands to support a 

raised vehicle. 

Jack stands are available in several 

styles. The best ones are made of 

heavy material for strength, have a 

wide base for stability, and are 

equipped to positively lock in their 

raised positions. Get the best ones 

available. 

Oil change equipment 

Changing engine oil requires a 17 mm 

socket or wrench to loosen and tighten 

the drain plug and a drain pan (at least 

8 qt. capacity). A wide, 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 normally 

available as a set, covering a range of 

sizes. 

Torque wrench 

A torque wrench is used to precisely 

tighten threaded fasteners to a 

predetermined value. Many of the

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repair procedures in this manual 

include BMW-specified torque values in 

Newton-meters (Nm) and the 

equivalent values in foot-pounds (ft-lb). 

Several types of torque wrenches are 

available. An inexpensive beam-type 

(top) is adequate but must be read 

visually. A ratchet-type (bottom) can be 

preset to indicate (click) when the 

torque value has been reached. They 

all do the same job, but offer different 

convenience features at different 

prices. The most convenient ones have 

a built-in ratchet, and can be preset to 

indicate when a specific torque value 

has been reached. Follow the wrench 

manufacturer’s directions for use to 

achieve the greatest accuracy. 

A torque wrench with a range up to 

about 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 

manual call for the measurement of 

resistance (ohms) or voltage values. 

For safe and accurate tests of sensitive 

electronic components and systems, a 

multimeter or Digital Volt/Ohmmeter 

(DVOM) with high input impedance (at 

least 10,000 ohms) should be used. 

Some meters have automotive 

functions such as dwell and pulse 

width that are useful for 

troubleshooting ignition and fuel 

injection problems.

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CAUTION! 

Vehicle electronic systems may be 

damaged by the high current draw of 

a test light with a normal 

incandescent bulb. As a general rule, 

use a high impedance digital 

multimeter or an LED test light for all 

electrical testing. 

BMW special tools 


Many repairs covered in this manual 

call for the use of BMW special tools. 

This, however, does not automatically 

mean that the job is too complicated or 

out of reach of the do-it-yourselfer. 

Many of the BMW special tools 

mentioned in this manual are simply 

the best thing to 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 the 

necessary experience and access to 

tools. For the do-it-yourselfer, the need 

for special tools is noted in the text, 

and whether or not BMW dealer service 

is recommended.

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Emergencies 

010-8 

Changing a tire 

- Stop car on as flat a surface as 

possible, in a place where you can 

be easily seen by other drivers. 

Avoid stopping just over the crest 

of a hill. 

- Turn on emergency flashers, and 

set out flares or emergency 

markers well behind car. Chock 

wheel (wheel chock located in 

trunk) diagonally opposite to the 

one being changed. Passengers 

should get out of car and stand 

well away from road. 

WARNING! 

If a tire goes flat while driving, pull 

well 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 point nearest wheel 

being changed. Use a board to provide 

a firm footing for jack if ground is soft. 

Raise car only far enough so that 

wheel is fully off ground and then

General 


2 of 8 2/25/2009 10:09 PM 

remove wheel nuts and wheel. 

- Install spare wheel. Install wheel 

nuts and tighten them hand tight 

using lug nut wrench. 

- Lower car. With all wheels on 

ground, fully tighten nuts in a 

crisscross pattern. Torque wheel 

nuts when installing wheel. Check 

inflation pressure of spare tire. 

Tightening torque 

Wheel to wheel 

hub 

100 ± 10 Nm (74 ± 

7 ft-lb) 

Car will not start 

If the engine turns over slowly or not at 

all, especially on cold mornings, the 

battery may not be sufficiently charged. 

Jump-starting the battery from another 

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. Do not rely on the fuel gauge 

as it may be faulty. Instead, remove the 

gas filler cap and rock the car. If there 

is gas in the tank, you should hear a 

sloshing sound at the filler neck. 

See 

OBD On Board Diagnostics at

General 


3 of 8 2/25/2009 10:09 PM 

the rear of this manual for diagnostic 

code reading procedures. 

Jump starting 

Cars with discharged or dead batteries 

can be jump-started using the good 

battery from another car. When 

jump-starting the engine, always note 

the following warnings. 

WARNING! 

Battery acid (electrolyte) can 

cause severe burns, and will 

damage the car and clothing. If 

electrolyte is spilled, wash the 

surface with large quantities of 

water. If it gets into eyes, flush 

them with water 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 boosting cables 

attached. Wait at least one 

minute before boosting the 

battery a second time. 

- Place cars close together, but do 

not allow them to touch each

General 


4 of 8 2/25/2009 10:09 PM 

other. 

- Turn off engine of car with 

good battery. 

- Turn off ignition switch of car 

with discharged battery. 

Connect one end of positive (+) cable 

to positive (+) post of good battery. 

Remove cover from the positive (+) 

junction post (A) in engine 

compartment and connect other end of 

the positive (+) cable to the junction 

post. 

- Connect one end of negative (–) 

cable to negative (–) battery post 

of good battery. Connect opposite 

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 engine should be run for at least an 

hour to recharge the battery. 

Indicator and warning lights

General 


5 of 8 2/25/2009 10:09 PM 

Many of the vehicle systems are 

self-monitored both statically and 

dynamically while driving. Generally, a 

red warning lamp that comes on during 

driving should be considered serious. If 

you cannot immediately determine the 

seriousness of the warning light, stop 

the vehicle in a safe place and turn the 

engine off as soon as possible. Consult 

the owner’s manual in the glove box for 

additional information on the warning 

lamp and the recommended action. 

If the Malfunction Indicator Lamp (MIL), 

“Check Engine” or “SERVICE ENGINE 

SOON” warning light, comes on or 

flashes, it indicates that an emissionsrelated 

fault has occurred. Faults such 

as a faulty oxygen sensor 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 this manual 

should be towed with a tow truck using 

wheel lift or flat bed equipment. Do not 

tow the car on all four wheels except 

for very short distances to move it to a 

safe place. 

CAUTION! 

Do not tow with sling-type 

equipment. The front spoilers and 

bumper covers may sustain damage. 

To access threaded towing eye socket, 

pry open trim (arrow) on front or rear

General 


6 of 8 2/25/2009 10:09 PM 

bumper. 

Note: 

A towing eye is provided in the luggage 

compartment tool kit. The towing eye 

can be screwed into the front or rear 

bumper. 

Install towing eye into threaded hole. 

- Standard transmission: A 

maximum towing distance of 20 

miles is acceptable with the rear 

wheels on the ground and the 

transmission out of gear. If the car 

needs to be towed further, have 

the rear wheels placed 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 

driveshaft. 

Note: 

- Be sure to drain or pump out 

added fluid once tow has 

been completed.

General 


7 of 8 2/25/2009 10:09 PM 

ATF draining and filling is covered 

in 240 Automatic Transmission. 

Be sure to read the filling and 

draining procedure, as special 

service equipment is required to 

check the fluid level. 

Driveshaft removal is covered in 

260 Driveshaft. 

Spare parts kit 

Carrying a basic set of spare parts can 

prevent a minor breakdown from 

turning into a major annoyance. 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 (upper and 

lower) 

Spare parts kit – additional 

contents

General 


8 of 8 2/25/2009 10:09 PM 

Spare parts kit – additional 

contents 

Exterior lighting bulbs 

(headlight, brake light, turn 

signal, and taillight) 

Wiper blades 

Brake fluid (new unopened 

bottle, DOT 4 specification) 

Main relay for DME system 

Copyright © 2006 Robert Bentley, Inc. All rights reserved.

Maintenance 


1 of 6 2/25/2009 10:01 PM 

General 

020-1 

The information given in this repair 

group includes the routine checks and 

maintenance steps that are both 

required by BMW under the terms of 

the vehicle warranty protection and 

recommended by BMW to ensure long 

and reliable vehicle operation. 

Note: 

Aside from keeping your car in the best 

possible condition, proper maintenance 

plays a role in maintaining full 

protection under BMW's new-car 

warranty coverage. If in doubt about the 

terms and conditions of your car's 

warranty, an authorized BMW dealer 

should be able to explain them. 

Service Interval Indicator (SII) 

For the 1999 and later 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 elapsed mileage, but also on such 

inputs as engine speed, engine 

temperature, number of starts, length 

of trips, and the amount of fuel used. 

At the appropriate time, the system 

indicates, through lights in the 

instrument cluster, when the next 

routine maintenance is due. 

6/2000 and later models. For the

Maintenance 


2 of 6 2/25/2009 10:01 PM 

mid-2000 models BMW introduced new 

service interval software which 

calculates service based on the 

amount of fuel used. When SII detects 

total fuel consumption that equals the 

preset limits (in gallons), the 

instrument cluster indicates that service 

is required. 

Using a 328i as an example: 

Standard transmission model: SII 

illuminates after consumption of 

601 gallons of fuel. 

Automatic transmission model: SII 

illuminates after consumption of 

667 gallons. 

After the service is performed the SII 

can be reset to zero. 

The SII displays the mileage remaining 

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 in front of the 

number indicate that the service 

interval has been exceeded by the 

distance displayed. 

The On-Board Computer uses the rate 

of fuel consumption in the period 

immediately preceding to calculate the 

mileage before the next service is due.

Maintenance 


3 of 6 2/25/2009 10:01 PM 

Service Interval Indicator (SII), 

resetting 

The SII signals the need for basic 

routine maintenance: 

Engine oil and oil filter change, 

after the engine has been warmed 

up. 

Note: 

BMW-recommended additional 

maintenance as listed in Table 

a. 

For reference, the BMW oil service 

requirements are approximately 

equivalent to the maintenance that 

other European manufacturers specify 

at intervals with a maximum of every 

15,000 miles or 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. If the reset 

procedures are done incorrectly, the 

reset tool or the electronic Service 

Interval Indicator may be damaged.

Maintenance 


4 of 6 2/25/2009 10:01 PM 

Aftermarket reset tools that can reset 

all models with the DLC can be 

purchased from one of the following 

suppliers: 

Assenmacher Specialty Tools 

6440 Odell Place, Boulder, CO 

80301 

303-530-2424 

http://www.asttool.com 

Baum Tools Unlimited, Inc. 

P.O. Box 5867, Sarasota, FL 

34277-5867 

800-848-6657 

http://www.baumtools.com 

Peake Research, Automotive 

Products Division 

P.O. Box 28776, San Jose, CA 95159 

408-369-0406 

http://www.peakeresearch.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 for approx. 5 

more seconds until any of the 

following appear in the display: 

"Oil Service" or "Inspection", with 

"Reset" or "Re".

Maintenance 


5 of 6 2/25/2009 10:01 PM 

Press button again and hold for 

approx. 5 seconds until "Reset" or 

"Re" flash. 

While display is flashing, press 

button briefly to reset SII. 

After display has shown new 

interval, the following will appear 

in display for approx. 2 seconds: 

"End SIA". 

The system can only be reset again 

after the vehicle has been driven 

approx. 50 to 75 miles (consumes at 

least 2.5 gal. fuel). If the display shows 

"Reset" or "Re" when resetting, the 

minimum driving distance has been 

fulfilled and the system can be reset 

again. It is possible to interrupt and 

end the reset procedure by changing 

the position 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 

after that will be Inspection I, and so 

on. 

Inspection I tasks are listed in Table 

b. Inspection II includes most of the 

tasks from Inspection I with additional 

Inspection II tasks. A complete listing of 

Inspection II tasks is in Table c. 

Note: 

For reference, the BMW Inspection I

Maintenance 


6 of 6 2/25/2009 10:01 PM 


and Inspection II requirements are 

approximately equivalent to the 

maintenance requirements that other 

European manufacturers specify. 

Inspection I is normally due at intervals 

with a maximum of 30,000 miles or 24 

months. Inspection II is normally due at 

intervals with a maximum of 60,000 

miles or 48 months.

Maintenance 


1 of 7 2/25/2009 10:02 PM 

Maintenance Tables 

The intervals for most tasks listed in the maintenance table below are determined by the SII. 

Except where noted, the maintenance items listed apply to all models and model years covered 

by this manual. The columns on the right side of each table give quick-reference information 

about the job. The text in the "additional repair information" column refers to repair groups. 

Table a. Oil service 

Maintenance item 

Tools 

required 

New parts 

required 

Warm 

engine 

required 

Dealer service 

recommended 

Additional 

repair 

information 

Engine compartment 

maintenance 

Change oil and oil filter 020 

Reset Service Interval 

Indicator (SII). 

Replace interior 

ventilation microfilter. 

020 

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 

wheels only). Check 

thickness of parking 

brake linings only when 

replacing rear brake 

pads. Check operation 

of parking brake and 

adjust as necessary. 

Check and adjust tire 

pressures, including 

spare 

340 

020

Maintenance 


2 of 7 2/25/2009 10:02 PM 

Table b. Inspection I service 


Tools 

required 

New parts 

required 

Warm 

engine 

required 


recommended 

Additional 

repair 

information 

Under car 

maintenance 

Change engine oil and 

filter. 

020 

Check transmission and 

differential(s) for 

external leaks. 

230 

240 

Check CV joint boots for 

damage or leaks. 

311 

331 

Visually check fuel tank, 

fuel lines and 

connections for leaks. 

160 

Check 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 is 

necessary: Examine 

brake disc surfaces. 

Clean brake pad 

contact points in 

calipers. Grease wheel 

340

Maintenance 


3 of 7 2/25/2009 10:02 PM 



Tools 

required 

New parts 

required 

Warm 

engine 

required 


recommended 

Additional 

repair 

information 

centering hubs (alloy 

wheels only). Check 

thickness of parking 

brake linings only when 

replacing rear brake 

pads. Check operation 

of parking brake and 

adjust as necessary. 

Check front control arm 

bushings for damage or 

wear. 

310 

Check brake system 

connections 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 

performed at least every 

two years.) 


maintenance 

Read out on-board 

diagnostic (OBD II) 

system. 

100 

130

Maintenance 


4 of 7 2/25/2009 10:02 PM 



Tools 

required 

New parts 

required 

Warm 

engine 

required 


recommended 

Additional 

repair 

information 

Check engine coolant 

system/heater hose 

connections for leaks. 

Check coolant level and 

antifreeze protection 

level. Add coolant as 

necessary. 

170 

Check windshield 

washer fluid level and 

antifreeze protection. 

Add washer fluid as 

necessary. 

611 

Replace ventilation 

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 and 

dimmer switch 

630 

Check instrument panel 

and dashboard lights. 

620 

Check wipers and 

windshield washer 611

Maintenance 


5 of 7 2/25/2009 10:02 PM 



Tools 

required 

New parts 

required 

Warm 

engine 

required 


recommended 

Additional 

repair 

information 

system. Check aim of 

washer jets and adjust if 

necessary. 

Check condition and 

function of seat belts. 

720 

Visually examine all 

airbag units for torn 

covers, obvious damage 

or attachment of decals, 

decorations or 

accessories. 

721 

Check central 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 all 

warning/indicator lights, 

check control. 

620 

Check operation of rear 

view mirrors. 

Road test

Maintenance 


6 of 7 2/25/2009 10:02 PM 



Tools 

required 

New parts 

required 

Warm 

engine 

required 


recommended 

Additional 

repair 

information 

Check braking 

performance, steering, 

heating, air conditioner 

operation. Check 

manual transmission 

and clutch operation or 

automatic transmission 

operation. 

Table c. Inspection II service 


Tools 

required 

New parts 

required 

Warm 

engine 

required 


recommended 

Additional 

repair 

information 


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 vehicle 

production date). 

170 

Oxygen sensor 

service 

Replace oxygen sensor 

every 100,000 miles. 

180

Maintenance 


7 of 7 2/25/2009 10:02 PM 

Table c. Inspection II service 


Tools 

required 

New parts 

required 

Warm 

engine 

required 


recommended 

Additional 

repair 

information 

Spark plug service 

Replace spark plugs 

every 100,000 miles. 

020 


Maintenance 


1 of 4 2/25/2009 10:02 PM 

Fluid and Lubricant 

Specifications 

020-3 

The illustration shows engine oil viscosity 

(SAE grade) vs. operating temperature 

range for the BMW engines covered in this 

manual. 

Fluid and lubricant capacities and 

specifications for E46 cars are listed in 

Table d. 

WARNING! 

The use of fluids that do not meet BMW's 

specifications may impair performance 

and reliability, and may void warranty 

coverage. 

Table d. Fluids and lubricants 

Fluid 

Approximate 

capacity 

Specification 

Engine oil with filter change 

Rear 

wheel 

drive 

All wheel 

drive 

6.5 liters 

(6.9 US qt.) Synthetic oil 

with API 

7.5 liters 

(8 US qt.) 

rating SH or 

higher 

Manual transmission oil 

Getrag 

S5D 250G 

ZF S5D 

320Z 

ZF S5D 

280Z 

1.1 liters 

(1.15 US qt.) 

1.3 liters 

(1.37 US qt.) 

1.35 liters 

(1.42 US qt.) 

BMW 83 22 9 

408 942 

(MTF-LT-1) 

Automatic transmission fluid (ATF) 

(drain and fill) 

(additional fluid required when installing 

a dry torque converter)

Maintenance 


2 of 4 2/25/2009 10:02 PM 

Table d. Fluids and lubricants 

Fluid 

ZF A5S 

325Z 

GM A5S 

360R 

GM A5S 

390R 

Approximate 

capacity 

Complete 

refill: 

9.0 liters 

(9.5 US qt.) 

Oil and filter 

change: 

4.0 liters 

(4.2 US qt.) 

Specification 


407 807 

(Exxon LT 

71141) 


024 359 

(Texaco ETL 

8072B) 

Differential, front or rear(drain and fill) 

(Lifetime fluid; no fluid change required) 

Front 

differential 

Rear 

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 

Power steering fluid 

All models 

Brake fluid 

All models 

Permanently 

sealed 

(no drain 

plug) 

Dexron III ® 

ATF 

SAE DOT4 

Engine coolant 

All models 8.4 liters (8.9 

US qt.) 

50% BMW 

anti-freeze/ 

50% distilled 

water 

CAUTION! 

Multi-viscosity engine oils should not be

Maintenance 


3 of 4 2/25/2009 10:02 PM 

used in the manual transmission. Use of 

such an oil could shorten the service life 

of the transmission. 

Brake fluid 

Brake fluid absorbs moisture easily, and 

moisture in the fluid affects brake 

performance and reliability. This is why 

brake fluid should be flushed from the 

system every two years. When replacing or 

adding brake fluid, use only new fluid from 

previously unopened containers. Do not 

use brake fluid that has been bled from the 

system, even if it is brand new. Use only 

DOT 4 brake fluid. 

Note: 

See 340 Brakes for more brake fluid 

information. 

Engine coolant (anti-freeze) 

BMW recommends coolant that is a 50/50 

mixture of distilled water and 

phosphate/nitrate free anti-freeze 

containing ethylene glycol. Anti-freeze 

raises the boiling point and lowers the 

freezing point of the coolant. It also 

contains additives that help prevent cooling 

system corrosion. 

Differential gear oil 

BMW recommends using only a specially 

formulated synthetic gear oil (SAF-XO) that 

is available through an authorized BMW 

dealer parts department. For additional 

information on this lubricant and any other 

lubricants that may be compatible, contact 

an authorized BMW dealer service 

department. 

Power steering fluid

Maintenance 


4 of 4 2/25/2009 10:02 PM 

The power steering fluid is Dexron III® ATF, 

or equivalent. The system is permanently 

filled and does not have a drain. Routinely 

adding ATF is not required unless the 

system is leaking. 

Transmission fluid, automatic 

The automatic transmissions installed in 

the E46 models are filled with special 

automatic transmission fluids, depending 

on transmission type and model year. 

Note: 

The transmission 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-upto-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 Transmission for further 

information.

Maintenance 


1 of 5 2/25/2009 9:28 PM 

Engine Oil Service 

020-4 

With the introduction of synthetic oil 

and extended oil change intervals, a 

new oil filter with improved filter paper 

design was introduced. The new filter 

paper resists deterioration caused by 

high oil temperatures over an extended 

time. 

Note: 

Early style oil filter numbers with BMW 

part numbers 11 42 1 427 908 or 11 42 

1 745 390 should not be used in the 

1999 and later BMW models. 

Use any synthetic low viscosity oil to 

top off the engine 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 

engine oil. 

BMW is constantly upgrading 

recommended maintenance 

procedures and requirements. The 

information contained here is as 

accurate as possible at the time of

Maintenance 


2 of 5 2/25/2009 9:28 PM 

publication. If there is any doubt 

about what procedures apply to a 

specific model or model year, or 

what intervals should be followed, 

remember that an authorized BMW 

dealer has the latest information 

on factory-recommended 

maintenance. 

Engine oil, checking level 

Engine oil level is checked with a 

dipstick (arrow) in engine block. 

Check oil level with car on a level 

surface, after engine has been 

stopped for at least a few minutes. 

Check level by pulling out dipstick 

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 requires new oil, 

a new oil filter insert kit, and a new 

drain plug sealing washer. The tools 

needed, a 17 mm drain plug socket or 

box wrench and a drain pan (8 - 10 US

Maintenance 


3 of 5 2/25/2009 9:28 PM 

qt. capacity), are described in 010 

General. 

Note: 

If using a "fast-lube" service facility for 

oil changes, make sure the technician 

hand-starts and torques the engine oil 

drain plug using hand-tools. Power 

tools can strip the threads of the plug 

and the oil pan. 

- Run engine for a few minutes to 

warm engine oil. Shut engine 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 oil drain into pan.

Maintenance 


4 of 5 2/25/2009 9:28 PM 

CAUTION! 

Pull the loose plug away from the 

hole quickly to avoid being scalded 

by hot oil. It will run out quickly 

when the plug is removed. If 

possible, use gloves to protect your 

hands. 

- When oil flow has diminished to 

an occasional drip, reinstall drain 

plug with a new metal sealing 

washer and torque plug. 

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 


Oil filter cover filter 

housing 

25 Nm (18 ft-lb)

Maintenance 


5 of 5 2/25/2009 9:28 PM 

- 

Refill crankcase with oil. 

Approximate oil capacity is listed 

in Table d. Use dipstick to 

check correct oil level. 

- Start engine and check that oil 

pressure warning light 

immediately goes out. 


- Allow engine to run for a few 

minutes to circulate new oil, then 

check for leaks at drain plug and 

oil filter. Stop engine and recheck 

oil level.

Maintenance 


1 of 8 2/25/2009 10:03 PM 

Engine Compartment 

Maintenance 

020-5 

The information under this heading 

describes routine maintenance other 

than oil change done in the engine 

compartment. It is not necessary for 

the car to be raised and supported off 

the ground. Information on oil change 

is given earlier in this group. 

Accelerator linkage 

The accelerator and throttle linkage 

should be lubricated periodically. Use a 

general purpose oil on the joints and 

bearings of the 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 filter housing 

clips (B). 

Lift air filter upper housing, and then 

remove filter element insert from 

cartridge. 

- On installation, install O-ring for

Maintenance 


2 of 8 2/25/2009 10:03 PM 

mass air flow sensor (arrow) into 

retaining clips in air filter upper 

housing. 

Cooling system service 

Routine cooling system maintenance 

consists of maintaining the coolant 

level and inspecting hoses. Because 

the coolant's anti-corrosion and 

anti-freeze additives gradually lose 

their effectiveness, replacement of the 

coolant every four years is 

recommended. 

CAUTION! 

Use only BMW approved 

phosphate-free anti-freeze when 

filling the cooling system. Use of 

anti-freeze containing phosphates is 

considered to be harmful to the 

cooling system. 

The float in the radiator tank indicates 

coolant level, and should be 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 the 

connection is dirty or corroded. Dried 

coolant has a chalky appearance. 

Hoses should be firm and springy. 

Replace any hose that is cracked, that 

has become soft and limp, or has been 

contaminated by oil. 

As a preventive measure, replacement 

of the cooling system hoses every four 

years is also recommended. The

Maintenance 


3 of 8 2/25/2009 10:03 PM 

illustration shows examples of damage 

to coolant hoses. Any of conditions 

shown is cause for replacement. 

(Courtesy of Gates Rubber Company, 

Inc.) 

Engine drive belt service 

Drive belts and pulleys transfer power 

from the engine crankshaft to various 

accessories. E46 models use two 

poly-ribbed (serpentine) belts: 

The outer belt only turns the A/C 

compressor 

The inner, longer belt activates the 

alternator, coolant pump and 

power steering. 

Automatic belt tensioners are used to 

keep the belts tensioned properly. 

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, 

store the old set in the luggage 

compartment for emergency use. 

To remove drive belts: 

Use long-handled wrench to turn 

A/C belt tensioner release lug (A) 

clockwise (against spring tension). 

Remove A/C belt.

Maintenance 


4 of 8 2/25/2009 10:03 PM 

Similarly, turn main engine drive 

belt tensioner lug (B) clockwise 

and remove belt. 

WARNING! 

Observe care when replacing belts. 

Personal injury could result if a 

tensioner springs back into position 

uncontrollably. 

CAUTION! 

Mark drive belt rotation direction if 

removing and reusing an old belt. 

- When installing a new belt, gently 

pry it over the pulleys. Too much 

force may damage the belt or the 

accessory. 

Idle speed 

Engine idle speed can change due to a 

number of factors, including normal 

wear. 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 helps to 

control the fuel injection system and 

exhaust emissions. The monitoring 

sensor is used by the on-board 

diagnostic (OBD II) system to monitor 

the function of the catalytic converter.

Maintenance 


5 of 8 2/25/2009 10:03 PM 

OBD II enhanced emission standards 

require the engine control module 

(ECM) to monitor the oxygen content in 

the exhaust both before and after the 

catalytic converter. This allows for 

tighter control of the tail pipe emissions 

and also allows the ECM to diagnose 

converter problems. If the ECM detects 

that catalytic converter or oxygen 

sensor efficiency has degraded past a 

certain pre-programmed limit, it will 

turn on the Check Engine light, and 

store a diagnostic trouble code (DTC) 

in the ECM. See OBD On Board 

Diagnostics in the rear of this manual 

for more information on OBD systems. 

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. 


Oxygen sensor to 

exhaust manifold 

50 Nm (37 ft-lb) 

Note: 

A special socket for replacing the 

oxygen sensor is available from most 

automotive parts stores. The socket 

has a groove cut down one side to allow 

the sensor to be installed without 

damaging the wire harness. 

Power steering fluid, checking 

level 

To check power steering fluid level in 

fluid reservoir:

Maintenance 


6 of 8 2/25/2009 10:03 PM 

Park car on level ground with 

engine off. 

Level is correct if it is between MIN 

and MAX marks on dipstick. 

If level is below MIN mark, start 

engine and add fluid to reservoir 

to bring level up. 

Stop engine and recheck level. 

Hand-tighten reservoir cap. 


Recommended fluid 

Dexron III® 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.

Maintenance 


7 of 8 2/25/2009 10:03 PM 

Remove plastic trim covers 

(arrows). 

Remove cover hold down bolts. 

Remove ignition coil grounding 

harnesses (arrows). 

Remove ignition coils: 

Pull up on spring clips to 

disconnect ignition coil harness 

connectors. 

Remove coil mounting bolts. 

Remove coils. 

- Remove spark plugs. 

- 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 crossthreading.

Maintenance 


8 of 8 2/25/2009 10:03 PM 

Be sure to reinstall coil grounding 

harness. 

Spark plug recommendations 

Bosch 

NGK 

FGR7 DQP 

BKR6 EQUP 


Spark plug to 

cylinder head 

25 Nm (18 ft-lb) 

Ventilation microfilter, 

replacing 

Working at cowl housing inside engine 

compartment, twist microfilter cover 

retainers (arrows) 90° each and pull 

cover up. 

Pull filter out and replace. 


Maintenance 


1 of 15 2/25/2009 10:03 PM 

Other Mechanical 

Maintenance 

020-6 

Battery, checking and cleaning 

The battery is located in the right side 

of the luggage compartment. Simple 

maintenance of the battery and its 

terminal connections will ensure 

maximum starting performance, 

especially in winter when colder 

temperatures reduce battery power. 

Note: 

Design characteristics of the 

convertible body cause vibrations in the 

trunk area. Therefore, E46 Convertibles 

require a special battery 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 corrosion: 

Disconnect battery cables. 

Disconnect negative (-) cable first. 

Remove battery from trunk. 

Clean terminal posts and cable 

clamps with a wire brush.

Maintenance 


2 of 15 2/25/2009 10:03 PM 

Clean main chassis ground 

terminal next to battery. Corrosion 

can be washed away with a 

baking soda and water solution 

that will neutralize acid. Apply 

solution carefully, though, since it 

will also neutralize acid inside 

battery. 

Reconnect cable clamps, positive 

(+) cable first. 

Lightly coat outside of terminals, 

hold down screws, and clamps 

with petroleum jelly, grease, or a 

commercial battery terminal 

corrosion inhibitor. 

WARNING! 

Prior to disconnecting the 

battery, read the battery 

disconnection cautions given at 

the front 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 plates or to the top of the 

indicator marks (if applicable). The 

battery plates and the indicator marks 

can be seen once the filler caps are 

removed. If the electrolyte level is low, 

replenish it by adding distilled water

Maintenance 


3 of 15 2/25/2009 10:03 PM 

only. 

Note: 

The original equipment battery in E46 

models is maintenance free. The 

original electrolyte will normally last the 

entire service life of the battery under 

moderate climate conditions. 

Battery, replacing 

The original equipment BMW battery is 

equipped with a built-in hydrometer 

"magic eye" (arrow). Battery condition 

is determined by the color of the eye: 

Green: Adequate charge 

Black: Inadequate charge; 

recharge 

Yellow: Defective battery; replace 

Batteries are rated by ampere hours 

(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! 





The battery is held in place by a single 

hand screw and plate. A secure battery 

hold-down is important in order to 

prevent vibrations and road shock from

Maintenance 


4 of 15 2/25/2009 10:03 PM 

damaging the battery. 

Note: 

Always disconnect the negative (-) 

cable first, and connect it last. 

While changing the battery, clean 

away any corrosion in or around 

the battery tray. 

Design characteristics of the 

convertible body cause vibrations 

to oscillate in the trunk area. 

Therefore, the convertible model 

uses a special battery and battery 

retaining mechanism designed for 

this constant vibration. 

More battery and charging system 

information is in 121 Battery, 

Alternator, Starter. 

Brake fluid, replacing 

BMW strictly recommends replacing 

the brake fluid every two years. This 

will help protect against corrosion and 

the effects of moisture in the fluid. 

Note: 

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, the system only monitors one 

wheel per axle. It is recommended that 

pad thickness should be checked 

whenever the wheels are off or brake 

work is being done.

Maintenance 


5 of 15 2/25/2009 10:03 PM 

Disc brake pad wear can be checked 

through opening in caliper: 

Measure distance (A) of brake pad 

"ear" to brake rotor. See 340 

Brakes. Compare to specification 

below. 

Unbolt caliper from steering arm to 

properly inspect: 

Brake pad thickness (A) 

Brake rotors 

Condition of caliper seal (B) 

Note: 

Condition of caliper slider bolts (C) 

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 damage:

Maintenance 


6 of 15 2/25/2009 10:03 PM 

Check that brake hoses are 

correctly routed to avoid chafing or 

kinking. 

Inspect unions and brake calipers 

for signs of fluid leaks. 

Inspect rigid lines for corrosion, 

dents, or other damage. 

Inspect flexible hoses for cracking. 

Replace faulty hoses or lines, see 

340 Brakes. 

WARNING! 

Incorrect installation or 

overtightening hoses, lines, and 

unions may cause chafing or 

leakage. This can lead to partial or 

complete brake system failure. 

Parking brake, checking 

The parking 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 frequently. 

This is due to corrosion build-up on the 

parking brake drum. To remove 

corrosion, apply the parking brake just 

until it begins to grip, then pull the lever

Maintenance 


7 of 15 2/25/2009 10:03 PM 

up one more stop (click). Drive the car 

approximately 400 meters (1,300 ft.) 

and release the brake. To recheck the 

adjustment of the parking brake see 

340 Brakes. 

Clutch fluid, checking 

The hydraulic clutch and the brake 

system share the same reservoir and 

the same brake fluid. Clutch fluid level 

and brake fluid level are checked at the 

same time. 

Note: 

See 340 Brakes for more 

information. 

See 210 Clutch for information 

on the clutch and the 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 Final Drive and 

331 Rear Axle Final Drive. 

Exhaust system, inspecting 

Exhaust system life varies widely 

according to driving habits and

Maintenance 


8 of 15 2/25/2009 10:03 PM 

environmental conditions. If shortdistance 

driving predominates, the 

moisture and condensation in the 

system will not fully dry out. This will 

lead to early corrosion damage and 

more frequent replacement. 

Scheduled maintenance of the exhaust 

system is limited to inspection: 

Check to see that all the hangers 

(arrow) are in place and properly 

supporting the system and that 

the system does not strike the 

body. 

Check for restrictions due to dents 

or kinks. 

Note: 

Check for weakness or perforation 

due to rust. 

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 front 

differential fluid level at front differential 

filler plug (arrow).

Maintenance 


9 of 15 2/25/2009 10:03 PM 

Check rear differential oil level at rear 

differential filler plug (arrow). 

- Check lubricant level with car on a 

level surface: 

Remove oil filler plug. 

Level is correct when fluid just 

reaches edge of filler hole. 

If necessary, top up fluid. 

Install and tighten oil filler plug 

when oil level is correct. 

The differential should be filled with a 

special BMW lubricant available 

through an authorized BMW dealer. 

Note: 

Use a 14 mm or 17 mm Allen 

socket to remove the drain plug. 

If the car is raised in the air, it 

should be level. 


Front differential 

filler plug to 

housing 

Rear differential 

filler plug to 

housing 

65 Nm (48 ft-lb) 

70 Nm (52 ft-lb) 

Fuel filter, replacing 

The fuel filter is located beneath the 

center of the car, approximately under

Maintenance 


10 of 15 2/25/2009 10:03 PM 

the driver's seat. A protective cover 

must be removed to access the filter. 

Fuel filter for M52 TU engine is shown 

in illustration. 

E46 cars with M54 engine are 

equipped with a fuel filter that has a 

built in fuel pressure regulator. 

- Disconnect battery negative (-) 

cable. 

- Drain fuel filter from inlet side 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

Maintenance 


11 of 15 2/25/2009 10:03 PM 

is removed. Do not smoke or work 

near heaters or other fire hazards. 

Keep a fire extinguisher handy. 

CAUTION! 

Clean thoroughly around the filter 

connections before removing them. 

Note: 

When installing fuel filter cover, take 

care to reinstall foam rubber seal in 

front of cover correctly to prevent 

flooding of filter with rain splash water. 

Fuel tank and fuel lines, 

inspecting 

Inspect the fuel tank, fuel lines, and 

fuel system for damage or leaks. 

Check for fuel leaks in the engine 

compartment or fuel odors in the 

passenger compartment. 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 ignite or explode 

causing serious personal injury. 

Ventilate the work area and clean up 

spilled fuel immediately. 

Note: 

See 130 Fuel Injection and 160 

Fuel Tank and Fuel Pump for 

component locations and additional 

information.

Maintenance 


12 of 15 2/25/2009 10:03 PM 

Suspension, front, inspecting 

Inspection of the front suspension and 

steering includes a check of all moving 

parts for wear and excessive play. 

Inspect ball joint and tie-rod rubber 

seals and boots for cracks or tears that 

could allow the entry of dirt, water, and 

other contaminants. 

On All wheel drive models check front 

differential fluid level and check CV 

joint boots for cracks. 

Note: 

See 310 Front Suspension and 

331 Rear Axle Final Drive 

Suspension, rear, inspecting 

Differential and rear drive axle service 

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 tire pressures are important to 

handling and stability, fuel economy, 

and tire wear. Tire pressures change 

with temperature. Pressures should be 

checked often during seasonal 

temperature changes. Correct inflation

Maintenance 


13 of 15 2/25/2009 10:03 PM 

pressures can be found on the driver's 

door pillar and in the owner's manual. 

Note that tire pressures should be 

higher when the car is more heavily 

loaded. 

WARNING! 

Do not inflate any tire to a pressure 

higher than the tire's maximum 

inflation pressure listed on the 

sidewall. Use care when adding air 

to warm tires. Warm tire pressures 

can increase as much as 4 psi (0.3 

bar) over their cold pressures. 

Tires, rotating 

BMW does not recommend tire 

rotation. Due to the car's suspension 

design, the front tires begin to wear 

first at the outer shoulder and the rear 

tires begin to wear first at the middle of 

the tread or inner shoulder. 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 specified ATF 

temperature during the checking 

procedure. 

Note: 

For more complete ATF service 

information, including checking ATF 

level and ATF filter replacement 

procedures, see 240 Automatic 

Transmission.

Maintenance 


14 of 15 2/25/2009 10:03 PM 

Transmission service, manual 

Manual transmission service consists of 

inspecting for leaks and checking the 

fluid. 

Evidence of transmission leaks is likely 

to be seen around the driveshaft 

mounting flange and at the bottom of 

the bellhousing. 

Note: 

For more information on identifying oil 

leaks and their causes, see 230 

Manual Transmission and 210 

Clutch. 

Transmission 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 recommends checking the front 

and rear alignment once a year and

Maintenance 


15 of 15 2/25/2009 10:03 PM 

whenever new tires are installed. 

Note: 


See 320 Steering and Wheel 

Alignment for a more detailed 

discussion of alignment requirements 

and specifications.

Maintenance 


1 of 5 2/25/2009 10:03 PM 

Body and Interior 

Maintenance 

020-7 

Body and hinges, lubricating 

The door locks and lock cylinders can 

be lubricated with an oil that contains 

graphite. 

The body and door hinges, the hood 

latch, and the door check rods should 

be lubricated with SAE 30 or SAE 40 

engine oil. Lubricate the seat runners 

with multipurpose grease. Do not apply 

any oil to rubber parts. If door weatherstrips 

are sticking, lubricate them with 

silicone spray or talcum powder. The 

hood release cable should be 

lubricated as well. 

The use of winter lock de-icer sprays 

should be kept to an absolute 

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 sunlight. 

If the engine hood is warm, allow it to 

cool. Beads of water not only leave 

spots when dried rapidly by the sun or 

heat from the engine, but also can act 

as small magnifying glasses and burn 

spots into the finish. Wash the car with 

a mixture of lukewarm water and a car

Maintenance 


2 of 5 2/25/2009 10:03 PM 

wash product. Rinse using plenty of 

clear water. Wipe the body dry with a 

soft cloth towel or chamois to prevent 

water-spotting. 

Interior care 

Dirt spots can usually be removed with 

lukewarm soapy water or a dry foam 

cleaner. Use spot remover for grease 

and oil spots. Do not pour the liquid 

directly on the carpet or fabric, but 

dampen a clean cloth and rub 

carefully, starting at the edge of the 

spot and working inward. Do not use 

gasoline, naptha, or other flammable 

substances. 

Leather upholstery and trim 

Leather upholstery and trim should be 

periodically cleaned using a slightly 

damp cotton or wool cloth. 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 cracking of the leather. 

Polishing 

Use paint polish only if the finish 

assumes a dull look after long service. 

Polish can be used to remove tar spots 

and tarnish, but afterwards a coat of 

wax should be applied to protect the 

clean finish. Do not use abrasive polish 

or cleaners on aluminum trim or 

accessories.

Maintenance 


3 of 5 2/25/2009 10:03 PM 

Seat belts 

Dirt and other abrasive particles will 

damage seat belt webbing. If it is 

necessary to clean seat belts, use a 

mild soap solution. Bleach and other 

strong cleaning agents may weaken 

the belt webbing and should be 

avoided. 

WARNING! 

Do not clean the seat belt webbing 

using dry cleaning or other 

chemicals. Allow wet belts to dry 

before allowing them to retract. 

The condition of the belt webbing and 

the function of the retractor 

mechanisms should be inspected. 

Note: 

See 720 Seat Belts for seat belt 

inspection 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 car, especially in winter, will help 

prevent accumulation of road salt and 

rust. The best time to wash the 

underside is just after the car has been 

driven in wet conditions. Spray the 

chassis with a powerful jet of water.

Maintenance 


4 of 5 2/25/2009 10:03 PM 

Commercial or self-service car washes 

may not be best for this, as they may 

recycle the salt-contaminated water. 

Waxing 

For a long-lasting, protective, and 

glossy finish, apply a hard wax after 

the car has been washed and dried. 

Use carnauba or synthetic based 

products. Waxing is not needed after 

every washing. You can tell when 

waxing is required by looking at the 

finish when it is wet. If the water coats 

the paint in smooth sheets instead of 

forming beads that roll off, a new coat 

of wax is needed. Wax should not be 

applied to black trim pieces, rubber, or 

other plastic parts. 

Windshield wiper blade 

maintenance 

Common 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. 

To replace wiper blade, depress 

retaining tab (arrow) and slide blade 

out of arm. 

On older cars, check the tension spring 

that holds the wiper to the glass. 

Replace the wiper arm if the springs 

are weak. 

Drops that remain behind after wiping 

are caused by oil, road film, or diesel 

exhaust coating the windshield. Use an

Maintenance 


5 of 5 2/25/2009 10:03 PM 

alcohol or ammonia solution, or a 

non-abrasive cleanser to clean the 

windshield. 

Wiper blade chatter may be caused by 

dirty or worn blades, by a dirty 

windshield, or by bent or twisted wiper 

arms. Clean the blades and windshield 

as described above. Adjust the wiper 

arm so that there is even 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.

On-Board Diagnostics 


1 of 11 2/25/2009 11:22 PM 


(OBD II) 

OBD-2 

OBD II is an acronym for On-Board 

Diagnostics II, the second generation of 

on-board self-diagnostic equipment 

requirements. These standards were 

originally mandated for California 

vehicles. Since 1996 they have been 

applied to all passenger vehicles sold 

in the United States. 

On-board diagnostic capabilities are 

incorporated into the hardware and 

software of the engine control module 

(ECM) to monitor virtually every 

component that can affect vehicle 

emissions. OBD II works to ensure that 

the vehicles remain as clean as 

possible over their 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 information about the 

detected malfunction so that a repair 

technician can accurately find and fix 

the problem. 

Note: 

Specialized OBD II scan tool 

equipment is needed to access the 

fault memory and OBD II data. 

The OBD II fault memory 

(including the MIL) can only be



2 of 11 2/25/2009 11:22 PM 

reset using the special scan tool. 

Removing the connector from the 

ECM or disconnecting the battery 

will not erase the fault memory. 

The extra hardware needed to operate 

the OBD II system consists mainly of 

the following: 

Additional oxygen sensors 

downstream of the catalytic 

converters 

Fuel tank pressure sensor and 

device to pressurize fuel storage 

system 

Several engine and performance 

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 Check Engine. On model 

year 2001 cars, the MIL is labeled 

Service Engine Soon.



3 of 11 2/25/2009 11:22 PM 

The MIL will come on under the 

following conditions. 

An engine management system 

fault is detected for two 

consecutive OBD II drive cycles. 

A catalyst damaging fault. 

A component malfunction (such 

as catalyst deterioration) causes 

emissions to exceed 1.5 times 

OBD II standards. 

Manufacturer-defined 

specifications are exceeded. 

An implausible 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. 


or automatic transmission control 

module (TCM) enters "limp home" 

operation mode. 

Key is in "ignition on" position 

before cranking (bulb check 

function).



4 of 11 2/25/2009 11:22 PM 

Additional information, MIL: 

A fault code is stored within the 

ECM upon the first occurrence of 

a fault in the system being 

checked. 

Two complete consecutive drive 

cycles with the fault present 

illuminate the MIL. The exception 

to the two-fault requirement is a 

catalyst damaging fault, which will 

turn the light on immediately. 

If the second drive cycle was not 

complete and the specific function 

was not checked as shown in the 

example, the ECM counts the third 

drive cycle as the next consecutive 

drive cycle. The 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. 

Note: 

The fault code will be cleared from 

memory automatically if the 

specific function is checked 

through 40 consecutive drive 

cycles without the fault being 

detected. 

In order to automatically clear a catalyst 

damaging fault from memory, the 

condition under which the fault occurred 

must be evaluated for 80 consecutive 

drive cycles without the fault 

reoccurring.



5 of 11 2/25/2009 11:22 PM 

With the use of a universal or 'generic' 

scan tool connected to the DLC 

(Diagnostic Link Connector), diagnostic 

trouble codes (DTCs) can be obtained, 

along with the conditions associated 

with the illumination of the engine 

service light. Using a more advanced or 

BMW-dedicated scan tool, additional 

'proprietary' information is normally 

available. 

Scan tool and scan tool display 

Owing to the advanced nature of OBD 

II adaptive strategies, all diagnostics 

need to start with a scan tool. The 

aftermarket scan tools can be 

connected to either the 16-pin OBD II 

Data Link Connector (DLC) or the BMW 

20-pin DLC in the engine compartment. 

Data from the OBD II DLC may be 

limited, depending on scan tool and 

vehicle. 

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 the engine 

compartment has been deleted. All 

diagnostic, coding and programming 

functions are incorporated into the 

OBD II diagnostic port, located under 

left side of dashboard. 

Note: 

On cars built up 06-2000: when 

accessing emissions related DTCs 

through the 16-pin OBD II DLC, the 

BMW 20-pin DLC cap must be



6 of 11 2/25/2009 11:22 PM 

installed. 

Professional diagnostic scan tools 

available at the time of this 

printing include the BMW factory 

tools (DISplus and MoDiC) and a 

small number of aftermarket 

BMW-specific tools. The CS2000 

from Baum Tools Unlimited, the 

Retriever from Assenmacher 

Specialty Tools, and the MT2500 

from Snap-On Tools are examples 

of quality OBD scan tools. 

In addition to the professional line 

of scan tools, inexpensive 

`generic' OBD II scan tool software 

programs and handheld units are 

readily available. These tools do 

have limited capabilities, but they 

are 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 diagnostic monitor is an operating 

strategy that runs internal tests and 

checks a specific system, component 

or function. This is similar to computer 

self tests. 

Completion of a drive cycle ensures 

that all monitors have completed their



7 of 11 2/25/2009 11:22 PM 

required tests. The ECM must 

recognize the loss or impairment of the 

signal or component and determine if a 

signal or sensor is faulty based on 3 

conditions: 

Signal or component shorted to 

ground 


B+ 

Signal or component missing 

(open circuit) 

The OBD II system must monitor all 

emission control systems that are 

on-board. Not all vehicles have a full 

complement of emission 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 using DME input 

sensors and output accouters based 

on preprogrammed data sets. If the



8 of 11 2/25/2009 11:22 PM 

ECM cannot determine the 

environment or engine operating 

conditions due to missing or faulty 

signals it will set a fault code and, 

depending on conditions, illuminate the 

MIL. 

Oxygen sensor monitoring: When drive 

conditions allow, response rate and 

switching time of each oxygen sensor 

is monitored. In addition, the heater 

function is also monitored. The OBD II 

"diagnostic executive" knows the 

difference between upstream and 

downstream oxygen sensors and reads 

each one individually. 

All oxygen sensors are monitored 

separately. In order for the oxygen 

sensor to be effectively monitored, the 

system must be in closed loop 

operation. 

Catalyst monitoring: This 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 

monitors crankshaft speed fluctuations 

and determines if a misfire occurs by 

variations in speed between each 

crankshaft sensor trigger point. This 

strategy is so finely tuned that it can 

even determine the severity of the 

misfire. 

The diagnostic executive must 

determine if misfire is occurring, as well 

as other pertinent misfire information.



9 of 11 2/25/2009 11:22 PM 

Specific cylinder(s) 

Severity of the misfire event 

Emissions relevant or catalyst 

damaging 

Misfire detection is an on-going 

monitoring process that is only 

disabled under certain limited 

conditions. 

Secondary air injection monitoring: 

Secondary air injection is used to 

reduce HC and CO emissions during 

engine warm up. Immediately following 

a cold engine start (-10 to 40ï¿½C), 

fresh air/oxygen is pumped directly into 

the exhaust manifold. 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, the 

signal at the oxygen sensor will reflect 

a lean condition. If the oxygen sensor 

signal does not change, a fault will be



10 of 11 2/25/2009 11:22 PM 

set and identify the faulty bank(s). If 

after completing the next cold start a 

fault is again present, the MIL will be 

illuminated. 

Fuel system monitoring: This monitors 

receives high priority. It looks at the 

fuel delivery needed (long/short term 

fuel trim) for proper engine operation 

based on programmed data. If too 

much or not enough fuel is delivered 

over a predetermined time, a DTC is 

set and the MIL is turned on. 

Note: 

Fuel trim refers to adjustments to base 

fuel schedule. Long-term fuel trim 

refers to gradual adjustments to the fuel 

calibration adjustment as compared to 

short term fuel trim. Long term fuel trim 

adjustments compensate for gradual 

changes that occur over 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. 

Evaporative system monitoring: This 

monitor checks the sealed integrity of 

the fuel storage system and related 

fuel lines. 

This monitor has the ability to detect 

very small leaks anywhere in the 

system. A pressure test is be 

performed on the EVAP system on a 

continuous basis as the drive cycle 

allows. 

On MS 42.0 cars, a leak detection 

pump (LDP) is used to pressurize and



11 of 11 2/25/2009 11:22 PM 

check system integrity. On MS 43.0 

cars, a more sophisticated DMTL 

(Diagnostic Module - Leak Detection) 

pump is used. 

Drive cycle 

The OBD II drive cycle is an important 

concept in understanding OBD II 

requirements. The purpose of the drive 

cycle is to run all of the emissionrelated 

on-board diagnostics over on a 

broad range of driving conditions. 

The drive cycle is considered 

completed when all of the diagnostic 

monitors have run their tests without 

interruption. For a drive cycle to be 

initiated, the vehicle must be started 

cold and brought up to 160ï¿½F and at 

least 40ï¿½F 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 determine if 

on-board diagnosis is complete as well 

as the status of the I/M codes. All 

required tests must be completed 

before the I/M readiness codes will be 

set to "Yes". 

Readiness codes



1 of 20 2/25/2009 11:23 PM 

BMW Fault Codes 

(DTCs) 

OBD-3 

Below is a comprehensive listing of 

BMW DTCs and the corresponding 

SAE P-codes. 

Table a. Diagnostic trouble codes (DTCs) 


code 

P-code 

Fault type and 

function 

Signal type and 

range 

Explanation 

1 Ignition coil cyl.2 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. 






occurred. 






occurred. 

5 P0202 Injector circuit cyl. 

2 


1 

Output digital 

pulse width (active 

low) 



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. 






exists.



2 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

8 P0101 Mass air flow 

circuit range/perf. 

10 Engine coolant 

temp. circuit 

range/perf. 

11 Coolant temp. 

coolant outlet 

14 P0111 Intake air temp. 

range/performance 

18 P1397 Exhaust cam 

position sensor 

malfunction 

19 P1529 VANOS solenoid 

activation, exhaust 


activation, intake 


3 


range 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

phase shift (0-5V) 



low) 



low) 



low) 

Explanation 

Failed signal range check 

against predefined diagnostic 

limits. 

Signal range is checked 


limits within specific engine 

operations. 




operations. 




operations. 

Internal check of phase shift 

from camshaft sensor - 

should change during every 

crankshaft revolution.Phase 

shift occurs due to 2:1 

relationship between 

camshafts. 






exists. 






exists. 






exists.



3 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


6 


4 

25 P0135 Oxygen sensor 

heater pre-cat 

(Bank1) 

27 P1550 Idle control valve 

closing coil 


range 



low) 



low) 



low) 



low) 

Explanation 






exists. 






exists. 






exists. 






exists. 












occurred. 






occurred. 






occurred.



4 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


5 

35 P1453 Secondary air 

injection pump 

36 MS 43 Main relay 

malfunction 

38 MS 43 Clutch switch 

faulty 

39 Brake light switch, 

and brake light 

plausibility test 


pedal sensor 


42 Multi functional 

steering wheel, 

redundant code 



control switch 


range 



low) 


on/off (active low) 

Input analog 

(0-12V) 

Input digital 

(0-12V) 

Input digital 

(0-12V) 

Input digital / 

analog (0-12V / 

0-5V) 

Input binary 

stream (0-12V) 

Input binary 


Explanation 






exists. 

TDME final stage will set flag 





exists. 

Signal range check between 

DME ignition analog input 

and main relay power circuit 

analog input. 

Plausibility check of clutch 

switch and DME internal 

values such as load and 

engine speed. 

When brake light switch is 

active, brake light test switch 

must be also active. If not, 

fault is stored. 

If pedal sensor is showing 

angle greater than "limp 

home angle" and additionally 

brake light switch is active, 


Every signal from cruise 

control switch is transferred 

redundantly. A fault is set 

whenever two redundant 

information paths are showing 

a different status. 

When status from cruise 

control showing 

set/accelerate and 

deceleration are same time, 

fault is set.



5 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 



toggle-bit 

47 MS 43 Torque monitoring 

level 1 

48 MS 43 Internal control 

module 


range 

Input binary 


DME internal 

values logical 

DME HW test 

memory 

Explanation 

Every 0.5 sec. a message that 

includes a toggle bit (toggles 

between 0->1 and 1->0) is 

transmitted. Change bit is 

monitored to indicate proper 

function. 

49 ECU internal test DME HW test 

50 P1145 

MS 42 

Running losses 

valve (3/2), final 

stage 








exists. 

MS 43 ECU internal test DME HW test 

51 MS 43 ECU internal test DME HW test 

52 Rear exhaust valve 

flap 


opening coil 



(Bank 2) 

56 Ignition feedback, 

interruption at 


steady (active low) 



low) 



low) 

Input analog (32V) 






exists. 






exists. 






exists. 

Check for correct signal 

voltage. If voltage is 32V



6 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

shunt resistor 

57 P0325 Knock sensor 1 

circuit, (Bank 1) 

circuit continuity 





heater post-cat 

(Bank 2) 


injection system 

switching valve 

65 P0340 Intake cam position 

sensor, 

malfunction 

68 EVAP system, 

purge control valve 

circuit 


range 

Input analog 

amplitude 

(13-19kHz) 

Input analog 

amplitude 

(13-19kHz) 



low) 



Input analog 

phase shift 0-5V 



low) 

Explanation 

(limitation voltage) then 

secondary ignition voltage is 

detected and shunt resistor 

may be faulty. 

Plausibility check between 

knock sensor amplitude 

during knocking with internal 

knock detection mapped DME 

values. 





values. 






exists. 






exists. 






exists. 






exists. 

69 Relay fuel pump Output digital 





disconnection between output



7 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

74 AC compressor 

relay 



(Bank 1) 

83 P0335 Crankshaft position 

sensor, 

malfunction 

100 P0601 Internal control 

module, memory 

check sum or 

communication 

103 P1519 VANOS faulty 

reference value 

intake 



exhaust 

105 P1522 VANOS stuck 

(Bank 1) intake 


(Bank 2) exhaust 

109 P1580 Motor throttle valve 

pulse width not 

plausible 


range 





low) 

Input digital 

(0-12V) 

DME internal 


DME internal 


DME internal 


DME internal 

values 

DME internal 

values 


pulse width 

(0-12V) 

Explanation 


exists. 






exists. 






exists. 

Checks for correct signal 

pattern and correct number of 

expected flywheel teeth. 

Internal hardware test of 

RAM, ROM, and Flash Prom. 

Maximum VANOS adjustment 

angle, checked at every 

engine start must be within a 

specified limit. 





Monitoring of a desired 

VANOS adjustment within a 

predefined diagnostic time 

limit. 




limit. 

Throttle position control 

algorithm checks for problems 

with mechanical coupling



8 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

110 P1542 Pedal sensor 

potentiometer 1 

111 P1542 Pedal Sensor 

Potentiometer 2 


range 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Explanation 

spring within motor throttle 

body. 



limits. 



limits. 

112 P0120 

MS 42 

Motor throttle valve 


Input analog 

(0-5V) 



limits. 

MS 43 

Throttle position 

sensor 1 

Input analog 

(0-5V) 



limits. 



Input analog 

(0-5V) 



limits. 

114 P1580 

MS 42 


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 


If pedal sensor malfunction is 

determined, followed by a 

second malfunction, a signal 

is sent. 

115 P1623 

MS 42 

Output voltage 5V 

for potentiometer 

operation 1 

DME internal (5V) 

Check for proper 5 volts 

supply to potentiometers is 

possible within a predefined 

voltage limit. 

MS 43 

Range check for 

throttle position 

adaptation 

Input analog 

(0-5V) 

Range check for closed 

position of throttle sensors. 

116 P1623 Output voltage for 

potentiometer 

operation 2 





voltage limit.



9 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


potentiometer 

plausibility 


range 

Input analog 

(0-5V) 

Explanation 

If there is a difference greater 

than specified between two 

redundant signals from 

potentiometer, fault will be 

set. 

118 P0120 

MS 42 

Motor throttle 

feedback 

potentiometer 

plausibility 

Input analog 

(0-5V) 





set. 

MS 43 


sensor 1; 

plausibility check 

sensor 1 to mass 

air flow meter 

DME internal 

values 


against predetermined 

diagnostic limits. Rationality 

check with mass air flow 

meter. 

119 P1580 

MS 42 

MDK, throttle 

mechanical 

sticking 


Throttle doesn't reach desired 

opening angle within a 

specified time. 

MS 43 


sensor 2; 




DME internal 

values 





meter. 

120 P1542 

MS 42 

Pedal sensor/ 

motor throttle valve 

potentiometer not 

plausible 

DME internal 


motor 

Signal from motor throttle 

valve potentiometer must be 

equal signal from pedal 

sensor potentiometer plus 

any adaptive values. 

MS 43 

Plausibility check 

between brake 

switch and pedal 

sensor 


analog 


constant pedal value and 

brake switch. First pedal 

value must be constant and 

for next step brake switch 

must be active. 

122 P1101 Oil temp. sensor 

malfunction 

123 P1622 Electric thermostat 

control, final stage 

Input analog 

(0-5V) 





limits and calculated 

temperature. 



short to battery voltage or a



10 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


range 

124 P1593 DISA, range/perf. Output digital 


Explanation 



exists. 






exists. 

125 Coolant fan, final 

stage 








exists. 

126 P1470 

MS 42 

LDP-magnetic 

valve 








exists. 

MS 43 DMTL valve Output digital 


127 Fuel pump Output digital 







exists. 






exists. 

128 EWS signal not 

present or faulty 

130 CAN time out 

(ASC1) 

Input binary 

stream bit data 

(0-12V) 

Input binary 


(0-12V) 

During time out check no 

signal was present within 

specific time or faulty 

information from serial 

interface (parity, overrun, 

etc.). 

CAN message between 

DME/EGS not received within 

expected time.



11 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

131 CAN time out (instr 

2) 


3) 


(ASC3) 

135 MS 43 Limp home 

position adaptation 

necessary 

136 MS 43 Motor throttle valve 

open / closing test 

failed 

140 P1475 LDP reed-switch 

not closed 

140 MS 43 DMTL pump final 

stage 

141 P1477 EVAP: reed switch 

not closed, doesn't 

open or doesn't 

close 




close 


range 

Input binary 


(0-12V) 

Input binary 


(0-12V) 

Input binary 


(0-12V) 

DME internal 


DME internal 


Input digital on/off 

(0-12V) 




(0-12V) 


(0-12V) 

Explanation 



expected time. 







Limp home position must be 

in specified range. If range is 

exceeded, a fault is set. 

From limp home mode 

position, throttle valve will be 

open, afterwards it must fall 

back into limp home position. 

If fall back position is not in 

specified range, fault is set. 

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. 






exists. 

Within predetermined time 

LDP reed switch signal must 

change from high to low or 

from low to high or LDP reed 

switch is "low" for longer than 

predetermined time. 




from low to high or LDP reed



12 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


range 

142 MS 43 DMTL module fault DME internal 


Explanation 



143 P1476 EVAP: clamped 

tube check 

146 MS 43 Range check 

voltage supply 

pedal sensor 2 and 


sensors 





sensors 

149 P1140 Motor throttle 

feedback 

potentiometer and 

air mass sensor 

signal not 

plausible 


pre-cat (Bank 1), 

short to battery 

volt. 



short to ground 



disconnection 

Input digital 

frequency (0-12V) 

DME internal input 

analog 


analog 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Frequency of LDP pumps 

reed switch is lower then 

predetermined limit. Volume 

of leak is determined to be too 

small (i.e. pinched or 

restricted hose) 

Supply voltage for sensors 

must be within a specified 

range. 



range. 



suitable to signal from air 

mass sensor. A fault is set if 

difference exceeds specified 

limit. 

Oxygen sensor signal range 

is checked to determine if 

electrical shorts exist on input 

line. Voltage signal has to be 

within a predetermined range 

(0.1V -1V) or a fault will set. 




line. Voltage signal must be 


(0.1V -1V) or fault will set. 



electrical disconnection exist



13 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 




volt. 

154 P0150 Oxygen 

sensorpre-cat 

(Bank 2), short to 

ground 



disconnection 


post-cat (Bank 1), 


volt. 


Post Cat. (Bank 1), 





volt. 





range 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Explanation 

on input line. 















electrical disconnection exist 

























(0.1V -1V) or fault will set.



14 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

160 MS 43 Throttle valve 

position controller 






position, throttle 

sticking 

169 MDK final stage 

shut off 

171 P0601 System has been 

shut down due to 

safety controller 


potentiometer 

short between two 

potentiometer 

paths 


potentiometer 

contact short 


potentiometer 

adaptation of idle 

end position 

175 Pedal sensor 


adaptation of the 

idle end position 






range 

DME internal 


DME internal 


DME internal 



calculated 



DME internal 

check 

Rationality check 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Explanation 

This fault indicates problem 

on pedal sensor, throttle 

potentiometer or throttle. A 

separately stored fault code 

indicates problem. 

Safety controller has shut 

down motor throttle valve 

function due to not plausible 

MDK input values. 

5 volts for potentiometers are 

switched on within a specific 

time pattern. 


potentiometer 

Signal for idle position must 

be within a specified range. If 

range is exceeded, fault is 

set. 




set. 




set.



15 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


heater, pre-cat 

(Bank 1), 

insufficient 



(Bank 2), 

insufficient 

190 P1186 Oxygen sensorheater, 

post-cat 

(Bank 1), 

insufficient 


heater, post-cat 

(Bank 2), 

insufficient 


range 



low) 



low) 



low) 



low) 

Explanation 

DME internally calculated 

heater power is checked 


limits. 




limits. 




limits. 




limits. 

197 MS 43 Signal range check DME internal 

analog input 

202 P0170 Fuel trim (Bank 1), 

O2 control limit 

203 P0173 Fuel Trim (Bank 2), 


204 P0505 Idle control 

system, idle speed 

not plausible 

208 EWS, engine 

speed check not 

ok 

209 EWS, content of 

message 


faulty (>2 

cylinders) 

DME internal 


DME internal 


DME internal 



Input binary 


(0-12V) 

Input analog 


Controller for lambda is too 

long beyond a min. or a max. 



Functional check between 

actual engine speed (RPM) 

and predetermined RPM 

exceeds maximum deviation 

of +200/-100 RPM. 

Engine speed signal is 

transferred by EWS to DME. 

Fault is set if transferred 

signal is not reflecting engine 

speed due to input problem in 

EWS. 

Content of binary message 

received from EWS invalid. 


timing after each ignition has 

been initiated by feedback



16 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


stuck 

214 P0500 Vehicle speed 

sensor 



disconnection 



disconnection 

217 P0505 CAN time out 

(EGS1) 


range 

DME internal 


Input digital 


Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input digital binary 

information(0-12V) 

Explanation 

signal. If more than two 

ignition signals are not 

recognized than there might 

be a problem in feedback line. 

Functional check against a 

calculated value by 

monitoring flow though air 

mass meter to determine if 

idle valve is mechanically 

stuck open. Tested during 

closed throttle. 



limits. No vehicle speed is 

observed after specific time 

when compared to engine 

speed and load equivalent to 

moving vehicle. 










DME/EGS was not received 

within expected time. 

219 CAN-chip, bus off Input digital binary 

information (0-12V) 

Hardware test determines if 

CAN bus is off line. Data 

transmission is disturbed. 


post-cat (Bank 1) 

slow response time 




Input analog (high 

is lean) (0-5V) 



Checks amount of time 

oxygen sensor stays in rich or 

lean state. If it remains there 

too long in either, fault will 

set. 




too long in either fault will set.



17 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

222 P0125 Insufficient coolant 

temp. to permit 

closed loop 

operation 



switching time slow 




225 P1192 Post-cat sensor 

(Bank 1); trim 

control 



control 


O2 control 

adaptation limit 


O2 control 



pre-cat (Bank 1, 







switch time too 

slow 


range 

Input analog 

(0-5V) 





Input analog 

(0-5V) 

Input analog 

(0-5V) 

DME internal 


DME internal 








Explanation 

Comparison of actual coolant 

temperature against 

calculated DME value which 

varies with load signal. 


oxygen sensor takes to switch 

from rich to lean and vice 

versa. If too long, fault will 

set. 





set. 

Rationality check for O2 

control adaptation with post 

catalyst sensor bank 1. 




Range control of adaptation 

values. 


values. 





set. 


oxygen sensor stays in its rich 

or lean state. If it remains 

there too long in either fault 

will set. 




versa. If it takes too long to



18 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 




slow 

233 P0420 Catalyst efficiency 

(Bank 1), below 

threshold 



threshold 

235 P1190 Pre-cat sensor 

(Bank 1):trim 

control 


(Bank 2):trim 

control 

238 P0301 Cyl. 1 misfire 

detected 


detected 


range 



Input analog 

(0-5V) 

Input analog 

(0-5V) 


is rich) (0-1V) 



DME internal 


DME internal 


Explanation 

switch fault will set. 




versa. If it takes too long to 


Compares value of pre-cat 

oxygen sensor to value of 

post-cat oxygen sensor to 

measure oxygen storage 

capability / efficiency of 

catalytic converter. Post-cat 

oxygen sensor must be 

relatively lean. 










control adaptation with 

pre-cat sensor bank 1 




Crankshaft 

speed/acceleration is 

monitored by crank sensor. 

Time for each cylinder 

combustion is compared 

against avg. of others. If time 

for cylinder 1 is longer, fault 

will set. 

Crankshaft 





against avg. of others. If time



19 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


detected 


detected 


detected 


detected 

244 Segment timing 

faulty, flywheel 

adaptation 


range 

DME internal 


DME internal 


DME internal 


DME internal 


Input analog 

(0-5V) 

Explanation 


will set. 

Crankshaft 







will set. 

Crankshaft 







will set. 

Crankshaft 







will set. 

Crankshaft 







will set. 

Flywheel segments are 

monitored during deceleration 

to establish baseline for 

misfire calculation. If 

segments are too long/short 

(bad flywheel) and exceed 

limit, fault will be set.



20 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


injection (Bank 1), 

flow too low 



flow too low 


valve stuck open 

248 P1184 Post-cat sensor; 

signal after decel 

phase not 

plausible; (Bank 1) 



phase not 


250 P0440 Functional check 

purge valve 


range 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Explanation 

Checks to see if oxygen 

sensor reacts to increase in 

unmetered airflow generated 

by secondary air pump 

operation. Oxygen sensor 

must sense lean condition or 

fault will set. 















Signal is checked for a lean 

signal in decel and a 

transition between lean to rich 

after decel 




after decel 

This functional check looks 

for reaction of oxygen sensor 

signal during canister 

purging. Oxygen sensor, air 

flow meter and RPM values 

must react to purging of 

canister. 


Engine-General 


1 of 19 2/25/2009 9:58 PM 

General 

100-1 

This section covers system descriptions 

and general information on engines 

and engine management systems. Also 

covered is basic engine 

troubleshooting. 

For specific repair procedures, refer to 

the appropriate repair group: 

110 Engine Removal and 

Installation 

113 Cylinder Head Removal 

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



2 of 19 2/25/2009 9:58 PM 

3.0 liter) engines were introduced. This 

engine incorporates all the technical 

features of the M52 TU engines with 

addition of fully electronic throttle 

control and enhanced emission 

controls. 

Table a. Engine specifications lists 

engine specifications for the vehicles 

covered by this manual. 

Table a. Engine specifications 

Model 

year 

Engine 

code 

No. of 

cylinders 

Displacement 

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 2979.3 (181.8) 

84 

mm 

(3.307 

in.) 

89.6 

mm 

(3.528 

10.2: 1 214/3,500 225/5,900



3 of 19 2/25/2009 9:58 PM 

Model 

year 

Engine 

code 

No. of 

cylinders 

Displacement 

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



4 of 19 2/25/2009 9:58 PM 

M54 2.5 liter 

M54 3.0 liter



5 of 19 2/25/2009 9:58 PM 

Cylinder block and crankshaft 

The cylinder block is cast aluminum 

alloy (AlSi9Cu3) with cast iron cylinder 

liners. The cylinders are exposed on all 

sides to circulating coolant. 

The counterweighted crankshaft rotates 

in replaceable split-shell main bearings. 

Oilways drilled into the crankshaft 

provide bearing lubrication. 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.



6 of 19 2/25/2009 9:58 PM 

Connecting rods and pistons 

The forged steel connecting rods use 

replaceable split-shell bearings at the 

crankshaft end and solid bushings at the 

piston pin end. 

The pistons are of the three-ring type 

with two upper compression rings and a 

lower one-piece oil scraper ring. 

Full-floating piston pins are retained with 

circlips. 

The 2.8 and 3.0 liter engines use a 

graphite coating on the piston skirts to 

reduce friction and noise. 

Cylinder head and valvetrain 

Cooling passages in the cylinder head 

are designed for optimum coolant 

circulation, allowing the head to operate 

at lower temperatures than the cylinder 

block. 

The aluminum cylinder head uses chaindriven 

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 provide lubrication 

for the camshafts and valvetrain. 

Valve clearance is set by self-adjusting 

(zero-lash) hydraulic lifters for reduced 

valve noise and the elimination of routine 

valve adjustment. 

Exhaust manifolds



7 of 19 2/25/2009 9:58 PM 

Each exhaust manifold assembly 

incorporates a catalytic converter. The 

converters are mounted close to the 

engine for faster heat up. Pre- and 

post-catalyst oxygen sensors are a 

mounted in each exhaust manifold. 

Cooling system 

The cooling system circulation is 

designed so that coolant flows directly 

from the coolant pump to the cylinder 

head. The coolant is fed from the coolant 

pump through a cast coolant feed 

passage to the rear of the cylinder head. 

From there it flows forward to the 

thermostat housing, radiator and heater 

valve. 

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 electrically heated thermostat 

controls the flow of coolant through the 

radiator based on coolant and outside 

temperature, engine load, and driving 

speed, rather than just coolant 

temperature. 

The DME-controlled heated thermostat



8 of 19 2/25/2009 9:58 PM 

allows the engine to be operated at 

higher controlled temperatures during 

low and part throttle. This optimizes 

operating temperatures in both cylinder 

head and block, reduces friction and 

thereby fuel consumption. 

The cooling system is designed to: 

Reduce operating temperatures of 

cylinder head. The result of lower 

temperatures is increased torque 

due to improved volumetric 

efficiency. 

Increase operating temperature of 

cylinder block. 

Lubrication system 

The lubrication system is pressurized 

whenever the engine is running. 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 filter become plugged. See 

119 Lubrication System for additional 

information. 

Resonance/turbulence intake 

system 

The intake manifold, made of molded 

plastic, is configured as two sets of three 

runners. This design enhances low end



9 of 19 2/25/2009 9:58 PM 

torque by changing the intake air flow 

configuration for varying engine speeds. 

This helps achieve optimum torque 

throughout the entire RPM range. 

During engine operation, a closed 

resonance valve gives the intake air 

charge the dynamic effect of long intake 

runners at low to mid-range RPM (up to 

3750 rpm). This helps increase torque. 

During mid-range to high rpm operation 

(above 4100 rpm), the solenoid is 

de-energized and the resonance valve is 

sprung open. This allows intake 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 

cylinder 1 air flow will stop and expand 

backward (resonance back pulse) to fill 

cylinder 5. The resonance wave along 

with the intake velocity enhances 

cylinder filling.



10 of 19 2/25/2009 9:58 PM 

The intake manifold includes intake 

turbulence ports. The 5.5 mm (0.217 in.) 

turbulence ports channel idle and low 

speed air directly from the idle speed 

control valved to one intake valve of each 

cylinder. 

Routing intake air to one intake valve per 

cylinder causes the air charge to swirl in 

the cylinder. Together with the high flow 

rate of intake air across the small (5.5 

mm) port, intake fluctuations are 

reduced for more stable combustion. 

VANOS (Variable Camshaft 

Timing) 

A double VANOS system is used on 

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 advantages: 

Increased torque at lower and 

medium RPM ranges 

More efficient combustion and 

improved idle quality 

Internal EGR in part-load range for 

lower NOx emissions. 

Quicker warm-up cycle for catalytic



11 of 19 2/25/2009 9:58 PM 

converter and faster reduction in 

emissions. 

Overall improved fuel economy. 

See 117 Camshaft Timing Chains for 

VANOS system testing and repair 

information. 

Engine management system 

The Siemens engine management 

systems used in E46 cars combine fuel 

injection, ignition and other functions 

under the control of the engine control 

module (ECM) They are compliant with 

second generation on-board 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 

1999 - 2000: 

M52 TU B25 

M52 TU B28 

2001: 

M54 B25 

M54 B30 

DME system 

Siemens MS 42.0 


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 flash-programmable 

and features 5 electrical harness 

connectors with a total of 134 pins.



12 of 19 2/25/2009 9:58 PM 

Connector 1: Voltages and grounds 

Connector 2: Ancillary signals 

(oxygen sensors, CAN, etc.) 

Connector 3: Engine signals 

Connector 4: Vehicle signals 

Note: 

Connector 5: Ignition signals 

The flash EEPROM (chip) is specifically 

`programmed' to the vehicle. It has the 

capability to be programmed up to 13 

times. 

ECM inputs: 

Hot film mass air flow (MAF) sensor 

monitors 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 detection. 

Engine coolant temperature sensor



13 of 19 2/25/2009 9:58 PM 

(ECT) in cylinder head supplies 

coolant temperature information to 

the ECM. 

ECM outputs: 

Fuel injector opening duration. 

Intake and exhaust valve timing via 

the VANOS system. 

The radiator cooling fan and the 

heated coolant thermostat. 

Motor-driven throttle valve: MDK in 

MS 42.0 or EDK in MS 43.0. 

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.



14 of 19 2/25/2009 9:58 PM 

Fuel purge valve and fuel tank 

leakage diagnosis pump (LDP or 

DM-TL). 

Fuel metering: The ECM meters 

pressurized fuel by changing the 

opening time (pulse width) of the fuel 

injectors. The exact amount of fuel 

injected is determined by the amount of 

time the injectors are open. To ensure 

that injector pulse width is the only factor 

that determines fuel metering, fuel pump 

pressure is maintained by a pressure 

regulator. The injectors are mounted to a 

common fuel rail. 

The ECM monitors engine operating 

conditions to determine injector opening 

duration. Each injector can be 

individually controlled for cylinder 

selective fuel trim. The fuel-injectors 

inject fuel at an angle in a dual cone 

spray 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 

corresponding to the mass of the intake 

air. 

Idle speed control: Idle speed is 

electronically controlled via the idle 

speed control valve by bypassing 

varying amounts of air around the closed 

throttle valve. Idle speed is not 

adjustable. The ECM determines idle 

speed by controlling a dual-winding 

rotary idle control valve. The basic 

functions and parameters of idle speed 

control are as follows:



15 of 19 2/25/2009 9:58 PM 

Control of cold air intake volume. 

For example, at air temperatures 

below 0°C (32°F), electronic throttle 

control (MDK/EDK) is also opened 

during idle. 

Smooth idle speeds regardless of 

load and inputs 

Lower rpm range 

Smooth transition from acceleration 

to deceleration 

Idle speed stabilization is active during 

the following conditions: 

Engine warm up 

A/C activation 

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 will illuminate to 

inform the driver of a fault.



16 of 19 2/25/2009 9:58 PM 

If the fault causes increased air flow 

(actuator failed open), VANOS and 

knock control are deactivated. This 

reduces engine performance 

noticeably. 

Throttle control: The throttle valve plate 

is electronically operated for precise 

throttle operation, OBD II compliant for 

fault monitoring, and ASC/DSC and 

cruise control. This integrated electronic 

throttle reduces additional control 

modules, wiring and sensors. Adjusting 

electronic throttles is not permitted and 

the throttle assembly must be replaced 

as a unit if found to be faulty. 

The throttle 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 

(Electronic Throttle Valve). The EDK is 

identified as follows: 

The accelerator position 

potentiometers (PWG) are located 

in the accelerator pedal assembly. 

The EDK is fully electronic. The 

accelerator pedal is not 

mechanically linked to the EDK.



17 of 19 2/25/2009 9:58 PM 

Ignition function: a distributorless ignition 

system with individual ignition coils for 

each cylinder is employed. The coils are 

mounted over the spark plugs and 

connect to the plugs via a short lead. 

The Siemens systems use multiple spark 

ignition to reduce emissions and extend 

spark plug life. 

Knock control. Knock (detonation) 

sensors monitor and control potentially 

damaging ignition knock through the 

ECM. The 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 (AKI). The 

adaptive engine management system, 

however, will allow use of fuel rated 87 

AKI. 

Siemens DME MS 42.0



18 of 19 2/25/2009 9:58 PM 

Siemens DME MS 43.0



19 of 19 2/25/2009 9:58 PM 




1 of 4 2/25/2009 9:59 PM 

Driveability 

Troubleshooting 

100-2 

The Siemens systems are 

sophisticated self-diagnosing OBD II 

systems. These systems continuously 

monitor components and record and 

store valuable diagnostic information. 

If the `Check Engine' or `Service 

Engine Soon' light [also known as the 

malfunction indicator lamp (MIL)] is 

illuminated, the first diagnostic test 

should be to hook up a 

BMW-compatible scan tool and check 

the fault memory. 

The powerful diagnostic capabilities of 

these systems have the potential to 

save hours of diagnostic time, incorrect 

component replacement and possible 

damage to system components. 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 charged and capable of 

delivering all its power to the electrical 

system. 

To make a quick check of the battery 

charge, measure the voltage across the 

battery terminals with all cables 

attached and the ignition off. A fully 

charged battery will measure 12.6 volts 

or slightly more, compared to 12.15



2 of 4 2/25/2009 9:59 PM 

volts for a battery with a 25% charge. 

Even a fully charged battery cannot 

deliver power unless it is properly 

connected to the electrical system. 

Check the battery terminals for 

corrosion or loose cable connections. If 

the battery does not maintain the 

proper voltage, the charging system 

may be at fault. See 121 Battery, 

Alternator, Starter. 

If a battery cable connection has no 

visible faults, but is still suspect, 

measure the voltage drop across the 

connection. A large drop indicates 

excessive resistance, indicating that the 

connection is corroded, dirty, or 

damaged. Clean or repair the 

connection and retest. 

Note: 

For instructions 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. 

Visually inspect all wiring, connectors, 

switches and fuses in the system. 

Loose or damaged connectors can 

cause intermittent problems, especially 

the small terminals in the ECM 

connectors. Disconnect the wiring 

harness connectors to check for 

corrosion, and use electrical cleaning 

spray to remove contaminants. 

Main grounds



3 of 4 2/25/2009 9:59 PM 

Good grounds are critical to proper 

DME operation. If a ground connection 

has no visible faults but is still suspect, 

measure the voltage drop across the 

connection. A large voltage drop 

indicates high resistance, indicating 

that the connection is corroded, dirty or 

damaged. Clean or repair the 

connection and retest. 

Note: 

For instructions 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 

connection (arrow) in left front of



4 of 4 2/25/2009 9:59 PM 

engine compartment, behind left 

headlight assembly (headlight 

assembly shown removed). 

Main fuel pump ground (arrow) behind 

right rear seat back rest. 


Engine Removal and Installation 


1 of 16 2/25/2009 9:36 PM 

Engine Removal and 

Installation 

110-2 

Be sure to cover all painted surfaces 

before beginning the removal 

procedure. As an aid to installation, 

label all components, wires and hoses 

before removing them. Do not reuse 

gaskets, O-rings or seals during 

reassembly. 

WARNING! 

Due to risk of personal injury, be 

sure the engine is cold before 

beginning the removal procedure. 

- Remove engine hood or place 

hood 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! 




manual on page viii.



2 of 16 2/25/2009 9:36 PM 

Remove housing for interior ventilation 

microfilter. 

Remove upper cover and 

microfilter. 

Open wiring harness loom cover 

(A) and remove wires. 

Unfasten screws (B) and remove 


Remove intake manifold cover: 


(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!



3 of 16 2/25/2009 9:36 PM 

If oxygen sensor harness connectors 

are separated, be sure to mark them 

so that they can be reassembled as 

before. 

Working at left rear of engine 

compartment: 

Peel rubber edge seal off top of 

panel. 

Twist plastic panel retainers 

(arrows) 90° and pull out to 

remove. 

Disengage panel from hoses and 

wiring harnesses and remove from 

engine compartment. 

Separate brake booster vacuum 

hose at one way valve (A). Plug 

hose ends. 

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 injectors.



4 of 16 2/25/2009 9:36 PM 

Lift off connector loom and lay 

aside. 

Remove complete air filter housing: 

Detach vacuum line at intake boot 

(A). 

Disconnect electrical harness 

connector on mass air flow sensor 

(B). 

Release mass air flow sensor clips 

(C). 

Remove filter housing mounting 

screws (D). 

Note: 

Detach air duct connection (E) 

and lift complete air filter housing 

out of engine compartment, 

pulling it forward away from mass 

air flow sensor. 

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 


6 - Mass air flow sensor 

7 - Idle control valve



5 of 16 2/25/2009 9:36 PM 



Where applicable: Pull throttle cable 

upwards out of rubber retainer (A) and 

unhook ball end of cable (B) from 

throttle actuator. 

Note: 

Models equipped with M54 engines 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. 


connector at idle speed control valve 

(arrow).



6 of 16 2/25/2009 9:36 PM 

Detach electrical harness connector at 

fuel tank venting valve (A). Disconnect 

hose at quick disconnect fitting 

(arrow). 

Remove dipstick guide tube: 

Detach wiring harness brackets 

from tube (A). 

Detach fuel lines from tube (B). 

Remove lower guide tube 

mounting bolt (C). 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



7 of 16 2/25/2009 9:36 PM 

pressure (approx. 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 the fuel tank 

cap to release pressure in the 

tank before working on the tank 

or lines. 

- Raise 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) using special fuel line 

removal tool 16 1 050 or equivalent. 

Seal off fuel line(s) with BMW special



8 of 16 2/25/2009 9:36 PM 

tools 13 5 281/13 5 282. 

CAUTION! 

Fuel may be expelled under 

pressure. Do not smoke or work near 

heaters or other fire hazards. Keep a 

fire extinguisher handy. Before 

disconnecting fuel hoses, wrap a 

cloth around fuel hoses to absorb 

any leaking fuel. Plug all open fuel 

lines. 

Working underneath 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).



9 of 16 2/25/2009 9:36 PM 

Lift up manifold just enough to detach 

positive cables from starter motor 

terminal 50 (arrow). 

- Remove intake manifold from 

cylinder head while carefully 

checking for electrical connections 

or hoses. 

CAUTION! 

Stuff clean rags into open intake 

ports to prevent any parts from 

falling into the engine intake. 

- Intake manifold Installation is 

reverse of removal. 

Use new 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. 


Intake manifold to cylinder head 

M7 

M8 

15 Nm (11 ft-lb) 

22 Nm (16 ft-lb)



10 of 16 2/25/2009 9:36 PM 

Engine assembly, removing 

and installing 

Note: 

The intake manifold must be removed 

as described earlier to facilitate engine 

assembly removal. 

Remove cylinder head top cover: 


(arrows). 


and lift off cover. 

Drain engine coolant and remove 

coolant hoses. 

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



11 of 16 2/25/2009 9:36 PM 

humans and pets. Pets are attracted 

to coolant because of its sweet smell 

and taste. Consult a veterinarian 

immediately if coolant is ingested by 

an animal. 

Note: 

Catch and dispose of drained coolant 

according to local, state, and federal 

laws. 

Remove hoses from 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).



12 of 16 2/25/2009 9:36 PM 

Detach coolant hose at front left side of 

engine by engine mount by releasing 

lock (arrow). 

- Unbolt power steering fluid 

reservoir and pull aside without 

detaching hoses. Tie to fender 

with cord or stiff wire. 

Working at E-box at left rear of engine 

compartment: 

Detach engine electrical harness 

connectors (arrows). 

Lift off harness looms and lay over 

engine. 

- Remove poly-ribbed 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 engine, and 

store lines in a clean environment.



13 of 16 2/25/2009 9:36 PM 

Remove power steering pump: 

Remove steering pump pulley. 

Remove front and rear pump 

mounting bolts (arrows). 

Hang pump from body using stiff 

wire. 

Remove A/C compressor mounting 

bolts (arrows) and A/C compressor 

from its mounting bracket without 

disconnecting, distorting, or deforming 

any refrigerant lines. Hang from body 

using stiff wire. 

- Remove 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 electrical harness from



14 of 16 2/25/2009 9:36 PM 

bottom of secondary air pump. 

Remove bracket from strut tower. 

Separate oxygen sensor electrical 

harness connectors (arrows) and 

mounting clip (A) on right side of 

engine. 

Remove chassis ground strap (arrow) 

at right engine mounting pedestal. 

Install an engine lifting device (BMW 11 

0 000 or equivalent) to the front and 

rear engine supports and raise engine 

until its weight is supported. Detach left 

and right engine mounts. 

- Carefully raise engine out of car, 

checking for any wiring, fuel lines, 

or mechanical parts that might 

become snagged as engine is 

removed.



15 of 16 2/25/2009 9:36 PM 

When reinstalling, make sure locating 

pin on left engine mount (arrow) seats 

correctly in slot of subframe boss. 


noting the following: 

Replace all gaskets, O-rings and 

seals. 

Change engine oil and filter and 

check all other fluid levels. See 

020 Maintenance. 

Refill and bleed cooling system. 

See 170 Radiator and Cooling 

System. 

Use new fuel injector seals. 







CAUTION! 





Check that engine drive belts 

properly engage pulley grooves. 

Install exhaust manifolds using 

new gaskets and self-locking nuts. 

Use copper paste on threads. 

See 180 Exhaust System.



16 of 16 2/25/2009 9:36 PM 


Coolant drain plug 

to cylinder block 

Engine mount to subframe 

M10 

25 Nm (18 ft-lb) 

45 Nm (33 ft-lb) 

Exhaust manifold to cylinder head 

M6 

M7 or M8 

10 Nm (8 ft-lb) 

20 Nm (15 ft-lb) 


M7 

M8 

Radiator cooling 

fan to coolant 

pump 

Radiator drain 

screw to radiator 


15 Nm (11 ft-lb) 

22 Nm (16 ft-lb) 

40 Nm (30 ft-lb) 

2.5 Nm (22 in-lb)

Cylinder Head Removal and Installation 


1 of 4 2/25/2009 9:48 PM 

General 

113-1 

This group covers E46 cylinder head 

removal and installation as well as 

cylinder head/valve diagnosis 

procedures. 


group assumes that the engine is 

installed in the engine bay. In order to 

remove the cylinder head from the 

engine block, the VANOS control unit 

and the camshafts must be removed 

from the cylinder head. For cylinder 

head and valvetrain reconditioning 

information, see 116 Cylinder Head 

and Valvetrain. 

Note: 

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 

camshafts and the Torx (E12) head 

bolts. Read the entire procedure 

through before beginning the job. 

Rotary angle dial gauge BMW special 

tool 00 9 120



2 of 4 2/25/2009 9:48 PM 

Torque wrench w/ flex extension BMW 

special tool 00 9 250 

E-12 Torx socket BMW special tool 11 

2 250 

Crankshaft locking tool BMW special 

tool 11 2 300 

Camshaft locking tool BMW special 

tool 11 3 240 

Camshaft locking tool bracket BMW 


Lifter retaining suction cup BMW 

special tool 11 3 250



3 of 4 2/25/2009 9:48 PM 

Camshaft bearing cap removal tool 

BMW special tool 11 3 260 /11 3 270 

Timing chain tensioner tool BMW 


VANOS adjustment plate BMW special 

tool 11 6 150 

Secondary sprocket setup tool BMW 


Air line adapter BMW special tool 11 3 

450



4 of 4 2/25/2009 9:48 PM 

Secondary chain tensioner lock pin 

BMW special tool 11 3 292 




1 of 25 2/25/2009 9:39 PM 

Cylinder Head Removal 

WARNING! 




113-2 

Cylinder head removal and installation 

is a complicated repair procedure. 

VANOS control unit, timing chain, and 

camshaft removal and installation all 

require special tools. Read the entire 

procedure before beginning the repair. 

CAUTION! 

Cover all painted surfaces before 

beginning the removal procedure. As 

an aid to installation, label all 

components, wires, and hoses 

before removing them. Do not reuse 

gaskets, O-rings or seals during 

reassembly. 

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 

Camshafts and valvetrain, removing 

Cylinder head assembly, removing 

Intake manifold, removing 


cable in trunk.



2 of 25 2/25/2009 9:39 PM 

CAUTION! 





viii. 

Disconnecting the battery may 

erase fault code(s) stored in 

control module memory. Check 

for fault codes using special 

BMW diagnostic equipment. 


ventilation. 


microfilter. 







(arrows).



3 of 25 2/25/2009 9:39 PM 


from intake cover and lift off cover. 

Working above engine, disconnect the 

following: 

A Positive engine lead at B+ 

terminal 

B Manifold vacuum line 

C Oxygen sensor connectors 

(label connectors before 

disconnecting) 

D Electrical harness connector for 

intake air temperature sensor 

E Positive lead hold-down bracket 

F Intake manifold resonance valve 

electrical connector 


compartment: 


panel. 


hose at intake jet pump (A). Plug 

hose ends. 



remove. 



engine compartment.



4 of 25 2/25/2009 9:39 PM 

Disconnect engine vent hose from 

cylinder head cover by squeezing sides 

of spring clip (arrows). Disconnect 

VANOS solenoid electrical harness 

connector (A). 

Disconnect fuel injector electrical 





Repeat for all injectors. 

Lift off connector loom and lay 

aside. 


Disconnect vacuum line at intake 

boot (A). 



(B). 


(C). 


screws (D). 

Disconnect air duct connection (E) 

and lift complete air filter housing 

out of engine compartment,



5 of 25 2/25/2009 9:39 PM 

Note: 

pulling it forward away from mass 

air flow sensor. 




mass air flow sensor and air duct. 



3 - Y-duct 

4 - Air duct 



7 - Idle control valve 



Where applicable: Pull throttle cable 




Note: 

Models with M54 engines do not use a 

throttle cable. 



throttle body.



6 of 25 2/25/2009 9:39 PM 

Working at throttle housing: 

Turn harness plug (arrow) 

counterclockwise and remove. 


connector at idle speed control valve 

(arrow) directly above throttle housing. 

Working under front corner of intake 

manifold, disconnect electrical harness 

connector at fuel tank venting valve 

(A). Disconnect vent hose at quick 

disconnect fitting (arrow).



7 of 25 2/25/2009 9:39 PM 


Disconnect wiring harness 

brackets from tube (A). 

Disconnect fuel lines from 

retaining clips (B). 

Remove lower dip stick guide tube 

mounting bolt (C). Pull out guide 

tube. 

Remove schræder valve cap (arrow). 

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 


-75 psi) and may be expelled 










Always unscrew fuel tank cap to 

release pressure in the tank 

before working on the tank or 

lines. 


manner. 

WARNING! 


supported at all times. Use a



8 of 25 2/25/2009 9:39 PM 





guard from beneath engine 

compartment. 



cover and clamp off fuel hose(s) 

(arrows). 

Note: 

M54 engines equipped with a non-return 

fuel rail use only a single supply line. 

Disconnect fuel hose(s) from fuel 

line(s) (arrows) using special fuel line 


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. 


(arrows). 

Carefully pry fuel rail off manifold.



9 of 25 2/25/2009 9:39 PM 



Thread fuel line(s) out of rear of 



Remove intake manifold mounting nuts 

(arrows). 

Lift up manifold enough to disconnect 

positive cables from starter motor 

terminal (arrow). 

Remove intake manifold from 

cylinder head 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: 


radiator. 

Place 3-gallon pail beneath 


Remove coolant drain plug 

located on exhaust side of cylinder



10 of 25 2/25/2009 9:39 PM 

2 of engine block (arrow). 

Drain radiator into a 3-gallon pail by 

removing plastic drain plug at lower left 

end of radiator (arrow). 

WARNING! 

Use caution when draining and 

disposing of engine coolant. Coolant 

is poisonous and lethal to humans 

and pets. Pets are attracted to 

coolant because of its sweet smell 

and taste. Consult a veterinarian if 

coolant is ingested by an animal. 

Dispose of drained coolant 

according to local, state, and federal 

laws. 

Remove hoses from thermostat 

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 fluid 

reservoir and pull aside without 

disconnecting hoses. Tie to fender 

with cord or stiff wire. 

- Remove windshield and headlight 

washer reservoir:



11 of 25 2/25/2009 9:39 PM 

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: 

Disconnect hose 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: 


(arrows). 

Remove cover hold down nuts and 

lift off cover.



12 of 25 2/25/2009 9:39 PM 

Remove ignition coils. 

Disconnect ignition coil harness 

connectors. 

Remove coil mounting fasteners. 

Remove coils. 

Remove ground straps. 

Set coil harness to left side of 


- 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. 

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.



13 of 25 2/25/2009 9:39 PM 

Double VANOS 

components (M52 

TU, M54 engine) 

1 - Impulse wheel 

mounting nut 

2 - Exhaust 

camshaft 

impulse wheel 

3 - Spring plate 

4 - Thrust spacer (T 

= 3.5 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 


chain lower 

guide



14 of 25 2/25/2009 9:39 PM 

14 - Sprocket 

mounting nut 



17 - Intake camshaft 

sprocket 

18 - Locating stud 

19 - Thrust spacer 


impulse wheel 

21 - Chain tensioner 

rail 

22 - Crankshaft 

sprocket 

23 - Primary chain 

tensioner 



26 - Guide rail 


28 - Woodruff key 


Disconnect electrical connections at 

exhaust camshaft position sensor and 

exhaust camshaft VANOS control valve 

(arrows).



15 of 25 2/25/2009 9:39 PM 

Remove banjo bolt from VANOS unit oil 

pressure line. Use banjo bolt to attach 

BMW special tool 11 3 450 (compressed 

air fitting) to VANOS control unit. 

Cover oil hole (arrow) in VANOS unit 

with shop towel to capture oil which will 

spray when compressed air is applied. 

- 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) 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, complete another two 

complete rotations.



16 of 25 2/25/2009 9:39 PM 

Remove sealing plug from special tool 

bore on lower left side of engine block 

near flywheel. Secure crankshaft in TDC 

position with BMW special tool 11 2 300 

(arrow). 

Unscrew and remove two cylinder head 

cover studs (arrows) at rear of cylinder 

head. 

Secure camshafts in TDC position using 

BMW special tools 11 3 240 and 11 3 

244. 

- Disconnect compressed air line, 

leaving compressed air fitting 

attached to VANOS unit. 

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.



17 of 25 2/25/2009 9:39 PM 

Oil will drain from plugs (arrows) when 

removed. Have a container and rags 

ready. Do not allow oil to run onto drive 

belts. 

Pull sealing caps straight out of VANOS 

unit with BMW special tool 11 6 170, or 

with short nose pliers. 

Note: 

Additional oil may drain from VANOS 

unit. 

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!



18 of 25 2/25/2009 9:39 PM 

Do not crank the engine with VANOS 

unit removed. The splined shaft on 

the intake camshaft might slip out of 

the VANOS spline teeth, causing the 

intake cam to no longer be positively 

connected to the timing chain, 

allowing for possible piston/valve 

interference. 

Note: 

The VANOS unit will contain a small 

quantity of oil. Place shop towels to catch 

oil as unit is removed or tilted. 

CAUTION! 

If 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 place using BMW 

special tool 11 3 292 or a similar size pin.



19 of 25 2/25/2009 9:39 PM 

Remove exhaust camshaft impulse 

wheel mounting nuts (arrows). Remove 

impulse wheel (A). 

Remove spring plate (A). 

Remove intake camshaft sprocket 

mounting nuts (arrows) and remove 

spring plate (labelled FRONT). 

Remove torx screws from exhaust 

camshaft sprocket (arrows).



20 of 25 2/25/2009 9:39 PM 

Lift off exhaust and intake sprockets 

together with secondary chain, thrust 

spacer (A) from exhaust camshaft, and 

splined shaft (B) from intake camshaft. 

CAUTION! 

Splined shafts share the same part 

number for both intake and exhaust 

camshafts. 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.



21 of 25 2/25/2009 9:39 PM 

Remove primary chain sprocket 

mounting studs (arrows) on exhaust 

camshaft. 

Lift primary chain sprocket off exhaust 

camshaft. Remove sprocket from chain. 

Place timing chain on end of exhaust 

camshaft. 

Remove locating studs (arrows) from 

intake camshaft. Lift off intake camshaft 

thrust spacer (A) and impulse wheel (B).



22 of 25 2/25/2009 9:39 PM 

Do not remove end spline retaining 

screws from camshafts (arrows). 

Remove cylinder head cover mounting 

studs (arrows) from center of cylinder 

head. 

- Remove flywheel locking tool from 

transmission bellhousing so that 

crankshaft is no longer secured. 

Lift primary chain and hold under 

tension, then 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



23 of 25 2/25/2009 9:39 PM 

centered with adapter sleeves. To 

avoid camshaft damage, it must be 

removed before any other caps. 

Fit BMW special tools 11 3 260 (A) and 

11 3 270 (B) to cylinder head and screw 

long bolts (arrows) into spark plug 

threads. Tensioners will align with the 

bearing caps on the intake camshaft. 

CAUTION! 

Do not over torque bolts into spark 

plug holes. 

Turn eccentric shaft of special tool to 

pretension intake camshaft bearing 

caps. Remove nuts on remaining 

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 carriers from 


CAUTION! 

Do not let the hydraulic lifters fall 

out as the camshaft carrier is 

removed.



24 of 25 2/25/2009 9:39 PM 

Hydraulic lifters should be stored 

in an upright position. 

Used hydraulic lifters must be 

replaced into original lifter bores. 

Cylinder head assembly, 

removing 

- Remove exhaust manifolds. See 

180 Exhaust System. 

Remove intake camshaft position sensor 

(arrow) from side of cylinder head. 

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).



25 of 25 2/25/2009 9:39 PM 

Using BMW special tool 11 2 250 or 

equivalent, loosen cylinder head bolts in 

several stages in sequence shown. 

Discard head bolts. 

Note: 


BMW special tool 11 2 250 is a 

thin-walled Torx E12 socket with an 

extended reach. 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.



1 of 21 2/25/2009 9:42 PM 

Cylinder Head 

Installation 

113-3 

Clean cylinder head and gasket 

surfaces of cylinder block and all 

timing chain covers. 

Remove foreign matter and liquid from 

bolt holes. 

CAUTION! 

Do not use a metal scraper or wire 

brush to clean the aluminum cylinder 

head or pistons. If necessary, use a 

hard wooden or plastic scraper. Also 

available are abrasive discs to be 

used in conjunction with an electric 

drill. Be sure to use the correct disc 

for the type of metal being cleaned. 

Evaluate cylinder head 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 shafts and spline 

hubs with assembly lubricant before 

installation. 

To assist the technician in cylinder 

head installation, the procedure has 

been organized as separate



2 of 21 2/25/2009 9:42 PM 

operations. Please be advised that 

these individual jobs must be 

accomplished in the order in which 

they appear. 

Cylinder head assembly, installing 

Camshafts and valvetrain, installing 

VANOS control unit, installing 

Cylinder head cover, manifolds, 

cooling system, installing 

Cylinder head assembly, 

installing 

Check that two cylinder head locating 

aligning sleeves (arrows) are correctly 

positioned in block and are not 

damaged. 

- 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 rotated approximately 30° 

opposite the direction of engine 

rotation from TDC, is still in that



3 of 21 2/25/2009 9:42 PM 

position before lowering the cylinder 

head into position. All pistons must 

be out of TDC position to prevent 

valve/piston interference when the 

camshafts are installed. 

- Lightly lubricate new cylinder 

head bolts. Install bolts and 

washers finger tight. Install 

cylinder head-to-lower timing 

chain cover bolts finger tight. 

Note: 

Cylinder head bolts should not be 

reused. They are stretch-type bolts 

and must always be replaced 

whenever loosened. 

Check that all washers for the 

head bolts are in place before 

installing the bolts. Some of the 

washers may be staked to the 


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 

torquing an additional 90° each for 

Stage 2 and 3. 


Cylinder head to engine block 

(Torx E12 M10 bolts) 

Stage 1 

40 Nm (30 ft-lb)



4 of 21 2/25/2009 9:42 PM 


Stage 2 +90° 

Stage 3 +90° 

Install intake camshaft position sensor 

(arrow). 

- Install exhaust manifolds. See 180 

Exhaust System. 

Install lower secondary chain guide. 

Tighten Torx bolts (arrows) to 

specifications. The bolt on the intake 

camshaft side is long and extends into 

the engine block. 


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!



5 of 21 2/25/2009 9:42 PM 

A minimum waiting time is required 

for the hydraulic lifters to "bleed 

down" after installing the camshafts 

into the cylinder head, but before 

synchronizing the crankshaft and 

valve train timing. When the 

camshafts are removed, the 

hydraulic lifters can expand. This 

expansion can cause increased valve 

lift when the camshafts are bolted 

down, possibly resulting in piston 

interference. 

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 intake 

camshaft on intake camshaft 

carrier.



6 of 21 2/25/2009 9:42 PM 

Rotate camshafts so that intake and 

exhaust lobes for cylinder 1 face each 

other (arrows). 

CAUTION! 

Be sure that crankshaft is still 

positioned at least 30° back from 

TDC. 

- Place bearing caps on cams, but 

do not install retaining nuts. 

Fit BMW special tools 11 3 260 (A) and 

11 3 270 (B) to cylinder head over 

intake camshaft and screw long bolts 

(arrows) into spark plug threads. 

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. 


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.



7 of 21 2/25/2009 9:42 PM 

- 

Repeat procedure for exhaust 

camshaft. 

Note: 

Before the next step, observe waiting 

time for lifter bleed down before 

continuing with camshaft installation. 

Crankshaft / valve timing waiting 

times 

68°F (20°C) and 

higher 

50 - 68°F (10 - 

20°C) 

32 - 50°F (0 - 

10°C) 

4 minutes 

11 minutes 

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.



8 of 21 2/25/2009 9:42 PM 

Lift timing chain and hold under 

tension. 

While maintaining tension on timing 

chain, rotate crankshaft from 30° 

before TDC in direction of rotation up to 

cylinder 1 TDC position (0|T on front 

pulley lined up with pointer on lower 

timing chain cover). 

Secure crankshaft in TDC position with 

BMW special tool 11 2 300 (arrow). 

Slide impulse wheel on intake 

camshaft, aligning boss with raised 

portion on camshaft (arrow).



9 of 21 2/25/2009 9:42 PM 

Fit thrust spacer to intake camshaft 

and tighten down with threaded 

locating studs (place longer threaded 

portion of studs into camshaft). 


Impulse wheel 

studs to intake 

camshaft (M7) 

20 Nm (15 ft-lb) 

Fit top sprocket to primary timing chain 

and install on exhaust camshaft so that 

pointer on sprocket (arrow) lines up 

with cylinder head sealing surface. 

Insert BMW special tool 11 4 220 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 

locating studs (arrows) in end of 

exhaust camshaft. 

Tightening torques



10 of 21 2/25/2009 9:42 PM 


Exhaust camshaft 

locating stud 

20 Nm (15 ft-lb) 

Install secondary chain tensioner on 

cylinder head (arrows). Keep tensioner 

compressed using BMW special tool 11 

3 292 or suitable pin. 

Fit exhaust camshaft splined sleeve. 

Confirm that gap in sleeve splines 

aligns with corresponding gap in 

camshaft splines (arrows). 

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.



11 of 21 2/25/2009 9:42 PM 

Place intake and exhaust sprockets in 

BMW special tool 11 6 180. Position 

spline gap on intake sprocket (arrow) 

as shown and place secondary chain 

on sprockets. 

Remove chain and sprockets from tool 

and slide sprockets on camshafts. 

Confirm that gap in intake sprocket 

splines lines up 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 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 

(arrows) on exhaust side camshaft



12 of 21 2/25/2009 9:42 PM 

assembly. 

Initially tighten to approx. 5 Nm 

(44 in-lb) and then back off by half 

a turn. 

Fit thrust spacer (A) on exhaust 

camshaft. 

Install spring plate (A) to exhaust 

camshaft. Make sure that F mark is 

visible. 

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.



13 of 21 2/25/2009 9:42 PM 

Pull out exhaust camshaft splined shaft 

to stop. 

- 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. 


Primary chain 

tensioner preload 

0.7 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!



14 of 21 2/25/2009 9:42 PM 

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 in-lb). 

Tighten mounting nuts (B) on 

exhaust and intake sprocket 

assemblies to approx. 5 Nm (44 

in-lb). 

Torque down mounting screws (A) 

and nuts (B) to final specifications. 


Sprocket assembly to camshaft 

initial torque 

Sprocket assembly wheel to 

camshaft 

5 Nm (44 in-lb) 

M7 Torx screws (A) 

M6 mounting nut 

(B) 

20 Nm (15 ft-lb) 

10 Nm (8 ft-lb) 




- Remove camshaft locking tools 

from cylinder head. 

Turn engine over twice in direction of 

rotation until cylinder 1 intake and 

exhaust camshaft lobes (arrows) face



15 of 21 2/25/2009 9:42 PM 

each other. 

- Secure crankshaft in TDC position 

with BMW special tool 11 2 300. 

Place BMW special tool 11 3 240 over 

camshafts and measure clearances. 

Note: 

If the exhaust side of the tool (A) is 

not flush with the head, camshaft 

timing is incorrect. Reset camshaft 

timing as described in 117 

Camshaft Timing Chains. 

Due to flexible sprocket design, 

VANOS unit tolerances and play in 

the VANOS splines, when the 

camshaft timing is set correctly, 

the intake side of special tool 11 3 

240 (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. 


Clean contact edges of cylinder head 

face and VANOS unit and apply a thin 

coat of sealing compound 

3-Bond®1209 or equivalent to 

surfaces. 

CAUTION! 

Make sure all gasket material is



16 of 21 2/25/2009 9:42 PM 

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 


Check locating dowel (A) and 

dowel sleeve (B) at top of 

cylinder head for damage or 

incorrect installation. 

- Replace steel gasket. 

- Install VANOS unit to front of 


Note: 

If Double VANOS control unit is being 

replaced, be sure to check and adjust 

camshaft timing as described in 117 


- Reinstall engine support hook. 


VANOS unit to cylinder head 

M6 nut 

M7 nut 

10 Nm (89int-lb) 

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 shafts on intake and exhaust 

camshafts. 

CAUTION!



17 of 21 2/25/2009 9:42 PM 

Set screws have left hand thread. 

Tighten counterclockwise. 


Hydraulic piston to splined shaft 

M6 set screw 

10 Nm (89 in-lb) 

Replace sealing caps inside VANOS 

unit with BMW special tool 11 6 170, or 

short flat nosed pliers. 

Insert and secure VANOS sealing 

plugs (arrows) with new sealing 

O-rings. 


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



18 of 21 2/25/2009 9:42 PM 


Oil line to VANOS 

unit (banjo bolt) 

32 Nm (24 ft-lb) 

- Remove BMW special tool 11 4 

220 and reinstall chain tensioner 

cylinder. 


Primary chain 

tensioner cylinder 

to cylinder head 

70 Nm (52 ft-lb) 


transmission bellhousing. Replace 

special tool bore sealing plug. 


from cylinder head. 

Cylinder head cover, 

manifolds, cooling system, 

installing 

Install intake camshaft cover and 


Check for correct seating of 

half-moon seals (A) in back of 


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.



19 of 21 2/25/2009 9:42 PM 


Cylinder head 

cover to cylinder 

head (M6) 

10 Nm (89 in-lb) 

- Install exhaust manifolds using 

new gaskets and nuts. Coat 

manifold studs with copper paste 

prior to installing nuts. 


Exhaust manifold 


(M7) 

20 Nm (15 ft-lb) 

- Install electrical harness 

connectors for oil pressure sender 

and coolant temperature sensor 

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 new fuel injector seals.



20 of 21 2/25/2009 9:42 PM 







CAUTION! 







M7 

M8 

Mounting bracket 


(M10) 


to intake manifold 

(M6) 

15 Nm (11 ft-lb) 

22 Nm (16 ft-lb) 

47 Nm (33 ft-lb) 

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 accelerator 

cable.



21 of 21 2/25/2009 9:42 PM 

Reconnect battery. 

CAUTION! 

To prevent damaging engine 

electronic systems, install all ground 

wires previously removed, including 

the ground wires for the ignition 

coils. 





fan to coolant 

pump 



Spark plug to 

cylinder head 

25 Nm (18 ft-lb) 

40 Nm (30 ft-lb) 

2.5 Nm (22 in-lb) 

25 Nm (18 ft-lb) 




1 of 5 2/25/2009 9:43 PM 

Diagnostic Testing 

113-4 

Cylinder compression, 

checking 

A compression gauge is needed to 

make a compression test. For accurate 

test, the battery and starter must be 

capable of cranking the engine at least 

300 rpm, and the engine should be at 

normal operating temperature. 

Note: 

Performing a compression test may 

cause a fault to set in the ECM and 

may illuminate the engine service light. 

The light can only be turned out using 

either BMW special service scan tools 

or an equivalent aftermarket scan tool. 

Disconnecting the battery will not erase 

the fault memory nor turn out the light. 

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 switched on or 

the engine running. 

Do not touch or disconnect 

ignition components while the 

engine is running or being 

cranked by the starter. 

CAUTION!



2 of 5 2/25/2009 9:43 PM 

Failure to remove the DME main 

relay or attempting to disable the 

ignition system by other methods 

may result in damage to the engine 

control module (ECM). 


microfilter. 


microfilter. 





- Remove oil filler cap. 

- Remove engine cover over ignition 

coils. Replace oil filler cap. 


Pull up on spring clips to 


connectors. 

Remove coil grounding straps. 

Remove coils. 

Note: 

Remove spark plugs. 

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 cylinder from which they were



3 of 5 2/25/2009 9:43 PM 

removed. 

Install compression gauge in first 

cylinder's spark plug hole, tight 

enough to form a good seal. 

- With parking brake set, 

transmission in PARK or 

NEUTRAL, and accelerator pedal 

pressed to floor, crank engine with 

starter. Record highest value 

indicated by gauge. 

Note: 

The compression gauge reading 

should increase with each 

compression stroke and reach 

near its maximum reading in about 

4-6 strokes. 

All 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 

Maximum 

difference between 

cylinders 

10 - 11 bar 

(142 - 156 psi) 

0.5 bar (7 psi) 

- Compression readings may be 

interpreted as follows:



4 of 5 2/25/2009 9:43 PM 

Low compression indicates a 

poorly sealed combustion 

chamber. 

Relatively even pressures that are 

below specification normally 

indicate worn piston rings and/or 

cylinder walls. 

Erratic values tend to indicate 

valve leakage. 

Dramatic differences between 

cylinders are often the sign of a 

failed head gasket, burned valve, 

or broken piston ring. 

- Reinstall spark plugs and ignition 

coils. 

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). 


Spark plug to 

cylinder head 

25 Nm (18 ft-lb) 

Wet compression test 

To further help analyze the source of 

poor compression, a wet compression 

test is the next step:



5 of 5 2/25/2009 9:43 PM 

- 

Repeat compression test, this time 

with about a teaspoon of oil 

squirted into each cylinder. (The 

oil will temporarily help seal 

between piston rings and cylinder 

wall, practically eliminating 

leakage past rings for a short 

time.) 

- If this test yields higher 

compression reading than "dry" 

compression test, there is 

probably leakage between piston 

rings and cylinder walls, due 

either to wear or to broken piston 

rings. 

- Little or no change in compression 

reading indicates other leakage, 

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 repair that 

requires major engine disassembly, 

use a leak-down test to confirm low 

compression.

Cylinder Head and Valvetrain 


1 of 3 2/25/2009 9:47 PM 

General 

116-1 

This repair group covers cylinder head 

and valvetrain service and repair. 

Procedures described here require that 

the cylinder head first be removed as 

described in 113 Cylinder Head 

Removal and Installation. 

Note: 

For timing chain and VANOS 

repair information, see 117 


If it is determined that the cylinder 

head will require significant 

reconditioning work, a 

remanufactured cylinder head may 

be a good alternative. 

Remanufactured cylinder heads 

are available from an authorized 

BMW dealer. 


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 cylinder head disassembled and 

removed by an authorized BMW 

dealer. Be sure to read each procedure 

thoroughly before starting a job to 

determine which special tools and 

equipment will be necessary.



2 of 3 2/25/2009 9:47 PM 

Most of the repairs to a cylinder head 

require precision machine work to 

specific tolerances. This type of work 

should be performed by an authorized 

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



3 of 3 2/25/2009 9:47 PM 

Valve stem seal guide BMW special 

tool 11 1 960 




1 of 5 2/25/2009 9:47 PM 

Cylinder Head 

116-2 

This section provides the specifications 

and special reconditioning information 

necessary to repair the cylinder heads 

covered by this manual. 

The disassembled cylinder head 

should be inspected for warpage and 

cracks. Check the valve guides and 

valve seats for wear before machining a 

warped head. Always decarbonize and 

clean the head before inspecting it. A 

high-quality straight edge can be used 

to check for warpage. 

Visually inspect the cylinder head for 

cracks. If a cracked cylinder head is 

suspected and no cracks are detected 

through the visual inspection, have the 

head further tested for cracks by an 

authorized BMW dealer or an ASE 

certified machinist. A cracked cylinder 

head must be replaced. 

Note: 

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 amount will reduce the size of 

the combustion chamber and adversely 

affect engine performance. A 0.3 mm 

thicker gasket is available from an 

authorized BMW parts department for 

machined heads. 

Before machining the head to correct 

for warpage, measure the total height 

(A) (thickness of the cylinder head). 

Minimum height specifications are



2 of 5 2/25/2009 9:47 PM 

given in Table a. 

Table a. Cylinder head height 

New 

140.0 mm (5.512 

in) 

Minimum height 

(dimension A) 

139.7 mm (5.500 

in) 

Valves, leak test 

To test the valves for leakage, the 

cylinder head must be disassembled 

with camshafts and camshaft carriers 

removed. Install the valve assemblies 

and the spark plugs in each cylinder. 

Place the cylinder head on a 

workbench with the combustion 

chamber facing upward. Fill each 

combustion chamber with 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 

specifications 

Axial play 

Radial play 

(Plastigage) 

0.150-0.330 mm 

(0.0060-0.013 in.) 

0.020-0.054 mm 

(0.0008-0.0021 

in.) 

CAUTION!



3 of 5 2/25/2009 9:47 PM 

If the camshaft is being replaced due 

to cam lobe wear, it is recommended 

that the corresponding lifters should 

also be replaced to avoid damaging 

the new camshaft. 

Hydraulic lifters, checking and 

replacing 

Modern BMW 6 cylinder engines use 

self-adjusting hydraulic lifters to keep 

the valve clearances within a limited 

working range. (A) section view of 

camshaft , (B) hydraulic lifters are 

sealed units and require no 

maintenance, (C) valve with conical 

valve spring. 

Under some circumstances, such as a 

cold start, the cam followers 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 checking hydraulic lifters, make 

sure engine oil is fresh and at the 

proper level. 

- Run engine until it reaches normal 

operating temperature. 



ventilation.



4 of 5 2/25/2009 9:47 PM 





- Remove engine cover. 

- Detach positive and ground 

connections from intake manifold 

and cylinder head cover, as 

necessary. 


Disconnect ignition coil harness 

connectors and lay harness aside. 

Remove coil grounding straps. 

Remove coils. 





Note: 


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.



5 of 5 2/25/2009 9:47 PM 

Use a plastic or wooden stick to press 

down on top of lifter. If there is any 

noticeable clearance, the lifter is faulty 

and should be replaced. 

Note: 

When checking a hydraulic lifter, make 

sure the corresponding camshaft lobe is 

facing up so that there is no valve 

spring pressure on the follower. 

- To replace 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.



1 of 6 2/25/2009 9:48 PM 

Valves 

116-3 

Valves, removing and installing 

- Remove cylinder head as 



CAUTION! 

Do not let the hydraulic lifters 

fall out as the camshaft carrier is 

removed. Special suction cups 

are available from BMW to hold 

the hydraulic lifters in place 

during carrier removal. 

Hydraulic cam lifters should be 

stored in an upright position. If 

necessary, use a magnetic tool 

to aid in removal of the lifters. 

- 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 listed in 

Table c. Remove carbon deposits from



2 of 6 2/25/2009 9:48 PM 

the valves using a wire brush or wire 

wheel. 

Table c. Valve specifications 

Specification M 52TU 2.5/2.8 

engines 

(1999 - 2000) 

M 54 2.5/3.0 

engines (2000 - 

2001) 

Valve head dia. 

Intake 33.0 mm (1.299 

in.) 

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.)



3 of 6 2/25/2009 9:48 PM 

Table c. Valve specifications 

Specification M 52TU 2.5/2.8 

engines 

(1999 - 2000) 

M 54 2.5/3.0 

engines (2000 - 

2001) 

Exhaust 

6.2 -0.040 mm 

(0.2441 -0.0016 

in.) 

Valve guides 

BMW does not supply valve guides as 

replacement parts. If a valve guide is 

excessively worn, it should be reamed 

to accept oversized valve stems. Valve 

guide specifications are listed in 

Table d. 

Valve guides should be checked for 

wear using a new valve. Be sure to 

thoroughly 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. Valve guide 

replacement requires special tools 

and a press. It is also necessary to 

heat the cylinder head and chill the



4 of 6 2/25/2009 9:48 PM 

valve guides when replacing the 

guides. 

BMW supplies oversize valves. See 

Table d for additional information. 

Table d.Valve guide specifications 

Specifications 

Valve guide wear, 

maximum (valve 

tilt clearance 

measured with 

new valve) 

M52TU / M54 

engine(1999 - 

2001) 

0.5 mm (0.020 

in.) 

Valve guide inside 

diameter, installed 

(tolerance per ISO 

allowance H7) 

Standard 6.0 mm (0.236 

in.) 

Oversize 1 6.1 mm (0.240 

in.) 

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 installed. 

Valve stem oil seal replacement 

requires that the cylinder head be



5 of 6 2/25/2009 9:48 PM 

disassembled and the valves removed 

as described above under Valves, 

removing and installing. 

Note: 

BMW special tools are available to 

remove the valve stem oil seals. As an 

alternative, standard valve seal removal 

tools are available from most 

automotive parts stores. 

Lubricate new seal and install using 

hand pressure only. Be sure to install 

valve spring seat(s) before installing 

seal. 

Valve seats 

The valve seats should be resurfaced 

whenever new valves or valve guides 

are installed. 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 for valve seat 

replacement for the engines covered by 

this manual. 

Table e. Valve seat specifications 

Specification 

A: Valve seat 

angle 

M52TU/M54 

engines 

(1999-2001) 

45°



6 of 6 2/25/2009 9:48 PM 

Table e. Valve seat specifications 

Specification 

B: Correction 

angle, outside 

C: Correction 

angle, inside 

M52TU/M54 

engines 

(1999-2001) 

15° 

60° 

D: Valve seat 

width 

intake 

exhaust 

1.65 ± 0.25 mm 

(0.065 ± 0.010 in) 

1.65 ± 0.25 mm 

(0.065 ± 0.010 in) 

E: Valve seat 

outside dia. 

intake 

exhaust 

32.4 mm (1.276 in) 

30.0 mm (1.181 in) 

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.

Camshaft Timing Chain 


1 of 4 2/25/2009 9:50 PM 

General 

117-1 

This repair group covers timing chain 

and Variable Camshaft Timing 

(VANOS) repair information. 

The timing chains are lubricated by 

engine oil and do not require 

maintenance. Worn timing chains and 

sprockets can lead to noisy operation 

and erratic valve timing. A faulty 

tensioner can also cause timing chain 

noises. 

Note: 

See 100 Engine–General for engine 

code and application information. 

Special tools 

Special BMW service tools are needed 

to remove and disassemble 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 MoDiC or equivalent. 

CAUTION! 

The VANOS system must be 

removed and installed exactly as 

described later in this repair group. 

Torque wrench w/ flex extension BMW 

00 9 250



2 of 4 2/25/2009 9:50 PM 

Crankshaft hub locking tools BMW 11 

2 150 /11 2 410 

Crankshaft locking tool BMW 11 2 300 

Seal extractor tool BMW 11 2 380 

Camshaft locking tools BMW 11 3 

240/11 3 244 

Installer bush BMW 11 3 280



3 of 4 2/25/2009 9:50 PM 

Secondary chain tensioner locking pin 


Air line fitting BMW 11 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



4 of 4 2/25/2009 9:50 PM 

Puller for crankshaft hub BMW 11 8 

210 




1 of 4 2/25/2009 9:50 PM 

Crankshaft Front Oil 

Seal 

117-2 

The crankshaft front seal is located in 

the lower timing cover on the front of 

the engine, behind the vibration 

damper. 

Note: 

Cars 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. 

- Disconnect negative (-) cable from 

battery. 

CAUTION! 










viii. 

Remove drive belts: 


A/C belt tensioner hex (A) 


Remove A/C belt.



2 of 4 2/25/2009 9:50 PM 


belt tensioner hex (B) clockwise 


- Secure crankshaft hub using 

special holding tools: 

Up to 1/2000 production: use 

special tools 11 2 150 and 11 2 

410. 

From 01/2000 production: use 

special tools 11 8 190 and 11 8 

200. 

CAUTION! 

Do not use BMW special tool 11 2 

300 to hold crankshaft stationary to 

loosen or tighten crankshaft hub 

center bolt. Use only the special 

tools specified, or equivalent hub 

holding tool. 

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 necessary, use BMW special tool 11 

8 219 or equivalent puller to remove



3 of 4 2/25/2009 9:50 PM 

hub from crankshaft. 

Place special tool 11 2 383 on end of 

crankshaft to cover threaded hole, and 

fit special tool 11 2 385, aligning groove 

in 11 2 385 with keyway on crankshaft 

(arrow). 

Put special tool 11 2 380 over tools 

installed on crankshaft, and screw in 

until it makes firm contact with the seal. 

Tighten screw in end of 11 2 380 to 

draw out seal. 

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 


Vibration damper 410 Nm (302



4 of 4 2/25/2009 9:50 PM 


hub to crankshaft 

ft-lb) 

CAUTION! 


300 to hold crankshaft stationary to 

loosen or tighten crankshaft hub 

center bolt. Use only the special 

tools specified, or equivalent hub 

holding tool. 

Install vibration damper mounting bolts, 

where applicable. Note hub locating 

dowel (arrow). 


Vibration damper 

to crankshaft hub 

(M8) 

22 Nm (16 ft-lb) 




1 of 16 2/25/2009 9:51 PM 

Camshaft Timing 

Chains, Removing 

117-3 

Camshaft timing chain removal 

requires that the engine oil pan be 

removed. This requires raising the 

engine and/or lowering the front 

suspension subframe. See 119 

Lubrication System. Also required is 

removal of the VANOS unit and 

disassembly of the intake and exhaust 

camshaft sprocket assemblies as 

described later in this repair group. 

Special BMW service tools are needed 

for timing chain removal and 

installation procedures. The special 

tools assure proper timing of the 

valvetrain. 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. 


battery. 

CAUTION! 









the front of this manual on page



2 of 16 2/25/2009 9:51 PM 

viii. 


ventilation. 








(A). 


screws (B). 

Note: 

Disconnect air duct connections 

(C) and lift complete air filter 

housing out of engine 

compartment, pulling it forward 

away from mass air flow sensor. 

Mass air flow sensor remains attached 

to air duct in above step.



3 of 16 2/25/2009 9:51 PM 

Remove engine covers: 


(arrows). 

Remove cover hold down bolts. 

Drain engine coolant and remove 

coolant hoses. 


radiator. 

Place a 3-gallon pail beneath 


Remove engine block drain plug 

on exhaust side near cylinder 2 

(arrow). 

WARNING! 

Allow 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.



4 of 16 2/25/2009 9:51 PM 

- 

Remove radiator cooling fan 

shroud and viscous clutch cooling 

fan (cars with automatic 

transmission) or electric cooling 

fan (cars with manual 

transmission). See 170 Radiator 

and Cooling System 

CAUTION! 

On cars with viscous clutch, 32 mm 

cooling fan mounting nut has left 

hand threads. 

Release locking clips and pull hoses 

from thermostat housing (arrows). 

Unbolt and remove thermostat houses. 

Remove drive belts: 


A/C belt tensioner hex (A) 


Remove A/C belt. 


belt tensioner hex (B) clockwise 


- Remove coolant pump pulley. 

- Remove alternator cooling duct at 

radiator support.



5 of 16 2/25/2009 9:51 PM 

- 

Drain engine oil and remove oil 

pan as described in 119 

Lubrication System. 

- On cars produced up to 1/2000 

with 2-piece vibration damper: 

Remove vibration damper 

mounting bolts and separate 

vibration damper and pulley from 

crankshaft hub. 

Note: 





hub assembly. 

- Using BMW special holding tool, 

secure crankshaft hub to prevent 

crankshaft from turning. Loosen 

but do not remove crankshaft hub 

center bolt. 

CAUTION! 


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) or 11 8 

190 and 11 8 200 (1/2000 and later 

models) should be used to hold the 

crankshaft stationary while the bolt is 

loosened. 

Working at top center of engine, 

disconnect vent hose by squeezing at



6 of 16 2/25/2009 9:51 PM 

fitting (arrows). 

- Disconnect electrical connection at 

intake camshaft position sensor 

(A). 

Remove ignition coils and spark plugs: 

Pull up on retaining clips to 


connectors. 

Remove grounding straps at coil 

mounting studs. 

Remove all ignition coils. 





Note: 


insulators, gaskets and coil grounds 

should be reinstalled in their original 

locations. 

Remove oil baffle cover from intake 

camshaft.



7 of 16 2/25/2009 9:51 PM 

Working at left front of cylinder head, 

disconnect electrical connections at 

exhaust camshaft position sensor and 

exhaust camshaft VANOS control valve 

(arrows). 

Remove banjo bolt from VANOS 

control unit oil pressure line. Use banjo 

bolt to attach BMW special tool 11 3 

450 (compressed air fitting) (arrow) to 

VANOS unit. 

Cover oil hole in VANOS unit (arrow) 

with shop towel to capture oil which will 

spray when compressed air line is 

connected. 



8 bar (30 - 110 psi). 


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! 

Do not rotate engine



8 of 16 2/25/2009 9:51 PM 

counterclockwise to reach the top 

dead center position. Instead, 

complete another two complete 

rotations. 

Remove sealing plug from bore on 

lower left side of engine block below 

starter. Secure crankshaft in TDC 

position with BMW special tool 11 2 

300 (arrow). 

Unscrew and remove threaded studs 

(arrows) at rear of cylinder head. 

Secure camshafts in TDC position 

using BMW special tools 11 3 240 and 

11 3 244. 

- Detach compressed air line, 

leaving compressed air fitting 

attached to VANOS unit. 

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.



9 of 16 2/25/2009 9:51 PM 

Have a container and rags ready. 

Pull sealing caps straight out of 

VANOS unit with BMW special tool 11 

6 170, or with short nose pliers. 

Note: 


unit. 

Remove set screws (left hand thread) 

on ends of intake and exhaust 

camshafts. 

CAUTION! 

Set screws have left hand threads. 

Remove with a clockwise motion. 


Remove fasteners from engine 

support eye. 


(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



10 of 16 2/25/2009 9:51 PM 

residual oil. Place shop towels 

beneath adjustment unit when 

removing. 

If the VANOS control unit is 

replaced, or if repair operations 

are completed that may change 

camshaft timing, the camshaft 

timing must be checked as 

described later in this chapter. 


tensioner (arrow) from timing chain 

cover. 

CAUTION! 




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).



11 of 16 2/25/2009 9:51 PM 

Remove spring plate (A). 

Remove intake camshaft sprocket 

mounting nuts (arrows) and remove 

spring plate (labelled FRONT). 

Remove torx screws from exhaust 

camshaft sprocket (arrows). 

Lift off exhaust and intake sprockets 

together with secondary chain, thrust 

spacer (A) and splined shaft (B). 

CAUTION! 

Splined shafts for both intake and 

exhaust camshafts share the same 

part number. Remove and mark used



12 of 16 2/25/2009 9:51 PM 

splined shafts in order to reinstall in 

original locations. 

Remove exhaust camshaft splined 

sleeve (A) and shaft (B). 

Remove secondary chain tensioner 


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.



13 of 16 2/25/2009 9:51 PM 

Set timing chain on exhaust camshaft 

end. 

Working in cylinder head cavity, 

remove timing chain cover bolts 

(arrows). 

Remove secondary chain lower guide 

bolts (arrows). Remove chain guide. 

Note: 

Bolt on intake camshaft side is long and 

extends into timing chain cover. 

- 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



14 of 16 2/25/2009 9:51 PM 

to rotate when the timing chains are 

loosened or removed. The pistons 

can contact the valves. 

Using a drift of less than 5 mm 

diameter, drive two locating dowels (A) 

in left and right sides of lower timing 

chain cover toward rear of car. Remove 

cover mounting bolts (arrows) and 

carefully lift cover off. 

CAUTION! 

Use care when removing the cover 

from the 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.) 


4 - Thrust spacer (T 

= 3.5 mm)



15 of 16 2/25/2009 9:51 PM 


tensioner 


7 - Exhaust 

secondary 

sprocket 


9 - Secondary 

timing chain 

10 - Splined sleeve 

11 - Primary 

sprocket 

12 - Threaded stud 


chain tensioner 

14 - Sprocket 

mounting nut 




sprocket 


chain lower 

guide 

19 - Thrust spacer 

20 - Camshaft 

impulse wheel 

(intake) 

21 - Chain tensioner 

rail 

22 - Crankshaft 

sprocket



16 of 16 2/25/2009 9:51 PM 










1 of 11 2/25/2009 9:51 PM 

Camshaft timing chains, 

Installing 

CAUTION! 

117-4 

The procedure outlined below 

assumes that the camshafts and the 

crankshaft are locked in the TDC 

installation position with special 

locking tools as shown earlier. 

Inspect timing chain sprockets. Inspect 

guide rail and tensioner rail for deep 

grooves caused by chain contact. 

Replace any part that is worn or 

damaged. 

1 - Primary chain tensioner 

2 - Chain tensioner rail 

3 - Crankshaft sprocket 

4 - Exhaust camshaft sprocket 


6 - Anchor bolt 


8 - Anchor bolt 


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 

information. 

- Install primary timing chain to 

crankshaft sprocket and hang



2 of 11 2/25/2009 9:51 PM 

upper end from exhaust camshaft. 

- If necessary, replace crankshaft 

seal as described earlier. 

- To install lower timing case cover: 

Clean cover and cylinder block 

sealing surfaces. 

Use new gaskets and coolant pipe 

O-ring. 

Drive timing cover dowels in until 

they just protrude slightly from 

sealing surface. 

Apply a 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



3 of 11 2/25/2009 9:51 PM 


Lower timing cover 


(M6) 

10 Nm (89 in-lb) 

- Install oil pan with new gasket. 

See 119 Lubrication System. 


Oil pan to engine block (M6) 

8.8 grade 10 Nm (89 in-lb) 

10.9 grade 12 Nm (9 ft-lb) 

Install crankshaft hub or vibration 

damper to crankshaft. Install 

crankshaft center bolt finger tight. 

Make sure hub is fully seated, noting 

alignment dowel (arrow), where 

applicable. 

Note: 





hub assembly. If the early vibration 

damper needs to be replaced, only the 

single piece with integral hub is 

available from BMW. 



to crankshaft hub 

(M8) 

22 Nm (16 ft-lb) 

Fit top sprocket to primary timing chain 

and install on exhaust camshaft so that 

pointer (arrow) on sprocket lines up 

with cylinder head sealing surface.



4 of 11 2/25/2009 9:51 PM 

Insert BMW special tool 11 4 220 in 

cylinder head and screw in adjustment 

screw by hand just until it contacts 

tensioning rail. 

Note: 



the function of the tensioner. 

- Make sure arrow on top primary 

sprocket 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. 



locating stud 

20 Nm (15 ft-lb) 

Install secondary chain tensioner on 


Make sure tensioner is locked in 

compressed position as described 

earlier.



5 of 11 2/25/2009 9:51 PM 

Fit exhaust camshaft splined sleeve, 

aligning gap in sleeve splines with 

corresponding gap on camshaft splines 

(arrows). 

Slide splined shaft onto exhaust 

camshaft, aligning larger tooth with 

corresponding gap of splined sleeve. 

Slide splined shaft in further until 

3 small slots in splined sleeve are 

centered on 3 threaded holes in 

sprocket. 

Place intake and exhaust sprockets in 

BMW special tool 11 6 180. Position 

spline gap on intake sprocket (arrow) 

as shown and place secondary chain 

on sprockets. 

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 onto intake 

camshaft until approx. 1 mm (0.04 in.) 

of splines can still be seen.



6 of 11 2/25/2009 9:51 PM 

Install intake camshaft spring plate so 

that FRONT mark is visible. Install 

mounting nuts (arrows) finger tight. 

Working at exhaust side, insert 

sprocket mounting Torx screws into 

threaded holes (arrows). 

Initially tighten screws to approx. 5 

Nm (44 in-lb). Back off half a turn. 

Fit thrust spacer (A) on exhaust 

camshaft.



7 of 11 2/25/2009 9:51 PM 

Install spring plate (A) to exhaust 

camshaft. Make sure that F marking is 

visible. 

Note: 

If F marking is no longer visible, install 

spring plate so that convex side points 

forward (toward front of car). 

Install exhaust camshaft impulse 

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: 


special tool 11 4 220 to specified 

torque.



8 of 11 2/25/2009 9:51 PM 


Primary chain 


0.7 Nm (6 in-lb) 


by pressing on impulse wheel while 

tightening mounting nuts (arrows) 

finger tight. 



cylinder head timing case. 

- Tighten tool mounting nuts 

(arrows) by hand, and then 

tighten down uniformly until 

special tool is firmly contacting 


CAUTION! 



Clean sealing face and keep free of 

oil. If any foreign material is present 

on the sealing surface, the camshaft 


Secure camshaft sprockets and 

impulse wheels: 

Tighten mounting screws (A) on 

exhaust camshaft impulse wheel 

to approx. 5 Nm (44 in-lb). 

Tighten mounting nuts (B) on



9 of 11 2/25/2009 9:51 PM 



in-lb). 

Torque down mounting screws (A) 

and nuts (B) to final specifications. 


Sprocket assembly 

to camshaft initial 

torque 

5 Nm (44 in-lb) 


M7 Torx screw (A) 


(B) 

20 Nm (15 ft-lb) 

10 Nm (89 in-lb) 





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. 


camshaft ends and measure clearance 

of tool to cylinder head surface. 

Note: 

If the exhaust side of the tool is not 

flush with the head (gap A), retime 

the camshafts as described later in



10 of 11 2/25/2009 9:51 PM 

this repair group. 


VANOS unit tolerances, and play 

in the VANOS splines, when the 

camshaft timing is set correctly, 

the intake side of special tool 11 3 

240 may be up to 1 mm (0.04 in) 

above the surface of the cylinder 

head (gap B).This is normal. 

Otherwise, retime the camshafts 

as described later in this repair 

group. 

- Remove VANOS setup bracket 

from front of cylinder head. 

- Install VANOS unit. See 

VANOS control unit, given later. 

- Install intake camshaft oil baffle 

Install cylinder head cover. 





3-Bond®1209 or equivalent 

sealant at corners (B) of 

half-moon cutouts. Seal corners in 

front of cylinder head at VANOS 

unit. 


Cylinder head 


head 

10 Nm (89 in-lb) 

- Reassemble remainder of engine:



11 of 11 2/25/2009 9:51 PM 

Torque crankshaft hub center bolt, 

using special tools 11 2 150/11 2 

410 (to 1/2000) or 11 8 190/11 8 

200 (from 1/2000). 

CAUTION! 


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. 

Reinstall air filter housing, engine 

covers, interior ventilation 

microfilter housing. 

Secure all coolant hoses, 

thermostat housing, engine 

coolant drains. 

Reinstall engine oil drain plug. 

Refill engine oil and coolant 

before running engine. Check for 

leaks. 





fan (viscous clutch) 

to coolant pump 




hub to crankshaft 

25 Nm (18 ft-lb) 

40 Nm (30 ft-lb) 

2.5 Nm (22 

in-lb) 

410 Nm (302 

ft-lb) 


- Use scan tool to check VANOS 

operation with engine idling.



1 of 19 2/25/2009 9:52 PM 

Vanos 

117-5 

The main components of the double 

VANOS system are: 

Intake and exhaust camshafts with 

helical spline inserts 

Camshaft sprockets with 

adjustable gears 

VANOS actuators (two position 

piston housing with 

internal/external helical spline 

cup) 

Three-way solenoid switching 

valves 

Camshaft position impulse wheels 

Hall effect camshaft 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 and controlling camshaft



2 of 19 2/25/2009 9:52 PM 

positions. 

The Double VANOS system allows full 

variability of camshaft timing up to the 

limits of the system. When the ECM 

detects that the camshafts are in 

optimum position, the solenoids are 

modulated at approximately 100 - 220 

Hz to maintain oil pressure on both 

sides of the actuator pistons to 

maintain timing. 

In models with DME MS 43.0 (model 

year 2001), the engine control module 

(ECM) detects camshaft position before 

the engine starts, thereby adjusting 

camshaft timing immediately upon 

start-up 

Note: 

BMW does not provide diagnostic 

information or specifications for 

the Double VANOS system. 

VANOS system troubleshooting 

and diagnostics is best 

accomplished using a scan tool. 

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 (high viscosity) 

may cause a DTC to be set in the 

ECM. If VANOS is deactivated 

(limp-home mode), there will be a 

noticeable loss of power. 

Table a. VANOS fault codes 


code 

P-code 

Fault 

description



3 of 19 2/25/2009 9:52 PM 

Table a. VANOS fault codes 


code 

P-code 

Fault 

description 

19 P1529 VANOS 

solenoid valve 

activation, 

exhaust 

21 P1525 VANOS 

solenoid valve 

activation, 

intake 



intake 



exhaust 




(Bank 2) 

exhaust 

Double VANOS components



4 of 19 2/25/2009 9:52 PM 

VANOS control unit 

1 - Bolt M6 

2 - Exhaust 

camshaft 


3 - Sealing ring 

4 - Camshaft end 

sealing plug 

tighten to 50 

Nm (37 ft-lb) 

5 - Camshaft seal 

cap 

6 - VANOS 

hydraulic piston 

set screw 

CAUTION: 

left hand 

thread 

7 - Nut M7 

tighten to 10 

Nm (89 in-lb) 

tighten to 14 

Nm (10 ft-lb) 

8 - Engine lifting 

hook



5 of 19 2/25/2009 9:52 PM 

9 - Stud M7 

10 - Nut M6 

11 - Gasket 

tighten to 10 

Nm (89 in-lb) 

12 - Cylinder head 



sensor 

15 - Bolt M6 

16 - VANOS control 

unit 

17 - Copper sealing 

ring 

18 - VANOS oil feed 

line 

19 - Banjo bolt 

tighten to 32 

Nm (24 ft-lb) 


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



6 of 19 2/25/2009 9:52 PM 

negative (-) battery cable. 

CAUTION! 





viii. 




for fault codes using special BMW 

diagnostic equipment. 

- Remove complete air filter housing, 

cylinder head cover, intake 

camshaft plastic cover and spark 

plugs, as described earlier 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 on top of unit. 

- Connect compressed air line (with 

line pressure set to 2 - 8 bar or 30 - 

110 psi) to air fitting.



7 of 19 2/25/2009 9:52 PM 


turn engine at least twice in direction of 


exhaust camshaft lobes (arrows) face 

each other. 

Remove sealing plug from bore on lower 

left side of engine block (flywheel end). 


BMW special tool 11 2 300 (arrow). 

- Unscrew and remove cylinder head 

cover studs at rear of cylinder head. 

Secure camshafts in TDC position using 

BMW special tools 11 3 240 ans 11 3 

244. 

- Detach compressed air line, leaving 

compressed air fitting attached to 

VANOS unit. 

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 container and rags ready. Do not 

allow oil to run onto drive belts.



8 of 19 2/25/2009 9:52 PM 

Remove sealing caps from inside 

VANOS unit with BMW special tool 11 6 

170, or with short flat nose pliers. 

Note: 


unit. 

Remove set screws (left hand thread) on 

ends of intake and exhaust camshaft 

hydraulic pistons. 

CAUTION! 

Set screws 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 fasteners from engine 

support eye. 


(arrows) from cylinder head. Slide 

VANOS unit and metal gasket off. 

CAUTION!



9 of 19 2/25/2009 9:52 PM 

Do not crank or turn over engine with 

VANOS unit removed. Piston/valve 

interference is possible. 


Clean contact edges of cylinder head 

face and VANOS unit and apply a thin 

coat of sealing compound (3-Bond®1209 

or equivalent) to surfaces. 

CAUTION! 


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. 

Note: 

Check locating dowel (A) and 

dowel sleeve (B) at top of cylinder 

head for damage or incorrect 

installation. 

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 however that the 

VANOS operation be checked using 

a compatible scan tool. 

- Using new gasket, install VANOS 

unit to cylinder head.



10 of 19 2/25/2009 9:52 PM 

Reinstall engine support eye. 


VANOS unit to cylinder head 

M6 nut 

M7 nut 

10 Nm (89 in-lb) 

14 Nm (10 ft-lb) 

Insert and tighten down VANOS 

hydraulic piston set screws on intake 

and exhaust camshafts. 

CAUTION! 

Set screws have left hand thread. 

Tighten counterclockwise. 


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. 


Sealing plug to 

VANOS unit 

50 Nm (37 ft-lb) 

- Remove compressed air fitting from 

VANOS unit.



11 of 19 2/25/2009 9:52 PM 

- 

Fit VANOS oil line banjo bolt with 

new seals. Attach oil line to VANOS 

unit. 




32 Nm (24 ft-lb) 

- Attach electrical harness connectors 

to camshaft position sensors and 

VANOS solenoid valves. 

- Remove BMW special locking tools 

from rear of cylinder head. 

- Remove BMW special locking tool 

from flywheel and replace dust 

guard. 

Install intake camshaft plastic baffle and 

then install cylinder head cover. 





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. 


Cylinder head 


head (M6) 

10 Nm (89 in-lb) 

- Remainder of installation is reverse



12 of 19 2/25/2009 9:52 PM 

of removal. 


Radiator fan 

(viscous clutch) to 

coolant pump 

Spark plug to 

cylinder head 

40 Nm (30 ft-lb) 

25 Nm (18 ft-lb) 

Camshaft timing, adjusting 

Use this procedure to check and, if 

necessary, adjust camshaft timing. This 

procedure assumes that the cylinder 

head cover and intake camshaft plastic 

baffle have been removed as described 

under Camshaft Timing Chains, 

Removing. Also, be sure the cooling fan 

behind the radiator and the spark plugs 

have been removed. 


tensioner cylinder (arrow). 

CAUTION! 



Insert BMW special tool 11 4 220 in 

cylinder head and bring adjustment 

screw into contact with tensioning rail. 

Note: 



the function of the tensioner.



13 of 19 2/25/2009 9:52 PM 

Preload primary chain tensioner rail: 


special tool 11 4 220. 


Primary chain 


0.7 Nm (6 in-lb) 

Unscrew oil pressure pipe from VANOS 

unit. Remove banjo bolt from oil 

pressure line and install BMW special 

tool 11 3 450. 

CAUTION! 

Cover top of VANOS unit with lint-free 

shop cloth. Attachment of compressed 

air line will force oil to spray out of 

bore. 



8 bar (30 - 110 psi). 


turn engine at least twice in direction of 


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 lower 

left side of engine block near flywheel. 


BMW special tool 11 2 300 (arrow).



14 of 19 2/25/2009 9:52 PM 

- 

Unscrew and remove cylinder head 

cover studs at rear of cylinder head. 


camshafts ends and measure clearance 


Note: 

If the exhaust side of the tool (A) is 

not flush with the head, retime the 

camshafts as described below. 




camshaft timing is set correctly, the 

intake side of special tool 11 3 240 

(B) may be up to 1 mm (0.04 in) 


head. This is normal. Reassemble 

engine. Otherwise, retime the 

engine as described below. 

- Remove Double VANOS unit as 

described earlier. 


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 cylinder head 

and just touching tensioning rail. Do 

not preload chain yet. 

Loosen intake camshaft sprocket 

mounting nuts (arrows) by 1 turn.



15 of 19 2/25/2009 9:52 PM 

Loosen exhaust camshaft sprocket 

mounting bolts (A) turn. 

Loosen exhaust camshaft impulse 

wheel mounting nuts (B) 2 turns. 

Slide out intake 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.



16 of 19 2/25/2009 9:52 PM 

Preload primary chain tensioning rail: 




Primary chain 


0.7 Nm (6 in-lb) 


by pressing on impulse wheel. Tighten 

mounting nuts (arrows) by hand. Do not 

tighten fully. 



cylinder head timing case. Tighten nuts 

(arrows) by hand, and then tighten 

down uniformly until special tool is in full 

contact with cylinder head. 

CAUTION! 



Clean sealing face and keep free of oil. 

If any foreign material is present on 

the sealing surface, the camshaft 


Secure camshaft impulse sprockets and 

wheels: 

Pretighten Torx screws (A) on 

exhaust camshaft impulse wheel to



17 of 19 2/25/2009 9:52 PM 

approx. 5 Nm (44 in-lb). 

Pretighten mounting nuts (B) on 



in-lb). 

Torque down Torx screws (A) and 

nuts (B) to final specifications. 


Sprocket assembly 

to camshaft initial 

torque 


5 Nm (44 in-lb) 

M7 Torx screw (A) 


(B) 

20 Nm (15 ft-lb) 

10 Nm (89 in-lb) 



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 



camshaft ends and measure clearance 


Note: 

If the exhaust side of the tool (A) is



18 of 19 2/25/2009 9:52 PM 

not flush with the head, camshaft 

timing is incorrect. Repeat camshaft 

timing procedure. 




camshaft timing is set correctly, the 

intake side of special tool 11 3 240 

(B) may be up to 1 mm (0.04 in) 


head. This is normal. Otherwise, 

repeat camshaft timing procedure. 

- Remove camshaft locking tools from 

rear of camshafts. 

- Remove BMW special tool 11 4 220 

(dummy primary chain tensioner). 

Reinstall primary chain tensioner. 


Primary chain 

tensioner cylinder 


70 Nm (52 ft-lb) 


transmission bellhousing Reinstall 

sealing plug. 

- Remove VANOS setup bracket from 

front of cylinder head. 

- Install VANOS control unit as 

described earlier in this group. 

- Remove compressed air fitting 

(special tool 11 3 450) from VANOS 

unit. 

- Fit VANOS oil line banjo bolt with



19 of 19 2/25/2009 9:52 PM 

new seals. Attach oil line to VANOS 

unit. 




32 Nm (24 ft-lb) 

- Remainder of engine assembly is 

reverse of disassembly. 



fan (viscous clutch) 

to coolant pump 

Cylinder head 


head 

Spark plug to 

cylinder head 

40 Nm (30 ft-lb) 

10 Nm (89 in-lb) 

25 Nm (18 ft-lb) 


Lubrication System 


1 of 6 2/25/2009 9:52 PM 

General 

119-1 

This repair group covers lubrication 

system troubleshooting as well as oil 

pan removal and oil pump 

replacement. 

Special tools 

The engine needs to be properly 

supported while the front suspension 

subframe is removed to access the 

lubrication system. If BMW special 

tools 00 0 200 / 00 0 208 are not 

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 4 050



2 of 6 2/25/2009 9:52 PM 

Engine lubrication 

Oil pressure is generated by a 

gear-type pump bolted to the bottom of 

the engine block. The oil pump is chain 

driven off the front of the crankshaft. 

Oil passages in the cylinder block and 

cylinder head connect the oil pump to 

components such as camshafts, 

crankshaft and valve lifters. 

Engine oil capacity (includes filter 

replacement) 

Rear wheel drive 

All wheel drive 

6.5 liters (6.9 qt.) 

7.5 liters (7.9 qt.) 


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 pressure warning light 

comes on or flashes on while 

driving, always assume that the oil 

pressure is low.



3 of 6 2/25/2009 9:52 PM 

Oil pressure, checking 

In some engines access to the oil 

pressure warning switch port may be 

extremely restricted. 

- Unscrew oil filter cap in order to 

allow engine oil to drain back 

down into oil pan. 

Disconnect harness connector from oil 

pressure switch (arrow) and remove 

switch. 

CAUTION! 

Running the engine with the oil 

pressure switch disconnected may 

set 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 results, the 

engine oil and filter should be new. The



4 of 6 2/25/2009 9:52 PM 

oil should be the correct grade. 

Oil pressure 

Idle (minimum) 

Regulated 

pressure (elevated 

engine speed) 

0.5 bar (7 psi) 

4.0 bar (59 psi) 

- Remove pressure gauge and 

reinstall pressure switch. 


Oil pressure switch 

to oil filter housing 

27 Nm (20 ft-lb) 

If testing shows low oil pressure, one or 

more of the following conditions may 

be indicated: 

Worn 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 before making tests. 

- Turn ignition switch on.



5 of 6 2/25/2009 9:52 PM 

Warning light on instrument panel 

must light up. 

- Remove connector from oil 

pressure switch. 

Warning light on instrument panel 

must go out. 

CAUTION! 

Running the engine with the oil 

pressure switch disconnected may 

set a fault code (DTC). 

Note: 

If the light does not go out, the wiring to 

the switch is most likely grounded 

somewhere between the switch terminal 

and the warning light. See Electrical 

Wiring Diagrams at rear of manual for 

electrical schematics. 

- If warning 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 in 

switch body and ground. With 

engine off, there should be 

continuity. With engine running, 

oil pressure should open switch 

and there should be no continuity.



6 of 6 2/25/2009 9:52 PM 

Replace a faulty switch. 

CAUTION! 


Keep in mind that low oil pressure 

may be preventing the switch from 

turning the light out. If the light 

remains on while the engine is 

running, check the oil pressure as 

described earlier. Do not drive the 

car until the problem is corrected. 

The engine may be severely 

damaged.



1 of 16 2/25/2009 9:53 PM 

Oil Pan 

119-2 

The oil pan removal procedure requires 

that the engine be supported from 

above and the front suspension 

subframe be unbolted and lowered 

from the chassis. 

Oil pan, removing and 

installing (rear wheel drive 

models) 

- Raise car and place securely on 

jack stands. 

WARNING! 






- 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 ATF cooler 

line brackets from oil pan and 

from transmission. 

Note:



2 of 16 2/25/2009 9:53 PM 

Place drain pan under lines to catch 

ATF drips. 

Remove oil dipstick guide tube: 

Detach mounting bolt (A) from left 

engine mounting bracket. 

Detach fuel lines and wiring 

harness brackets (B). 

Note: 

Disconnect oil separator hose (C) 

from base of guide tube and 

remove tube from oil pan. 

The guide tube is sealed in the block 

using an O-ring. Check that the O-ring 

comes 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 

power steering rack from suspension 

subframe.



3 of 16 2/25/2009 9:53 PM 

Remove power steering pump pulley. 

Remove two mounting bolts from the 

front (arrows) 

Note: 

Do not detach power steering fluid lines 

from pump. 

Remove third power steering mounting 

bolt (arrow) and remove pump from its 

mounting bracket. Use stiff wire to 

suspend pump from chassis. 

Detach electrical harness connector 

(arrow) at oil level sensor. 

Loosen top engine mount fasteners 

(arrow). 

Note:



4 of 16 2/25/2009 9:53 PM 

Right side is shown in photo. Left is 

similar. 

Loosen lower engine mount fasteners 

(arrows). 

Note: 


similar. 

If applicable, remove 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: 


similar. 

- Detach left and right stabilizer bar 

anchors from frame rails.



5 of 16 2/25/2009 9:53 PM 

Remove left control arm ball joint 

mounting nut (arrow) at front 

suspension subframe. 

Drive ball joint out from subframe 

using soft hammer. 

Push control arm aside. 

Repeat for left side. 

Support suspension subframe from 

below using appropriate jacking 

equipment. Remove subframe 

mounting bolts (arrows) and lower 

subframe as far as possible. 

Note: 


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



6 of 16 2/25/2009 9:53 PM 

material from mating surfaces and 

use a new gasket. 

Apply a small amount of 

non-hardening sealer (3-Bond 

1209® or equivalent) to oil pan 

gasket directly below joints 

(arrows) for end cover and front 

timing case cover. Apply a bead 3 

mm wide by 2 mm high. 

Tighten oil pan bolts to cylinder 

block evenly all around. 

Tighten transmission bellhousing 

bolts last. 


Oil drain plug to 

oil pan (M12) 

Oil pan to engine block 

25 Nm (18 ft-lb) 

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 

M8 Torx 

24 Nm (17 ft-lb) 

21 Nm (15 ft-lb) 



Replace self-locking nuts when 

reinstalling front suspension 

components. 

Match up key ways while installing 

steering column shaft. See 320 

Steering and Wheel Alignment for 

more specific procedures.



7 of 16 2/25/2009 9:53 PM 

Use new oil dipstick tube sealing 

O-ring. 

Fill engine with oil as described in 


Note: 

After adding engine oil, start and 

run engine. Raise engine speed to 

2,500 rpm until oil pressure 

warning lamp goes out (about 5 

seconds). 

BMW does not recommend a front end 

alignment following this procedure. 


Control arm ball 

joint to suspension 

subframe 

90 Nm (66 ft-lb) 

Front subframe to frame rails (M12, 

use new bolts) 


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) 

Steering column 

universal joint 

clamping screw 

(M8 bolt, use new 

bolt) 

22 Nm (16 ft-lb) 

22 Nm (16 ft-lb)



8 of 16 2/25/2009 9:53 PM 

Oil pan, removing and 

installing (all wheel drive 

models) 

- Raise car and place securely on 

jack stands. 

WARNING! 







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. 

- 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 catch 

ATF drips. 

Remove oil dipstick guide tube:



9 of 16 2/25/2009 9:53 PM 

Detach mounting bolt (A) from left 

engine mounting bracket. 

Detach fuel lines and wiring 

harness brackets (B). 

Note: 

Disconnect oil separator hose (C) 

from base of guide tube and 

remove tube from oil pan. 

The guide tube is sealed in the block 

using an O-ring. Check 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.



10 of 16 2/25/2009 9:53 PM 

Remove third power steering mounting 

bolt (arrow) and remove pump from its 

mounting bracket. Use stiff wire to 

suspend pump from chassis. 

Detach electrical harness connector at 

oil level sensor. 

- Remove lower engine mount 

fasteners. 

If applicable, remove front ride level 

sensor mounting bolt (arrow) and lay 

sensor aside. 

Working at rear right corner of front 

subframe, unhook heatshield from 

subframe (arrow). 

- Detach stabilizer bar anchors from 

frame rails.



11 of 16 2/25/2009 9:53 PM 

Remove control arm rear bracket and 

ball joint mounting bolts (arrows) from 

subframe. 

- Remove control arms and front 

drive axles as described in 310 

Front Suspension. 

- Remove front differential and right 

axle inner bearing pedestal as 

described in 311 Front Axle 

Final Drive. 

Support subframe while removing four 


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).



12 of 16 2/25/2009 9:53 PM 

Lower oil pan to remove. 

CAUTION! 

If the oil pan does not separate 

easily from the engine cylinder 

block, a few taps with a rubber 

mallet should break it free. Do not 

pry the oil pan loose. 

- When reinstalling oil pan: 

Thoroughly clean all old gasket 

material from mating surfaces and 

use a new gasket. 

Apply a small amount of 

non-hardening sealer (3-Bond 

1209® or equivalent) to oil pan 

gasket directly below joints 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. 


Oil drain plug to 

oil pan (M12) 


25 Nm (18 ft-lb) 

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) 


M8 Allen 

24 Nm (17 ft-lb)



13 of 16 2/25/2009 9:53 PM 


M8 Torx 

21 Nm (15 ft-lb) 

Reinstall front differential and right axle 

inner bearing pedestal. See 311 

Front Axle Final Drive. 

Fill differential to lower edge of fill 

plug. 


Fill or drain plug to 

front differential 

Front differential to 

oil pan (M10) 

65 Nm (48 ft-lb) 

45 Nm (33 ft-lb) 

- Reinstall front axles, control arms 

and 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. 


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, 

be sure that left engine mount locating



14 of 16 2/25/2009 9:53 PM 

tab (arrow) is seated correctly in 

subframe slot. 


Engine mount to subframe 

M10 self-locking 

nut 

45 Nm (33 ft-lb) 

Front of subframe to frame rail (M12 

bolt, always replace) 


10.9 grade 110 Nm (81 

ft-lb) 

12.9 grade 105 Nm (77 

ft-lb) 

Rear of subframe to mounting 

adapter 


replace) 

110 Nm (81 

ft-lb) 



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 


Note: 

After adding engine oil, start and 

run engine. Raise engine speed to 

2,500 rpm until oil pressure 

warning lamp goes out (about 5 

seconds).



15 of 16 2/25/2009 9:53 PM 

Be sure to align the front end after this 

procedure. 


Stabilizer bar to 

frame rail (M8 nut) 



clamping screw 

(M8 bolt, use new 

bolt)- 

22 Nm (16 ft-lb) 

22 Nm (16 ft-lb) 

All wheel drive oil 

pan, front 

differential and 

front subframe 

assembly 

1 - Front subframe 

1a 

1b 

- Right engine 

mounting point 

- 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)



16 of 16 2/25/2009 9:53 PM 


to 105 Nm (77 ft-lb) 

6 - Bolt M12 


tighten to 110 Nm 

(81 ft-lb) 

7 - Bolt M10 


tighten to 59 Nm (44 

ft-lb) 

8 - Bolt M10 



ft-lb) 

9 - Bolt M12 


ft-lb) 

10 - Front control 

arm with ball 

joint and rear 

mounting 

bracket 

11 - Front 

differential 

12 - Bolt M10 


ft-lb) 

13 - Left front axle 




1 of 4 2/25/2009 9:53 PM 

Component 

Replacement 

119-3 

Oil pressure warning switch 

The pressure warning switch is located 

under the intake manifold, in the rear of 

the oil filter housing. 

Note: 

Switch removal may require intake 

manifold removal. 


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:



2 of 4 2/25/2009 9:53 PM 

Oil pump removal requires lowering the 

front suspension subframe to remove 

the oil pan. 

- Drain oil as described in 020 

Maintenance. 

- Remove oil pan as described 

earlier. 

Remove oil pump sprocket mounting 

nut (left-hand thread) (arrow). Lift 

sprocket off together 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



3 of 4 2/25/2009 9:53 PM 

11 - Oil pick-up pipe 

12 - Bolt M6 -tighten to 10 Nm (89 

in-lb) 

- On engines with integrated oil 

pump and oil scraper: Remove oil 

pump with scraper. 

- On engines with separate oil 

pump and scraper: 

First remove mounting bolts and 

withdraw oil pump intake pipe. 

Note: 

Remove oil pump mounting bolts. 

Remove oil pump assembly. 

Note any spacers between 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. 



Align sprocket splines to oil pump 

shaft splines before tightening 

sprocket nut. 


Oil drain plug to oil 

25 Nm (18 ft-lb)



4 of 4 2/25/2009 9:53 PM 


pan (M12) 


M6, 8.8 grade 10 Nm (89 in-lb) 

M6, 10.9 grade 12 Nm (106 

in-lb) 

M8, 8.8 grade 22 Nm (16 ft-lb) 

Oil pump to engine 

block (M8) 

22 Nm (16 ft-lb) 

Oil pump sprocket to oil pump shaft 

M10x1 left-hand 

thread 

25 Nm (18 ft-lb) 


M8 Allen 

M8 Torx 

24 Nm (17 ft-lb) 

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 


4 - Sleeve 

5 - Circlip 


Ignition System 


1 of 11 2/25/2009 9:54 PM 

General 

120-1 

This repair group covers component 

replacement information for the ignition 

system. 

When diagnosing engine management 

problems, including on-board 

diagnostics (OBD II) fault code 

analysis, also refer to these repair 

groups: 

100 Engine–General 

130 Fuel Injection 

Electrical Wiring Diagrams at the 

rear of this manual 


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



2 of 11 2/25/2009 9:54 PM 

Primary voltage test harness BMW 12 7 

020 

Secondary voltage test harness BMW 

12 7 030 

Ignition coil test adapters BMW 12 7 

040 

Engine management 

BMW E46 engines use an advanced 

engine management system known as 

Digital Motor Electronics (DME). DME 

incorporates on-board diagnostics, fuel 

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.



3 of 11 2/25/2009 9:54 PM 

Additional information about DTCs and 

engine management system electronic 

system diagnosis is provided in OBD 

On Board Diagnostics at the rear of this 

manual. 

Table a. Engine management 

systems 

Year: 

Engine 

1999 - 2000: 

M52 TU B25 

M52 TU B28 

2001: 

M54 B25 

M54 B30 

DME system 



Ignition system 

All engines use a distributorless 

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 Diagrams for specific 

wiring information. 

WARNING!



4 of 11 2/25/2009 9:54 PM 

Do not touch or disconnect any 

cables from the coils while the 






terminals. Use extreme caution 

when working on a car with the 

ignition switched on or the 

engine running. 

Connect and disconnect the 

DME system wiring and test 

equipment leads only when the 

ignition is OFF. 

Before operating the starter 

without starting the engine (for 

example when making a 

compression test) always 

disable the ignition. 

Knock sensors (arrows) monitor the 

combustion chamber for enginedamaging 

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. 

Ignition timing is electronically mapped 

and not adjustable. The ECM uses 

engine load, engine speed, coolant 

temperature, knock detection and 

intake air temperature as the basic 

inputs for timing control. A three



5 of 11 2/25/2009 9:54 PM 

dimensional map similar to the one 

shown is digitally stored in the ECM. 

The initial ignition point is determined 

by the crankshaft speed sensor during 

cranking. Once the engine is running, 

timing is continually adjusted based on 

operating conditions. 

Basic troubleshooting 

principles 

Poor driveability may have a variety of 

causes. The fault may lie with the 

ignition system, the fuel system, parts 

of the emission control system, or a 

combination of the three. Because of 

these interrelated functions and their 

effects on each other, it is often difficult 

to know where to begin looking for 

problems. 

For this reason, effective 

troubleshooting should 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. Additional 

OBD II information, including a DTC 

lookup table can be found in the back 

of this manual under OBD On Board 

Diagnostics. 

Note: 




Service Engine Soon. 

An engine that starts and runs 

indicates that the ignition system is



6 of 11 2/25/2009 9:54 PM 

fundamentally working-delivering 

voltage to the spark plugs. A 

hard-starting or poor-running engine, 

however, may indicate a problem with 

how well the spark is delivered. Faulty 

or worn ignition components, such as 

old spark plugs, or an individual coil 

problem may be the cause. 

WARNING! 

Inefficient combustion (rich air/fuel 

mixture) can cause elevated 

hydrocarbon exhaust emissions and 

catalytic converter damage. For this 

reason, if a severe misfire is 

detected, the fuel injector will be 

turned off to the specific cylinder 

and the MIL illuminated. 

One 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 faulty coil. 

A normal oscilloscope pattern for a six 

cylinder engine. 

1 - Start of ignition voltage peak 

2 - Level of ignition voltage 

3 - Level of combustion voltage 

4 - Period of combustion 

5 - Combustion curve characteristics 

6 - Start of decay process



7 of 11 2/25/2009 9:54 PM 

7 - Termination oscillations 

Note: 

See Ignition coil assembly, testing 

and replacing as described later. 

Table b. Ignition trace diagnostics 

Parameter 

Spark plug 

electrode 

gap 

Ignition 

voltage 

low 

too small 

Ignition 

voltage 

high 

too big 

Spark plug 

electrode 

condition 

- worn/burnt 

Spark plug 

electrode 

temperature 

Engine 

compression 

too high 

too low 

too low 

too high 

Spark plug 

wire(s) 

Fuel air 

mixture 

- faulty 

- 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 fault 

codes. For a detailed list of fault codes 

see OBD On Board Diagnostics.



8 of 11 2/25/2009 9:54 PM 

Once engine misfire has been detected 

and the fault codes downloaded from 

the ECM, it is necessary to follow a 

diagnostic path to correct the problem. 

The ignition subset of the diagnostic 

path is shown in Table d. Ignition 

system problems 

Table c. Misfire fault codes 

P code 


fault 

code 

Fault code 

Possible cause(s) 

P0301 

P0302 

238 

239 

Misfire cylinder 1 

Misfire cylinder 2 

Ignition fault: Defective or incorrect spark plug(s) 

or connector(s); defective ignition coil(s) 

Mechanical fault: Crankshaft pulse wheel loose 

or damaged; damaged piston(s), valve(s) or 

P0303 240 Misfire cylinder 3 

camshaft(s); oil pressure low 

Catalyst fault: Excessive exhaust backpressure 

due to restricted catalyst 

P0304 241 Misfire cylinder 4 

Fuel supply fault: Contaminated fuel; fuel 

delivery fault (blocked filter, low fuel in tank, 

defective fuel pump); running loss system fault; 

P0305 242 Misfire cylinder 5 leaking or blocked fuel injector(s); fuel pressure 

regulator fault; evaporative system fault 

P0306 243 Misfire cylinder 6 ECM/sensor input fault: Implausible sensor 

signal; oxygen sensor(s) faulty; ECM faulty 

P1396 244 Crankshaft sensor 

adaptation at limit 

Misfire detection fault: Varying pulse wheel 

tolerances or loose pulse wheel 

Table d. Ignition system problems 

Component Condition Test Repair 

Spark plug 

Incorrect spark plug 

Electrode gap too 

small 

Electrode(s) missing 

Oil or fuel fouled 

spark plug 

Ceramic insulation 

cracked 

Inspect spark plugs. 

Verify correct spark 

plugs. 

Replace plugs if 

defective. 

Check crankcase 

ventilation and oil 

level.



9 of 11 2/25/2009 9:54 PM 

Component Condition Test Repair 

Secondary circuit 

Wet coil 

Corroded coil 

connections 

Secondary circuit 

Check for water leak. 

Check resistance 

values (see Table 

e). 

Ignition coil 

Primary or secondary 

circuit on or shorted 

Housing cracked, 

damaged 

Primary and 

secondary circuits 

(see Table e) 

Replace coil as 

necessary. 

Ignition coil harness 

connector 

Power supply, 

primary control circuit 

or ground (shunt 

signal) circuits 

impaired 

Primary ignition and 

terminal 4A feedback 

preset measurements 

Look for open, loose 

connector, corrosion, 

crossed or damaged 

connector 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! 










ignition switched on or the engine 

running.



10 of 11 2/25/2009 9:54 PM 

Connect and disconnect the DME 

system wiring and test equipment 

leads only when the ignition is 

OFF. 

Before operating the starter 

without starting the engine (for 

example when making a 

compression test) always disable 

the ignition. 

CAUTION! 





Do not attempt to disable the 

ignition by removing the 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. An 

LED test light should be used in 

place of an incandescent-type test 

lamp. 

In general, make test connections



11 of 11 2/25/2009 9:54 PM 


only as specified by BMW, as 

described in this manual, or as 

described by the instrument 

manufacturer.



1 of 10 2/25/2009 9:54 PM 

Ignition System Service 

120-2 

Ignition firing order 

Each ignition coil is mounted above the 

corresponding spark plug. Cylinder 1 is 

at the front of the engine. 

Ignition firing order 

M52 TU/M54 

engine 

1 - 5 - 3 - 6 - 2 - 

4 

Disabling ignition system 

The ignition system operates in a lethal 

voltage range and should therefore be 

disabled any time engine service or 

repair work is being done that requires 

the ignition to 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 Locations. 

Checking for spark 

CAUTION! 

If a spark test is done incorrectly, 

damage to the Engine Control Module



2 of 10 2/25/2009 9:54 PM 

(ECM) or the ignition coils may result. 

Note: 

Spark plug replacement is covered in 


Checking for spark is difficult on 

engines with distributorless ignition 

systems. 

Try removing the spark plugs and 

inspecting for differences between 

them. A poor-firing plug may be wet 

with fuel and/or black and sooty, but not 

always. 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 (A) and 

remove wires.



3 of 10 2/25/2009 9:54 PM 



- Remove plastic engine cover from 

top of valve cover by prying off bolt 

covers and removing cover 

mounting bolts. 

Disconnect harness connector from coil. 

Connect multimeter between terminal 

15 (+) in connector and ground. 

- Turn ignition on and check for 

battery voltage. 

If battery voltage is not present, 

check wire between terminal 15 

and ignition switch. 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 coil ground straps 

before coil removal; reinstall in the 

same location. 

- Use a multimeter to test:



4 of 10 2/25/2009 9:54 PM 

Coil primary resistance at coil 

terminals 

Spark plug connector resistance 

Compare results to specification in 

Table e. 

Table e. Ignition coil resistance 

Component Terminals Resistance 

Coil primary 

Coil 

secondary 

Spark plug 

connector 

1 (-) and 

15 (+) 

approx. 0.8 

N.A. 

Bosch 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. 


(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.



5 of 10 2/25/2009 9:54 PM 

Note: 

Compare scope pattern with 

diagrams in Basic 

troubleshooting principles. 

When replacing ignition coils, ensure 

that the replacements are from the same 

manufacturer with the same part/code 

numbers. If individual coils with the 

correct specifications are not available, 

all coils should be replaced. 

Crankshaft speed sensor, 

replacing 

The crankshaft speed sensor is 

mounted in the left rear side of the 

cylinder block below the starter. The 

sensor reads a toothed pulse wheel 

(arrow) 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 the crankshaft speed sensor pulse 

wheel is damaged, the engine will have 

to be disassembled down to the 

crankshaft to replace the wheel. 

- Make certain ignition has been 

turned off.



6 of 10 2/25/2009 9:54 PM 

- 

Raise car and support in a safe 

manner. 

WARNING! 






- Remove under-engine splash 

guards. 

Working just underneath starter: 

Cut off 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. 



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



7 of 10 2/25/2009 9:54 PM 

ECM fault memory. 

Camshaft position sensors 

The camshaft position sensors are used 

by the engine management system for 

VANOS control, sequential fuel injection 

and knock control. 

Intake camshaft position 

sensor, replacing 


turned off. 

- Remove housing for the microfilter 

for interior ventilation as shown 

earlier. 

- Remove plastic cover from above 

fuel injectors by prying off bolt 

covers and removing cover 





(B). 


(A). 


screws (D). 

Loosen hose clamp at intake boot 

and detach air duct connections 

(C).



8 of 10 2/25/2009 9:54 PM 

Disconnect cold air duct tube (E). 

- Disconnect harness connector 

from VANOS solenoid and unscrew 

solenoid from VANOS control unit. 

Be prepared with shop rags to 

catch oil released from VANOS 

unit. 

Remove camshaft sensor (arrow) from 

left front of cylinder head, next to top of 

oil filter housing. 

- Disconnect camshaft sensor 

harness from under intake 

manifold. Prior to removal, 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. 


orientation. 

Use scan tool to read out and clear 



Intake camshaft 

sensor to cylinder 

head 

VANOS solenoid to 

VANOS control unit 

5 Nm (3.5 ft-lb) 

30 Nm (22 ft-lb) 

Exhaust camshaft position



9 of 10 2/25/2009 9:54 PM 



turned off. 

Working at front of engine on exhaust 

(right) side, detach exhaust camshaft 

position sensor electrical harness 

connector (arrow). 

- Remove camshaft sensor from 

right front of cylinder head. 


Use a new O-ring when installing 

sensor. 


orientation. 

Use scan tool to read out and clear 




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 



Disconnect knock sensor electrical 

harness connector (arrow) on left side 

of engine cylinder block.



10 of 10 2/25/2009 9:54 PM 

Remove knock sensor mounting 

bolts (A) on side of cylinder block. 

Remove sensors. 

CAUTION! 

Note the installed angle of the knock 

sensor on the block before removing 

it. Reinstall the sensor in the same 

position. Be sure to use a torque 

wrench when tightening the sensor 

mounting bolt. 

Clean knock sensor contact surface on 

engine block and sensor (arrows) 

before installing knock sensor. 


Knock sensor to 

cylinder block 

20 Nm (15 ft. 

lbs.) 


- Use scan tool to read out and clear 

ECM fault memory.

Fuel Injection 


1 of 8 2/25/2009 9:55 PM 

General 

130-1 

This repair group covers service and 

repair for the Siemens engine 

management systems used on the E46 

models covered by this manual. 

Additional engine management 

information may also be found in the 

following repair groups: 


120 Ignition System 

160 Fuel Tank and Fuel Pump 

Note: 

Electrical Wiring Diagrams 

Fuel pressure testing and fuel pump 

repair information is covered in 160 

Fuel Tank and Fuel Pump. 

Table a. Engine management 

systems 

Model Year: 

Engine code 

1999 - 2000: 

M52 TU B25 

M52 TU B28 

2001: 

M54 B25 

M54 B30 

DME system 



The Siemens systems are 

sophisticated self-diagnosing OBD II 

systems. These systems continuously 

monitor components and record and 

store valuable diagnostic information. 

When faults arise, or if the MIL



2 of 8 2/25/2009 9:55 PM 

(malfunction indicator lamp) in the 

instrument cluster is illuminated, begin 

troubleshooting by hooking up a 

BMW-compatible scan tool. The rich 

diagnostic capabilities of these systems 

have the potential to save hours of 

diagnostic time, incorrect component 

replacement and possible damage to 

system components. See OBD On 

Board Diagnostics 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 DTC scan tool BMW 

DIS/MoDiC



3 of 8 2/25/2009 9:55 PM 

Fuel line plugs BMW 13 5 281 / 13 5 

282 

Aftermarket DTC scan tool Baum 

CS2000 (Source: Baum Tools 

Unlimited) 

Fuel line clamp BMW 13 3 010 

Fuel rail to pressure gauge fitting BMW 

13 5 220 

Note: 






BMW-specific tools. The `CS2000' 


`Retriever' from Assenmacher 


from Snap-on are three examples



4 of 8 2/25/2009 9:55 PM 


In addition to the BMW 

professional line of scan tools, 

there are many inexpensive 


programs and handheld units 

available. Although these tools 

have limited capabilities as 

compared to the dedicated tools, 

they are powerful diagnostic tools. 

These tools read live data 

streams, freeze frame information 

for DTCs (diagnostic trouble 

codes) and impending DTCs, as 

well as a host of other valuable 

diagnostic data. 

For the DIY 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. 

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 

speed and many other engine 

operating parameters are measured 

electronically and the information is 

supplied to the engine control module 

(ECM). 

Based on input information, the ECM 

controls the ignition coils, fuel injectors,



5 of 8 2/25/2009 9:55 PM 

motor driven throttle valve, double 

VANOS system, radiator cooling fan, 

electrically heated thermostat, as well 

as other outputs. 

The illustration on the following page 

shows the MS 42.0 ECM inputs and 

outputs. The MS 43.0 system is similar 

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



6 of 8 2/25/2009 9:55 PM 


For personal safety, as well as the 

protection of sensitive electronic 

components, adhere to the warnings and 

cautions on the following pages. 

WARNING! 

Gasoline is highly flammable and 

its vapors are explosive. Do not 

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, as prolonged contact 

with fuel can cause illnesses and 

skin disorders. 






ignition switched on or the engine



7 of 8 2/25/2009 9:55 PM 

running. 





Connect and disconnect the DME 

system wiring and test equipment 

leads only when the ignition is 

switched off. 

Renew fuel system hoses, clamps 

and O-rings any time they are 

removed. 

Before making any electrical tests 

that require the engine to be 

cranked using the starter, disable 

the ignition system as described 

in 120 Ignition System. 

CAUTION! 





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 

equipment maker. 

Only use a digital multimeter for 

electrical tests. 

Only use an LED test light for



8 of 8 2/25/2009 9:55 PM 

quick tests. 



memory. Check for fault codes 

prior to disconnecting the battery 

cables. 

Wait at least 40 seconds after 

turning off the ignition before 

removing the engine control 

module (ECM) connector. If the 

connector is removed before this 

time, residual power in the system 

relay may damage 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.



1 of 6 2/25/2009 9:55 PM 

Electrical Checks and 

Component Testing 

130-2 

Troubleshooting and fault diagnosis on 

OBD II cars is best performed using an 

electronic scan tool. However, it may 

be necessary to perform basic tests of 

the engine management main 

components, fuel system or wiring. 

CAUTION! 

The tests in this section may set 

fault codes (DTCs) in the ECM 

and illuminate the MIL. After all 

testing tests is completed, 

access and clear DTC fault 

memory using a BMW 

compatible scan tool. See 


the back of this manual. 


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 engine management 

components and subsystems. If this 

relay is faulty, the engine will not start. 

With ignition off, remove main relay 

(arrow) in electronics box (E-box) at



2 of 6 2/25/2009 9:55 PM 

left rear of engine compartment. 

Check for voltage at terminal 6 of main 

relay socket (30- red wire). 

If battery voltage is present 

continue testing. 

If battery voltage is not present, 

check large red wire in relay 

socket. See Electrical Wiring 

Diagrams. 

- Reinstall relay and turn ignition 

on. Gain access to underside 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.



3 of 6 2/25/2009 9:55 PM 

If battery voltage is not present 

and all earlier tests are OK, relay 

is faulty and should be replaced. 

Fuel pump relay, testing 

The ECM energizes the fuel pump 

relay by providing the coil side of the 

relay with ground. During starting, the 

fuel pump runs as long as the ignition 

switch is in the start position and 

continues to run once the engine 

starts. If the relay is faulty the fuel 

pump will not run. 

Fuel pump relay (arrow) is located 

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 START position. 

- With ignition in START position, 

use digital multimeter to check for 

ground at terminal 4 (black/violet 

wire). 

Note:



4 of 6 2/25/2009 9:55 PM 

The ground at terminal 4 is switched by 

the ECM. The ECM harness must be 

connected to check the switched ground 

connection. 

- If no faults are found up to this 

point, turn ignition key off. Using a 

fused (14 gauge) jumper wire, 

connect relay connector terminal 6 

to terminal 2. The fuel pump 

should run. 

If pump runs and all other tests 

are as specified, fuel pump relay 

is probably faulty. 

If pump does not run, test fuel 

pump operation as described in 

160 Fuel Tank and Fuel Pump. 

CAUTION! 

The jumper wire should be 1.5 mm 2 

(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 directly influences fuel 

delivery. Procedures for measuring the 

fuel pressure and fuel volume are 

given in 160 Fuel Tank and Fuel 

Pump. 

Relieving fuel pressure



5 of 6 2/25/2009 9:55 PM 

The fuel system retains fuel pressure in 

the system when the engine is turned 

off. To prevent fuel from spraying on a 

hot engine, system fuel pressure 

should be relieved before 

disconnecting fuel lines. One method 

is to tightly wrap a shop towel around a 

fuel line fitting and loosen or 

disconnect the fitting. 

Cleanliness is essential when working 

with fuel circuit components. 

Thoroughly clean the unions before 

disconnecting fuel lines. 

WARNING! 

Gasoline 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 

housing. 


microfilter. 


move wiring out of way. 


lower microfilter housing.



6 of 6 2/25/2009 9:55 PM 

Remove fuel rail cover by prying off nut 

covers (arrows) and removing nuts. 

Unscrew schræder valve cap (arrow) 

from fuel rail. Unscrew fuel tank cap to 

release pressure to vent tank. 

- Using a brief burst of compressed 

air (maximum of 3 bar or 43.5 psi) 

blow fuel back through return line 

into fuel tank. 

WARNING! 

Fuel in fuel line is under 


-75 psi) and may be expelled 











Always unscrew fuel tank cap to 

release pressure in the tank 

before working on the tank or 

lines.



1 of 19 2/25/2009 9:55 PM 

Component 

Replacement 

130-3 

After diagnosing and replacing a faulty 

engine management component, be 

sure to use a BMW-compatible scan 

tool to check and clear the fault 

memory in the ECM. Diagnostic trouble 

codes are given in OBD On Board 

Diagnostics at the back of this book. 

Fuel rail and injectors, 

removing and installing 


cable. 

CAUTION! 








microfilter. 


remove wires. 



Remove fuel rail cover by prying off nut 

covers (arrows) and removing nuts.



2 of 19 2/25/2009 9:55 PM 

Working above engine, disconnect 

electrical harness connectors: 

VANOS control unit harness 

connector (A) 

Connectors for oxygen sensors 

(B) 

Connector for intake air 

temperature sensor (C) 

CAUTION! 

Mark oxygen sensor harness 

connectors in order to avoid 

reversing them during installation. 

Incorrect reconnection can cause 

serious engine damage. 

Disconnect fuel injector electrical 





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 through return line 

into fuel tank.



3 of 19 2/25/2009 9:55 PM 

WARNING! 

Do not smoke or work near 

heaters or other fire hazards. 

Keep a fire extinguisher handy. 

Before disconnecting fuel 

hoses, wrap a cloth around fuel 

hoses to absorb any leaking 

fuel. Catch and dispose of 

escaped fuel. Plug all open fuel 

lines. 

Always unscrew the fuel tank 

cap to release pressure in the 

tank before working on the tank 

or lines. 


manner. 

CAUTION! 







guard. 



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 fuel rail. Only 

a single fuel line leads to the engine 

compartment. 

Disconnect fuel hose(s) from fuel 

line(s) (arrows) using special fuel line



4 of 19 2/25/2009 9:55 PM 


Seal off fuel line(s) with BMW special 

tools 13 5 281/13 5 282. 

CAUTION! 

Fuel may be expelled under 

pressure. Do not smoke or work near 

heaters or other fire hazards. Keep a 

fire extinguisher handy. Before 

disconnecting fuel hoses, wrap a 

cloth around fuel hoses to absorb 

any leaking fuel. Plug all open fuel 

lines. 


(arrows). 

Carefully pry fuel rail off manifold. 



Guide fuel line(s) out of rear of 



Remove individual injectors: 

Pry retaining clip from injector (1). 

Pull injector from rail (2). 


Fit new O-rings when installing 

injectors. For ease of installation, 

lightly lubricate all fuel system 

O-rings with assembly lubricant. 

Check that injector electrical 

connections are correctly fitted 

and that injectors are fully seated 

prior to installing fuel rail mounting



5 of 19 2/25/2009 9:55 PM 

bolts. 

Replace any wire ties removed 

during removal procedure. 

CAUTION! 

Replace any flexible fuel lines which 

were pinched shut during testing. 

Fuel pressure regulator, 

replacing 

E46 fuel pressure regulator 

location 

DME MS 42.0 

DME MS 43.0 

under left side of 

car, in 3/2-way 

valve 

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 


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.



6 of 19 2/25/2009 9:55 PM 

- 

Remove locking spring clip 

retaining fuel pressure regulator. 

- Wrap a shop rag around 

regulator, then remove regulator 

from 3/2 way valve by pulling 

straight down. 


Replace sealing O-rings. 

Mass air flow (MAF) sensor, 


CAUTION! 

Be sure the ignition is OFF before 

replacing DME system 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. 


Note: 

Replace sealing O-ring between 

sensor and air filter housing.



7 of 19 2/25/2009 9:55 PM 

No adjustment to air flow sensor is 

possible. 

Engine coolant temperature 

(ECT) sensor, replacing 

The engine coolant temperature (ECT) 

sensor is located toward the rear of the 

cylinder head below intake runner no. 

6. Intake manifold removal is required 

to access the ECT sensor. 

CAUTION! 

Be sure the ignition is OFF before 

replacing DME system components. 

- Remove intake manifold as 

described in 110 Engine 


WARNING! 




Working at rear of cylinder head, 

disconnect harness connector (arrow) 

from ECT sensor. 

- Remove sensor. Catch any 

coolant that leaks out with shop 

rags. 


Use a new copper sealing washer 

when installing new sensor. 

Replace lost coolant. 

Tightening torque



8 of 19 2/25/2009 9:55 PM 


ECT sensor to 

cylinder head 

13 Nm (10 ft-lb) 

Intake air temperature (IAT) 


The intake air temperature (IAT) sensor 

is located at the top center of the intake 

manifold. The intake air temperature 

sensor functions to adapt or fine tune 

the fuel mixture and engine timing 

based on varying intake air 

temperatures. 




microfilter. 


remove wires. 



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.



9 of 19 2/25/2009 9:55 PM 

- 

Depress locking clip on side of 

temperature sensor and pull 

straight out of intake manifold. 


Use a new sealing O-ring at base 

of sensor and lubricate with 

assembly lubricant for ease of 

installation. 

Throttle assembly, removing 


Some throttle assembly faults will reset 

the engine control module (ECM) 

adaptation values. BMW's diagnostic 

tool (DIS or MoDiC) or aftermarket 

equivalent tool is necessary to reset 

ECM adaptations after throttle 

assembly replacement. 

CAUTION! 

After replacement of the throttle 

valve assembly, and/or on MS 43.0 

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! 





Remove complete air filter housing:



10 of 19 2/25/2009 9:55 PM 


boot (A). 



(B). 


(C). 


screws (D). 

Note: 


(E) and lift complete air filter 










3 - Y-duct 

4 - Air duct 






On MS 42.0 vehicles: Pull throttle cable



11 of 19 2/25/2009 9:55 PM 







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)



12 of 19 2/25/2009 9:55 PM 


connectors (arrows) at oil pressure 

sender and oil temperature sender at 

base of oil filter housing. 


Disconnect wiring harness 

brackets from tube (A). 

Unclip fuel lines from tube (B). 

Remove lower guide tube 

mounting 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. 


Replace sealing ring between 

throttle assembly and intake 

manifold.



13 of 19 2/25/2009 9:55 PM 

Reattach throttle assembly 

harness connector with care. 

Arrow on fully tightened connector 

must line up with corresponding 

arrow on throttle assembly 

housing. 

On DME MS 42.0: Reattach 

throttle cable and adjust as 

described later. 

Use BMW scan tool to reset ECM 

adaptation values. 

Throttle cable, adjusting (MS 

42.0) 

Models with DME MS 42.0 are 

equipped with a throttle cable. Cable 

adjustment should be adjusted any 

time it is disconnected or replaced. 

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 by turning knurled adjustor 

(arrow) on end of throttle cable 

sheath at throttle housing. 

Throttle cable clearance



14 of 19 2/25/2009 9:55 PM 

Throttle cable clearance 

Max. play at 

throttle plate lever 

3 mm (0.125 in.) 

- Full throttle adjustment (manual 

transmission): 

With ignition key on press pedal 

fully to stop. Check throttle angle 

using scan tool. Adjust pedal stop 

if necessary. 

Throttle angle specifications 

Manual 

transmisssion: 

Full throttle 80° - 84° 

- Full throttle adjustment (automatic 

transmission): 

With 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. 


Automatic 

transmission:



15 of 19 2/25/2009 9:55 PM 


Kickdown stop 

contacted 76° - 80° 

Kickdown pressure 

point range 84° - 88° 

Full-load downshift 100% 

Idle speed control valve, 

replacing 

The idle speed control valve is 

mounted under the intake manifold 

adjacent to the dipstick tube bracket. 

The valve can be removed with the 

manifold in place, although the job is 

easier if the manifold is first removed. 

Intake manifold removal is described in 

113 Cylinder Head Removal and 

Installation. 


cable in trunk. 

CAUTION! 







boot (A). 



(B). 


(C).



16 of 19 2/25/2009 9:55 PM 


screws (D). 

Note: 


(E) and lift complete air filter 





remains attached to intake duct. 





3 - Y-duct 

4 - Air duct 






DME MS 42.0: Pull throttle cable 

upwards out of rubber retainer (A) but 

leave attached to throttle actuator (B).



17 of 19 2/25/2009 9:55 PM 

Working at side of intake manifold, 

disconnect electrical harness 

connectors: 

Idle control valve (A) 

Intake manifold resonance valve 

(B) 

- Disconnect bypass hose from idle 

control valve. 

- Remove idle control valve: 

Remove idle control valve bracket 

mounting fasteners. 

Slide control valve with bracket out 

from between intake manifold and 

throttle assembly. 

Pull control valve from rubber 

retainer. 


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), 

removing and installing



18 of 19 2/25/2009 9:55 PM 

Note: 

Replacement ECMs must be coded with 

application information (i.e. engine 

code, transmission type, etc.) prior to 

installation. Consult an authorized 

BMW dealer before replacing the ECM. 

Alternatively, coded ECMs may be 

available at an additional cost. 


cable. Wait at least three minutes. 

CAUTION! 





- 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. 

- Remove ECM from retaining 

brackets and pull from its holder.



19 of 19 2/25/2009 9:55 PM 

- 

Installation is reverse of removal. 




1 of 9 2/25/2009 9:56 PM 

ECM Pin Assignments 

130-4 

ECM pin assignments are given in 

Table b. ECM pin assignment-DME 

MS 42.0 and MS 43.0. This information 

may be helpful when diagnosing faults 

to or from the ECM. If all inputs and 

wiring are OK but operational problems 

still exist, the ECM itself may be faulty. 

Generally, absence of voltage or 

continuity means there is a wiring or 

connector problem. Test results with 

incorrect values do not necessarily 

mean that a component is faulty. 

Check for loose, broken or corroded 

connections and wiring before 

replacing components. If the results 

are still incorrect, check the component 

itself. 

For engine management system 

electrical schematics, see Electrical 


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 disconnect 

the control module connector 

and meter probes with the 

ignition off. 

When making checks at the ECM itself, 

a breakout box should be used to allow 

tests to be made with the connector 

attached to the ECM. This also 

prevents damage to the small terminals



2 of 9 2/25/2009 9:56 PM 

Table b. ECM pin assignment-DME MS 42.0 and MS 43.0 

in the connector. As an alternative, the 

harness connector housing can be 

separated so that electrical checks can 

be made from the back of the 

connector. 

Connector X60001 9-pin black 

Pin Signal Component/function Notes 

1 Output Terminal 15 Unloader relay terminal 15 

2 not used 

3 not used 

4 Ground Ground Ground point 

5 Ground Ground Ground connector 


7 Input Terminal 30 (Fuse 80 

amp) 

B+ Terminal 

8 Input Voltage supply (Fuse 2) Fuse carrier, engine electronics 

9 Input Voltage supply Fuse carrier, engine electronics 



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 used 

6 Input/output Transmit diagnosis line 

(TXD) data link signal 

7 Input Heater, post-catalyst 


Transmission control module 

Heated oxygen sensor 1 

behind catalytic converter 

8 not used



3 of 9 2/25/2009 9:56 PM 



9 not used 

10 not used 

11 not used 

12 Input Signal, 3/2-way valve, 

running losses (MS 

42.0) 

13 Input Heater, precatalyst 


14 Input Signal, precatalyst 


15 Input Signal, precatalyst 


16 Input Signal, post-catalyst 


3/2 way valve, running losses 

(MS 42.0) 









17 not used 

18 Input Signal, post-catalyst 


19 Input Heater, post catalyst 


20 Ground Ground, precatalyst 


21 Ground Ground, precatalyst 


22 Ground Ground, post-catalyst 


23 Input DME main relay signal 

activation 

24 Ground Ground, post-catalyst 












DME main relay 





1 Input Signal, mass air flow Hot film mass air flow sensor



4 of 9 2/25/2009 9:56 PM 



sensor 

2 Input Signal, exhaust 

camshaft sensor 1 

Camshaft position sensor II 

3 Input Signal, suction jet pump 

valve (2.8 L, 3.0 L) 

4 Output Throttle valve supply 

(MS 42.0) 

5 Input Signal, intake camshaft 


Suction jet pump valve 

Throttle valve (MS 42.0) 

Camshaft position sensor I 

6 not used 

7 Output Throttle valve supply Throttle valve 

8 Input Signal, crankshaft 


9 Input Signal, pedal position 

sensor 2 (MS 42.0) 

10 Input Signal, throttle position 


Crankshaft position sensor 


Throttle valve 

11 not used 

12 Input Feedback signal, 

engine start 

13 Input Signal, battery charge 

indicator lamp 

14 Ground Ground, throttle position 

sensor (MS 42.0) 

15 Ground Ground, exhaust 


16 Input Signal, pedal position 

sensor 1 (MS 42.0) 

17 Ground Ground, mass air flow 

sensor 

18 Ground Ground, intake 


Starter 

Generator (Alternator) 


Camshaft position sensor II 


Hot film mass air flow sensor 

Camshaft position sensor I



5 of 9 2/25/2009 9:56 PM 



19 Input Signal, throttle 


20 Ground Ground, throttle position 

sensor 

21 Ground Ground, crankshaft 


22 Output Signal, intake air 

temperature 

23 Ground Ground, intake air 

temperature sensor 

24 Output Signal, coolant 


25 Ground Ground, coolant 




Crankshaft position sensor 

Intake air temperature sensor 

Intake air temperature sensor 

Coolant temperature sensor 

Coolant temperature sensor 

26 Input Signal, oil pressure Oil pressure switch 

27 Output Signal, engine oil 

temperature 

28 Ground Ground, engine oil 


Oil temperature sensor 

Oil temperature sensor 

29 Output Signal, knock sensor Knock sensor 




33 Input Signal, cylinder 1 fuel 

injector 


injector 


injector 


injector 


injector 

Cylinder 1 fuel injector 




Cylinder 5 fuel injector



6 of 9 2/25/2009 9:56 PM 




injector 


39 Input Signal, oil level sensor Oil level sensor 

40 Input Signal, VANOS inlet 

valve 

41 Input Signal, VANOS outlet 

valve 

42 Input Signal, evaporative 

emissions valve 

43 Input Signal, throttle valve 

drive 

44 Input Signal, throttle valve 

drive 

45 Input Signal, engine coolant 

thermostat 

46 Input Signal, close idle speed 

control valve 

47 Input Signal, open idle speed 

control valve 

48 Ground Signal shield, knock 

sensor 

49 Input Signal, resonance valve 

intake system 

VANOS inlet valve 

VANOS outlet valve 

Evaporative emissions valve 



Engine coolant thermostat 

(map controlled) 

Idle speed control valve 

Idle speed control valve 

Shield, knock sensor 

Resonance valve intake system 

50 not used 

51 not used 

52 Input Signal, secondary air 

injection pump valve 

Secondary air injection valve 



1 Input Signal, battery charge 

indicator lamp 

Instrument cluster control unit



7 of 9 2/25/2009 9:56 PM 



2 Input Feedback signal, 

engine start 

3 Input Signal, secondary air 


Instrument cluster control 

module 

Secondary air injection pump 

relay 

4 Input Signal, electric fan Auxiliary fan motor 

5 not used 

6 not used 

7 Pedal position sensor 

(PWG) (MS 43.0) 

8 Signal, pedal position 

sensor (PWG) (MS 

43.0) 


(PWG) (MS 43.0) 

10 Input Signal, fuel pump relay 

1 

11 Input Signal, oil pressure 

switch 


(PWG) (MS 43.0) 

13 Signal, pedal position 

sensor (PWG) (MS 

43.0) 


(PWG) (MS 43.0) 

Pedal position sensor (PWG) 

(MS 43.0) 


(MS 43.0) 


(MS 43.0) 

Fuel pump relay 1 

Instrument cluster control 

module 


(MS 43.0) 


(MS 43.0) 


(MS 43.0) 

15 not used 

16 not used 

17 Input Speed signal (MS 42.0 

up to 6-00)(MS 42.0 

from 6-00 and MS 43.0) 

Data link connector OBDII 16 

pin connector) 

18 not used 

19 not used



8 of 9 2/25/2009 9:56 PM 



20 Output Diagnostic module tank 

leak (DMTL) detection 

(MS 43.0) 

Leak detection (DMTL) (MS 

43.0) 

21 Input Signal, oil level sensor Instrument cluster control 

module 

22 Input Signal, processed 

wheel speed, right rear 

23 Output Signal, clutch pedal 

position switch 

24 Input Signal, brake light 

switch 

ABS/ASC module, ABS/DSC 

module 

Clutch pedal position switch 

Light switching center control 

unit 

25 not used 

26 Input Terminal 15 Fuse F29 

27 Output Voltage supply, 

multifunction steering 

wheel 

28 Input Signal, brake light 

switch 

29 Input Signal, relay, A/C 

compressor 

30 Signal, leakage 

diagnosis pump (MS 

42.0)Signal diagnostic 

module (MS43.0) 

Volute spring 

Brake light switch 

A/C compressor relay 

Leakage diagnosis pumpLeak 

detection (MS 43.0) 

31 not used 

32 Input/output Transmit diagnosis line 

(TXD) data link signal 

33 Input Electronic vehicle 

immobilization 

34 Signal, leakage 

diagnosis pump (LDP) 

(MS 42.0) 

Data link connector (MS 

42.0)OBD II connector (MS 

43.0) 

Electronic immobilizer control 

module 

Leakage diagnosis pump (LDP) 

(MS 42.0) 

35 not used 

36 Input/output CAN bus signal, high Connector, CAN bus



9 of 9 2/25/2009 9:56 PM 



37 Input/output CAN bus signal, low Connector, CAN bus 

38 Ground Ground, coolant outlet 


39 Output Signal, coolant outlet 

temperature 

Temperature sensor 

Temperature sensor 

40 not used 



1 Input Signal, ignition coil 3 Ignition coil 3 



4 not used 









1 of 6 2/25/2009 9:56 PM 

General 

170-1 

This section covers component repair 

information for the engine cooling 

system. 

The E46 cooling system uses a 

centrifugal-type belt-driven coolant 

pump, an electric primary cooling fan, 

and an electrically heated thermostat. 

The cooling system is unique in that 

the cooling fan and the thermostat 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



2 of 6 2/25/2009 9:56 PM 

Expansion tank cap test adapter BMW 

17 0 007 

Cooling system (DME MS 42.0)



3 of 6 2/25/2009 9:56 PM 

Coolant pump 

A centrifugal-type coolant pump is 

mounted to the front of the engine. The 

belt-driven pump circulates coolant 

through the system whenever the engine 

is running. 

Thermostat 

An electrically heated thermostat 

regulates the engine coolant 

temperature and is controlled by the 

DME control module. The heated 

thermostat allows the engine to be 

operated at higher temperatures at idle 

and at part throttle. Having the ability to 

control the engine coolant temperature 

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 

heat exchanger (ATF cooler). 

Cooling fan (primary) 

The are two cooling fan configurations 

used on the cars covered by this 

manual, depending on transmission



4 of 6 2/25/2009 9:56 PM 

application. 

On cars with automatic transmissions, 

the main fan is electric and mounted on 

the bumper side of the radiator. The fan 

is controlled by the DME control module 

via the output final stage. Additionally a 

belt-driven fan via a viscous fluid 

coupling (clutch) is attached to the front 

of the coolant pump. The fan clutch 

controls the speed of the fan based on 

engine compartment temperature. 

On cars with manual transmissions, a 

single multi-speed electric cooling fan is 

used. The fan is mounted on the engine 

side of the radiator and controlled by the 

DME control module via the output 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 (calculated pressure) 

When the vehicle is first started, The 

ECM activates the electric fan briefly at 

20% of its maximum speed, then 

switches off. This is for diagnostic 

monitoring. The voltage generated by 

the fan when it slows down (acting as a 

generator) must match the stored `rpm'



5 of 6 2/25/2009 9:56 PM 

values in the fan power output stage to 

confirm that the fan is operating 

correctly. 

Note: 

If the ECM stored a cooling fan 

fault, check that the fan is not 

seized and that is spins freely. 

When A/C is switched ON, the 

electric fan is not immediately 

turned on. 

After the engine is switched OFF, 

the fan may continue to run at 

varying speeds for up to 10 minutes, 

based on calculated catalyst 

temperature. 


The following 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 suddenly. Use heavy gloves 

and wear eye and face protection 

to guard against scalding. 

Use extreme care when draining



6 of 6 2/25/2009 9:56 PM 

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 

coolant is ingested by an animal. 

CAUTION! 

Avoid adding cold water to the 

coolant while the engine is hot or 

overheated. If it is necessary to 

add coolant to a hot system, do 

so only with the engine running 

and coolant pump turning. 

To avoid excess silicate gel 

precipitation in the cooling 

system and loss of cooling 

capacity, use BMW coolant or 

equivalent low silicate antifreeze. 

If oil enters the cooling system, 

the radiator, expansion tank and 

heating circuit must be flushed 

with cleaning agent. 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. 






viii.



1 of 5 2/25/2009 9:57 PM 


170-2 

Begin the diagnosis of cooling system 

problems with a thorough visual 

inspection. If no visual faults are found, 

it is recommend that the DME system 

be checked for stored diagnostic fault 

codes (DTCs) using BMW scan tools 

DIS (Diagnostic Information System) or 

MoDiC (Mobile Diagnostic Computer) or 

an aftermarket equivalent. 

Common cooling system faults can be 

grouped into one of four categories: 

Cooling system leaks 

Poor coolant circulation 

Radiator cooling 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, from 

the engine side out. 

To check coolant pump: 

Lever tensioner clockwise using 

wrench on hex (large arrow) and 

slip belt off pulley. 

Firmly grasp opposite sides of



2 of 5 2/25/2009 9:57 PM 

pulley and check for play in all 

directions. 

Note: 

Spin pulley and check that shaft 

runs smoothly without play. 

The coolant provides lubrication for the 

pump shaft, so an occasional drop of 

coolant leaking from the pump is 

acceptable. If coolant drips steadily 

from the vent hole, the pump should be 

replaced. 

The cooling system becomes 

pressurized at normal operating 

temperature, which raises the boiling 

point of the coolant. Leaks may prevent 

the system from becoming pressurized, 

allowing 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 belt. 

Failed thermostat or coolant pump 

impeller. Some pumps may be 

fitted with plastic impellers. 

Clogged/plugged radiator or 

coolant passages. 

Cooling system pressure test



3 of 5 2/25/2009 9:57 PM 

A cooling system pressure test is used 

to check for internal leaks. Some of the 

common sources of internal leaks are a 

faulty cylinder head gasket, a cracked 

cylinder head, or a cracked cylinder 

block. 

To do a cooling system pressure test, a 

special pressure tester is needed. 

WARNING! 

At normal operating temperature the 

cooling system is pressurized. Allow 

the system to cool before opening. 

Release the cap slowly to allow safe 

release of pressure. 

With engine cold, install pressure 

tester (BMW special tools 17 0 002/17 

0 005 or equivalent) to expansion tank. 

Pressurize system to specification 

listed in 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 


Also test expansion tank cap 

using pressure tester and correct 

adapter (BMW special tool 17 0 

007 or equivalent). Replace faulty 

cap or cap gasket. 

Table a. Cooling system test 

pressures 

Component 

Test pressure 

Radiator 1.5 bar (21.75



4 of 5 2/25/2009 9:57 PM 

Table a. Cooling system test 

pressures 

Component 

Radiator cap 

Test pressure 

psi) 

2 bar (29 psi) 

CAUTION! 

Exceeding the specified test 

pressure could damage the radiator 

or other system components. 

Combustion chamber leak test 

- If you suspect that combustion 

chamber pressure is leaking into 

the cooling system past the 

cylinder head gasket, use an 

exhaust gas analyzer to test the 

vapors rising 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 the engine overheats or runs too cool 

and no other cooling system tests



5 of 5 2/25/2009 9:57 PM 

indicate trouble, the electrically heated 

thermostat may be faulty. 

Check for thermostat diagnostic fault 

codes (DTCs) using BMW scan tools 

DIS or MoDiC or equivalent. DTCs 

pertaining to cooling system 

malfunctions are listed in Table b. 

See also OBD On Board Diagnostics 

at the back of this manual. 

Table b. Cooling system fault 

codes 


fault 

code 

Explanation 

Possible 

cause(s) 

10 Engine 

coolant 

temperature 

out of 

predefined 

range 

222 Insufficient 

coolant 

temperature 

signal to 

permit closed 

loop operation 

Faulty 

thermostat or 

cooling fan. 

Faulty wiring 

to cooling fan 

or 

thermostat. 

Faulty 

thermostat. 

Faulty 

thermostat 

electrical 

circuit. 




1 of 16 2/25/2009 9:57 PM 

Cooling System Service 

170-3 

Coolant, draining and filling 

WARNING! 

Allow the cooling system to cool 

before opening or draining the 


- Raise front of car and support 

safely. 

CAUTION! 







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!



2 of 16 2/25/2009 9:57 PM 

Coolant is poisonous. It is especially 

lethal to pets. Clean up spills 

immediately and rinse the area with 

water. 

Place empty 3-gallon pail underneath 

exhaust side of engine block. Loosen 

and remove engine block coolant drain 

plug (arrow). 

Note: 

The block drain plug is located on the 

exhaust side of the engine block at 

cylinder 2. 

- Reinstall radiator 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 when filling cooling system.



3 of 16 2/25/2009 9:57 PM 

Tap water may cause corrosion of 

radiator, engine and coolant 

hoses. 

Coolant can often be reused 

provided it is clean and less than 

two years old. Do not reuse 

coolant when replacing damaged 

engine parts. Contaminated 

coolant may damage the engine or 


Table c. Cooling system capacity 

Engine 

M52 TU/M54 

Capacity 

8.4 liters (8.8 qt.) 


Engine block drain 

plug to block 


plug to radiator 

25 Nm (18 ft-lb) 

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 

warm, set blower to low setting 

and turn ignition to ON position 

(do not start engine).



4 of 16 2/25/2009 9:57 PM 

- 

Slowly add coolant until it spills 

from bleed screw. When coolant 

spilling from bleed screws is free 

of air bubbles, tighten screw. 

Run engine until it reaches operating 

temperature. 

After engine has cooled, recheck 

coolant level. 

Top up so that coolant level 

indicator is at MAX. 

CAUTION! 

Always use genuine BMW coolant or 

its equivalent to avoid the formation 

of harmful, clogging deposits in the 

cooling system. Use of other 

antifreeze solutions may be harmful 

to the cooling system. 


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 intake duct.



5 of 16 2/25/2009 9:57 PM 

Working at top of fan shroud, remove 

screw and expansion rivet (arrows) 

holding fan shroud to radiator. Unclip 

or disconnect electrical connector(s) 

from right side of shroud. 

Note: 

Shroud is detached from radiator at this 

point but can only be removed later 

when fan and clutch assembly is 

removed. 

Using 32 mm wrench (BMW special 

tool 11 5 040) on fan clutch nut 

(arrow), turn wrench quickly in a 

clockwise direction (working from 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 


- To replace fan clutch, remove fan 

mounting bolts and separate 

viscous clutch from fan. 



Clutch nut to coolant pump (left-hand 

threads) 

without BMW tool 

11 5 040 40 Nm (29 ft-lb)



6 of 16 2/25/2009 9:57 PM 


with BMW tool 11 

5 040 30 Nm (22 ft-lb) 

Fan to viscous 

clutch 

10 Nm (89 in-lb) 

Electric cooling fan, replacing 

(models with manual 

transmission) 

On models with manual transmission, 

the primary cooling fan is electrically 

operated and is mounted on the engine 

side of the radiator. 

- Remove air intake duct as 

described above. 

Working at top of fan shroud, remove 

screw and expansion 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. 


Electric cooling fan, replacing 

(models with automatic



7 of 16 2/25/2009 9:57 PM 

transmission) 

The electric cooling fan on cars with 

automatic transmission is mounted 

behind the front bumper, in front of the 

A/C condenser. 

- Remove air intake duct as 

described above. 

- Remove front bumper. See 510 

Exterior Trim, Bumpers. 

- 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. 


Install front bumper. See 510 

Exterior Trim, Bumpers. 

Thermostat, replacing



8 of 16 2/25/2009 9:57 PM 

The electrically-heated thermostat is an 

integral part of the thermostat housing. 

The operation of the thermostat is 

monitored by the DME control module. 

If a faulty thermostat is suspected, the 

DME control module should be 

interrogated for stored fault codes 

using an appropriate scan tool. 

1 - Bolt M6 

2 - Bolt M8 

3 - Housing with heated thermostat 

4 - Gasket 

- Drain radiator and engine block as 

described above under 

Coolant, draining 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. 


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 facilitate removal. 



Keep sealing faces free of oil.



9 of 16 2/25/2009 9:57 PM 

Use new sealing gasket. 

Fill system with coolant as 

described under Coolant, 

draining and filling 



plug to block 



25 Nm (18 ft-lb) 

2 - 3 Nm (18 - 27 

in-lb) 

Coolant pump, replacing 

The engine coolant pump is mounted 

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! 


opening or draining system. 



earlier.



10 of 16 2/25/2009 9:57 PM 

Remove engine drive belt: Lever 

tensioner hex (large arrow) in 

clockwise direction (facing engine) and 

slip belt off coolant pump pulley. 

Note: 

Mark direction of drive belt rotation if 

reusing belt. 

- Remove coolant pump pulley bolts 

and remove pulley from pump. 

- Remove pump mounting nuts 

(qty. 4). 

Note: 

The coolant pump is mounted on studs 

and retained by nuts. 

Insert two M6 screws (arrows) in 

tapped bores and tighten uniformly 

until pump is free from timing chain 

cover. (Thermostat and hoses have 

been removed for visual access.) 



Be sure to replace sealing O-ring 

and gaskets. 

Coat O-ring with lubricant during 

installation. 


Coolant pump to 

timing chain cover 

Coolant pump 

pulley to coolant 

pump 


plug to block 

10 Nm (89 in-lb) 

10 Nm (89 in-lb) 

25 Nm (18 ft-lb)



11 of 16 2/25/2009 9:57 PM 




2-3 Nm (18-27 

in-lb) 

Radiator, removing and 

installing 


safely. 

CAUTION! 







engine. 



WARNING! 



- Remove complete air filter 

housing. 



earlier. 

Working on left side of radiator, lever 

out hose retaining clips and disconnect 

coolant hose fittings from radiator (A) 

and radiator expansion tank (B).



12 of 16 2/25/2009 9:57 PM 

Working on ride side of radiator, 

release hose retaining clips (A) and 

disconnect lower coolant hose fitting 

from radiator (B). 

- Working underneath radiator, 

disconnect harness connector 

from coolant level sensor. 

Where applicable, disconnect 

automatic transmission fluid (ATF) 

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.



13 of 16 2/25/2009 9:57 PM 

Note: 

Alternatively, detach ATF cooler from 

radiator by pulling up on quick release 

clips and pulling cooler from radiator 

tank. 

Remove plastic bolts at top of radiator 

(arrows). Pull radiator up and out of 

car. 



Do not coat sealing O-rings with 

anti-seize paste. 

Fill radiator and cooling system as 



Check ATF level and, if necessary, 

top up. See 240 Automatic 

Transmission. 



plug to block 



25 Nm (18 ft-lb) 

2 - 3 Nm (18 - 27 

in-lb) 

Coolant expansion tank, 



safely. 

CAUTION! 



professional automotive lift or jack



14 of 16 2/25/2009 9:57 PM 




engine. 



WARNING! 



- Remove complete air 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.



15 of 16 2/25/2009 9:57 PM 

Remove coolant level sensor (9) by 

twisting counterclockwise and pulling 

out of bottom of tank. 

1 - Thermostat (ATF heat exchanger) 

2 - Expansion tank cap 

3 - Label 

4 - Radiator 

5 - Mounting bracket 


7 - Self-tapping screw 

8 - Connector (ATF heat exchanger) 

9 - Coolant level sensor 

10 - Locking clip 

- Pull out expansion tank by 

detaching from radiator at top. 

Then pull up from mounting 

bracket at bottom. 


Do not coat O-rings with anti-seize 

paste. 

Fill radiator and cooling system as 





plug to block 

25 Nm (18 ft-lb)



16 of 16 2/25/2009 9:57 PM 





2 - 3 Nm (18 - 27 

in-lb)

Exhaust System 


1 of 3 2/25/2009 10:12 PM 

General 

200-1 

This section covers the repairs related 

to the clutch, manual and automatic 

transmissions, shift linkages, 

driveshafts, and transfer case (all 

wheel drive vehicles only). For repairs 

related to drive axles and front and rear 

final drive differentials, see 311 

Front Axle Final Drive and 331 Rear 

Axle Final Drive. 

Drivetrain 

E46 models are equipped with a 

longitudinal drivetrain. The 

transmission is bolted directly to the 

rear of the engine. In rear wheel drive 

models, a driveshaft connects the 

output shaft of the transmission to the 

rear final 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 

different manual transmissions are 

used in models covered by this 

manual. Manual transmission 

applications are given in Table a. 

Manual transmission applications. 

Note: 

For transmission gear ratio information 

and repair information, see 230 

Manual Transmission.



2 of 3 2/25/2009 10:12 PM 

The manual transmissions use a single 

clutch disc with dual-mass flywheel. 

For further information, see 210 

Clutch. 

Manual transmissions have a metal ID 

plate mounted on the side of the 

transmission. Do not rely on numbers 

cast on the transmission case for 

identification. 

Table a. Manual transmission applications 

Model Year Engine Transmission 

323i/Ci 

325i/Ci 

1999 - 2000 

2000 - 2001 

M52 TU 

M54 

Getrag S5D 250G 

328i/Ci 

330i/Ci 

1999 - 2000 

2000 - 2001 

M52 TU 

M54 

ZF S5D 320Z 

325xi330xi 2000 -2001 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 

Transmission. 

Transmission Identification codes for 

automatic transmissions are located on 

metal ID tags mounted to the body of the 

transmission. 

Note: 

323 i/Ci and 328 i/Ci models



3 of 3 2/25/2009 10:12 PM 

manufactured from 08/98 to 03/00 are 

equipped with the A5S 360R automatic 

transmission. Vehicles produced after 

03/00 use the A5S 325Z transmission. 

GM manufactured transmissions have 

the ID tag located on the left hand side 

of the transmission housing, behind the 

transmission selector cable, just above 

the transmission pan (arrow). 

ZF manufactured 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 


323i/Ci 

328i/Ci 

1999 - 2000 

2000 - 2001 

M52TU 

GM A5S 360R 

ZF A5S 325 Z 

325i/Ci 

330i/Ci 

325xi 

330xi 

2000 - 2001 M54 ZF A5S 325 Z 

2000 - 2001 M54 GM A5S 390R 


Transmission lubricants

Clutch 


1 of 3 2/25/2009 10:15 PM 

General 

210-1 

This repair group covers replacement 

of the clutch mechanical and hydraulic 

components. Read the procedure 

through before beginning a job. 

Note: 

See 200 Transmission–General for 

transmission application information. 

Special tools 

The 3 Series BMW employs a 

traditional style clutch layout with a self 

adjusting 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 installation tool BMW 11 2 

350

Clutch 


2 of 3 2/25/2009 10:15 PM 

Clutch lining gauge BMW 21 2 080 

Clutch 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 


3 of 3 2/25/2009 10:15 PM 

SAC locating ring BMW 21 2 180 


Clutch 


1 of 7 2/25/2009 10:15 PM 

Clutch Hydraulics 

210-2 

The clutch is hydraulically actuated by 

the master and slave cylinders. Clutch 

disc wear is automatically taken up 

through the self adjusting pressure 

plate springs, making periodic 

adjustments unnecessary. 

A soft or spongy feel to the clutch 

pedal, long pedal free-play, or grinding 

noises from the gears while shifting 

can all indicate problems with the 

clutch hydraulics. In these 

circumstances it is best to start with a 

clutch fluid flush, followed, if 

necessary, by replacement 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 safely support vehicle. 

- Remove under transmission 

splash guard if applicable. 

- Remove brake fluid reservoir cap. 

Using a clean syringe, remove 

brake fluid from reservoir. Refill 

reservoir with clean DOT 4 brake 

fluid.

Clutch 


2 of 7 2/25/2009 10:15 PM 

Attach pressure brake bleeder to fluid 

reservoir and pump bleeder a few times 

to pressurize hydraulic fluid system. 

CAUTION! 

Do not exceed 2 bar (29 psi) 

pressure at the fluid reservoir 

when bleeding or flushing the 

hydraulic system. 

Brake fluid is poisonous, highly 

corrosive and dangerous to the 

environment. Wear safety 

glasses and rubber gloves when 

working with brake fluid. Do not 

siphon brake fluid with your 

mouth. Immediately clean away 

any fluid spilled on painted 

surfaces and wash with water, 

as brake fluid will remove paint. 

Always use new brake fluid from 

a fresh, unopened container. 

Brake fluid will absorb moisture 

from the air. This can lead to 

corrosion problems in the 

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 allow 

brake fluid to expel until clean 

fluid comes out free of air 

bubbles. 

- Close bleeder valve and 

disconnect pressure bleeding 

equipment from fluid reservoir. 

Hose on bleeder valve remains 

connected.

Clutch 


3 of 7 2/25/2009 10:15 PM 

- 

Slowly operate clutch pedal about 

10 times. Fill reservoir with clean 

fluid as necessary. 

- Unbolt slave cylinder from 

transmission. Fit BMW special tool 

21 5 030. Press slave cylinder 

pushrod completely into slave 

cylinder. 

- Hold slave cylinder so that bleeder 

valve is at the highest point. 

- Open bleeder valve. 

Once brake fluid appears with out 

air bubbles, 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. 


Clutch slave 

cylinder to 

transmission 

22 Nm (16 ft-lb) 

Clutch master cylinder,

Clutch 


4 of 7 2/25/2009 10:15 PM 

replacing 

The clutch master cylinder is mounted 

to the pedal assembly directly above 

the clutch pedal. 


battery. 

CAUTION! 






- Remove under transmission 

splash 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. 


compartment: 


panel. 



remove.

Clutch 


5 of 7 2/25/2009 10:15 PM 





hose at one way valve (A). Plug 

hose ends. 

- Disconnect clutch pedal from 

clutch master cylinder push rod by 

removing securing pin. 

Remove master cylinder mounting 

bolts (arrows). 

Remove clip (arrow) 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. 


Fill fluid reservoir with clean fluid.

Clutch 


6 of 7 2/25/2009 10:15 PM 

Bleed clutch hydraulics as 

described earlier. Connect 

negative cable to battery last. 


Clutch master 

cylinder to pedal 

cluster 

Fluid line to 

master cylinder or 

slave cylinder 

22 Nm (16 ft-lb) 

20 + 5 Nm 

(15 + 4 ft-lb) 

Clutch slave cylinder, replacing 

- Pinch off brake fluid supply hose 

to clutch master cylinder using 

BMW special tool 13 3 010 or 

equivalent fuel line clamp tool. 

- Remove transmission splash 

guard if applicable. 

- Disconnect fluid hose from slave 

cylinder. Place a pan under hose 

to catch any excess fluid. 

Remove mounting nuts (arrows) from 

slave cylinder on left side of 

transmission. 



Check for wear on slave cylinder. 

Any other wear except on tip is 

caused by misalignment of clutch 

components. 

Lightly coat pushrod tip with 

molybdenum disulfide grease 

(Molykote® Longterm 2 or

Clutch 


7 of 7 2/25/2009 10:15 PM 

equivalent). 

During installation be sure 

pushrod tip engages recess in 

clutch release lever. 

Fill fluid reservoir with clean fluid. 

Bleed clutch hydraulics as 



Clutch slave 

cylinder to 

transmission 

Fluid line to slave 

cylinder 

22 Nm (16 ft-lb) 

20 + 5 Nm 

(15 + 4 ft-lb) 


Clutch 


1 of 8 2/25/2009 10:15 PM 

Clutch Mechanical 

210-3 

The transmission must be removed 

from the engine to access the clutch 

mechanical components. It is 

recommended that the clutch disc, 

pressure plate and release bearing be 

replaced during a clutch overhaul. Be 

sure to check the bottom of the 

bellhousing for oil. If engine oil is 

found, check for a faulty rear 

crankshaft oil seal. 

Due to the construction of the self 

adjusting clutch (SAC) disc special 

tools must be used when removing the 

SAC style clutch. The pressure 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 disc diameter 

Model 

323i/Ci 

325i/Ci/xi 

328i/Ci 

330i/Ci/xi 

Diameter 

228 mm (8.98 

in.) 

240 mm (9.45 

in.) 

Clutch, removing 

- On all wheel drive vehicles: 

Remove transfer case. See 270 

Transfer Case.

Clutch 


2 of 8 2/25/2009 10:15 PM 

- 

Remove transmission from engine. 

See 230 Manual Transmission. 

- Remove release bearing from 

transmission input shaft. 

Remove clutch release lever by pulling 

away from spring clip in direction of 

arrow. 

Lock flywheel in position using BMW 

special tool 11 2 170 or equivalent. 

Install BMW special tool 21 2 160 or 21 

2 170 with feet (arrows) clamping on to 

pressure plate at openings for 

self-adjusting springs. Tighten down 

head nut (A) to lock feet into position. 

CAUTION! 

Self adjusting clutch tool feet must 

engage in the openings for adjusting 

springs to safely remove the SAC 

pressure plate.

Clutch 


3 of 8 2/25/2009 10:15 PM 

- 

Turn tool handle in until clutch 

diaphragm spring is fully 

tensioned. 

- Remove six bolts from perimeter of 

pressure plate. Remove self 

adjusting clutch unit and clutch 

disk. 

Clutch assembly and hydraulics 

Clutch, inspecting 

- Inspect clutch disc for wear, cracks, 

loose rivets, contamination or

Clutch 


4 of 8 2/25/2009 10:15 PM 

Note: 

excessive runout (warping). 

Replace if necessary. 

Measure the depth of clutch lining at 

lining rivets. If shallowest rivet depth is 

less than 1 mm (0.04 in.), replace clutch 

disk. 

- Inspect flywheel for scoring, hot 

spots, cracks or loose or worn guide 

pins. Replace flywheel if any faults 

are found. 

WARNING! 

If flywheel is removed from vehicle, 

use new bolts 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 shaft splines. 

Clutch, installing new pressure 

plate

Clutch 


5 of 8 2/25/2009 10:15 PM 

New self adjusting clutch (SAC) 

pressure plates come with a locking 

plate installed that maintains spring 

tension on the self adjusting springs. 

This locking ring must not be removed 

until the pressure plate is securely 

installed on the flywheel with the clutch 

disk in place. 

Center clutch disk on flywheel using 

BMW special tool 21 2 142, or an 

equivalent clutch alignment tool. 

Note: 

The sides of a replacement clutch disk 

are labelled engine side and 

transmission side. Be sure to install 

clutch disk orientated in the 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 


Clutch to flywheel 

M8 (8.8 grade) 

M8 (10.9 grade) 

24 Nm (18 ft-lb) 

34 Nm (25 ft-lb) 

- Using a 14 mm allen wrench, 

carefully screw out locking plate in 

a clockwise direction. 

- Remove BMW special tool 21 2 142 

with bolt or screw enclosed with 

replacement clutch disk. 

Clean and inspect release bearing guide 

sleeve on transmission. Install release 

lever and release bearing. Bearing tabs 

(A) align with contact points (B) on

Clutch 


6 of 8 2/25/2009 10:15 PM 

release lever. 

- Install transmission. See 230 

Manual Transmission. 


Transmission to engine (Torx bolts) 

M8 

M10 

M12 

22 Nm (16 ft-lb) 

43 Nm (32 ft-lb) 

72 Nm (53 ft-lb) 

Clutch, installing used pressure 

plate 

Note: 

Before installing a used Self 

Adjusting Clutch (SAC) pressure 

plate, be sure to reset self adjusting 

ring to the new position 

Locating hooks of BMW special tool 

21 2 180 must engage in openings 

of SAC pressure plate 

- Place self adjusting clutch pressure 

plate on clean work surface. 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 2 170 until 

diaphragm spring of SAC pressure 

plate is pretensioned.

Clutch 


7 of 8 2/25/2009 10:15 PM 

Center clutch disk with BMW special tool 

21 2 142. A comparable clutch alignment 

tool may be used. Remove threaded 

handle of clutch alignment tool 

WARNING! 

Be sure clutch disc is facing the 

correct way. The disc should be 

marked engine side or transmission 

side. 

- Mount self adjusting clutch 

assembly on flywheel, noting 

location of alignment pins. 

- Tighten each bolt one turn at a time 

until pressure plate is fully seated, 

and then torque to specification. 


Clutch to flywheel 

M8 (8.8 grade) 

M8 (10.9 grade) 

24 Nm (17-ft-lb) 

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 

bearing tabs (A) align with contact points 

(B) on release lever. 

- Install transmission. See 230 

Manual Transmission. 

Tightening torques

Clutch 


8 of 8 2/25/2009 10:15 PM 


Transmission to engine (Torx bolts) 

M8 

M10 

M12 

22 Nm (16 ft-lb) 

43 Nm (32 ft-lb) 

72 Nm (53 ft-lb) 

Transmission pilot bearing, 

replacing 

- Remove clutch 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. 


Manual Transmission 


1 of 2 2/25/2009 10:16 PM 

General 

230-1 

This repair group covers external 

transmission service, including removal 

and installation of the transmission 

unit. Internal transmission repair is not 

covered. Special press tools and 

procedures are required to 

disassemble and service the internal 

geartrain. 

Special tools 

BMW specified tools are required for 

removal and installation of the manual 

transmission, as well as the removal 

and installation of seals at the 

transmission input, output, and 

selector shafts. 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



2 of 2 2/25/2009 10:16 PM 

Selector seal drift BMW 23 0 22 

Output seal drift BMW 23 2 300 

Manual transmissions used are based 

on engine application. Consult 200 

Transmission–General for transmission 

application information. Table a. 

Manual transmission gear ratios lists 

gear ratio specifications. 

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 




1 of 2 2/25/2009 10:16 PM 

Transmission Fluid 

Service 

230-2 

Manual transmissions installed in the 3 

Series are normally filled with a 

"Lifetime" manual transmission fluid 

(BMW MTF LT-1) and do not require 

periodic fluid changes. Transmissions 

filled with MTF LT-1 lifetime oil are 

identified with a yellow label near the 

transmission fill plug labeled "Lifetime 

Oil MTF-LT-1". 

Transmission fluid level, 

checking 

Checking the transmission fluid level 

involves simply removing the side fill 

plug and inserting 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! 






Place a drain pan under transmission 

and remove drain plug (A) at bottom of 

transmission.



2 of 2 2/25/2009 10:16 PM 

Install and torque drain plug. 

Remove fill plug (B) from side of 

transmission. 

Slowly fill transmission with fluid 

until fluid overflows fill hole. 

Install and torque fluid fill 

plug.nothing 

Fluid capacity 

Getrag 

transmission 

1.0 liter (1.1 US 

qts) 

ZF transmission 1.2 liters (1.3 

US qts) 


Transmission drain 

or fill plug 

50 Nm (37 ft-lb) 




1 of 8 2/25/2009 10:17 PM 

Transmission Service 

230-3 

Back-up light switch, replacing 

Raise and safely support vehicle to 

access back-up light switch. Unscrew 

switch from transmission. 

Note: 

The back-up light switch (arrow) 

on Getrag transmissions is in the 

left side of the transmission. 

The back-up light switch on ZF 

transmission is in the right front of 

the transmission. 

- Install new switch. 


Back-up light 

switch to 

transmission 

20 Nm (15 ft-lb) 

- Check transmission fluid level 

before lowering vehicle. 

Selector shaft seal, replacing 

(transmission installed) 


- Support transmission with 

transmission jack. 

On rear wheel drive cars:



2 of 8 2/25/2009 10:17 PM 

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. 

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.



3 of 8 2/25/2009 10:17 PM 

Coat new selector shaft seal with 

transmission fluid. Drive new seal in 

flush with housing. Use BMW special 

seal installation tool 23 1 140 or 

equivalent and a soft-faced (plastic) 

hammer. 


noting the following; 

Install driveshaft using new lock 

nuts. 

Check transmission oil level, 

topping up as necessary. 


Center bearing 

(driveshaft) to body 

Clamping sleeve 

(driveshaft) 

Driveshaft to final drive flange 

With U-joint (M10 

ribbed nut) 


compressed nut) 

21 Nm (15 ft-lb) 

10 Nm (89 in-lb) 

80 Nm (59 ft-lb) 

64 Nm (47 ft-lb) 

Flex-disc to driveshaft or transmission 

flange 

M10 (8.8 grade) 

48 Nm (35 ft-lb)



4 of 8 2/25/2009 10:17 PM 


M10 (10.9 grade) 

60 Nm (44 ft-lb) 

M12 (10.9 grade) 100 Nm (74 

ft-lb) 

Transmission / 

transfer case 

crossmember to 

chassis (M8) 

Transfer case to 

transmission (M10) 

21 Nm (15 ft-lb) 

41 Nm (30 ft-lb) 

Output shaft seal, replacing 

(transmission installed) 



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.



5 of 8 2/25/2009 10:17 PM 

CAUTION! 




clearance. 

- Bend back and remove 

transmission output collar nut 

lockplate. 

Remove collar nut with 30 mm 

thin-walled deep socket. Counterhold 

output flange 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:



6 of 8 2/25/2009 10:17 PM 

On Getrag S5D 250G transmissions 

BMW recommends heating the output 

flange to about 176F (80C) to aid in 

installation. This can be done by 

placing the flange in hot water. 

- Coat bearing surface of collar nut 

with sealer and install nut. Tighten 

collar nut in two stages. Install 

new lockplate. Bend tabs into 

flange grooves. 

Note: 

BMW recommends the use of a sealer 

such as Loctite ® 242 when installing 

the flange collar nut to prevent oil from 

leaking past the threads. 



Install driveshaft using new nuts. 

See 260 Driveshaft. 

Check transmission and transfer 

case fluid level, if applicable, 

topping up as necessary. 


Transmission crossmember to 

chassis 

M8 

21 Nm (15 ft-lb) 

Transmission output flange to output 

shaft 

Stage I 190 Nm (140 

ft-lb) 

Stage II (after 

loosening) 

120 Nm (89 

ft-lb) 

Input shaft seal, replacing



7 of 8 2/25/2009 10:17 PM 

(transmission removed) 

Replacement of the input shaft seal 

requires the removal of the 

transmission from the vehicle as 

describedlater in this repair group. 

- Remove clutch release bearing 

and release lever from inside 

bellhousing. 

Remove bolts (arrows) for clutch 

release-bearing guide sleeve, noting 

bolt lengths (Getrag transmission 

shown). Remove sleeve and any 

spacers (shims) under it. 

- With transmission on a 

workbench, remove input shaft 

seal cover from 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 surfaces, 

and threads in case. Apply sealer 

(Loctite ® 242 or equivalent) to 

guide sleeve sealing surface and 

bolts. Reinstall guide sleeve and 

spacer(s).



8 of 8 2/25/2009 10:17 PM 


Guide sleeve to transmission 

M6x12 bolt 

10 Nm (89 in-lb) 




1 of 6 2/25/2009 10:17 PM 

Transmission Removal 


230-4 

Removal and installation of the 

transmission is best accomplished on a 

lift using a transmission jack. The 

engine must be supported from above 

using appropriate support equipment. 

This allows the engine to pivot on its 

mounts to access the upper Torx-head 

bolts at the bellhousing. 

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. 

The removal of the transmission 

may upset the balance of the 

vehicle on a lift. 

Transmission, removing and 

installing 


battery. 

CAUTION! 





Remove engine cooling intake hood 

fasteners (arrows) at front of engine 

compartment.



2 of 6 2/25/2009 10:17 PM 


microfilter. 


microfilter. 





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. 


- 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



3 of 6 2/25/2009 10:17 PM 

wheel drive 3 Series sedans and 

wagons built up to 11/00 and 

coupes built up to 10/99. 

Pan style front end reinforcements 

are used on rear wheel drive 

sedans and wagons built after 

12/00, coupes built after 11/99 and 

all convertibles. 

All wheel drive models require no 

reinforcement due to the 

construction of the front subframe. 

Attach BMW special tool 11 8 022 to 

left and right lower control arms. 

Tighten knurled screws until tool 

makes contact with engine oil pan. 


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. 


Remove transfer case. See 270 

Transfer Case. 

Disconnect shift rod from selector shaft 

coupling. 

- Disconnect shift console from top



4 of 6 2/25/2009 10:17 PM 

of transmission. See 250 

Gearshift Linkage. 

- Unbolt clutch slave cylinder from 

side of transmission. Do not 

disconnect fluid hose. Suspend 

slave cylinder from chassis using 

stiff wire. 

CAUTION! 

Do not operate clutch pedal with 

slave cylinder removed from 

transmission. 

- Loosen knurled screws of BMW 

special tool 11 8 022 until 

transmission/engine assembly is 

just above, but not in contact with 

fire wall and heater connections. 

CAUTION! 




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 downwards. 

Lower jack and remove 

transmission. 

Installation is reverse of removal, 

keeping in mind the following:



5 of 6 2/25/2009 10:17 PM 

When installing a new 

transmission, be sure to transfer 

parts from old transmission if 

applicable. 

Thoroughly clean input shaft and 

clutch disc splines. Lightly 

lubricate transmission input shaft 

before installing. 

Be sure bellhousing dowels 

(arrows) are correctly located. 

Center rear of transmission in 

driveshaft tunnel before tightening 

transmission support bracket. 

Note: 

Always replace front end 

reinforcement mounting fasteners 

on vehicles equipped with the 

plate style reinforcement. 

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 

Transmission Fluid Service earlier 

in this repair group. 


Front end reinforcement to chassis 

and subframe (M10)



6 of 6 2/25/2009 10:17 PM 


(tubular style) 

(pan style) 

Rubber mount to 

transmission or 

bracket nut (M8) 

Slave cylinder to 

transmission 

42 Nm (31 ft-lb) 

59 Nm (44 ft-lb) 

+ 90° 

21 Nm (15 ft-lb) 

22 Nm (16 ft-lb) 

Transmission crossmember to 

chassis 

M8 

21 Nm (15 ft-lb) 

Transmission to engine (Torx-head) 

M8 

M10 

M12 

Transmission 

drain/fill plug 


22 Nm (16 ft-lb) 

43 Nm (32 ft-lb) 

72 Nm (53 ft-lb) 

50 Nm (37 ft-lb)

Automatic Transmission 


1 of 3 2/25/2009 10:17 PM 

General 

240-1 

This section covers maintenance and 

replacement of the E46 automatic 

transmission. Internal repairs to the 

automatic transmission are not 

covered. Special tools and procedures 

are required to disassemble and 

service internal automatic transmission 

components. 

Automatic transmissions are identified 

by code letters found on a data plate 

located on the side or rear of the 

transmission case. See 200 

Transmission–Generalfor application 

information. For gear ratio 

specifications, see Table a. 

Automatic transmission applications. 

CAUTION! 

ATF does not circulate unless the 

engine is running. When 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-board diagnostic codes stored in 

the TCM must be downloaded and 

interpreted by trained technicians using 

special BMW diagnostic equipment. 

Special tools 

Some special tools are required for the 

removal and installation of an 

automatic transmission on the E46 

BMW models. While these tools are not



2 of 3 2/25/2009 10:17 PM 

absolutely necessary, they are 

especially helpful when dealing with 

the removal and replacement of the 

torque converter. 

Engine support bracket BMW 00 0 200 

/ 208 

Oil pan support bracket BMW 11 8 022 

Torque converter socket BMW 24 1 100 

Spline bore alignment tool BMW 24 2 

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



3 of 3 2/25/2009 10:17 PM 

dealer about a factory reconditioned 

unit or a transmission rebuild. 

323i/Ci and 328i/Ci models 

manufactured from 08/98 to 03/00 are 

equipped with the A5S 360R automatic 

transmission. Vehicles produced after 

03/00 are equipped with the A5S 325Z 

transmission. 

Table a. Automatic transmission applications 


323i/Ci 

328i/Ci 

1999 - 2000 

2000 - 2001 

M52TU 

GM A5S 360R 

ZF A5S 325 Z 

325i/Ci 

330i/Ci 

325xi 

330xi 

2000 - 2001 M54 ZF A5S 325 Z 

2000 - 2001 M54 GM A5S 390R 




1 of 5 2/25/2009 10:18 PM 

Transmission Service 

240-2 

The automatic transmissions installed 

in the 3 Series are filled with either 

Dexron III ATF, or Texaco 8072B a 

special life-time oil. 

CAUTION! 

Mixing different types of 

transmission fluids will lead to 

transmission failure. 

Note: 

The transmission lubricant installed can 

be found on a sticker on the 

transmission pan. Dexron III ATF (black 

sticker) reads "ATF-Oil!". Special 

life-time oil (green sticker) reads 

"Life-Time Oil". In addition, a sticker 

may be located on the fluid sump 

indicating the type of transmission 

lubricant used. If in doubt, consult an 

authorized BMW dealer for alternate 

fluid use and current information 

regarding transmission operating fluids. 

Automatic transmission fluid 

(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 the checking procedure. The 

checking temperature is not fully warm 

or cold (the ATF pan should be 

approximately warm to the touch). 

- Raise and safely support vehicle 

to access ATF fill plug. 

CAUTION!



2 of 5 2/25/2009 10:18 PM 






- Warm up drivetrain by running 

engine until ATF reaches specified 

temperature. Apply brake and, 

while idling engine, shift through 

all gears several times. Turn 

engine off. 

ATF level checking 

Fluid temperature 30° - 50°C (85° - 

120°F) 

- Connect vehicle to BMW 

diagnostic scan tool DIS or MoDiC 

using the Data Link Connector 

(DLC) in the engine compartment, 

or under driver's side of dash 

(model year 2000 and later cars) 

in order to read transmission 

temperature. 

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 fill hole. 

WARNING! 

Hot ATF can scald. Wear eye 

protection and protective clothing 

and gloves during the check. If the 

transmission was overfilled, hot ATF



3 of 5 2/25/2009 10:18 PM 

will spill from the filler hole when the 

fill plug is removed. 

- Reinstall fill plug using new 

sealing ring. 


ATF drain plug to ATF sump 

A5S 360R / 

A5S 390R (M14) 

A5S 325Z 

ATF fill plug to ATF sump 

A5S 360R / 

A5S 390R (M14) 

A5S 325Z 

20 Nm (15 ft-lb) 

35 Nm (26 ft-lb) 

20 Nm (15 ft-lb) 

30 Nm (22 ft-lb) 

ATF, draining and filling 

The procedure given here 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 gasket and clean 

gasket sealing surface.



4 of 5 2/25/2009 10:18 PM 

Pull ATF fluid strainer from 

transmission pump housing. If strainer 

sealing ring remains in pump housing 

remove using a seal puller. 


Always replace seal for drain plug 

and all gasket(s) and O-rings. 

Clean sump and sump magnet(s) 

using a lint-free cloth. 

Tighten transmission pan bolts in 

sequential order. 

Fill transmission with approved 

fluid. 

Note: 

Check fluid level as described 

under Automatic transmission 

fluid (ATF) level, checking 

Use new sump bolts purchased from 

BMW. Alternatively, clean old bolts and 

coat with Loctite® thread locking 

compound or equivalent. 


capacity 

A5S 360R / A5S 390R 

with torque 

converter 

without torque 

converter 

A5S 325Z (2.5 liter) 

with torque 

converter 

9 liters (9.5 qt) 

4 liters (4.2 qt) 

8.9 liters (9.4 qt)



5 of 5 2/25/2009 10:18 PM 


capacity 


converter 

A5S 325Z (3.0 liter) 

with torque 

converter 


converter 

6.2 liters (6.5 qt) 

8.7 liter (9.2 qt) 

6.1 liter (6.4 qt) 



A5S 360R / 

A5S 390R (M14) 

A5S 325Z 


A5S 360R / 

A5S 390R (M14) 

A5S 325Z 

ATF sump to transmission 

A5S 360R / 

A5S 390R (M14) 

A5S 325Z 


18 Nm (14 ft-lb) 

35 Nm (26 ft-lb) 

18 Nm (14 ft-lb) 

30 Nm (23 ft-lb) 

10 Nm (7 ft-lb) 

6 Nm (4 ft-lb)



1 of 7 2/25/2009 10:18 PM 

Transmission Removal 


240-3 

Removal and installation of the 

transmission is best accomplished on a 

lift using a transmission jack. Use 

caution and safe workshop practices 

when working beneath car and 

lowering transmission. 

CAUTION! 

Be sure the vehicle is properly 

supported. The removal of the 

transmission may upset the 

balance of the vehicle on a 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 


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 


battery. 

CAUTION! 

Prior to disconnecting the battery,



2 of 7 2/25/2009 10:18 PM 




Remove engine cooling intake hood 

fasteners (arrows) at front of engine 

compartment. 

- Remove engine driven cooling fan, 

unfasten cooling fan cowl and pull 

slightly upwards. See 170 



microfilter. 


microfilter. 









mounting lip. 




Install engine support across engine 

bay. Raise and safely support vehicle. 

CAUTION!



3 of 7 2/25/2009 10:18 PM 

Make sure the car is stable and 

well supported at all times. Use 

a professional automotive lift or 

jack stands designed for the 

purpose. A floor jack is not 

adequate support. 

Removal of transmission will 

cause engine to tip unless 

engine support is used. 

- Remove engine splash guard from 


- Remove front suspension 

reinforcement at lower control 

arms and front subframe. 

- Drain ATF from transmission as 


- 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 selector 

lever cable clamping nut (B). 

Loosen cable clamping nut and



4 of 7 2/25/2009 10:18 PM 

remove cable from bracket. (A5S 

325Z transmission shown.) 


connector(s) from transmission by 

turning bayonet lock ring(s) (arrows) 

counterclockwise. 

On A5S 325Z disconnect two 

connectors on the left side of the 

transmission. 

On A5S 360R / A5S 390R 

disconnect the harness connector 

at the right rear of the 

transmission. 

Remove wiring harness(s) from 

transmission housing. 

- Disconnect transmission cooler 

line clamps from engine. 

Disconnect cooler lines from 

transmission. 

Attach BMW special tool 11 8 022 to 

lower control arms. 


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 plate on 

right side of engine block and remove 

torque converter bolts. Turn crankshaft 

to access bolts.



5 of 7 2/25/2009 10:18 PM 

Remove bellhousing-to-engine 


- Install BMW special tools 24 4 131 

and 24 4 135 to secure torque 

converter in place during 

transmission removal. 

CAUTION! 

Do not allow the torque converter to 

fall off the transmission input shaft. 

- Remove transmission by pulling 

back and down. Lower jack to 

allow transmission to clear vehicle. 



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.



6 of 7 2/25/2009 10:18 PM 

Install new O-rings on 

transmission cooler lines, where 

applicable. 

Inspect engine drive plate for 

cracks or elongated holes. 


Check to be sure torque converter 

is seated correctly in transmission 

during final installation. 

When mounting transmission to 

engine, the three mounting tabs 

on torque converter must be 

aligned with indentations on drive 

plate. Use an alignment dowel 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 


Note: 

Adjust gearshift mechanism. See 

270 Transfer Case. 

Torx-head mounting bolts should 

always be used with washers to prevent 

difficult removal in the future. 



A5S 325Z 

A5S 360R 


A5S 325Z 

A5S 360R 

35 Nm (26 ft-lb) 

20 Nm (15 ft-lb) 

30 Nm (22 ft-lb) 

20 Nm (15 ft-lb)



7 of 7 2/25/2009 10:18 PM 


Front suspension 

reinforcement to 

chassis (M10) 

Torque converter to 

drive plate (M10) 

Transmission 

support 


chassis 

42 Nm (30 ft-lb) 

45 Nm (33 ft-lb) 

23 Nm (17 ft-lb) 

Transmission to engine (Torx-head 

with washer) 

M8 

M10 

M12 


21 Nm (15 ft-lb) 

42 Nm (31 ft-lb) 

72 Nm (53 ft-lb)

Gearshift Linkage 


1 of 1 2/25/2009 10:19 PM 

General 

250-1 

This repair group covers transmission 

gearshift and linkage service for both 

manual and automatic transmission 

equipped vehicles. 

Special tools 

BMW suggests the use of one special 

tool in the removal of the gear shift 

lever for manual transmission equipped 

vehicles. 

Pin wrench BMW 25 1 110 

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. 




1 of 4 2/25/2009 10:19 PM 


Gearshift 

250-2 

Manual 

Transmission 

Gearshift Linkages 

1 - Rubber boot 

2 - Shift lever 

bearing 

3 - Shift arm 

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)



2 of 4 2/25/2009 10:19 PM 

Use the above illustration as a guide 

when removing and installing the 

linkage. 

- Remove shift knob by pulling knob 

straight off the manual gearshift. 

Note: 

Removal of the shift knob will require 

about 90 lbs. of force. Do not twist knob 

or locating key can be damaged. 

- Pry up on rear of shift boot to 

unclip, then remove boot from front 

retainers. 

- Raise vehicle to gain access to 


WARNING! 






- 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 gearshift linkage. 

CAUTION! 


transmission can lead to damage to



3 of 4 2/25/2009 10:19 PM 


clearance. 

Working above transmission, disconnect 

shift rod from gearshift lever by pulling 

off shift rod retaining clip in direction of 

arrow (1). Disengage shift rod from 

gearshift lever (2). Note washers on 

either side of shift rod end. 

Release gearshift lever retaining ring 

from below using BMW special tool 25 1 

110. Turn tool 90° ( turn) 

counterclockwise. 

- Raise transmission and temporarily 

install transmission crossmember. 

- 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 rubber grommet with arrow 

pointing forward. Install shift rod 

and shift boot. 

Note:



4 of 4 2/25/2009 10:19 PM 

Install rubber grommet correctly so that it 

seals out water. 

- Connect shift rod to shift lever. 

Install transmission crossmember. 

Lift transmission and tighten 

crossmember bolts. 

Before connecting the shift rod to the 

lever, be sure the gearshift lever is 

facing the correct way as illustrated. 

- Install driveshaft(s) and heat shield. 


- Reinstall exhaust system. See 

180 Exhaust System 

- Lower vehicle. Install shift boot 

cover. Push shift knob onto lever. 


Rear driveshaft to final drive flange 


ribbed nut) 


compressed nut) 

80 Nm (59 ft-lb) 

64 Nm (47 ft-lb) 


flange 

M10 (8.8 grade) 

M10 (10.9 grade 

M12 (10.9 grade) 

Front driveshaft to 

final drive flange 

(with U-joint) (M10) 

Transmission 


body (M8) 


48 Nm (35 ft-lb) 

60 Nm (44 ft-lb) 

100 Nm (74 ft-lb) 

70 Nm (52 ft-lb) 

21 Nm (15 ft-lb)



1 of 4 2/25/2009 10:19 PM 

250-3 


Gearshift 

In E46 models, the electronic 

immobilizer (EWS) prevents starter 

operation unless the gear position is 

Park or Neutral. 

Gearshift mechanism, 

adjusting (automatic 

transmission) 

- Position gearshift lever in Park. 

- Raise vehicle to gain access to 

shift linkage. 

WARNING! 




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 . 


Shift cable 

clamping nut 

10 - 12 Nm 

(7.5 - 9 ft-lb)



2 of 4 2/25/2009 10:19 PM 

Automatic shiftlock, checking 

function (automatic 

transmission) 

The automatic shiftlock uses an electric 

solenoid to lock the selector lever in 

Park or Neutral. Depressing the foot 

brake with the ignition on energizes the 

solenoid, allowing the lever to be 

moved into a drive gear. The solenoid 

is energized only when the engine 

speed is below 2,500 rpm and the 

vehicle speed is below 3 mph. The 

solenoid is mounted in the right-hand 

side of the selector lever housing. 

Automatic shiftlock prevents 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 in an 

open area with the parking brake on 

and with extreme caution. 

- With selector lever in Park or 

Neutral and brake pedal 

depressed, raise engine above 

2,500 rpm. Check that selector



3 of 4 2/25/2009 10:19 PM 

lever cannot be moved out of Park 

or Neutral. 

If any faults are found check the 

electrical operation of the shiftlock 

solenoid and check for wiring faults to 

or from the transmission control 

module (TCM). See 610 Electrical 

Component Locations and Electrical 


Note: 

The solenoid is controlled via the TCM, 

using brake pedal position, engine 

speed, and road speed as controlling 

inputs. 

Automatic transmission gearshift mechanism



4 of 4 2/25/2009 10:19 PM 

Shift interlock, checking 

function (automatic 

transmission) 

The shift interlock uses a cable between 

the ignition switch and the shift lever to 

lock the shift lever in the park position 

when the key is in the off position or 

removed. This feature also prevents the 

key from being removed from the ignition 

lock until the selector lever is in Park. 

- Shift selector lever to Park position 

and turn ignition key to the off 

position. 

- Remove ignition key. Check that 

selector lever 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 position. 

If any faults are found check cable for 

kinks and check cable attachment points 

for damage or faults.

Driveshafts 


1 of 7 2/25/2009 10:20 PM 

General 

260-1 

This repair group covers the repair and 

replacement of driveshafts and 

driveshaft components. Drive axles are 

covered in 311 Front Axle Final Drive 

and 331 Rear Axle Final Drive. 

Special tools 

BMW suggests the use of a special 

tool in the release of the clamping 

sleeve which acts as a grease seal for 

the splined shaft to the rear of the 

driveshaft center bearing. 

Clamping sleeve adjustment tool BMW 

26 1 040 

Front and rear driveshafts 

The rear driveshaft is a two-piece unit 

joined in 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 rear driveshaft is a 

two-piece unit with splined center 

coupling much like that of a rear wheel 

drive model, but it is shorter and 

connects the transfer case to the rear 

differential. A short, one-piece

Driveshafts 


2 of 7 2/25/2009 10:20 PM 

driveshaft runs from the transfer case 

to the front differential. The front 

driveshaft bolts to the transfer case 

and differential directly, using no 

flexible rubber disk. 

Rear wheel drive driveshaft assembly 


driveshaft 

assemblies 

1 - Front driveshaft 

assembly 

2 - Torx screw M10 


ft-lb) 

3 - Transfer case 

4 - Flex disc 

5 - Bolt M12

Driveshafts 


3 of 7 2/25/2009 10:20 PM 


(74 ft-lb) 

6 - Rear driveshaft 

assembly 

7 - Driveshaft 

center bearing 

mount 


The source of driveline vibrations and 

noise can be difficult to pinpoint. Engine, 

transmission, front and rear axle, or 

wheel vibrations can be transmitted 

through the driveshaft to the car body. 

Noises from the car may be caused by 

final drive problems, or by faulty wheel 

bearings, drive axles, or even worn or 

improperly inflated tires. 

Note: 

For drive axle repair information, see 

311 Front Axle Final Drive or 331 

Rear Axle 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 rubber of the flex-disc and 

center bearing for deterioration or tearing 

and check for preload at the center 

bearing with a visual inspection. Check 

the driveshafts for broken or missing 

balance weights. The weights are welded

Driveshafts 


4 of 7 2/25/2009 10:20 PM 

tabs on the driveshaft tubes. In addition 

to inspecting for faulty driveshaft parts, 

the installed angles of the driveshaft 

should also be considered. 

Further inspection requires removal of 

the driveshafts. Check the front centering 

guide on the transmission output flange 

for damage or misalignment. Also check 

runout at the transmission or transfer 

case output flange and output shaft, and 

at the final drive input flange. Check the 

bolt hole bores in the flange for wear and 

elongation. 

Driveshaft flange runout (max. 

allowable) 

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 (Molykote® Longterm 2or 

equivalent). 

Check the universal joints for wear or 

binding. If any joint is difficult to move or 

binds, the driveshaft section should be 

replaced. 

Universal joint play 

Maximum allowable 0.15 mm (0.006 

in.)

Driveshafts 


5 of 7 2/25/2009 10:20 PM 

Table a. Driveshaft troubleshooting 

lists symptoms of driveshaft problems 

and their probable causes. Most of the 

repair information is contained within this 

repair group. 

Note: 

With the driveshaft installed, the actual 

amount that the universal joints pivot is 

limited. For the most accurate test, check 

universal joints in their normal range of 

movement. 

If inspection reveals nothing wrong with 

the driveshaft, it may need to be 

rebalanced. This can be done by a 

speciality driveshaft repair shop. Also, 

check the alignment of the driveshaft as 

described below. 

Note: 

Minor driveshaft vibrations can often be 

corrected simply by disconnecting the 

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. 


rubber deteriorated. 

Flex-disc damaged 

or worn. 

Engine or 

transmission mounts 

faulty. 

Front centering guide 

worn, or driveshaft 

mounting flanges out 

of round. 

Check preload of center bearing. Readjust 

preload. 

Inspect center bearing and rubber. Replace if 

necessary. 

Inspect flex-disc. Replace if necessary. 

Inspect engine and transmission mounts. Align 

or replace, if necessary. 

Check front centering guide and replace if 

necessary. Check runout of driveshaft flanges.

Driveshafts 


6 of 7 2/25/2009 10:20 PM 


Noise during on/off 

throttle or when 

engaging clutch. 

Vibration at 25 to 

30 mph (40 to 50 

km/h). 

Vibration, audible 

rumble over 35 

mph (60 km/h). 

Universal joints worn 

or seized. 

Sliding coupling 

seized. 

Driveshaft 

misaligned. 

Final drive 

components worn or 

damaged (excessive 

pinion-to-ring-gear 

clearance). 

Drive axle or CV joint 

faulty. 


seized. 




of round or 

damaged. 


or seized. 

Flex-disc damaged 

or worn. 


rubber deteriorated. 


seized. 

Misaligned installed 

position. 




of round or 

damaged. 

Check universal joint play and movement. 

Replace driveshaft if necessary. 

Remove driveshaft and check movement of 

sliding coupling. Clean coupling splines and 

replace parts as necessary. 

Check driveshaft alignment. 

Remove final drive and repair. 

Inspect drive axles and CV joints. Repair or 

replace as necessary. 





necessary. Check runout of driveshaft mounting 

flanges. 



Inspect flex-disc. Replace if necessary. 

Inspect center bearing. Replace if necessary. 






necessary. Check runout of driveshaft mounting 

flanges.

Driveshafts 


7 of 7 2/25/2009 10:20 PM 


Mounting flange 

bolts loose or holes 

worn. 

Driveshaft 

unbalanced. 


or seized. 


seized. 

Incorrect preload of 

center bearing. 


faulty. 

Final drive rubber 

mount faulty. 

Driveshaft 

misaligned. 

Remove driveshaft and check transmission 

output flange and final drive input flange. 


Check driveshaft for loose or missing balance 

weights. Have driveshaft rebalanced or replace if 

necessary. 




sliding coupling. Clean coupling splines or 


Check preload of center bearing. Readjust if 

necessary. 

Replace center bearing. 

Inspect final drive rubber mount and replace if 

necessary. 



Driveshafts 


1 of 11 2/25/2009 10:20 PM 

Rear Driveshaft Service 

260-2 

Repair kits for the universal joints are 

not available for BMW driveshafts. 

Worn or damaged universal joints 

usually require replacement of the 

driveshaft. 

1 - Hex bolt, M12 

2 - Centering sleeve 

3 - Flexible disk 

4 - Front section of driveshaft 

5 - Clamping sleeve 

6 - Clamping ring 


8 - Rear section of drive shaft 

9 - Center bearing 

10 - Nut 

11 - Center 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 does 

not normally need to be checked 

unless the engine/transmission or the

Driveshafts 


2 of 11 2/25/2009 10:20 PM 

final drive have been removed and 

installed. If all other parts of the 

driveshaft have been inspected and 

found to be okay, but there is still noise 

or vibration, driveshaft alignment 

should be checked. 

There are two important driveshaft 

alignment checks. The first is to make 

sure that the driveshaft runs straight 

from the transmission to the final drive, 

without any variation from side-to-side 

caused by misalignment of the 

engine/transmission in its mounts. 

Make a basic check by sighting along 

the driveshaft from back to front. Any 

misalignment should be apparent from 

the center bearing forward. 

To adjust the side-to-side alignment, 

loosen transmission or engine mounts 

to reposition them, then retighten 

mounts. The driveshaft should be 

exactly 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 some other 

means of measuring the angle of the 

engine and the final drive and 

comparing these angles to the angle of 

the driveshaft sections. 

To change the deflection angle, shims 

can be placed between the center 

bearing and the body or between the 

transmission and its rear support. 

When using shims to change a 

deflection angle, keep in mind that the 

angle of adjacent joints will also 

change. Deflection angles should be 

as small as possible.

Driveshafts 


3 of 11 2/25/2009 10:20 PM 

Rear driveshaft, removing 

WARNING! 

Be sure the wheels are off the 

ground before removing the 

driveshaft. Set the parking brake 

before removing the driveshaft. 

Once the driveshaft has been 

removed, the vehicle can roll 

regardless of whether the 

transmission is in gear or not. 

The driveshaft is mounted to the 

transmission and final drive 

with self-locking 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 driveshaft sections from 

body using stiff wire.

Driveshafts 


4 of 11 2/25/2009 10:20 PM 

Using BMW special tool 26 1 040, 

loosen threaded clamping sleeve on 

driveshaft a few turns. 

- Remove center support bearing 


- Remove driveshaft but do not 

separate two halves. Pull down on 

center of driveshaft to facilitate 

removal. 

Note: 

If driveshaft halves were separate and 

not matchmarked, see Rear 

driveshaft, installing. If a vibration 

occurs, disassemble driveshaft and 

rotate one section 180°. 

Rear driveshaft, installing 

Align 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 bearing by 

pushing bearing forward (arrow) 4-6 

mm (0.16-0.24 in.) from center. Tighten 

attaching bolts. 

CAUTION! 

The maximum allowable change in

Driveshafts 


5 of 11 2/25/2009 10:20 PM 

height of the center bearing or 

transmission support using shims is 

3 mm (0.12 in.). 

- Tighten threaded sleeve on 

driveshaft to proper torque. 

- Install heat shields. 

- Install exhaust system. See 180 

Exhaust System. Connect wiring 

harness to oxygen sensors. 

- Road test vehicle to check for 

noise or vibration. 

WARNING! 

Do not reuse self-locking nuts. 

These nuts are designed 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. 


Center bearing to 

body 


21 Nm (15 ft-lb) 

10 Nm (89 in-lb) 

Drive axle to differential flange 

M10 Torx bolt 

M10 with locking 

teeth (replace bolts) 

M10 with ribbed 

teeth (black) 


teeth (silver) ZNS 

83 Nm (61 ft-lb) 

96 Nm (71 ft-lb) 

100 Nm (74 

ft-lb) 

80 Nm (59 ft-lb)

Driveshafts 


6 of 11 2/25/2009 10:20 PM 


(replace bolts) 


flangE 

M10 (8.8 grade) 

M10 (10.9 grade) 

48 Nm (35 ft-lb) 

60 Nm (44 ft-lb) 

M12 (10.9 grade) 100 Nm (74 

ft-lb) 

Transmission 


body (M8) 

Note: 

21 Nm (15 ft-lb) 

Bolt grade is marked on the bolt head. 

When replacing bolts, only use bolts of 

the same strength and hardness as the 

originals installed. 

Flex-disc, replacing 

The flex-disc between the front section 

of the rear driveshaft and the output 

flange 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 loosened and the center 

bearing bracket is unbolted. Suspend 

the driveshaft using stiff wire in as 

close to the installed position as 

possible. If the driveshaft hangs

Driveshafts 


7 of 11 2/25/2009 10:20 PM 

unsupported, the rear universal joint 

may be damaged. 

- Unbolt flex-disc from driveshaft. 

Note: 

Removal and installation of the bolts 

may be made easier by placing a large 

hose clamp around the flex-disc, and 

tightening the clamp slightly to 

compress the coupling. 

Install new flex-disc using new 

self-locking nuts. Molded arrows on 

coupling should face flange arms. 

- Install driveshaft as described 

earlier. 

Note: 

Torque only the nuts while holding the 

bolt heads. This will prevent damaging 

or fatiguing the rubber. 


Center bearing to 

body 


21 Nm (15 ft-lb) 

10 Nm (89 in-lb) 


M10 Torx bolt 

M10 with locking 

teeth (replace bolts) 


teeth (black) 


teeth (silver) ZNS 


83 Nm (61 ft-lb) 

96 Nm (71 ft-lb) 

100 Nm (74 

ft-lb) 

80 Nm (59 ft-lb) 


flange 

M10 (8.8 grade) 

48 Nm (35 ft-lb)

Driveshafts 


8 of 11 2/25/2009 10:20 PM 


M10 (10.9 grade) 

60 Nm (44 ft-lb) 

M12 (10.9 grade) 100 Nm (74 

ft-lb) 

Transmission 


body (M8) 

21 Nm (15 ft-lb) 

Center bearing assembly, 

replacing 

To replace the center bearing 

assembly, the driveshaft must be 

removed from the car. The center 

bearing assembly consists of a grooved 

ball bearing in a rubber mount. The 

bearing assembly is pressed onto the 

front 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 center bearing circlip (arrow) 

and dust guard. 

- Install puller so that it pulls on

Driveshafts 


9 of 11 2/25/2009 10:20 PM 

inner hub of bearing. Pulling on 

outer ring of mount may tear 

rubber, and entire bearing 

assembly will need to be replaced. 

- Before installation, make sure dust 

guard is on driveshaft, and then 

press center mount onto 

driveshaft flush with dust guard. 

- Place clamping sleeve, washer, 

and rubber bushing on front 

driveshaft section. Lubricate 

splines with molybdenum disulfide 

Note: 

grease (Molykote ® Longterm 2 or 

equivalent) and then reassemble 

driveshaft. 

Do not retighten clamping sleeve until 

driveshaft is installed. 

- Install driveshaft as described 

earlier 

- Tighten 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 and slides onto 

the transmission output shaft. 

No specifications are given for wear of 

the guide, but generally the guide

Driveshafts 


10 of 11 2/25/2009 10:20 PM 

should fit snugly on the transmission 

output shaft. 

Note: 

Some driveshafts have a dust cap 

installed on the end of the driveshaft, 

over the centering guide. The dust cap 

may become bent or distorted when the 

driveshaft is removed or installed. 

Damage to the dust cap should not 

affect the centering guide and should 

not be mistaken for guide wear. 

- Remove driveshaft as described 

earlier. 

- Pack cavity behind centering 

guide with heavy grease until 

grease is flush with bottom edge 

of guide. 

- Insert 14 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. 

When installing new driveshaft 

centering guide, the sealing lip of the 

guide should face outward and it 

should be driven into the driveshaft to 

drive guide to a protrusion depth of 4.5 

mm (.177 in.).

Driveshafts 


11 of 11 2/25/2009 10:20 PM 

- 

Install driveshaft as described 

earlier. 


Driveshafts 


1 of 2 2/25/2009 10:21 PM 

Front Driveshaft Service 

Repair kits for the universal joints are 

not available for BMW driveshafts. 

Worn or damaged universal joints 

usually require replacement of the 

driveshaft. 

260-3 

Front driveshaft, removing and 

installing 

CAUTION! 

Do not move vechicle using engine 

power once front driveshaft has 

been removed. 

- Raise vehicle and safely support 

to access front driveshaft. 

WARNING! 





A suitable liner (wood, rubber, 

etc.) should be placed between 

the jack and the car to prevent 

body damage. 




the car may roll slightly and the 

jack may shift. 

- Remove underbody splash guard. 

Remove bolts holding driveshaft to 

transfer case output flange and front 

differential input flange (arrows).

Driveshafts 


2 of 2 2/25/2009 10:21 PM 

- 



Driveshaft to drive 

flange (M10) 

70 Nm (52 ft-lb) 


Transfer Case 


1 of 1 2/25/2009 10:21 PM 

General 

270-1 

This repair group covers removal and 

installation of the all wheel drive 

transfer case. Internal transfer case 

repair is not covered. Special press 

tools and procedures are required to 

disassemble and service the internal 

geartrain. 

Some procedures covered in this repair 

group will require you to refer to the 

following repair groups: 

180 Exhaust System 

260 Driveshaft 


The transfer case is 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 engaged to drive all four 

wheels all of the time.

Transfer Case 


1 of 3 2/25/2009 10:22 PM 

Transfer Case 

270-2 

Transfer case, removing and 

installing 

- Raise vehicle and safely support 

to access transfer case. 

WARNING! 








body damage. 






- Remove engine splash guard from 


- Remove exhaust system. See 

180 Exhaust System. 

Remove exhaust system heat shields 

(arrows). 

- Remove front drive shaft. See 



transmission jack or suitable shop 

hoist.

Transfer Case 


2 of 3 2/25/2009 10:22 PM 

Remove transmission crossmember 

(arrows). 

- Detach transfer case vent tube. 

- Keeping the driveshaft in place, 

remove nuts retaining rear 

driveshaft to transfer case at 

flexible disc. 

CAUTION! 

Do not allow the driveshaft to hang 

down. This may damage universal 

joints at drive shaft ends. 

- Support rear driveshaft center 

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. 



Replace dowel pins in transfer 

case mounting surface if 

damaged. 

Coat dowel pins with anti-seize

Transfer Case 


3 of 3 2/25/2009 10:22 PM 


Note: 

On manual transmission cars: 


transmission and transfer case. 

When refilling transfer case, recheck oil 

level again after driving car 

approximately 200 meters (600 ft). 


Transmission 


body (M8) 

Transfer case to 

transmission (M10) 

Transfer case filler 

plug (M18) 

21 Nm (15 ft-lb) 

41 Nm (30 ft-lb) 

33 Nm (24 ft-lb) 

Fluid capacities 

Transfer case oil 

change 

New transfer case 

fill 

0.16 liter (0.16 

qt.) 

0.24 liter (0.25 

qt.) 


Suspension, Steering and Brakes — General 


1 of 7 2/25/2009 10:23 PM 

General 

300-1 

This section covers general information 

for front and rear suspension, steering 

system, and the electronic braking and 

stability control systems. 

Front and rear syspension systems (rear wheel drive) 

Front suspension 

In rear wheel drive cars, the control arm 

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.



2 of 7 2/25/2009 10:23 PM 

Each front strut assembly includes a 

tubular strut housing with an integrated 

shock absorber and a large coil spring. 

The upper strut mount includes a coil 

spring seat and strut bearing. A rubber 

bump stop limits suspension travel. The 

steering arm clamps the lower end of the 

strut assembly. The strut assembly 

pivots between the upper strut mount 

bearing and a ball joint on the control 

arm. 

The front suspension is designed with 

minimum positive steering offset. This 

geometry contributes to stability when 

traction 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 front-to-rear and side-to-side position 

of the strut, while the flexibility of the 

joints and mounts also allows the 

movement necessary for suspension 

travel. The control arm mounting points



3 of 7 2/25/2009 10:23 PM 

are designed with anti-dive geometry. 

This design reduces the normal 

tendency for the front of the vehicle to 

dive under hard braking. 

Control arm position is fixed, with no 

adjustment provisions on the control 

arms for altering front wheel alignment. 

A stabilizer bar mounted to both strut 

housings helps to reduce body roll when 

cornering. 

Front suspension, all wheel drive 

For model year 2001, the E46 Sedan 

and Sport Wagon are offered with 

optional all wheel drive. The all wheel 

drive models are known as 325xi or 

330xi. 

Note: 

The internal BMW designation of these 

models is E46/16. 

The all wheel drive system adds approx. 

100 kg (220 lbs.) to the weight of the car. 

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. Four bolts 

(arrows) attach it to the undercarriage of 

the vehicle. 

The steel control arms, smaller than the 

aluminum arms used on rear wheel drive 

models, attach at the rear to the 

subframe. The control arm inner ball 

joints are bolted to the subframe. The 

hydraulic engine mounts are different



4 of 7 2/25/2009 10:23 PM 

from the rear wheel drive version and 

have also been relocated to provide front 

axle clearance. 

The front stabilizer bar has been 

increased in diameter to accommodate 

the additional weight. See Table a. 

The struts are shorter than the rear 

wheel drive version. Reinforcement 

plates have been added between the 

strut upper mounting and the strut 

towers to prevent sheet metal 

deformation when traveling on poor road 

surfaces. The spring travel of the E46 all 

wheel drive is approximately 20 mm ( 3/4 

in.) less than the rear wheel drive 

version. The shorter front axle spring 

travel is due to the limited angle of 

deflection of the front axle shafts. 

Each front drive axle shaft has a 

conventional constant velocity (CV) joint 

at 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 of the driveshaft. 

The sport suspension option is not 

available for all wheel drive models. 

Steering 

The variable-assist power steering 

system consists of an engine-driven 

hydraulic pump, a rack-and-pinion type 

steering gear, and connecting linkage to 

the road wheels. E46 models utilize an 

engine-speed dependent variable effort 

steering system. At low speeds, 

maximum power assist is provided to



5 of 7 2/25/2009 10:23 PM 

ease parking and city driving. At high 

speeds, assist is reduced to ensure 

stability. 

The steering linkage connects the 

rack-and-pinion unit through tie rods to 

the steering arms. The tie rod ends allow 

the wheels to pivot and react to 

suspension travel. 

On all wheel drive models, the rack and 

pinion steering is constructed with a 

larger diameter piston than the rear 

wheel drive version. This is necessary to 

counter the additional drag of the all 

wheel drive system and the wider 

standard wheels and tires. 

The lower steering column in all wheel 

drive models connects to the steering 

rack via a universal joint, whereas there 

is flexible ("guibo") joint on the rear 

wheel drive models. The 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 springs, shock absorbers and 

stabilizer bar. Drive axles with constantvelocity 

(CV) joints at both ends transfer 

power from the differential to the road 

wheels. The differential is mounted to 

the subframe through rubber mounts 

and bushings to help isolate drivetrain 

noise and vibration. 

In all wheel drive models, the rear 

suspension and the rear differential have



6 of 7 2/25/2009 10:23 PM 

the same layout as the rear wheel drive 

version. 

The rear suspension travel of the E46 all 

wheel drive is approx. 17 mm (0.67 in.) 

less than the rear wheel drive version. 

The reason for the reduced travel in the 

rear is to prevent excessive body roll as 

a result of the higher body profile. 

The rear stabilizer bar diameter has 

been increased to accommodate the 

additional vehicle weight. See Table 

a. 

Table a. E46 stabilizer bars 

Model 

Rear wheel 

drive 

All wheel 

drive 

Sport 

suspension 

(n/a on awd) 

Front 

diameter 

23.0 mm 

(0.906 in.) 

23.5 mm 

(0.925 in.) 

24.0 mm 

(0.945 in.) 

Rear 

diameter 

18 mm 

(0.709 in.) 

20 mm 

(0.787 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 does not normally 

result in total brake failure. 

Each disc brake uses a caliper with a 

single hydraulic cylinder. Brake pads in 

the left front and right rear contain wear 

sensors. When the pads need 

replacement, the sensors illuminate a



7 of 7 2/25/2009 10:23 PM 

light on the dashboard. 

Tires and wheels 

Tire size is critical to the proper operation 

of the anti-lock brake system and 

traction control system. Several different 

styles of wheels in 15, 16, and 17 inch 

diameters are available from an 

authorized BMW dealer. 

On all wheel drive cars, standard wheel 

size is 17x 7.0 to ensure there is enough 

room for the front axles and brakes. Tire 

size is 205/50 R17. 

Tire and rim size applications are listed 

in Table b. Rim and tire sizes. 

Note: 

Aftermarket 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 

245/45R 17 

330i/Ci 17 x 7 205/50R 17 17 x 7.5/8.5 225/45R 17 

245/45R 17 

325xi 

330xi 

17 x 7 205/50R 17 




1 of 24 2/25/2009 10:24 PM 

Electronic Brake and 

Stability Control 

Systems 

300-2 

All E46 vehicles are equipped with an 

Antilock Braking System (ABS). Early 

production models featured ABS with 

Automatic Stability Control (ABS/ASC). 

Later models came equipped with ABS 

and Dynamic Stability Control 

(ABS/DSC). DSC builds upon the 

existing ABS/ASC system to provide 

electronic control of drive and braking 

systems to insure vehicle stability. 

This manual will refer to these systems 

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 

cylinder 

3 - Rear wheel speed sensor, at each 

rear wheel hub 

4 - Front wheel speed sensor, at each 

front steering arm



2 of 24 2/25/2009 10:24 PM 

DSC 

1999 - 2000 Dynamic Stability Control 

Teves MK 20 DSC 

1 - DSC control module and hydraulic 

unit, right rear of engine 

compartment 

2 - Brake fluid reservoir, master 

cylinder and DSC brake pressure 

sensors, left rear of engine 

compartment 

3 - DSC precharge pump, left rear of 

engine compartment, under brake 

master cylinder 




front steering 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 

compartment, under brake master 

cylinder 


rear wheel hub



3 of 24 2/25/2009 10:24 PM 





6 - Lateral acceleration sensor, 

behind driver’s kickpanel 

7 - Rotational acceleration (yaw) 



Note: 

There is no precharge pump in this 

system. 

2001 all wheel drive Dynamic Stability 

Control Bosch DSC III 5.7 

1 - DSC control module, hydraulic 

unit and DSC brake pressure 

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 








7 - Lateral acceleration sensor and 

rotational acceleration (yaw) 



ABS system description



4 of 24 2/25/2009 10:24 PM 

The electronically controlled ABS 

maintains vehicle stability and control 

during emergency braking by 

preventing wheel lock-up. ABS 

provides optimum deceleration and 

stability during adverse conditions. It 

automatically adjusts brake system 

hydraulic pressure at each wheel to 

prevent wheel lock-up. 

The system's main components are the 

wheel speed (pulse) sensors, the 

ABS/ASC or ABS/DSC control module, 

and the hydraulic control unit. 

The wheel speed sensors continuously 

send wheel speed signals to the 

control module. The control module 

compares these signals to determine, 

in fractions of a second, whether any of 

the wheels are about to lock. If any 

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 control. The main 

function of the ASC system is to 

maintain the rolling contact between 

the tires and the road surface under all 

driving conditions. This is achieved 

through exact application and 

management of braking and drivetrain 

forces. 

Note: 

The traction control system referred to 

as ASC (Automatic Stability Control)



5 of 24 2/25/2009 10:24 PM 

may also be referred to as ASC+T 

(Automatic Stability Control+Traction). 

The ASC system improves traction by 

electronically applying the rear brakes 

when the rear drive wheels are 

spinning at a faster rate than the front 

wheels. The combined ABS/ASC 

control module, operating through the 

ABS hydraulic control unit, modulates 

braking force at the rear wheels. 

In addition, ASC will deactivate 

individual fuel injectors and override 

the motor driven throttle to reduce 

engine torque and maintain vehicle 

traction. Because the throttle is 

controlled electronically the driver 

cannot increase the engine power 

output during ASC intervention 

regardless of how far the accelerator 

pedal is pushed. 

The components that comprise the 

ASC system also function 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. 

Decelerating on snowy or icy road 

surfaces can lead to rear wheel slip. If 

a rear wheel starts to drag or lock up, 

the ASC system can limit the problem 

by adjusting throttle, fuel injection and 

ignition timing. 

A switch on the center console is used 

to toggle the ASC on or off. 

The ASC system is designed to be 

maintenance free. There are no 

adjustments that can be made. Repair 

and troubleshooting of the ASC system



6 of 24 2/25/2009 10:24 PM 

requires special test equipment and 

knowledge and should be performed 

only by an authorized BMW dealer. 

Table c. ASC indicator lamp function 

lists the conditions indicated by the 

ASC indicator light in the instrument 

cluster. 

ABS/ASC traction 

control system 

1 - Wheel 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



7 of 24 2/25/2009 10:24 PM 

Indicator lamp Condition Action / Use 

Light off ASC monitoring mode Automatic ASC operation 

Press ASC button, light 

comes on 

Press ASC button, light goes 

out 

ASC off (disabled) 

ASC monitoring mode 

Rocking the car to get out of 

snow or other loose surface 

Driving with snow chains 

Automatic ASC operation 

Light flashes ASC active mode Normal ASC operation as it 

controls wheel speed 

Light stays on after start up or 

comes on while driving 

Defect in ASC 

Consult BMW dealer for 

diagnosis/repair 

(vehicle operation remains 

normal) 

Dynamic Stability Control (DSC) 

Dynamic Stability Control (DSC), 

standard in 2000 and later E46 models, 

utilizes many principles and 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 

inputs to determine vehicle instability 

during braking, cornering, or reduced 

traction situations. Based upon these 

inputs the ABS/DSC control module 

sends outputs to the engine control 

module and the ABS/DSC hydraulic unit 

to activate torque reduction protocols 

and braking intervention. 

Inputs 

1 - Lateral acceleration sensor



8 of 24 2/25/2009 10:24 PM 

2 - Steering angle sensor 

3 - Rotational rate (yaw) sensor 

4 - Brake pressure sensor 

5 - ABS wheel speed sensors 

6 - Engine control module 

Outputs 

7 - ABS/DSC hydraulic system 

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



9 of 24 2/25/2009 10:24 PM 

System functions 

Each of the electronic braking and 

stability control systems include 

sub-systems which use the hydraulic 

unit/control module and sensors to carry 

out additional system functions. The 

foundation of the stability control 

systems is Antilock Braking System 

(ABS) with the following basic functions: 

Cornering brake control (CBC) 

Electronic brake 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 build up on the inside rear



10 of 24 2/25/2009 10:24 PM 

wheel brake circuit during cornering if 

activation threshold values are 

exceeded. 

Electronic brake proportioning (EBV) 

Electronic brake proportioning adjusts 

braking force to the rear wheels based 

upon the vehicle's loading, front to rear, 

to maximize the vehicle's braking power. 

Using wheel speed sensors, the control 

module compares individual wheel 

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 

Pressure hold



11 of 24 2/25/2009 10:24 PM 

Pressure release 

When intervention is necessary: 

The changeover valve in the 

hydraulic unit energizes and closes 

inlet valves for the two front wheels 

and the rear wheel with traction. 

The rear brake circuit intake valve is 

energized and opened to rear wheel 

without traction. 

Return/pressure pump is activated 

and draws in brake fluid from the 

master cylinder and delivers 

pressurized brake fluid to wheel 


Pressure hold and pressure release 

cycles are run by cycling inlet and 

outlet valve to rear brake caliper 


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 

Retarding ignition 

Cutting off individual cylinder fuel 

injectors



12 of 24 2/25/2009 10:24 PM 

Drag torque reduction (MSR) 

During deceleration and engine braking 

conditions engine drag torque can cause 

the rear wheels of a vehicle to lock on 

low traction surfaces, especially in high 

speed, low gear driving. This can lead to 

loss of traction in the rear. When drive 

wheel speed is slower than front wheel 

speed the ECM will suspend vehicle 

coasting by increasing throttle opening 

angle and engine torque. 

Dynamic brake control (DBC) 

The DBC function 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 

Pressure sensor self test completed 

and sensors OK 

Vehicle travelling forward 

Not all wheels in ABS regulation 

range



13 of 24 2/25/2009 10:24 PM 

When DBC function is activated, braking 

pressure will increase at all wheels up to 

the ABS regulation point. DBC will 

continue until the driver releases the 

brake pedal, brake pressure drops, or 

the vehicle slows to under 3 mph. 

Maximum brake control (MBC) 

Maximum brake control is designed to 

assist in stability control by increasing 

rear brake pressure when the front 

wheels are under ABS regulation. MBC 

intervention is triggered 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 conditions: 

Front wheels drop out of ABS 

regulation 

Driver releases brake pedal 

Brake pressure falls below



14 of 24 2/25/2009 10:24 PM 

threshold 

Vehicle road speed drops below 3 

mph 

Teves MK 20 ASC diagram



15 of 24 2/25/2009 10:24 PM 

Teves MK 20 DSC Diagram



16 of 24 2/25/2009 10:24 PM 

Vehicle network 

The hydraulic unit/control module 

communicates with some sensors and 

many other control modules over the 

CAN-bus. The CAN-bus is a system of 

wiring that functions like a computer 

network, allowing different components 

to communicate over the same data line, 

at the same time, by varying electronic 

signals. 

Component communication dialogs take 

place between multiple control units and 

sensors over the 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, lateral 

acceleration & steering angle 

sensor information 

ABS control module receives signal



17 of 24 2/25/2009 10:24 PM 

from ASC/DSC switch on dash. 

ABS control module signals turn 

instrument cluster warning lamps 

on during ASC/DSC regulation. 

Hydraulic unit/control module 

The hydraulic unit is mounted in 

conjunction with the control module. 

While the hydraulic unit and control 

module function as one unit, they are 

replaceable individually. All ABS/ASC or 

ABS/DSC processing functions are 

performed by the control module. The 

control module is linked to 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 used in the E46 electronic 

braking and stability control systems: 

1999 - 2000 Teves MK 20 ASC / 

DSC: Inductive



18 of 24 2/25/2009 10:24 PM 

2001 Bosch DSC III 5.7: Hall effect 

2001 Teves MK 60 DSC: 

Magnetoresistive 

1 - Fastening element 

2 - Ground contact 

3 - Sensor wiring 

4 - Sensor housing 

5 - Metal pulse wheel 

6 - Sensor element support 

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.



19 of 24 2/25/2009 10:24 PM 

DSC lateral acceleration sensor 

The lateral acceleration sensor provides 

the DSC control module with an input 

signal based on the degree of lateral 

acceleration (g forces) that the vehicle 

experiences. Based on a 5 volt reference 

voltage, the sensor will return an output 

voltage that ranges between 0.5 and 4.5 

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



20 of 24 2/25/2009 10:24 PM 

Bosch DSC III 5.7 diagram



21 of 24 2/25/2009 10:24 PM 

DSC rotational rate (yaw) sensor 

The rotational rate sensor provides a 

analog voltage signal to the DSC control 

module to indicate the rotational speed 

(yaw) of the vehicle on its vertical axis. 

The control module supplies a 5 volt 

reference voltage to the sensor. The 

sensor returns a voltage between 0.25 

and 4.65 volts based on the amount of 

yaw. If the vehicle's yaw exceeds preset 

parameters, the DSC control module will 

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 control unit via 

the vehicle's CAN-bus network. Sensor 

recalibration is required after steering



22 of 24 2/25/2009 10:24 PM 

angle sensor replacement or repairs to 

the steering column. This recalibration is 

performed using either the DIS or MoDiC 

BMW scan tools. 

DSC pressure sensor 

The DSC pressure sensor(s) provides 

the ABS/DSC control module an analog 

voltage signal in proportion to brake 

pressure in the master cylinder. 

The DSC MK 20 and MK 60 systems use 

two switches installed at the brake 


The Bosch DSC III 5.7 system uses one 

switch installed at the DSC hydraulic 

unit. 

DSC precharge 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 indicators 

ASC/DSC control button 

The control button is used to deactivate 

the stability control functions of either 

the ASC system or the DSC system.



23 of 24 2/25/2009 10:24 PM 

Brake light switch 

The brake light switch input signal is 

used by the control module to determine 

which stability control routine is 

necessary. The control module will 

interrupt Automatic Stability Control 

(ASC) functions if the brake pedal is 

depressed during ASC operation. On 

vehicles equipped with DSC, DSC 

operation is not cancelled during braking 

situations. 

Note: 

Bosch DSC III 5.7 control module 

compares input from the brake light 

switch with pressure sensor value. 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 brake fluid available 

in the brake fluid reservoir. When an 

adequate amount of fluid is present, the 

switch completes a ground circuit for the



24 of 24 2/25/2009 10:24 PM 

control module. When fluid level is too 

low, the circuit is broken and the 

ASC/DSC functions are turned off. 

Normal braking and ABS remains 

unaffected. 

Warning lamps 

Braking and stability control warning 

lights 

1 - ASC/DSC warning light. llluminates 

solidly when ASC/DSC system has 

been turned off, or blinks when 

ASC/DSC system is activate. 

2 - Brake warning light. Indicates when 

the parking brake is engaged, or 

when brake system 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 

vehicle without diagnosing the 

problem.



1 of 6 2/25/2009 10:24 PM 


300-3 

Table d. Suspension and steering troubleshooting 

Stable handling and ride comfort both 

depend on the integrity of the 

suspension and steering components. 

Any symptom of instability or imprecise 

road feel may be caused by worn or 

damaged suspension components. 

When troubleshooting suspension and 

steering problems, also consider the 

condition of tires, wheels and their 

alignment. Tire wear and incorrect 

inflation pressures can dramatically 

affect handling. Subtle irregularities in 

wheel alignment angles also affect 

stability. Mixing different types or sizes 

of tires, particularly on the same axle, 

can affect alignment and may 

unbalance a car's handling. 

Table d. Suspension and steering 

troubleshootinglists 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. 

Symptom Probable cause Repairs 

Breaking away while braking 

Car pulls to one side, 

wanders 

Front end or rear end 

Worn struts or shock 

absorbers 

Incorrect tire pressure 

Incorrect wheel alignment 

Faulty brakes (pulls only 

when braking) 


absorbers 

Replace struts or shock 

absorbers. 310, 330 

Check and correct tire 

pressures. 020 

Check and adjust wheel 

alignment. 320 

Check for sticking/damaged 

front caliper. 

340 


absorbers. 310, 330



2 of 6 2/25/2009 10:24 PM 


vibration or shimmy 

Worn suspension bushings 

(control arm or trailing arm) 

Worn front suspension ball 

joints (control arm, steering 

arm or steering tie-rod end) 

Unbalanced or bent 

wheels/tires Loose wheel lug 

bolts 

Loose wheel lug bolts 

Replace worn bushings. 

310, 330 

Replace worn ball joints. 

310 

Balance tires. 

Check tires for uneven wear 

patterns. 

Check wheels for damage. . 

Tighten lug bolts to proper 

torque. 

Poor handling, poor 

directional stability 

Poor stability, repeated 

bouncing after bumps, 

suspension bottoms out easily 

Rear end hop with hard 

braking 

Rear control arm or rear 

subframe bushings worn or 

damaged 

Rear alignment incorrect 


absorbers 

Rear trailing arm busing worn 

or damaged 

Replace rear suspension 

bushings as necessary. 

330 

Check and adjust wheel 

alignment. 320 


absorbers. 310, 330 

Replace trailing arm 

bushing. 330 

Steering heavy, poor returnto-center 

Worn upper strut mounts Replace strut mounts. 310 

Incorrect tire pressure 

steering system faulty 

Check and correct tire 


Check power steering fluid 

level. 320 

Steering loose, imprecise Incorrect tire pressure Check and correct tire 


Loose steering rack mounting 

bolt(s) 

Worn tie rod end(s) 

Faulty front wheel bearing 

Worn or damaged steering 

rack 

Worn tires 

Inspect and tighten bolts. 

320 

Replace tie rod(s) and align 

wheels. 320 

Replace wheel bearing. 

310 

Adjust or replace steering 

rack. 320 . 

Replace tires.



3 of 6 2/25/2009 10:24 PM 


Suspension noise, especially 

over bumps (drumming, 

rattling) 

Tail skid when braking 

Tire flat spots 

Worn front upper strut 

mounts 

Worn suspension bushings 

(control arm or trailing arm) 

Worn stabilizer bar rubber 

mounts 

Loose suspension subframe 

Rear trailing arm front 

bushing worn or damaged 


absorbers 

Replace upper strut mounts. 

310 

Replace worn bushings. 

310, 330 

Replace stabilizer bar rubber 

mounts. 310 , 330 

Check subframe for damage. 

Tighten mounting bolts. 

Replace trailing arm 

bushing. 330 


absorbers. 310 , 330 

Uneven ride height Incorrect coil springs Measure ride height. 300 

Unsteady in curves, 

self-steering, poor rear end 

stability 

Wheel noise, continuous 

growling, may be more 

noticeable when turning 

Wheel-hop on normal road 

surface 

Bent or damaged suspension 

components 

Sagging coil springs 

Rear subframe bushings 

worn or damaged 

Differential bushings worn or 

damaged 

Rear shock absorbers worn 

Worn wheel bearing 


absorbers 

Inspect, repair/replace as 

necessary. 310 , 330 

Replace springs as 

necessary. 310 , 330 



330 



330 

Replace rear shock 

absorbers. 330 

Replace wheel bearing. 

310 , 330 


absorbers. 310 , 330 

ABS troubleshooting 

ABS is designed to be maintenance free. 

There are no adjustments that can be 

made to the system. Repair and



4 of 6 2/25/2009 10:24 PM 

troubleshooting of major ABS 

components requires special test 

equipment and knowledge and should 

be performed by an authorized BMW 

dealer. 

ABS is self-tested by the control module 

each time the car is started. Once the 

test is complete, the ABS dashboard 

warning light turns off. If the light 

remains lit or comes on at any time 

during driving, a system fault has 

occurred and ABS is electronically 

disabled. The conventional braking 

system remains fully functioning. 

When a system or component failure 

occurs in the electronic braking and 

stability control systems, either the brake 

warning light, ABS warning light, or the 

ASC / DSC warning light will 

illuminate.Troubleshooting 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 on, have the 

system diagnosed by an authorized 


Carefully inspect the entire ABS wiring 

harness, particularly the pulse sensor 

harnesses and connectors near each 

wheel. Look for chafing or damage due 

to incorrectly routed wires. 

Carefully remove the wheel speed 

sensors. Clean the sensor tips. Inspect 

toothed wheel on wheel hub. Check for



5 of 6 2/25/2009 10:24 PM 

missing, clogged or corroded teeth, or 

other damage that could alter the 

clearance between the sensor tip and 

toothed wheel. 

Ride height 

Ride height measurement (A) at either 

axle is taken from center of wheel arch to 

bottom of wheel rim. 

If the ride height is outside the 

specification listed, new springs should 

be installed. Be sure to have the old 

spring code number on hand when 

ordering new spring. 

Table e. Front ride height 

specifications (measurement A) lists 

front suspension ride height 

specifications, Table f. Rear ride 

height 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 

Rear seat (center) 

Trunk 

Fuel tank 

68 Kg (150 lbs) 

68 Kg (150 lbs) 

21 Kg (46 lbs) 

full 

Table e. Front ride height specifications (measurement A) 

Wheel size 

Standard 

suspension 

Sport 

suspension 

Rough road 

suspension 


suspension 

15 inch 576 mm 

(22.67 in.) 

561 mm 

(22.08 in.) 

593 mm 

(23.35 in.)



6 of 6 2/25/2009 10:24 PM 

Wheel size 

Standard 

suspension 

Sport 

suspension 

Rough road 

suspension 


suspension 


(23.19 in.) 

574 mm 

(22.59 in.) 

606 mm 

(23.86 in.) 

606 mm 

(23.85 in.) 


(23.77 in.) 

589 mm 

(23.19 in.) 

621 mm 

(24.44 in.) 

621 mm 

(24.44 in.) 


(24.29 in.) 

602 mm 

(23.71 in.) 

634 mm 

(24.96 in.) 

634 mm 

(24.96 in.) 

Maximum variation between sides: 10 mm (0.4 in) 

Maximum deviation from specifications: 10 mm (0.4 in) 

Table f. Rear ride height specifications (measurement A) 

Wheel size 

Standard 

suspension 

Sport 

suspension 

Rough road 

suspension 


suspension 


(21.33 in.) 

526 mm 

(20.70 in.) 

562 mm 

(22.12 in.) 


(21.85 in.) 

539 mm 

(21.22 in). 

575 mm 

(22.64 in.) 

572 mm 

(22.52 in.) 


(22.44 in.) 

554 mm 

(21.81 in.) 

590 mm 

(23.22 in). 

587 mm 

(23.11 in.) 


(22.95 in.) 

567 mm 

(22.32 in.) 

603 mm 

(23.74 in.) 

600 mm 

(23.62 in.) 

Maximum variation between sides: 10 mm (0.4 in) 

Maximum deviation from specifications: 10 mm (0.4 in) 


Front Suspension 


1 of 5 2/25/2009 10:25 PM 

General 

310-1 

This repair group covers the repair and 

replacement of components that make 

up the front suspension of E46 cars. 

See 300 Suspension, Steering and 

Brakes-General for a description of the 

front suspension and components, as 

well as specification for setting ride 

height. 

Special tools 

Special 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



2 of 5 2/25/2009 10:25 PM 

Upper strut nut removal socket BMW 

31 2 210 

Front coil spring 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



3 of 5 2/25/2009 10:25 PM 

Slide hammer with adapter BMW 33 4 

201/202/203 33 2 116 

Inner bearing race puller set BMW 33 4 

400 

Front suspension construction 

Some front suspension components 

are constructed of weight saving 

materials. For example, the control 

arms (in rear wheel drive models) are 

forged aluminum. This allows for 

weight reduction in the car, as well as a 

lower unsprung 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 


Do not reuse self-locking nuts or 

bolts. They are designed to be 

used only once and may fail if 

reused. Always replace



4 of 5 2/25/2009 10:25 PM 

self-locking fasteners any time 

they are loosened or removed. 

Do not install bolts and nuts 

coated with undercoating wax, 

as the correct tightening torque 

cannot be assured. Always 

clean the threads with solvent 

before installation, or install 

new parts. 

Do not attempt to weld or 

straighten any suspension 

components. Replace damaged 

parts. 

CAUTION! 

Due to the aluminum 

construction of 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 other 

highly corrosive materials; or 

steel welding splashes. 

Front suspension



5 of 5 2/25/2009 10:25 PM 

assembly (6 cylinder 

models) 

1 - Upper strut 

mount 

2 - Coil spring 

3 - Strut assembly 

4 - Control 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 




1 of 10 2/25/2009 10:25 PM 

Shock Absorbers and 

Springs 

310-2 

Note: 

Setting the ride height is covered in 

300 Suspension, Steering and Brakes- 

General. 

The front suspension shock absorbers 

in E46 cars are McPherson struts. The 

strut is a major component of the 

suspension and supports the spring. 

Most strut assembly components are 

available as replacement parts. Struts 

and/or springs should always be 

replaced in pairs. 

Front strut, upper strut 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 suspension parts. 

Pull brake fluid hose and ABS sensor 

wire harness off bracket at steering arm 

pinch bolt.



2 of 10 2/25/2009 10:25 PM 

Note: 

Right side shown is in illustration. Left 

side bracket also holds brake pad wear 

sensor wire. 

- Unbolt brake caliper assembly, 

keeping brake hose connected. 

Suspend brake caliper from 

chassis using stiff wire. See 

340 Brakes. 

Remove ABS wheel speed sensor 

mounting bolt (arrow). Slide 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



3 of 10 2/25/2009 10:25 PM 

of stabilizer bar link ball joint while 

removing mounting nut. 

Remove tie rod outer end nut. Use 


equivalent to press tie rod end off 

steering arm. 

- Remove lower ball joint nut. Use 


equivalent to separate steering 

arm from control arm. 

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. 

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



4 of 10 2/25/2009 10:25 PM 

strut tower slots (arrows). 

CAUTION! 

Do not remove center strut retaining 

nut. 

- Lower strut assembly from car. 

When installing strut assembly into car: 

Make sure locating pin (arrow) of 

strut bearing is positioned 

correctly in strut tower. 

If factory alignment locating pin is 

missing, make sure three upper 

mounting studs are positioned 

correctly in slotted holes 

according to marks made 

previously. 

When installing steering arm 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. 



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 threadlocking 

compound. 

When attaching stabilizer link to 

strut, use a thin wrench to 

counterhold hold link ball joint 

while tightening nut.



5 of 10 2/25/2009 10:25 PM 

Have car professionally aligned 

when job is complete. 


Brake caliper to 

steering arm 

Road wheel to hub 

Stabilizer bar link 

to strut 

Steering tie rod to 

steering arm 

Steering arm to 

control arm 

Steering arm pinch 

bolt at strut 

housing 

Strut assembly to 

strut tower (selflocking 

nuts) 

110 Nm (81 

ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

59 Nm (44 ft-lb) 

65 Nm (48 ft-lb) 

65 Nm (48 ft-lb) 

81 Nm (60 ft-lb) 

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 


ft-lb)



6 of 10 2/25/2009 10:25 PM 

3 - Rivet (all wheel 

drive or rough 

road package 

only) 

4 - Strut bearing 

reinforcement 

(all wheel drive 

or rough road 

package only) 

5 - Self locking 

flanged nut M8 

tighten to: 

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 


9 - Flat washer 

10 - Upper spring 

seat 

11 - Upper spring 

pad 

12 - Rubber stop 

13 - Dust seal 

14 - Spring 

15 - Lower spring



7 of 10 2/25/2009 10:25 PM 

pad 

16 - Strut 

Strut assembly, disassembling 

and assembling 

Replacing the strut, upper strut mount or 

spring requires that the strut assembly 

first be removed from the car and 

disassembled. For a guide to parts used 

during component replacement, see the 

accompanying diagram. 

- Remove strut assembly as 

described earlier. Place in shop 

vice, or support securely. 

- Using spring compressor, 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. 

Counterhold strut shaft using 6 mm 

Allen wrench. 

- Remove upper strut bearing and



8 of 10 2/25/2009 10:25 PM 

related components. 

- Replace strut, upper strut mount or 

spring, as needed. 

Note: 

Springs and/or struts should always be 


Be sure that replacement struts are 

marked with the same code as the ones 

being removed. 

Note: 

Aftermarket struts are not marked. 

Vehicles with "rough road" package are 

equipped 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.



9 of 10 2/25/2009 10:25 PM 

Assembly is reverse of disassembly, 


Line up slot in spring pad with 

corresponding slot in lower spring 

seat. 

Use a new upper strut self locking 

nut. Tighten nut fully before 

releasing spring compressor. 

Be sure upper spring pad is 

correctly installed to upper spring 

seat and spring end is correctly 

seated in upper and lower spring 

seats. 

Release spring compressor 

carefully and evenly, allowing 

spring to expand slowly. 



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 


7 - Rubber bump-stop 

8 - Dust shield 

9 - Lower spring pad



10 of 10 2/25/2009 10:25 PM 

10 - Strut housing 

11 - Locating pin 

12 - Protective cap 

13 - Upper spring pad 

14 - Washer 

15 - Upper spring seat 

16 - Spring 

17 - Lower spring seat 


Upper strut mount 

to strut shaft M14 

self-locking nut 

64 Nm (47 ft-lb) 




1 of 2 2/25/2009 10:25 PM 

Front End 

Reinforcement 

310-3 

In rear wheel drive models, a front end 

reinforcement is bolted to the rear of 

the subframe and attached to the 

frame rails. 

CAUTION! 

Do not drive vehicle without the front 

end reinforcement in place. Damage 

to the front suspension may result. 

The tubular front end reinforcement is 

installed with 4 bolts (A) in the 

following cars: 

Rear wheel drive Sedan and Sport 

Wagon models manufactured until 

production date 12/2000. 

Coupe models manufactured until 


- The aluminum plate type front end 

reinforcement is installed in the 

following cars: 

All Convertible models 

Coupe models manufactured from 


Rear wheel drive Sedan and Sport 

Wagon models manufactured 

from production date 12/2000. 

CAUTION! 

After 2/2001, the front reinforcement 

plate was produced with larger cast 

depressions to accommodate the



2 of 2 2/25/2009 10:25 PM 

larger (66 mm) front control arm 

bushings. The difference in the early 

production and later plates can only 

be discerned by removing the plate. 

In order to safely use an early 

production plate in a car with larger 

bushings, insert appropriate sized 

washers between frame rails and 

reinforcement plate at 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. 


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°



1 of 24 2/25/2009 10:26 PM 

Front Subframe 

310-4 

The front subframe provides rigid 

mounting points for the engine, 

suspension, and steering components. 

The subframe is not normally subject 

to wear and should only be replaced if 

structurally damaged. 

Rear wheel drive and all wheel drive 

models differ significantly in the design 

of the front subframe. 

Removing the front subframe requires 

engine lifting equipment to support the 

weight of the engine from above so that 

the subframe 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 


models) 

Using engine support equipment, raise 

engine until weight of engine is 

supported. 

- Raise car and remove front 

wheels. 

WARNING! 



for the purpose. Place the jack



2 of 24 2/25/2009 10:26 PM 




- Remove splash shield under 


- Remove front end reinforcement. 

See Front End Reinforcement 

earlier in this group. 


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.



3 of 24 2/25/2009 10:26 PM 

Repeat for left side. 

Remove steering rack mounting bolts 

(arrows) at front of subframe. Suspend 

rack out of the way with stiff wire. 

Remove right lower engine mount 

fastener (arrow). 

- Repeat on left side 

Support suspension subframe from 

below using appropriate jacking 

equipment. Remove subframe 


subframe. 

Note: 


similar. 

Installation is reverse of removal, noting 


Make sure all bolts, bolt holes,



4 of 24 2/25/2009 10:26 PM 

and mating surfaces are clean to 

ensure proper tightening and 

alignment. Use new self-locking 

nuts or bolts, where applicable. 

Lower engine onto engine mounts, 

allowing it to settle fully before 

tightening engine mount bolts. 

When the job is completed, have 

front end professionally aligned. 


2 - inner ball joint nut -tighten to 90 

Nm (66 ft-lb) 

3 - Subframe mounting bolt (See 

torque table.) 



Control arm ball 

joint to subframe 


nut (always 

replace) 

Control arm 

bushing carrier to 

body M10 bolt 


90 Nm (66 ft-lb) 

59 Nm (43 ft-lb) 


subframe or body frame rails: M10 

bolt (always replace) 

Stage 1 

59 Nm (43 ft-lb) 


+ 30° 

Steering rack to 

subframe (M10 

bolt) 

Subframe to body 

M12-8.8 bolts 

42 Nm (31 ft-lb) 

77 Nm (57 ft-lb)



5 of 24 2/25/2009 10:26 PM 


M12-10.9 bolts 110 Nm (81 

ft-lb) 

M12-12.9 bolts 105 Nm (77 

ft-lb) 

Front subframe, removing and 


models) 

Using engine support equipment, raise 

engine until weight of engine is 

supported. 

- Raise car and remove front 

wheels. 

WARNING! 







- Remove splash shield under 



headlights: Remove front ride level 

sensor mounting fastener (arrow) and 

lay sensor aside.



6 of 24 2/25/2009 10:26 PM 

Working at rear right corner of front 

subframe, unhook heatshield from 

subframe (arrow). 

Remove left engine mount fastener 

(arrow). 

- Repeat for right side. 

- Working at right front of subframe, 

detach power steering lines. 

Remove stabilizer bar anchor fasteners 

(arrows) from front corners of 

subframe. Suspend stabilizer bar from 

chassis using stiff wire. 

Working at left rear corner of subframe, 

remove control arm rear bracket 

mounting bolts (arrows).



7 of 24 2/25/2009 10:26 PM 

- 

Repeat for right side. 

Working at left side of subframe, 

remove inner control arm ball joint 

mounting bracket bolts (arrows) from 

subframe. Hang control arm using stiff 

wire. 

WARNING! 

Do not allow the control arm to hang 

from the outer (steering arm) ball 

joint. 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.



8 of 24 2/25/2009 10:26 PM 



Make sure all bolts, bolt holes, 

and mating surfaces are clean to 

ensure proper tightening and 

alignment. Use new self-locking 

nuts or bolts, where applicable. 

Lower engine onto engine mounts, 

making sure locating pin on left 

mount (arrow) seats correctly in 

slot of subframe boss. 

Allowing engine to settle fully on 

mounts before tightening engine 

mount fasteners. 

When the job is completed have 

front end professionally aligned. 


Control arm rear 

bracket to 

subframe M10 bolt 


Engine mount to 

subframe M10 self 

locking nut 

Inner ball joint to 

control arm M14 



Inner ball joint 

mount to subframe 

M12 bolt 

Stabilizer anchor to 

subframe (M8) 

59 Nm (44 ft-lb) 

45 Nm (33 ft-lb) 

80 Nm (59 ft-lb) 

77 Nm (57 ft-lb) 

22 Nm (16 ft-lb)



9 of 24 2/25/2009 10:26 PM 


Steering rack to 

subframe (M10 

bolt) 

Subframe adapter 

to body M10 bolt 


Subframe front to body 

M12-8.8 bolt 

42 Nm (31 ft-lb) 

59 Nm (44 ft-lb) 

77 Nm (57 ft-lb) 

M12-10.9 bolt 110 Nm (81 

ft-lb) 

M12-12.9 bolt 105 Nm (77 

ft-lb) 

Subframe rear to 

adapter M12 bolt 


110 Nm (81 

ft-lb) 

All wheel drive front 

subframe 


2 - Blind rivet nut 

3 - Engine 

mounting flange 

4 - Steering rack 

mounting flange 


mounting 

6 - Subframe to 

body adapter 

7 - Bolt M10 



(44-ft-lb)



10 of 24 2/25/2009 10:26 PM 

8 - Bolt M10 



ft-lb) 

9 - Control arm rear 

bracket 

10 - Bolt M12 



(81 ft-lb) 

11 - Jack point 

12 - Subframe 

mounting bolt 

M12 (see torque 

table) 


inner ball joint 

14 - Bolt M12 


ft-lb) 

15 - Self locking nut 

M14 (always 

replace) 


ft-lb) 

Control Arms 

In all models each front control arm has 

three attachment points:



11 of 24 2/25/2009 10:26 PM 

A Outer ball joint attached to 

steering arm 

B Inner ball joint attached to front 

subframe 

Note: 

C Bushing and bracket attached to 

the frame rail (rear wheel drive 

models) or front subframe (all wheel 

drive models) 

Rear wheel drive front control arm is 

shown in the illustration. 

On all models the rear bushing of the 

control arm is available as a replacement 

part. 

On rear wheel drive models, both ball 

joints are pressed into the control arm at 

the factory. On 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 control arm. Make sure 

a replacement control arm is identical to 

the original. 

1 - Ball joint nut 



4 - Bushing 

5 - Bushing bracket



12 of 24 2/25/2009 10:26 PM 

6 - Bracket mounting bolt 

7 - Inner ball joint (all wheel drive only) 

8 - Ball joint mounting bolt 

Control arm, removing and 


models) 

- Raise car and remove wheel. 

WARNING! 


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. 

- Remove front end reinforcement. 


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 control arm.



13 of 24 2/25/2009 10:26 PM 

Remove control arm inner ball joint 

mounting nut (arrow) at subframe. 

Drive ball joint shaft out of subframe 

using soft faced hammer. 

Support control arm while removing 

control arm bracket bolts (arrows) from 

frame rail. 

- Remove control arm. 

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.



14 of 24 2/25/2009 10:26 PM 

Note: 

If one control arm rear rubber 

bushing is damaged, bushings on 

both sides must be replaced. 

Control arm rear bushing replacement is 

covered later in this group. 



Make sure all thread bores, bolts, 

nuts and mating surfaces are clean. 

Use new self-locking nuts or bolts, 

where applicable. 

Have vehicle alignment checked 

after assembly. nothing 

WARNING! 


bolts. They are designed to be used 

only once and may fail if reused. 



bracket to frame 

rails M10 bolt 


59 Nm (44 ft-lb) 


subframe or body frame rails: M10 bolt 


Stage 1 

59 Nm (44 ft-lb) 


+ 30° 


subframe M14 



90 Nm (66 ft-lb)



15 of 24 2/25/2009 10:26 PM 


Outer ball joint to 

steering arm M12 




65 Nm (48 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

Control arm, removing and 


models) 


WARNING! 








compartment. 


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 from control arm.



16 of 24 2/25/2009 10:26 PM 

Remove inner ball joint mounting bracket 

bolts (arrows) from subframe. 

Support control arm. Working at rear of 

subframe, remove control arm rear 

bracket mounting bolts (arrows). 

- Remove control arm. 

Inspect rear bracket rubber bushing 

for wear. 

Check ball joints for damage, 

looseness, or torn boots. 

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:



17 of 24 2/25/2009 10:26 PM 

Inner ball joint and control arm rear 

bushing replacement is covered later in 

this group. 




nuts and mating surfaces are clean. 

Use new self-locking nuts or bolts, 


Have vehicle alignment checked 

after assembly. nothing 

WARNING! 


bolts. They are designed to be used 




bracket to subframe 


replace) 



M12 bolt 

Outer ball joint to 

steering arm M12 




59 Nm (44 ft-lb) 

77 Nm (57 ft-lb) 

65 Nm (48 ft-lb) 

100 ± 10 N 

(74 ± 7 ft-lb) 

Inner ball joint, replacing (all 

wheel drive models) 

- Raise car and support safely



18 of 24 2/25/2009 10:26 PM 

WARNING! 








compartment. 

Remove inner ball joint fasteners from 

control arm and 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. 



Make sure thread bores, bolts, nuts 

and mating surfaces are clean. 

Use new self-locking nuts or bolts. 




M12 bolt 

77 Nm (57 ft-lb)



19 of 24 2/25/2009 10:26 PM 



control arm M14 



80 Nm (59 ft-lb) 

Control arm bushings, rear 

wheel drive 

CAUTION! 

Never reuse a rubber bushing that 

has been pulled off the control 

arm. The rubber coated inner 

sleeve is destroyed when it is 

pulled off dry. 

Check with an authorized BMW 

parts dealer for the latest 

information about control arm 

bushing applications on E46 cars. 

Control arm bushings should always be 

replaced in pairs. 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: 

Control arms with pin shape A have been 

superseded by parts with pin shape B.



20 of 24 2/25/2009 10:26 PM 

Inspect bushing bracket. Replace 

bracket if there is a center punch mark at 

boss A. 

WARNING! 

If a bushing bracket with the center 

punch mark is reused with a new 

bushing, the bushing may fall out. 

Use press tools to remove old bushing 

and press in new. Be sure to line 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



21 of 24 2/25/2009 10:26 PM 

protrusion (rear wheel drive models) 

Dimension 

A = Total 

bushing 

length 

(nominal) 

60 mm 

bushing 

50.5 mm 

(1.99 in.) 

66 mm 

bushing 

53.5 mm 

(2.11 in.) 

B = Bracket 

width 

(nominal) 

34.0 mm (1.36 in.) 

C = Fixed 

measurement 

D = 

Protrusion 

8.5 mm 

(0.33 in.) 

8.0 mm 

(0.31 in) 

12.0 mm 

(0.47 in.) 

7.5 mm 

(0.29 in.) 

When installing bushing on control arm: 

Use soapy water on control pin and 

rubber bushing 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. 



59 Nm (44 ft-lb)



22 of 24 2/25/2009 10:26 PM 


bracket to frame rail 


replace) 

Control arm bushings, all wheel 

drive 

CAUTION! 

Never reuse a rubber bushing that 

has been pulled off the control 

arm. The rubber coated inner 

sleeve is destroyed when it is 

pulled off dry. 

Check with an authorized BMW 

parts dealer for the latest 

information about control arm 

bushing applications on E46 cars. 

Control arm bushings should always be 

replaced in pairs. 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. 

Note: 

Align bushing with bracket as 

shown in accompanying illustration. 

Brackets are marked L or R for left or 

right.



23 of 24 2/25/2009 10:26 PM 

CAUTION! 

Never reuse a rubber bushing that has 

been pulled off the control arm. The 

rubber coated inner sleeve is 

destroyed when it is pulled off dry. 

When installing bushing on control arm: 

Coat control arm pin and rubber 

mount with appropriate lubricant to 

facilitate installation. 

Note: 

Make sure dimension A(distance 

from first bore in control arm to 

outer edge of control arm bushing) 

is correct after assembly. See 

Table c. 

Slacken pressing 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 centering bores 

facing subframe surface. 



bracket to subframe 


replace) 

59 Nm (44 ft-lb)



24 of 24 2/25/2009 10:26 PM 

WARNING! 

After installation, the car must be 

left undisturbed for a minimum of 

30 minutes. Leave car on the 

ground but avoid major 

movement. 

After approx. 30 minutes, the 

lubricant used to slide on the 

bushing will have evaporated and 

the control arm will be correctly 

seated in the rubber. 


Serious handling problems could 

result if these instructions are not 

carried out.



1 of 2 2/25/2009 10:26 PM 

Stabilizer Bar 

310-5 

Stabilizer bar, removing and 

installing 

On E46 models the stabilizer bar links 

attach to the strut assemblies. 

- Raise car and support safely. 

WARNING! 







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.



2 of 2 2/25/2009 10:26 PM 

If necessary, loosen and remove 

stabilizer bar link mounting nut (arrow) 

from strut. Detach link from strut 

housing. 

Note: 

Use a thin wrench to counterhold shaft 

of stabilizer bar link ball joint while 

removing mounting nut. 


noting the following 

Use new self-locking nuts on 

connecting links. 

When attaching stabilizer link to 

strut or bar, use a thin wrench to 

counterhold 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. 


Stabilizer bar 

bushing brackets 

to subframe 


to stabilizer bar 

M10 self locking 

nut (always 

replace) 


to strut M10 self 

locking nut (always 

replace) 

22 Nm (16 ft-lb) 

65 Nm (48 ft-lb) 

65 Nm (48 ft-lb) 




1 of 9 2/25/2009 10:26 PM 

Front Wheel Bearings 

310-6 

The front wheel bearings are 

permanently sealed and require no 

maintenance. 

On rear wheel drive models, the 

bearing is integral with the wheel hub 

and ABS pulse wheel and pressed on 

the steering arm stub axle. 

1 - Steering arm and stub axle 

2 - Dust guard 

3 - Wheel hub, bearing and ABS 

pulse wheel 

4 - Stub axle collar nut -tighten to 290 

Nm (214 ft-lb) 

5 - Dust cap 

On all wheel drive models, the 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, replacing 

(rear wheel drive models) 


WARNING! 

Make sure that the car is firmly



2 of 9 2/25/2009 10:26 PM 






Pry off dust cap from center of wheel 

hub. Bend back staked part (arrow) of 

wheel hub (axle) collar nut. 

- 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 290 Nm (214 ft-lb). 

Make sure the car is firmly on the 

ground. 



(arrow). 

- Remove brake caliper assembly 

and brake rotor as described in 

340 Brakes. Leave brake hose 

connected to caliper. Suspend 

caliper assembly from chassis 


- Remove wheel hub collar nut. 

Remove wheel hub with integral wheel 

bearing from steering arm using a slide 

hammer puller (BMW special tools 33 4 

201, 33 4 202, 33 4 203 and 33 2 116) 

or conventional puller as illustrated.



3 of 9 2/25/2009 10:26 PM 

- 

If outermost bearing inner race 

stays on steering arm stub axle, 

use BMW special tool set 33 4 400 

or two-jaw puller to remove race. 

CAUTION! 

Do not reuse a wheel bearing 

assembly once it has been removed. 

The removal process destroys the 

bearing. 

To remove innermost inner race: 

Unbolt brake rotor dust shield. 

Bend back wheel bearing dust 

guard. 

Use BMW special tools 00 7 500 

and 31 2 106 to pull 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 nut to its final torque at 

this time. 

Install brake rotor and brake 

caliper. See 340 Brakes.



4 of 9 2/25/2009 10:26 PM 

Mount wheel and lug bolts. Lower 

car to ground to gain leverage. 



steering arm 

Brake rotor to 

wheel hub 


110 Nm (81 ft-lb 

16 Nm (12 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

- With an assistant applying brakes, 

tighten collar nut. 


Collar nut to stub 

axle 

290 Nm (214 

ft-lb) 


- 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. 


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



5 of 9 2/25/2009 10:26 PM 

accomplished by removing the steering 

arm and wheel hub from the car and 

separating the components on the 

bench. 


WARNING! 







Bend back staked part of wheel hub 

(axle) collar nut (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). 


ground. 



(arrow). 


and brake rotor as described in 

340 Brakes. Leave brake hose 



using stiff wire.



6 of 9 2/25/2009 10:26 PM 

Remove tie rod outer end nut. Use 


equivalent to press tie rod end off 

steering arm. 

- Detach control arm from front axle 

subframe as described earlier. 

- Remove outer ball joint nut. Use 


equivalent to separate steering 

arm and strut assembly from 

control arm. 

- Attach BMW special tool 33 2 111 

/116 /117, or equivalent puller, to 

steering arm using five lug bolts 

and press outer CV joint stub axle 

inward, out of steering arm. 

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 (BMW special tools 33 4 

201, 33 4 202, 33 4 203 and 33 2 116). 

- If bearing inner race stays on 

wheel hub, use BMW special tool 

set 33 4 400 or two-jaw puller to 

remove race.



7 of 9 2/25/2009 10:26 PM 

Remove circlip (3) from steering arm. 

1 - Steering arm 

2 - Wheel bearing 

3 - Circlip (always replace) 

4 - Dust guard 

5 - Wheel hub 

- Drive wheel bearing out of 

steering arm using a press with 

appropriate adapters. 

CAUTION! 

Do not reuse a wheel bearing 

assembly once it has been removed. 

The removal process destroys the 

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.



8 of 9 2/25/2009 10:26 PM 

- 

Replace circlip, making sure ring 

is correctly seated. 

- Place dust guard over steering 

arm hub. 

- Drive wheel hub into bearing 

using a shop press. 

CAUTION! 

Press only on the inner race. The 

bearing is damaged if it is not 

pressed on using the inner race. 

- Installation of steering arm to car 

is reverse of removal, noting the 

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. 


Ball joint to 

steering arm 


steering arm 

Brake rotor to 

wheel hub 

Collar nut to wheel 

hub 

Control arm 

bracket to 

subframe 

65 Nm (48 ft-lb) 

110 Nm (81 

ft-lb) 

16 Nm (12 ft-lb) 

420 Nm (310 

ft-lb) 

59 Nm (44 ft-lb)



9 of 9 2/25/2009 10:26 PM 


Steering arm pinch 

bolt at strut 

housing 


Tie rod to steering 

arm 

81 Nm (60 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

65 Nm (48 ft-lb) 


Front Axle Final Drive 


1 of 5 2/25/2009 10:27 PM 

General 

311-1 

This repair group covers the service 

and replacement of components that 

make up the front drive axle for 

vehicles equipped with all wheel drive. 

This drive system is integrated into the 

front suspension of these models. 

For a general description of the front 

suspension and components, see 

300 Suspension, Steering and Brakes- 

General. 

Some procedures will require you to 

also refer to the following repair 

groups: 


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 specified tools. 



Engine support bracket BMW 00 0 200



2 of 5 2/25/2009 10:27 PM 

Transmission flange holder BMW 23 0 

020 

Inner CV joint puller BMW 31 1 170 

Impact drift BMW 31 5 130 

Outer CV joint removal tool BMW 33 2 

111/116/117 

System description 

The front axle final drive unit is 

integrated into the engine oil pan on all 

wheel drive equipped models. The 

front differential and the right side



3 of 5 2/25/2009 10:27 PM 

bearing pedestal bolt to each side of a 

modified oil pan. Power is transmitted 

to the front differential from the transfer 

case via a driveshaft, and out to front 

drive hubs through two drive axles. 

All wheel drive front 

differential and front 

subframe 


2 - Right axle 

bearing pedestal 


4 - Oil pan 

5 - Bolt M12 



77 Nm (57 ft-lb) 


to 110 Nm (81 ft-lb) 


to 105 Nm (77 ft-lb) 

6 - Bolt M12 



(81 ft-lb) 

7 - Bolt M10 



ft-lb)



4 of 5 2/25/2009 10:27 PM 

8 - Bolt M10 



ft-lb) 

9 - Bolt M12 


ft-lb) 

10 - Front control 

arm with ball 

joint and rear 

mounting 

bracket 

11 - Front 

differential 

12 - Front 

differential drain 

plug 


ft-lb) 

13 - Bolt M10 


ft-lb) 

14 - Drive axle radial 

seal 

15 - Drive axle 

16 - Front 

differential fill 

plug 


ft-lb)



5 of 5 2/25/2009 10:27 PM 




1 of 13 2/25/2009 10:27 PM 

Drive Axles 

311-2 

The front drive axles for all wheel drive 

equipped models use two different 

types of constant-velocity (CV) joint. 

The outer CV joints are a traditional 

design that allows power to be 

delivered from the axle to the joint 

continuously through rotation. 

The inner CV joints are triple roller 

bearing joints. This design minimizes 

the amount of vibration and noise 

transmitted back through the vehicle 

drivetrain, while also allowing the axle 

to 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. 

- Lift vehicle and support safely. 

WARNING! 



professional automotive lift or jack



2 of 13 2/25/2009 10:27 PM 



- Remove front wheel. 

- Remove splash shield from below 


- If working on right side, remove 

right side heat shield from front 

axle support. 

Remove ABS sensor (arrow) from 

steering arm. 

- Unclip brake hose from mounting 

bracket. 

- Unbolt brake caliper and 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) from subframe.



3 of 13 2/25/2009 10:27 PM 




- 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. 



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 

bushing bracket to front axle 

subframe.



4 of 13 2/25/2009 10:27 PM 

Be sure to restake new collar nut 

at outboard end of drive axle after 

tightening to correct torque 

specifications. Caulk axle threads. 

Top up differential fluid. See 

Front differential oil, checking and 

filling 



steering arm 

Control arm 

bushing bracket to 

front axle subframe 


Drive flange collar 

nut to front hub 


bracket to front 

axle subframe 


Stabilizer link to 

stabilizer bar 

110 Nm (81 

ft-lb) 

59 Nm (44 ft-lb) 

420 Nm (310 

ft-lb) 

77 Nm (57 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

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. The 

front suspension may be partially 

disassembled for radial seal 

replacement. 

- Lift vehicle and support safely.



5 of 13 2/25/2009 10:27 PM 

WARNING! 

Make sure car is stable and well 








bracket bolts (arrows) from subframe. 




- Tilt steering arm to one side, out 

of the way. 


or equivalent pry bar, pry inboard 

CV joint out of front differential or 


Note: 



pedestal. 

Pry radial seal out of differential 

housing or bearing pedestal using a 

flat screwdriver.



6 of 13 2/25/2009 10:27 PM 

1 - Right axle bearing pedestal 

2 - Front differential 

3 - Input shaft seal 

4 - Small dustcover 

5 - Large dustcover 

6 - Differential plug 

7 - Plug sealing ring 

8 - Drive axle radial seal with lock 

ring, left 

9 - O-ring 

10 - Engine oil pan 

11 - Drive axle radial seal with lock 

ring, right 

Note: 

Remove protective sleeve from new 

drive axle radial seal before installing 

seal 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. 


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 


Insert protective sleeve into radial 

seal.



7 of 13 2/25/2009 10:27 PM 

Insert inboard end of drive axle 

partially into differential housing or 


Withdraw protective sleeve from 

sealing lip, cut protective sleeve 

and remove sleeve. 

Note: 

Continue installing drive axle until 

spring clip snaps audibly into 

place. 

Always replace spring clip on inboard 

end of drive axle before reinstalling into 

differential housing or bearing pedestal. 



Make sure inboard end of drive 

axle audibly snaps into place. 




filling 




axle subframe 


steering arm 

Control arm 


axle subframe 


77 Nm (57 ft-lb) 

110 Nm (81 

ft-lb) 

59 Nm (44 ft-lb)



8 of 13 2/25/2009 10:27 PM 

Outer CV joint boot, replacing 

Note: 

When replacing CV boots, use 

complete boot repair kits. A kit will 

include a new boot, clamping bands, 

special lubricant, and a new outer CV 

joint axle circlip. A kit is available from 

an authorized BMW dealer parts 

department. 

- Remove drive axle from vehicle as 


- Release retaining clamps from 

both ends of outer CV boot. 

- Using a hammer, pound outer CV 

joint off 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 new clamping bands and 

CV boot over drive axle. 

- Replace spring clip on splined 

end of drive axle.



9 of 13 2/25/2009 10:27 PM 

- 

Apply Loctite® 270 or an 

equivalent heavy-duty locking 

compound to drive axle splines. 

WARNING! 

Do not let locking compound contact 

balls in joint. Apply only a thin coat 

to cover splines. 

- Pack outer CV joint with fresh 

grease. Tap CV joint onto splined 

end of drive axle until spring clip 

snaps audibly into place. 

CV joint lubricant capacity 

Outer CV joint 

80 gram (2.8 oz.) 

- Using clamp pliers, secure 

retaining clamp into position 

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. 




axle audibly snaps into place.



10 of 13 2/25/2009 10:27 PM 








filling 


Ball joint bracket to 



steering arm 

Control arm 

bushing bracket to 




77 Nm (57 ft-lb) 

110 Nm (81 

ft-lb) 

59 Nm (44 ft-lb) 

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 


- Release retaining clamp on both 

ends of inner CV boot. Pull back 

inner boot and detach inner CV 

joint housing.



11 of 13 2/25/2009 10:27 PM 

- 

Remove circlip retaining triple 

roller bearing to drive axle and 

remove triple roller bearing. 

- Slide boot off drive axle. Separate 

inner CV joint boot adapter from 

boot. 

- Clean all old lubricant off axle 

splines and triple roller bearing 

splines. 

- Install new inner CV joint boot: 

Attach boot to boot adapter. 

Slide retaining clamps and boot 

over drive axle. 

Secure retaining 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. 


Inner CV joint 

85 gram (3.0 oz.) 

- Insert triple roller bearing into 

inner CV joint housing. 

- Secure boot connection to boot 

adapter using clamp supplied with



12 of 13 2/25/2009 10:27 PM 

boot kit. 




axle audibly snaps into place. 








filling 


Ball joint bracket to 



steering arm 

Control arm 


axle subframe 




77 Nm (57 ft-lb) 

110 Nm (81 

ft-lb) 

59 Nm (44 ft-lb) 

420 Nm (310 

ft-lb) 

Inner CV joint 

assembly 

1 - Spring clip 

2 - Inner CV joint 

housing



13 of 13 2/25/2009 10:27 PM 

3 - Circlip 

4 - Triple roller 

bearing 


boot adapter 

6 - Clamp 


boot 

8 - Drive axle shaft 

9 - Clamp 




1 of 12 2/25/2009 10:28 PM 

Front Differential 

311-3 

Procedures for replacement of O-ring 

seal between the engine oil pan and 

the front differential or right side 

bearing pedestal are covered in 

Front axle differential, removing and 

installing and Right axle bearing 

pedestal, removing and installing. 

Front differential oil, checking 

and filling 

Note: 

BMW supplies the E46 all wheel drive 

models with lifetime lubrication in the 

front differential. 

Front differential drain plug and fill 

plug (arrows). 

Note: 

Use an Allen bit socket to remove drain 

plug. 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 

bottom of fill plug bore. 

- Install and tighten fill plug. 

Final drive drain and fill



2 of 12 2/25/2009 10:28 PM 

Final drive drain and fill 

Oil specifications 

Front axle 

differential oil 

capacity 

BMW SAF-XO 

synthetic oil 

0.7 liters (0.74 

US qts.) 


Front axle 

differential drain / 

fill plug 

65 Nm (48 ft-lb) 

Front axle differential, 



ground at battery. 

CAUTION! 

Prior to disconnecting battery, read 

battery disconnection cautions given 

at front of this manual on page viii. 


WARNING! 




stands designed for purpose. A floor 

jack is not adequate support. 



Support engine using appropriate 

lifting device.



3 of 12 2/25/2009 10:28 PM 

Release nut at top on right engine 

mount (arrow). 

Remove nut (arrow) at bottom on left 

engine mount. 

- Raise engine approximately 10 

mm (0.4 in.). 

- Remove front wheels. Unbolt 

brake calipers and suspend from 

body using stiff wire. See 340 

Brakes. 

- Remove front driveshaft. See 


Remove left inner ball joint mounting 

bracket bolts (arrows) from subframe. 

- Repeat for right side.



4 of 12 2/25/2009 10:28 PM 

Support left control arm. Working at 

rear of subframe, remove control arm 

rear bracket mounting bolts (arrows). 


Remove left tie rod outer end nut 

(arrow). Use BMW special tool 32 3 

090 or equivalent to press tie rod end 

off steering are. 


Remove left ABS sensor (arrow) from 

steering arm. 


- 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.



5 of 12 2/25/2009 10:28 PM 

Note: 



pedestal. 

Working on left side of car: 

Release pinch bolt (arrow) at top 

of steering arm. 

Pull steering arm down from strut 

assembly. 

Remove steering arm, drive axle, 

and control arm assembly as one 

unit. 

Repeat for right side. 

- Remove lower steering column. 


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 


- Remove front axle subframe and 

steering rack from frame rails. 

See 310 Front Suspension 

Note: 

Make sure heat shields, wiring



6 of 12 2/25/2009 10:28 PM 

harnesses and other under body 

components are clear during removal. 

Detach vent tube from port (A) on front 

axle differential. Remove mounting 

bolts (B) and remove front axle 

differential. 

- Install new sealing ring, coating 

inside edge with assembly 

lubricant. 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 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. 



Always replace drive axle radial 

seal of differential before installing 

drive axles. 



filling 

Replace sealing rings when 

reinstalling banjo bolts to steering 

rack.



7 of 12 2/25/2009 10:28 PM 



steering arm 

Control arm 


suspension 

subframe (replace 

bolts) 

Engine mount to 

subframe M10 self 

locking nut 

Front axle 

differential to oil 

pan 

Front axle 

differential fill plug 

110 Nm (81 

ft-lb) 

59 Nm (44 ft-lb) 

45 Nm (33 ft-lb) 

45 Nm (33 ft-lb) 

65 Nm (48 ft-lb) 

Hydraulic hoses to power steering 

pump 

M14 banjo bolt 



front suspension 

subframe 

Stabilizer bar 

bushing brackets 

to subframe 


lower ball joint 

Steering arm 

clamping bolt at 

strut housing 

Steering column to 

steering rack 


steering arm 

Subframe front to body 

M12-8.8 bolt 

35 Nm (26 ft-lb) 

40 Nm (30 ft-lb 

77 Nm (57 ft-lb) 

22 Nm (16 ft-lb) 

65 Nm (48 ft-lb) 

81 Nm (60 ft-lb) 

22 Nm (16 ft-lb) 

65 Nm (48 ft-lb) 

77 Nm (56 ft-lb)



8 of 12 2/25/2009 10:28 PM 


M12-10.9 bolt 110 Nm (81 

ft-lb) 

M12-12.9 bolt 105 Nm (77 

ft-lb) 

Subframe rear to 

adapter M12 bolt 


110 Nm (81 

ft-lb) 

Right axle bearing pedestal, 



WARNING! 






- 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. 


bracket bolts (arrows) from subframe.



9 of 12 2/25/2009 10:28 PM 





or equivalent pry bar, pry inner CV 

joint out of bearing pedestal. 

- Release pinch bolt at top of 

steering arm. Pull steering arm 

down from strut assembly and 

remove steering arm, drive axle, 

and control arm assembly. 

- Remove 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 installed. 

When bearing pedestal is installed



10 of 12 2/25/2009 10:28 PM 

on oil pan, the assembly ring is 

forced over sealing ring and 

remains in place. 



Always replace drive axle radial 

seal before installing drive axle. 



filling 


Bearing pedestal to 

oil pan 


steering arm 

Control arm 


suspension 

subframe (replace 

bolts) 


front suspension 

subframe 


lower ball joint 

Steering arm 

clamping bolt at 

strut housing 


steering arm 

45 Nm (33 ft-lb) 

110 Nm (81 

ft-lb) 

59 Nm (44 ft-lb) 

77 Nm (57 ft-lb) 

65 Nm (48 ft-lb) 

81 Nm (60 ft-lb) 

65 Nm (48 ft-lb) 

Input flange radial seal, 

replacing 

- Lift vehicle and support safely.



11 of 12 2/25/2009 10:28 PM 

WARNING! 






- Remove front driveshaft. See 


- Pry out input flange retaining nut 

lock plate. 

Using a centerpunch, mark relation of 

input flange retaining nut to output 

shaft. 

Counterhold input flange in place 

using BMW special tool 23 0 020 and 

remove nut. 

- Pull input flange out from 

differential using a hub puller. 

- Remove input seal dust shields. 

- 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



12 of 12 2/25/2009 10:28 PM 


equivalent drift. 

- Replace dust shields. 

- Clean input flange and install into 

differential housing. 

Tighten down nut until punch 

marks align. 

Install new input flange retaining 

nut locking plate. 

CAUTION! 

Do not torque input flange 

retaining nut beyond 

matchmarks. Over-torquing can 

damage differential internals. 

Do not replace input flange or 

input flange locking nut. 



Input flange collar 

nut to differential 

until matchmarks 

align 


Steering and Wheel Alignment 


1 of 4 2/25/2009 10:28 PM 

General 

320-1 

This repair group covers steering wheel 

and column removal and steering 

system service, including wheel 

alignment information. 

Note: 

Ignition lock cylinder replacement 

is covered in this section. 

For information on steering column 

mounted switches 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



2 of 4 2/25/2009 10:28 PM 

Tie rod end removal tool BMW 32 3 090 

Front camber adjusting tool BMW 32 3 

140 

Steering system 

The variable-assist power steering 

system consists of an engine-driven 

hydraulic pump, a rack-and-pinion 

steering rack assembly with an integral 

hydraulic control valve, and connecting 

linkage to the road wheels. 

At low speeds, maximum power assist 

is provided to ease parking and city 

driving. At high speeds, assist is 

reduced to ensure 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 power steering fluid is fed from the 

fluid reservoir to the pump and to the 

rack via rubber/metal hoses. The return



3 of 4 2/25/2009 10:28 PM 

line from the steering rack to the 

reservoir loops into the airstream in 

front of the vehicle and is used as a 

steering fluid cooler. 

The steering rack and linkage require 

no maintenance other than alignment 

and periodic inspection for worn 

components. The rubber rack boots 

and tie-rod end boots should be 

inspected periodically for tears or 

damage and replaced if necessary. 

WARNING! 

The BMW airbag system (MRS II) 

is complex. Special precautions 

must be observed when 

servicing the system. Serious 

injury may result if system 

service is attempted by persons 

unfamiliar with the BMW airbag 

system and its approved service 

procedures. BMW specifies that 

all inspection and service 

should be performed by an 


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). 

BMW airbags are equipped with 

a back-up power supply inside 

the MRS II control module. A 5 

second waiting period should 

be observed after the battery 

cable has been disconnected. 

This will allow the reserve 

power supply to discharge.



4 of 4 2/25/2009 10:28 PM 

Do not reuse self-locking nuts. 

They are designed to be used 


Always replace them with new 

locking nuts. 

Do not install bolts and nuts 

coated with undercoating wax, 

as correct tightening torque 

cannot be assured. Always 

clean the threads with solvent 

before installation, or install 

new parts. 

Note: 


Do not attempt to weld or 

straighten any steering 

components. Always replace 

damaged parts. 

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).



1 of 2 2/25/2009 10:29 PM 

Steering Wheel 

320-2 

Steering wheel, removing and 

installing 

- Center steering wheel. Make sure 

front wheels are pointed straight 

ahead. 


battery. 

CAUTION! 





- Carefully remove airbag from front 

of steering wheel. See 721 

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 models. 

Remove steering wheel center bolt. 

Note:



2 of 2 2/25/2009 10:29 PM 

The steering column and steering wheel 

are matchmarked (arrow) at the 

factory. Confirm these marks before 

removing wheel from column. 

- Remove steering wheel. 

- When reinstalling steering wheel: 

Align steering wheel and column 

match marks. 

Align steering wheel to alignment 

pins located on steering column 

switch block. 

Install steering column center bolt. 

Do not over-torque. 


Steering wheel to 

steering shaft 

63 Nm (46 ft-lb) 

- Carefully install airbag. See 721 

Airbag System (SRS) 


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.



1 of 8 2/25/2009 10:29 PM 

Steering Column 

320-3 


assembly 

1 - Hex bolt (M14 x 

1.5) 


ft-lb) 

2 - Cable duct 

3 - Steering column 

adjustment lever 

4 - Upper steering 

column 

5 - Lower steering 

column with 


6 - Torx bolt (M8 x 

33) 


ft-lb) 

7 - Flexible joint 

(guibo) 

8 - Steering angle 

sensor 

9 - Steering angle 

sensor bracket 

10 - Column pivot 

bushing 

11 - Bolt (M8 x 36)



2 of 8 2/25/2009 10:29 PM 


ft-lb) 


mounting 

bracket 

13 - Column return 

spring 

14 - Nut (M8) 

tighten to 4.8 Nm 

(3.5 ft-lb) 

recheck as 

necessary 

Ignition lock cylinder, removing 


To remove the ring antenna prior to 

removing ignition lock cylinder, it is 

necessary to remove the upper and 

lower steering column trim. Use BMW 

special tool 61 3 300 to force off the ring 

antenna. Alternatively, remove the 

ignition switch key cylinder first. 

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.



3 of 8 2/25/2009 10:29 PM 

Reinstallation is reverse of removal. 

Lower steering column, 


Note: 

Once the lower steering column has been 

removed there will be no end stop for the 

steering wheel. In order to prevent 

damage to contact ring in steering 

column, follow procedural steps as listed. 

1. Unlock steering wheel. 2. Move 

steering wheel to straight ahead position. 

3. Lock steering wheel and remove 

ignition key. 


WARNING! 






- 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 shaft. 

Note: 

Do not remove alignment flange from 

steering rack.



4 of 8 2/25/2009 10:29 PM 

Working near firewall, remove pinch bolt 

at universal joint and remove lower 

steering column. 

Note: 

Upper steering column is keyed to lower 

steering column universal joint. It can 

only be installed in one position. 



Replace flexible and universal joint 

pinch bolts. 

Align lower steering column to 

keyed upper steering column. 

Align tab (arrow) on steering rack 

flange with lower steering column 

flexible joint. 


Pinch bolts at 

steering columns 

joints 

22 Nm (16 ft-lb) 

Upper steering column, 


- Remove steering wheel as 


Fully lower and extend (arrows) 

adjustable steering column. 

- Remove retaining screw from top of 

steering column upper trim cover.



5 of 8 2/25/2009 10:29 PM 

Push in sides of upper trim cover 

(arrows) to release from lower trim. Pull 

back and up on upper trim. 

Pry gently to detach flexible cover from 

upper trim. Lift off trim. 

Remove left footwell (pedal cluster) trim 

panel. 

Remove screws (A). 

Remove fasteners (B). 


at left footwell trim panel and remove 

panel:



6 of 8 2/25/2009 10:29 PM 

Unplug connector at footwell interior 

light (A), if equipped. 

Slide lock at OBD II connector (B) in 

direction of arrow. 

Unplug connector at cellular phone 

speaker (C) if equipped. 

- Remove lower steering column as 


To remove steering column lower trim, 

drive pins into expansion rivets (arrows) 

to release. Pull down on trim. 

Working at steering column: 

Remove screws (arrows). 

Slide switch block out from steering 

column. 


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).



7 of 8 2/25/2009 10:29 PM 

Remove shift interlock cable (A) if 

necessary. 


connector at EWS 3.3 ring antenna 

(B). 

- Working at steering column, detach 

wiring harness from cable duct. 

Drill out steering column mounting shear 

bolt (A), and remove mounting bolt (B). 

Remove lower steering column mounting 

bolts (arrows). Remove upper steering 

column. 



Replace shear bolt at steering 

column mounting bracket. Tighten



8 of 8 2/25/2009 10:29 PM 

until bolt head shears off. 

Make sure lock of interlock cable 

snaps into place. 

When installing column top trim 

panel, replace expansion nut for 

trim retaining screw. 

When installing lower trim panel, 

push expansion rivet pin into rivet 

until pin head is flush with rivet 

head. 


Universal joint 

pinch bolt at 

steering column 


dashboard carrier 

22 Nm (16 ft-lb) 

22 Nm (16 ft-lb) 




1 of 11 2/25/2009 10:29 PM 

Power Steering System 

The power steering fluid reservoir is 

located on the lower left front of the 

engine. 

CAUTION! 

Maintain clean conditions when 

working with open power 

steering fluid lines. 

320-4 

Plug off power steering lines 

and connections to keep out 



Recommended 

fluid 

ATF (automatic 

transmission 

fluid) 

Power steering 

system 

1 - Power steering 

fluid reservoir 

2 - Fluid supply 

line 


pump 

4 - Copper sealing 

ring 

5 - Banjo bolt M14 


ft-lb)



2 of 11 2/25/2009 10:29 PM 

6 - Banjo bolt M16 


ft-lb) 


rack 

8 - Pressurized 

fluid line 

9 - Fluid return line 

10 - Fluid cooler 

11 - Rack boot kit 

12 - Tie rod nut 


ft-lb) 

13 - Outer tie rod 

end 

14 - Clamp ring 

15 - Outer tie rod 

end lock nut 


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



3 of 11 2/25/2009 10:29 PM 

fluid reservoir with clean fluid. Fill 

level to MAX mark on dip stick. 

- Start engine. Slowly turn steering 

wheel from lock to lock a minimum 

of two times. 

- Turn engine off and check fluid 

level, adding more if necessary. 

Power steering pump, removing 


- Empty power steering fluid reservoir 

using clean syringe. Do not reuse 

fluid. 

- Raise front of car. Remove 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 




- Remove power steering pump drive 

pulley. 

- Remove fluid hoses from pump. 

Plug openings in pump and hose 

ends. 

- Remove brake cooling ducts on left 

side.



4 of 11 2/25/2009 10:29 PM 

- 

Remove front stabilizer bar anchors 

and swing stabilizer bar down out of 

the way. See 310 Front 

Suspension. 

Remove pump mounting bolts (arrows) 

and remove pump. Rear wheel drive 

model shown. 




nuts, fluid couplings and mating 

surfaces are clean, and inside 

surface of multi-ribbed-belt is free of 

grease and dirt. 

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. 


Hydraulic hoses to power steering 

pump 




pump to bracket M8 

self-locking nuts 


pump bracket to 

engine block M8 


35 Nm (26 ft-lb) 

40 Nm (30 ft-lb) 

22 Nm (16 ft-lb) 

22 Nm (16 ft-lb)



5 of 11 2/25/2009 10:29 PM 

Steering rack, removing and 

installing 

- Empty power steering fluid reservoir 

using clean syringe. Do not reuse 

fluid. 

- Raise front of car, and remove 

wheels. Remove splash shield from 

under engine. 

Make reference measurement (A) of left 

outer tie rod end to tie rod. 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. 

Note correct placement of inner 

taper on locking ring 


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 right tie rod.



6 of 11 2/25/2009 10:29 PM 

Working underneath car, remove fluid 

line banjo bolts (arrows) from steering 

rack. 

CAUTION! 

Plug off power steering lines and 

connections to keep out 


Note: 

It may be necessary to remove other 

components to gain access to steering 

rack. 

Remove lower steering column flexible 

joint pinch bolt (arrow). Pull flexible joint 

off steering rack shaft. 

- Move steering wheel to straight 

ahead position and remove ignition 

key to lock steering. 


Support front subframe with a shop 

hoist or appropriate jack. 

Detach subframe from engine and 

lower approx. 20 mm ( in.). See 


Remove steering rack mounting bolts 

(arrows). Remove steering rack from 

subframe by pulling it forward. 


the following:



7 of 11 2/25/2009 10:29 PM 


nuts, splines and mating surfaces 

are clean. Use anti-seize paste on 

inner tie rod threads. 

Use new self-locking nuts wherever 

applicable. 

Use keyed components to 

reassemble steering column flexible 

joint to steering rack shaft. Make 

sure wheels are straight ahead. 

Use new sealing rings on banjo 

fittings. Do not over-torque banjo 

bolts. 

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. 


Outer tie rod end to 

steering arm 

replace self-locking 

nut 

Outer tie rod end 

lock nut 


flexible joint to 

steering rack shaft 

Steering rack to subframe 

M10 bolt 

Steering fluid lines 

65 Nm (48 ft-lb) 

45 Nm (33 ft-lb) 

22 Nm (16 ft-lb) 

42 Nm (32 ft-lb)



8 of 11 2/25/2009 10:29 PM 




35 Nm (26 ft-lb) 

40 Nm (30 ft-lb) 

Outer tie rod end, replacing 

- Raise front of car. Remove road 

wheel. 

WARNING! 







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: 





installed.



9 of 11 2/25/2009 10:29 PM 



Loosen outer tie rod end lock nut 

(arrow). 

- Unscrew tie rod end from tie rod 

shaft. 


Make sure all threaded parts are 

clean. Use antiseize paste on inner 

tie rod threads. 

Use new self-locking nuts, where 

applicable. 

Use tie rod measurement (A) to set 

toe. 




steering arm 

replace self locking 

nut 


lock nut 

65 Nm (48 ft-lb) 

45 Nm (33 ft-lb) 

Tie rod or rack boot, replacing 

- Raise front of car. Remove splash 

shield from under engine. 

WARNING! 


on jack stands designed for the



10 of 11 2/25/2009 10:29 PM 





- Remove outer tie rod end 

self-locking nut, and separate outer 

tie rod end ball joint as described 

above. 

Make a reference measurement of outer 

tie rod end to tie rod. Record 

measurement. 

Note: 





installed. 



- 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 tie rod, turn steering 

until end of rack is as far as possible 

in housing



11 of 11 2/25/2009 10:29 PM 

When reassembling, grease tie rod taper 

so that rack boot support buffer or small 

end of rack boot (inset) slides on tie rod 

when tie rod is tightened, preventing 

rack boot from twisting. 



Make sure all threaded parts are 

clean. Replace self-locking nuts. 

Install outer tie rod end to new tie 

rod using reference measurement 

(A) recorded earlier. 




steering arm 


lock nut 

Inner tie rod to 

steering rack 

65 Nm (48 ft-lb) 

45 Nm (33 ft-lb) 

100 + 10 Nm 

(74 + 7 ft-lb) 




1 of 5 2/25/2009 10:29 PM 

Wheel Alignment 

320-5 

Proper handling, stability, tire wear and 

driving ease depend upon the correct 

alignment of all four wheels. The front 

axle is aligned in relation to the rear 

axle, then the front wheels are aligned 

in relation to one another. This is 

known as a four-wheel or thrust-axis 

alignment. 

The BMW E46 uses a sophisticated 

multi-link suspension at the front and 

rear of the car. Proper alignment 

requires computerized alignment 

equipment. 

Alignment specifications only apply 

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 Table a. Front wheel alignment 

specifications for front wheel alignment 

specifications, Table b. Rear wheel 

alignment specifications for rear wheel 

alignment specifications.



2 of 5 2/25/2009 10:29 PM 

WARNING! 

While performing alignment 

procedures, make sure the car is 

stable and well supported at all 

times. Use a professional automotive 

lift or jack stands designed for the 

purpose. A floor jack is not adequate 

support. 

Normal loaded position 

Each front seat 

Rear seat (center) 

Trunk 

Fuel tank 

68 Kg (150 lb) 

68 Kg (150 lb) 

21 Kg (46 lb) 

full 

Table a. Front wheel alignment specifications 

Parameter 

Standard 

suspension 

All wheel 

drive 

suspension 

Sport 

suspension 

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 


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 alignment specifications 

Parameter 

Standard 

suspension 

All wheel 

drive 

suspension 

Sport 

suspension 

Rough road 

suspension 

Toe angle (total) 0° 16' ± 6'



3 of 5 2/25/2009 10:29 PM 

Parameter 

Camber (difference between 


maximum allowable 

deviation between sides 

Standard 

suspension 

All wheel 

drive 

suspension 

Sport 

suspension 

Rough road 

suspension 

-1° 30' ± 15' -1° 15' ± 15' -2° 04' ± 15' -46' ± 15' 

Geometrical axis deviation 0° ± 6' 

Front wheel camber 

Any change to the camber will also 

change the toe setting. Always adjust 

camber prior to adjusting toe. 

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). 


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 rod by turning inner tie 

rod (B) to change length.



4 of 5 2/25/2009 10:29 PM 

Note: 

Steering rack can be centered by 

aligning centering mark on steering 

shaft with lug on steering rack. 

To keep steering wheel centered, 

adjust both tie rods equal amounts. 

Make sure the rubber boot on the 

rack moves freely on the tie rod and 

does not become twisted. 


Tie rod lock nut 

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. 


Rear lower control 

arm to rear trailing 

arm 

77 Nm (57 ft-lb) 

Rear wheel toe 

Loosen trailing arm bracket mounting 

bolts (arrows).



5 of 5 2/25/2009 10:29 PM 

- Install BMW special tool 32 3 030 

over alignment lug (A) and adjacent 

bolt. 

Use tool to adjust position of 

bracket. 

Remove tool and tighten trailing 

arm bracket mounting bolts. 


Rear trailing arm 

bracket to body 

77 Nm (57 ft-lb) 




1 of 3 2/25/2009 10:30 PM 

General 

330-1 


replacement of E46 rear suspension 

components. 

A general description of the rear 

suspension, ride height specifications 

and a troubleshooting guide can be 

found in 300 Suspension, Steering 

and Brakes-General. 

Additional component replacement 

information specific to all wheel drive 

models can be found in the following 

repair groups: 


311 Front Axle Final Drive 

331 Rear Axle Final Drive 

Alignment information can be found in 


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. 



Bearing splitter BMW l 00 7 500



2 of 3 2/25/2009 10:30 PM 

Drive axle press BMW set 33 2 

115/116/119 

Flange puller BMW set 33 2 116/4 

201/4 202/4 203 

Inner bearing race puller BMW set 33 4 

400 

Wheel bearing extractor B90 (Source: 

Baum Tools Unlimited) 

Rear suspension 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



3 of 3 2/25/2009 10:30 PM 

suspension. 

The rear subframe (final drive carrier) 

supports the rear differential and 

provides mounting points for the upper 

and lower control arms. The upper 

control arm on each side provide the 

lower spring perch for the coil spring. 

The upper and lower control arm on 

each side are attached to the trailing 

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 


bracket 

7 - Coil spring 

8 - Lower control 

arm 





1 of 6 2/25/2009 10:30 PM 

Rear Shock Absorbers 

and Springs 

Replace shock absorbers and springs 

in pairs only. 

330-2 

Rear shock absorber, removing 


- Raise car and remove rear wheels. 

WARNING! 







Support trailing arm from 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 shock absorber 

mounting nuts (arrows). 

- On Convertible models: Open 

convertible top storage



2 of 6 2/25/2009 10:30 PM 

compartment to access upper 

shock absorber mount. 

- On Sport Wagon models: Working 

in cargo compartment, remove 

side trim next to rear seat 

backrests. 

- Support shock absorber from 

below while removing upper 

mounting nuts. Lower shock 

absorber out of wheel housing. 

Transfer shock top mounting plate, 

dust cover (if applicable) and related 

components to new 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 

mounting seal and new 

self-locking nuts.



3 of 6 2/25/2009 10:30 PM 

Make sure rectangular thrust 

washer on lower mounting bolt is 

between bolt head and shock 

absorber rubber. 

Tighten lower shock absorber bolt 

to its final torque once car is on 

ground. 



Shock absorber to 

trailing arm (car in 

normal loaded 

position) 


upper mount 

Shock absorber 

upper mount to 

body M8 


100 ± 10 Nm 

(74 ± 7 ft-lb) 

100 Nm (74 

ft-lb) 

14 Nm (10 ft-lb) 

28 Nm (21 ft-lb) 

Coil spring, removing and 

installing 

- Raise car and remove rear wheel. 

Remove drive axle to final drive 


Detach drive axle from final drive. 

Suspend drive axle from chassis 


- Remove fuel tank protective panel. 

- Detach stabilizer bar from rear



4 of 6 2/25/2009 10:30 PM 

subframe. 

Remove rear brake line bracket 

mounting bolt (arrow). Detach bracket 

from trailing arm. 

CAUTION! 

Avoid damaging the brake hose by 

stretching when the trailing arm is 

lowered. 

Support trailing arm from below using 

an adjustable jackstand. Remove 

shock absorber lower mounting bolt 

(arrow). 

- 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. 

Note: 

Replace any parts showing 

evidence of wear or damage. 

In the "rough road package", the top 

spring seat pad is 14.5 mm (0.57 in.) 

thick.



5 of 6 2/25/2009 10:30 PM 

- 

To install spring: 

Coat top spring pad with 

anti-friction paste (e.g., tire 

mounting paste). 

Slowly lift suspension back into 

position, making sure coil spring is 

correctly seated in upper and 

lower spring seats. 

When suspension has been lifted 

sufficiently, reattach shock 

absorber to trailing arm. Make 

sure rectangular thrust washer on 

lower shock absorber mounting 

bolt is between bolt head and 

shock absorber rubber. 

Tighten lower shock absorber bolt 

to its final torque once car is on 

ground. 




Drive axle to final drive flange 

M10x20 mm Torx 

bolt 

M10x46 mm bolt 

(black) 


(silver) (always 

replace) 




normal loaded 

83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

100 Nm (74 ft-lb)



6 of 6 2/25/2009 10:30 PM 


position) 




1 of 19 2/25/2009 10:30 PM 

330-3 

Rear Suspension Arms, 

Subframe and Bushings 

The trailing arms, control arms and 

their mounting bushings control the 

position of the rear wheels. A damaged 

suspension arm or worn bushings will 

change the rear wheel alignment and 

may adversely affect handling and 

stability. 

WARNING! 

Do not attempt to straighten a 

damaged suspension arm. 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. 


arms, assembly 



arm inner bolt 

self-locking M12 

nut 


ft-lb) 


arm



2 of 19 2/25/2009 10:30 PM 


arm outer bolt 


nut 


(81 ft-lb) 



arm eccentric 

bolt eccentric 

flat M12 washer 

self locking M12 

nut 


(81 ft-lb) 


front bolt 


nut 


(81 ft-lb) 


front bracket 

9 - Bracket 

mounting bolt 


ft-lb) 

10 - Drive axle 


arm 


arm plastic 

shield



3 of 19 2/25/2009 10:30 PM 


arm inner M12 

bolt lock plate 


(81 ft lb) 

Trailing arm, removing and 

installing 

- Raise rear end of car and remove 

wheel. 

WARNING! 







- Remove drive axle as described in 


- 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). Detach bracket 

from trailing arm.



4 of 19 2/25/2009 10:30 PM 

CAUTION! 

Avoid damaging the brake hose by 

stretching when the trailing arm is 

lowered. 

- Remove fuel tank protective panel, 

if equipped. 

Remove ABS pulse sensor from trailing 

arm. 

- Unclip pulse sensor and pad sensor 

(if applicable) harnesses from 

control arm and lay aside. 

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.



5 of 19 2/25/2009 10:30 PM 

- 

Unbolt upper and lower control 

arms from trailing arm. Note 

direction of bolt insertion in both 

arms. 

To remove trailing arm: 

Make reference marks to locate 

trailing arm bracket to body in order 

to maintain alignment 

specifications. 

Remove trailing arm front bracket 


Working with trailing arm on 

workbench, detach front bracket 

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). 


Trailing arm to front 

bracket 

110 Nm (81 ft-lb) 

- Remainder of installation is reverse 

of removal, noting the following:



6 of 19 2/25/2009 10:30 PM 

Install new rear wheel bearings. 

Insert control arm mounting bolts in 

direction previously marked. 

Always use new self-locking nuts. 

Transfer brake system components 

to new arm as described in 340 

Brakes. 

Note: 



BMW-supplied replacement trailing arms 

come with control arm bushings installed. 

A new wheel bearing will have to be 

installed. 


Drive axle collar nut to drive flange 

M24 250 Nm (184 

ft-lb) 

M27 300 Nm (221 

ft-lb) 



bolt 


(black) 



replace) 




83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

100 Nm (74 ft-lb)



7 of 19 2/25/2009 10:30 PM 


normal loaded 

position) 

Trailing arm bracket 

to body (M12 bolt) 

Trailing arm to 

upper or lower 

control arm (M12 

bolt) 

77 Nm (57 ft-lb) 

110 Nm (81 ft-lb) 

Upper control arm, removing 




WARNING! 







- 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 this repair group.



8 of 19 2/25/2009 10:30 PM 

- 

If necessary, remove ride level 

sensor from upper control arm. 

- Unbolt upper control arm from both 

trailing arm and rear subframe. 

Note direction of bolt insertion. 

Note: 

For clearance reasons, it may be 

necessary to unbolt the differential from 

the subframe and push it toward the rear 

of the car in order to remove the control 

arm mounting bolt from the subframe. 


noting the following; 

Insert mounting bolts in direction 

previously marked 

Always use new self-locking nuts. 





M24 250 Nm (184 

ft-lb) 

M27 300 Nm (221 

ft-lb) 



bolt 


(black) 



replace) 

83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb)



9 of 19 2/25/2009 10:30 PM 




trailing arm car in 

normal loaded 

position 

Upper control arm 

to rear subframe 

M12 bolt 


to trailing arm M12 

bolt 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

100 Nm (74 ft-lb) 

77 Nm (57 ft-lb) 

110 Nm (81 ft-lb) 

Lower control arm, removing 


- Raise rear end of car and support it 

securely on jackstands. Remove 

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 to remove the control 

arm mounting bolt from the subframe.



10 of 19 2/25/2009 10:30 PM 

- 

Use a soft hammer to tap control 

arm out of its mounting points. 


Welded seam of control arm faces 

upward. 

To install mounting hardware at 

subframe, insert lock plate into 

opening in subframe from below. 

Line up eccentric bolt head with 

marks made previously. 




Lower control arm 


M12 bolt 



eccentric bolt 

110 Nm (81 ft-lb) 

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.



11 of 19 2/25/2009 10:30 PM 

Detach rear driveshaft from rear 

differential. See 260 Driveshaft. 

Detach rear drive axles from rear 

differential. Remove rear differential. 

See 331 Rear Axle Final Drive. 

Detach rear control arms as 

described earlier 

Remove rear subframe mounting 

fasteners (arrows) while supporting 

subframe securely. 

- In case of damage to subframe 

mounting stud threads, replace 

stud. 


mounting stud threads in body, 

repair using Helicoil thread insert 

M12 x 1.5 x 18. 


Differential to 

subframe front bolt 

(M12) 

Differential to 

subframe rear bolt 

(M14) 



bolt 


(black) 



replace) 

Driveshaft to differential flange 

110 Nm (81 ft-lb) 

174 Nm (128 

ft-lb) 

83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb)



12 of 19 2/25/2009 10:30 PM 


M10 compression 

nut 

M10 Torx bolt 

Lower control arm to 

subframe (M12) 


(M12) 


to subframe (M12) 

64 Nm (47 ft-lb) 

85 Nm (63 ft-lb) 

110 Nm (81 ft-lb) 

77 Nm (57 ft-lb) 

77 Nm (57 ft-lb) 

Rear subframe 

assembly 


(final drive 

carrier) 

2 - M12 mounting 

stud 


ft-lb) 

3 - Bushing 

4 - Bushing 

5 - M12 bolt with 

washer 


(81 ft-lb) 

6 - Rear 

suspension 

reinforcement 

7 - M12 self-locking 

collar nut



13 of 19 2/25/2009 10:30 PM 


ft-lb) 

8 - M8 bolt 


21 Nm (15 ft-lb) 


to 30 Nm (22 ft-lb) 

9 - M14 bolt 


(128 ft-lb) 

10 - Bushing 

11 - M14 self-locking 

collar nut 

12 - Bushing 

13 - Stop washer 

14 - M12 reduced 

shaft bolt 


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.



14 of 19 2/25/2009 10:30 PM 

Support car securely before starting 

work underneath rear suspension. 

WARNING! 







Trailing arm front bushing 

- Before removing trailing arm, be 

sure to mark position of trailing arm 

front bracket 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 



Trailing arm to front 

110 Nm (81 ft-lb)



15 of 19 2/25/2009 10:30 PM 


bracket 

Trailing arm 

bracket to body 

77 Nm (57 ft-lb) 

Upper or lower control arm outer 

bushing (in trailing arm) 

- Upper control arm bushing: 

Remove trailing arm from car as 

described earlier. Note direction of 

bolt insertion. 

- Lower control arm bushing: Detach 

lower control arm from trailing arm. 

There is no need to remove trailing 

arm. 

- Before 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 



Drive axle collar nut to drive flange



16 of 19 2/25/2009 10:30 PM 


M24 250 Nm (184 

ft-lb) 

M27 300 Nm (221 

ft-lb) 



bolt 


(black) 



replace) 



eccentric bolt 



trailing arm car in 

normal loaded 

position 



M12 bolt 



bolt 

83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb) 

110 Nm (81 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

100 Nm (74 ft-lb) 

77 Nm (57 ft-lb) 

110 Nm (81 ft-lb) 

Upper control arm inner bushing 

- Remove upper control arm as 


- Press old bushing out using 

appropriate press tools. 

Press new bushing starting at inner 

bevelled end (arrow) of control arm 

bore.



17 of 19 2/25/2009 10:30 PM 

Be sure that longer collar of 

bushing (A) is on same side as 

bevel in control arm. 

Outer bushing housing must be 

flush with control arm bore when 

fully pressed in. 





M24 250 Nm (184 

ft-lb) 

M27 300 Nm (221 

ft-lb) 



bolt 


(black) 



replace) 




normal loaded 

position) 



M12 bolt 



bolt 

83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

100 Nm (74 ft-lb) 

77 Nm (57 ft-lb) 

110 Nm (81 ft-lb)



18 of 19 2/25/2009 10:30 PM 

Rear subframe bushing 

- Remove subframe as described 

earlier. 


mounting stud threads, replace 

stud. 


mounting stud threads in body, 

repair using Helicoil thread insert 

M12 x 1.5 x18. 

- Press old bushing out and install 

new bushing using appropriate 

press tools. 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. 





M24 250 Nm (184 

ft-lb) 

M27 300 Nm (221 

ft-lb) 

Drive axle to final drive flange



19 of 19 2/25/2009 10:30 PM 



bolt 


(black) 



replace) 




normal loaded 

position) 


(M12) 



M12 bolt 



bolt 

83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

100 Nm (74 ft-lb) 

77 Nm (57 ft-lb) 

77 Nm (57 ft-lb) 

110 Nm (81 ft-lb) 




1 of 1 2/25/2009 10:31 PM 

Rear Stabilizer Bar 

330-4 

The rear stabilizer bar is mounted to 

the rear subframe and attached via 

stabilizer bar links to the rear upper 

control arms. 


2 - Self-locking nut M8 

3 - Rubber mounting 

4 - Clamping support 

5 - Bolt M8 

6 - Bolt M 

7 - Stabilizer link support bracket 

8 - Bolt M8 

9 - Self-locking nut 

10 - M8 Self-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



1 of 4 2/25/2009 10:31 PM 

Rear Wheel Bearings 

330-5 

The rear wheel bearing is a unitized 

assembly and is not repairable 

separately. 

Special press tools, to be used with the 

trailing arm attached to the car, are 

required to replace a wheel bearing. 

Read the procedure through before 

beginning the job. 

Rear wheel bearing, replacing 



WARNING! 







- Right side: Detach brake pad 

sensor connector at brake caliper. 


and rotor as described in 340 

Brakes. Leave brake hose 




Remove ABS pulse sensor at trailing 

arm.



2 of 4 2/25/2009 10:31 PM 

Remove drive flange from bearing 

assembly using impact style puller 

(BMW special tools 33 2 116, 33 4 

201/202/203 or equivalent). 

CAUTION! 

The wheel bearing is destroyed 

when the drive flange is removed. Do 

not attempt to reuse bearing. 

Note: 

Use BMW special tool set 33 4 400 or 

equivalent to separate inner bearing 

race from drive flange. 

- Remove bearing retaining circlip 

from bearing housing in trailing 

arm. 

- 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.



3 of 4 2/25/2009 10:31 PM 

Make sure all mating surfaces are 

clean 

- Install new bearing assembly 

using press tools (BMW special 

tools 33 3 261/264/265 or 

equivalent. 

- Install new circlip. 

CAUTION! 

Apply force only to outer race 

when installing bearing. 

Make sure that the bearing is 

pressed in far enough to contact 

the shoulder at the back side of 

the housing and that the circlip 

is fully seated 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 brake caliper assembly and 

rotor as described in 340 

Brakes.



4 of 4 2/25/2009 10:31 PM 

- 

Reinstall drive axle. 


Brake rotor to drive 

flange (M8) 


trailing arm (M12) 

16 Nm (12 ft-lb) 

67 Nm (50 ft-lb) 


M24 250 Nm (184 

ft-lb) 

M27 300 Nm (221 

ft-lb) 



bolt 


(black) 



replace) 



83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb)

Rear Axle Final Drive 


1 of 2 2/25/2009 10:32 PM 

General 

331-1 

This repair group cover removal and 

repair information for the rear drive axle 

shafts, CV joints and CV joint boots. 

Also covered is rear differential (final 

drive) removal procedures and seal 

replacement information. 

Internal repairs of the differential 

assembly are 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



2 of 2 2/25/2009 10:32 PM 

Output flange seal drift BMW 33 3 400 

Input flange seal drift BMW 33 3 430 




1 of 7 2/25/2009 10:32 PM 

Drive Axles 

331-2 

The drive axles use constant-velocity 

(CV) joints on both ends. Two different 

styles of CV joints have been supplied 

with E46 vehicles. Refer to the 

accompanying illustration: 

Ball cage CV joint. Traditional 

design CV joint with thick metal 

housing (approx. 40 mm/1.6 in. 

thick). Balls slide in non-parallel 

grooves. 

Slip sleeve CV joint. Thin bolt-on 

flange (approx. 15 mm/0.6 in. 

thick). CV joint has splined shaft 

that slides into end of axle. 

For replacement parts, only CV joints 

boots or complete axles are offered by 

BMW. To replace a CV joint boot, the 

drive axle must be removed from the 

car. The rear axle shafts are different in 

length. 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 hub. Do not 

remove completely. 

Note: 

The drive flange collar nut is tightened 

to a torque of over 250 Nm (184 ft-lb). 


ground.



2 of 7 2/25/2009 10:32 PM 

- 

Raise rear of car. Remove rear 

wheel. 

WARNING! 







- Detach rear stabilizer bar anchor 

bolts from rear subframe and tilt 

stabilizer down. 

- Working 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. 


Apply a light coating of oil to 

contact face of collar nut and 

install it loosely.



3 of 7 2/25/2009 10:32 PM 

Install road wheel and lower car to 

ground. 

With an assistant applying brakes, 

tighten drive axle collar nut to its 

final torque. 

Stake and caulk collar nut. 



M24 250 Nm (184 

ft-lb) 

M27 300 Nm (221 

ft-lb) 



bolt 


(black) 



replace) 


83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb) 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

Rear drive axle assembly



4 of 7 2/25/2009 10:32 PM 

CV joint boots 

Note: 

When replacing a CV joint boot, use 

a complete CV joint boot repair kit. 

The kit will include a new boot, 

clamping bands, special lubricant, 

and a new inner CV joint circlip. The 

kit is available from an authorized 

BMW dealer parts department. 

The outer CV joint cannot be 

removed from the axle shaft. In 

order to replace the outer CV boot, it 

is necessary to remove the inner 

joint and boot first. 

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 joint and 

remove circlip (arrow) retaining joint



5 of 7 2/25/2009 10:32 PM 

inner hub to axle shaft. 

Support inner hub at arrowswhen 

pressing axle shaft out of joint. 

- Clean all old lubricant off shaft 

splines and inner joint's splines. 

CAUTION! 

If the CV joint must be disassembled 

for cleaning and inspection, be sure to 

matchmark inner and outer race and 

intermediate ball cage. This allows 

reassembly of parts in their 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 on shaft so that raised or taller



6 of 7 2/25/2009 10:32 PM 

side of hub is facing shaft. 

WARNING! 

Do not let the locking compound 

contact the balls in the joint. Apply 

only a thin coat to cover the splines. 

- While supporting axle shaft, press 

inner hub of CV joint onto shaft. 

Install new circlip. 

Note: 

Do not let the ball hub pivot more 

than 20 in the outer ring of the joint. 

The balls will fall out if the hub is 

pivoted too far. 

Before installing each small boot 

clamp be 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. 


Wheel hub end 

Differential end 

80 gram (2.8 oz.) 

85 gram (3.0 oz.) 

- Use sealing gel to seal dust cover 

to CV joint prior to reinstallation. 

Slip sleeve CV joint boot 

- Pull CV joint partially out of axle 

shaft. Matchmark relative position of



7 of 7 2/25/2009 10:32 PM 

joint to shaft. 

CAUTION! 

If the joint and shaft are not 

reassembled in their original position 

the assembly may be out of balance 

and vibrate during operation. 

When reinstalling joint, push joint into 

shaft as far as it will go, then pull it out 

to measurement A(16 mm / 0.6 in.). 

Note: 

This step insures uniform lubrication of 

the CV joint. 

- Keep joint in position while 

installing inner (small) 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 

Outer boot 

65 mm (2.6 in.) 

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 

are offset by 180°.



1 of 5 2/25/2009 10:33 PM 

Rear Differential 

331-3 

All rear differential work requires some 

method of raising the car and 

supporting it securely while the work is 

performed. Jack stands and a floor jack 

can easily be used, but use extreme 

caution when working beneath the car. 

See 010 General. 

Note: 

Removal of rear subframe (differential 

carrier) is covered in 330 Rear 

Suspension. 

Rear differential oil, checking 

and filling 

Note: 

BMW supplies the E46 rear differential 

with lifetime lubricant. 

To check rear differential oil level: 

Remove oil filler plug. 

Note: 

Insert finger into fill hole. If finger 

is wetted from oil, level is correct. 

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, fill differential with 

appropriate type and quantity of 

lubricant. 

Note:



2 of 5 2/25/2009 10:33 PM 

The differential fluid level is correct 

when the fluid begins to spill from the 

fill plug. 

- Install and tighten fill plug. 

Differential oil 

Differential oil capacity 



Oil specification 

0.9 liter (0.95 US 

qt.) 

1.0 liter (1.06 US 

qt.) 


synthetic oil 


Differential drain or 

fill plug 

70 Nm (52 ft-lb) 

Rear differential, removing and 

installing 

- Raise rear end of car and support 

it securely on jack stands. 

WARNING! 







- Remove rear drive axles. 

- If necessary, drain differential oil. 

Remove rear suspension reinforcement 

brace:



3 of 5 2/25/2009 10:33 PM 

Remove heat shield between 

reinforcement brace and exhaust 

pipe. 

Remove bolts (A) mounting brace 

to undercarriage. 

Remove nuts (B) mounting brace 

and front of rear subframe to 

undercarriage. 

Note: 

Lower and remove reinforcement. 

If necessary, tilt rear half of exhaust 

system down. Support exhaust system 

securely. 

- Detach driveshaft from differential 

input shaft flange and suspend. 


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. 


In order to prevent excess 

vibration and noise, follow 

sequence for tightening



4 of 5 2/25/2009 10:33 PM 

differential mounting bolts: 

Install bolts finger tight. 

Tighten front bolts (B). 

Tighten rear bolt (A). 



fill plug 

Differential to rear subframe 

Front mount (M12 

bolts) 

Rear mount (M14 

bolt) 

70 Nm (52 ft-lb) 

95 Nm (70 ft-lb) 



bolt 


(black) 



replace) 

174 Nm (128 

ft-lb) 

83 Nm (61 ft-lb) 

100 Nm (74 

ft-lb) 

80 Nm (59 ft-lb) 



nut 

M10 Torx bolt 

64 Nm (47 ft-lb) 

85 Nm (63 ft-lb) 

Rear suspension reinforcement to 

undercarriage 


nut 

M8 bolt 8.8 grade 

M8 bolt 10.9 grade 

77 Nm (57 ft-lb) 

21 Nm (15 ft-lb) 

30 Nm (22 ft-lb) 

- Be sure to refill differential.



5 of 5 2/25/2009 10:33 PM 






0.9 liter (0.95 US 

qt) 

1.0 liter (1.06 US 

qt.) 


synthetic oil 

Differential mounting bushings 

- If rear differential mounting 

bushing are worn, damaged or oil 

soaked: 

Remove differential from rear 

subframe. 

Working at subframe, use bushing 

press tools to remove old 

bushings and install new ones. 

Note: 


Carefully note installation marks 

(arrows) on new bushings. 

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.



1 of 5 2/25/2009 10:33 PM 

Rear Differential Oil 

Seals 

331-4 

Low oil level caused by faulty oil seals 

may be the cause of noisy differential 

operation. The drive flange (side) and 

input shaft (front) oil seals can be 

replaced while the differential is 

installed. 

Note: 

Do not mistake leaking CV joints for 

flange seal leaks. It may be helpful to 

degrease the differential to pinpoint the 

source of the leak prior to replacing 

seals. 

Output drive flange oil seal, 

replacing 


WARNING! 







- If working on left side: Detach rear 

of exhaust system and tilt down. 

Support rear muffler securely. 

- Detach stabilizer bar from rear 

subframe. 

- Detach drive axle from differential 

as described earlier. 

CAUTION!



2 of 5 2/25/2009 10:33 PM 

Suspend the detached drive axle 

from the car body with a stiff wire 

hook to prevent damage to the outer 

CV joint. 

Pry output flange from differential. For 

leverage, use a wooden dowel as 

shown. 

Note: 

Be prepared to catch dripping oil in 

a pan. 

Inspect flange at the point where 

the oil seal rides on the shaft. 

Replace the flange if there is a 

groove worn in the shaft. 

- Pry old oil seal from its recess 

using BMW special tool 00 5 010 

or equivalent seal puller. 

CAUTION! 

Be careful not to mar the differential 

housing when removing the seal. 

- 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 pushing. 

- Attach drive axle and tighten bolts. 

- Top off differential with oil.



3 of 5 2/25/2009 10:33 PM 




bolt 


(black) 



replace) 

83 Nm (61 ft-lb) 

100 Nm (74 ft-lb) 

80 Nm (59 ft-lb) 

Input drive flange oil seal, 

replacing 


Remove rear suspension reinforcement 

brace: 

Remove heat shield between 

reinforcement brace and exhaust 

pipe. 

Remove bolts (A) mounting brace 

to undercarriage. 

Remove nuts (B) mounting brace 

and front of rear subframe to 

undercarriage. 

Note: 

Lower and remove reinforcement. 

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



4 of 5 2/25/2009 10:33 PM 

side. 

Make matching marks on differential 

input shaft, collar nut and driveshaft 

flange. 

- Pry lock plate from nut. 

Counterhold input flange with 


equivalent and remove collar nut. 

- If necessary, use puller to remove 

input flange. 

Note: 

Be prepared to catch dripping oil in a 

pan. 

- Pry old oil seal from its recess 

using BMW special tool 00 5 010 

or equivalent seal puller. 

CAUTION! 

Be careful not to mar the differential 

housing when removing the seal. 

- 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 the marks, interior components 

of the differential will be damaged.



5 of 5 2/25/2009 10:33 PM 






0.9 liter (0.95 US 

qt) 

1.0 liter (1.06 US 

qt.) 


synthetic oil 

- Remainder of assembly is reverse 

of disassembly. 




nut 

M10 Torx bolt 


fill plug 

64 Nm (47 ft-lb 

85 Nm (63 ft-lb) 

70 Nm (52 ft-lb) 


Brakes 


1 of 9 2/25/2009 10:33 PM 

General 

340-1 

This repair group covers brake service: 

Brake pads, calipers, and disks 

Master cylinder, brake booster, 

and parking brake 

ABS/ASC and ABS/DSC 

component replacement 

ABS/ASC and ABS/DSC system 

descriptions are covered in 300 


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 


2 of 9 2/25/2009 10:33 PM 

Brake pad lining gauge BMW 34 1 260 

Vacuum tester BMW 34 3 100 

Factory diagnostic tool DISplus or 

MoDiC 

E46 brake system 

BMW E46 models are equipped with 

vacuum power-assisted four-wheel disc 

brakes with an integral Antilock Brake 

System (ABS). Single-piston calipers 

act on 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 


3 of 9 2/25/2009 10:33 PM 

conjunction with engine management 

controls to control wheel spin and 

maintain vehicle stability while braking. 

Added midway through the 1999 model 

year was Dynamic Stability Control 

(DSC). This system uses ASC 

technology, but implements wheel 

speed modulation throughout all 

stages of driving. DSC is able to 

reduce understeer by applying differing 

amounts of braking force to each 

wheel, as well as overriding the engine 

management system during hard 

cornering. 

A summary of distinguishing 

characteristics of the various systems is 

shown in Table a. E46 Electronic 

braking and stability control systems. 

For ABS system and component 

descriptions, see 300 Suspension, 

Steering and Brakes-General. 

WARNING! 

Table a. E46 Electronic braking and stability control systems 

A car with electronic stability control 

is still subject to normal physical 

laws. Avoid excessive speeds for the 

road conditions encountered. 

Year 

(model) 

System 

(manufacturer) 

Identifiers 

ASC 1999 - 2000 Automatic Stability 

Control 

(Teves MK 20) 

DCS 1999 - 2000 Dynamic Stability 

Control 

(Teves MK 20 DSC) 

Control 

module/hydraulic unit 

under master cylinder 

No precharge pump 

Control 


in right rear 

compartment of 

engine bay 

Precharge pump 

under master cylinder

Brakes 


4 of 9 2/25/2009 10:33 PM 

Year 

(model) 

DSC 2001 

(rear wheel drive) 

DSC 2001 

(all wheel drive) 

System 

(manufacturer) 

Dynamic Stability 

Control 

(Teves MK 60 DSC) 

Dynamic Stability 

Control 

(Bosch DSC III 5.7) 

Identifiers 

Control 


mounted under 


No precharge pump 

Control 


in right rear 

compartment of 

engine bay 

Precharge pump 

under master cylinder 


Brake performance is mainly affected by 

three things: 

Level and condition of brake fluid 

The system's ability to create and 

maintain hydraulic pressure 

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 

starting at the master cylinder. To check 

the function of the master cylinder hold 

the brake pedal down hard with the 

engine running. The pedal should feel 

solid and stay solid. If the pedal slowly 

falls to the floor, either the master

Brakes 


5 of 9 2/25/2009 10:33 PM 

cylinder is leaking internally, or fluid is 

leaking externally. Check all brake fluid 

lines and couplings for leaks, kinks, 

chafing and corrosion. If no leaks can be 

found, the master cylinder is faulty and 

should be replaced. 

Check brake booster: 

Remove vacuum hose (A) from 

brake booster and install BMW 

special tool 34 3 100 between 

connection and hose on non-return 

valve (B). 

Start engine and check build-up of 

partial vacuum. 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 cannot be reached, 

brake booster must be replaced. 

Worn or contaminated brake pads will 

cause poor braking performance.

Brakes 


6 of 9 2/25/2009 10:33 PM 

Oil-contaminated or glazed pads will 

cause stopping distances to increase. 

Inspect the rotors for glazing, 

discoloration and scoring. Steering 

wheel vibration while braking at speed is 

often caused by warped rotors, but can 

also be caused by worn suspension 

components. 

When troubleshooting, keep in mind that 

tire inflation, wear and temperature can 

all have an affect on braking. See 300 


General for additional suspension and 

brake system troubleshooting. 

Table b. Brake system 

troubleshooting lists symptoms of brake 

problems, probable causes, and 

suggested 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 brake pads or 

shoes may produce dangerous 

dust. 

Brake fluid is poisonous, 

corrosive and dangerous to the 

environment. Wear safety glasses 

and rubber gloves when working 

with brake fluid. Do not siphon 

brake fluid with your mouth. 

Immediately clean fluid spilled on 

painted surfaces and wash with

Brakes 


7 of 9 2/25/2009 10:33 PM 

water, as brake fluid will remove 

paint. 

Always use new brake fluid from 

a fresh, unopened container. 

Brake fluid will absorb moisture 

from the air. This can lead to 

corrosion problems in the braking 

system, and will also lower the 

brake fluid's boiling point. 

Dispose of brake fluid properly. 

Do not reuse self-locking nuts, 

bolts or fasteners. They are 

designed to be used only once 

and may fail if reused. Always 

replace them with new 

self-locking fasteners. 

Table b. Brake system troubleshooting 


Brake squeal 

Pedal goes to floor 

when braking 

Incorrectly installed 

brake pads or 

parking brake shoes, 

or brake parts. 

Brake pad carriers 

dirty or corroded 

Brake pads 

heat-glazed or 

oil-soaked 

Wheel bearings worn 

(noise most 

pronounced when 

turning) 

Brake fluid loss due 

to system leaks 

Master cylinder or 

electronic control 

system faulty 

Check component installation. Check/replace 

anti-rattle springs. 

Remove brake pads and clean calipers. 

Replace brake pads. Clean rotors. Replace 

leaking calipers as required. 

Replace worn bearings. See 310 Front 

Suspension or 330 Rear Suspension. 

Check fluid level and inspect for signs of 

leakage. 

Replace master cylinder. Diagnose electronic 

control system using factory or compatible 

diagnostic tool.

Brakes 


8 of 9 2/25/2009 10:33 PM 


Low pedal after 

system bleeding 

Pedal spongy or 

brakes work only 

when pedal is 

pumped 

Excessive braking 

effort 

Brakes pulsate, 

chatter or grab 

Uneven braking, 

car pulls to one 

side, rear brakes 

lock 

Brakes drag, bind 

or overheat 

Master cylinder faulty 

Air in brake fluid 



system faulty 

Brake pads wet 

Brake pads 

heat-glazed or fluidsoaked 

Vacuum booster or 

vacuum hose 

connections to 

booster faulty 

Warped brake rotors 

Brake pads worn 

Brake pads 

heat-glazed or 

oil-soaked 

Incorrect tire 

pressures or worn 

tires 

Brake pads on one 

side of car 

heat-glazed or fluidsoaked 

Caliper or brake pads 

binding 

Worn suspension 

components 

Brake caliper or 

brake pads binding 



system faulty 

Replace master cylinder. 

Bleed system using factory or compatible 

diagnostic tool 

Replace master cylinder. Diagnose system using 

factory or compatible diagnostic tool. 

Use light pedal pressure to dry pads while 

driving. 

Replace brake pads and rotors. Replace leaking 

calipers. 

Inspect vacuum lines. Test vacuum booster and 

replace as required. Test vacuum non-return 

valve for one-way flow. 

Resurface or replace rotors. 

Replace brake pads. 


leaking calipers. 

Inspect tire condition. Check and correct tire 

pressures. 


leaking calipers. . 

Clean and recondition brakes. 

Inspect for worn or damaged suspension 

components. See 310 Front Suspension or 

330 Rear Suspension. 

Clean or replace caliper. 

Replace master cylinder. Diagnose electronic 

control system using factory or compatible 

diagnostic tool.

Brakes 


9 of 9 2/25/2009 10:33 PM 


Brakes 


1 of 3 2/25/2009 10:34 PM 

Bleeding brakes 

340-2 

Brake bleeding is usually done for one 

of two reasons: Either to replace old 

brake fluid as part of routine 

maintenance or to expel trapped air in 

the system that resulted from opening 

the brake hydraulic system during 

repairs. 

Always use new brake fluid from an 

unopened container. It is important to 

bleed the entire system when any part 

of the hydraulic system has been 

opened. Be sure to have the special 

equipment needed before beginning 

the job. 

WARNING! 

E46 cars require special BMW 

service equipment to properly bleed 

either the ABS/ASC or the ABS/DSC 

system. For safety reasons, the 

brake system on these cars must not 

be bled without the use of a factory 

diagnostic computer. 

When bleeding the brakes, start at the 

wheel farthest from the master cylinder 

and progress in the following order: 

right rear brake 

left rear brake 

right front brake 

left front brake 

Pressure bleeding brakes 

- Top off brake fluid in reservoir and

Brakes 


2 of 3 2/25/2009 10:34 PM 

connect BMW Diagnosis and 

Information System (DIS) to 20 pin 

Data Link Connector (DLC) under 

hood (1999 models), or 16 pin 

DLC/OBD II connector under dash 

(2000- 2001 models). Call up 

service function Bleeding 

ABS/ASC or service function 

Bleeding ABS/DSC, depending on 

which system the vehicle is 

equipped with. 

- Connect pressure bleeding device 

to brake fluid expansion tank and 

pressurize. 

CAUTION! 

Do not exceed a pressure of 2 bar (29 

psi) when pressure bleeding the 

brake system. Excessive pressure 

will damage the brake fluid 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 bubbles, close bleeder 

screw and release brake pedal. 

CAUTION! 

Bleeder hose must always remain 

submersed in clean brake fluid 

whenever the bleeder valve is open. 

- Refill brake fluid reservoir and 

proceed to rear left wheel.

Brakes 


3 of 3 2/25/2009 10:34 PM 

- 

Proceed with remaining wheels in 

order as listed earlier. 



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)

Brakes 


1 of 9 2/25/2009 10:34 PM 

Brake Pads, Calipers, 

and Rotors 

340-3 

Brake pads can be replaced without 

disconnecting the brake fluid hose from 

the caliper or having to bleed the 

brakes. The rotors can be replaced 

without disassembling wheel hub and 

bearing. Always machine or replace 

rotors in pairs. Replace pads in sets. 

Refer to the accompanying illustration 

(previous 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 


guide bolts 

7 mm Allen head

Brakes 


2 of 9 2/25/2009 10:34 PM 

Torque to 30 Nm 

(22 ft-lb) 


Brake line: torque to 

18 Nm (13 ft-lb) 

See Caliper 

removal 

3 - Brake pad wear 

sensor 

See Brake pad 

wear sensor 

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 


(12 ft-lb) 

7 - Front brake 

rotor 

Make sure contact 

surfaces are clean

Brakes 


3 of 9 2/25/2009 10:34 PM 

and free from 

grease 

See Front brake 

rotor 

8 - Rear brake rotor 

retaining screw 


(12 ft-lb) 

9 - Rear brake rotor 


surfaces are 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 


4 of 9 2/25/2009 10:34 PM 



and free from 

grease 

See Brake pad 

carrier 

13 - Brake pad 

carrier retaining 

bolts 

Front: torque to 110 

Nm (81 ft-lb) 

Rear: torque to 65 

Nm (48 ft-lb) 

Oil bolts lightly. 



and free from 

grease. 

Caliper removal 

Remove plastic caps from caliper 

mounting bolts and remove caliper 


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 


5 of 9 2/25/2009 10:34 PM 

caliper piston will have to be 

pressed back into caliper before 

caliper can be removed. 

CAUTION! 

Pressing caliper piston in may cause 

brake fluid reservoir to overflow. To 

prevent this, use a clean syringe to 

first remove some fluid from reservoir. 

Open caliper bleeder screw only 

when applying force to the piston. 

Do not allow air to be drawn in 

through bleeder screw. Catch 

expelled fluid in appropriate 

container. 

Do not let brake 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 caliper has been removed or 

replaced. See Bleeding brakes. 


Caliper to brake 

pad carrier 

mounting bolts 

30 Nm (22 ft-lb)

Brakes 


6 of 9 2/25/2009 10:34 PM 

Brake pad wear sensor 

Carefully pry pad wear sensor from 

brake pad. 

Insert brake pad wear sensor into 

cutout in new pad where applicable. 

If brake lining indicator light 

illuminated prior to brake pad 

replacement, replace wear sensor. 

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 


7 of 9 2/25/2009 10:34 PM 

Brake pad lining thickness 

To measure brake pad lining thickness: 

- Insert BMW special tool 34 1 260 at 

either front right wheel or left rear 

wheel 

- Move wheel until notch for brake 

wear indicator can be seen through 

wheel opening. 

- Insert tip of tool into notch so that 

the body of tool rests on brake pad 

backing plate (A), and tip touches 

brake disc (B). 

- Replace pads 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 minimum 

thickness requirements or is 

damaged replace rotor.nothing

Brakes 


8 of 9 2/25/2009 10:34 PM 

Table c. Brake rotor reconditioning 


Vented rotor 

wear limit 

(min. 

thickness) 

Max. 

machine 

limit per 

friction ring 

side 

Front 

20.4 mm 

(0.80 in.) 

0.8 mm 

(0.03 in.) 

Rear 

17.4 mm 

(0.68 in.) 

0.8 mm 

(0.03 in.) 

WARNING! 

Confirm rotor wear limit specifications 

given in Table c with specifications 

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 

330 i / Ci / 

xi 

300 x 22 

mm 

(11.8 x 0.9 

in.) 

325 x 25 

mm 

(12.8 x 1.0 

in.) 

294 x 19 

mm 

(11.6 x 0.7 

in.) 

320 x 22 

mm 

(12.6 x 0.9 

in.) 

Brake rotors should always be 


Clean rotor with brake cleaner

Brakes 


9 of 9 2/25/2009 10:34 PM 


When installing new rear brake 

rotors, the parking brake should be 

adjusted. See Parking brake. 


Brake rotor to hub 

mounting screw 

16 Nm (12 ft-lb) 

Brake pad carrier removal 

Remove brake pad carrier mounting 

bolts (arrows) and remove pad carrier 

from steering arm or trailing arm. 


Pad carrier to front 

steering arm 

Pad carrier to rear 

trailing arm 

110 Nm (81 ft-lb) 

65 Nm (48 ft-lb) 


Brakes 


1 of 4 2/25/2009 10:34 PM 

Master cylinder 

340-4 

The brake master cylinder is mounted 

to the front of the vacuum booster on 

the driver side bulkhead. 

CAUTION! 

All U.S. market E46 vehicles are 

equipped with Antilock Braking 

System (ABS) and either Automatic 

Stability Control (ASC) or Dynamic 

Stability Control (DSC). Replacing 

the master cylinder requires that the 

braking system be properly bled by 

an authorized BMW repair facility. 

This procedure is necessary for the 

braking and stability controls to 

function properly. 

Master cylinder, removing and 

installing 

- Using a clean syringe, empty 

brake fluid reservoir. 

WARNING! 

Brake fluid is highly corrosive and 

dangerous to the environment. 

Dispose of it properly. 


housing: 


microfilter. 


remove wires. 


lower microfilter housing.

Brakes 


2 of 4 2/25/2009 10:34 PM 

Remove side trim panel from left rear of 

engine compartment: 

Remove rubber strip from top of 

trim panel at brake booster. 

Detach vacuum line (A) from 

brake booster Y-connector, 

unhook from trim panel and push 

to side. 

Unhook plastic vacuum line and 

positive starter cable (B) from trim 

panel and pull forward off trim 

panel. 

Release locking clips (C) on 

edges of trim panel and remove 

panel by pulling upwards. 

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 


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 pump is installed 

below brake master cylinder: 

Release hose clamp (arrow) at 

brake fluid reservoir and remove

Brakes 


3 of 4 2/25/2009 10:34 PM 

precharge pump supply hose. 

Plug hose and reservoir to prevent 

fluid leakage or contamination. 

- Remove brake fluid reservoir. 

- Working at master cylinder: 

Disconnect brake fluid lines and 

electrical harness connectors from 

master cylinder as needed. 

On vehicles equipped with Teves 

DSC: remove brake system 

pressure sensors if replacing 


Unscrew mounting nuts and 

remove master cylinder from brake 

booster. 

Plug open brake lines to prevent 


- 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. 


Brake master 

cylinder to brake 

booster 

26 Nm (19 ft-lb) 

CAUTION! 

Be sure to align master cylinder

Brakes 


4 of 4 2/25/2009 10:34 PM 

pushrod and booster pushrod. 

Use care not to over-torque 

master cylinder mounting nuts. 

This could damage brake 

booster and prevent proper 

vacuum build-up. 

- Connect brake fluid lines to 



Brake fluid lines to 


18 Nm (13 ft-lb) 

Note: 

On Teves MK 20 ASC equipped 

vehicles: Be sure to leave flex 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. 



reverse of removal. Bleed entire 

brake system as described earlier.

Brakes 


1 of 4 2/25/2009 10:35 PM 

Brake booster 

340-5 

The brake booster is mounted to the 

bulkhead on driver's side of engine 

compartment, directly behind brake 


A is vacuum hose from intake manifold. 

B is one-way valve. Intake manifold 

vacuum acts on a large diaphragm in 

brake booster to reduce brake pedal 

effort. 

Brake booster, removing and 

installing 

CAUTION! 

On cars with Automatic Stability 

Control (ASC) or Dynamic 

Stability Control (DSC), special 

BMW service equipment is 

required to properly bleed the 

brakes. Removal of the 

hydraulic unit is not 

recommended unless this 

equipment is available. For 

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 fluid lines at 

the hydraulic unit. Label all

Brakes 


2 of 4 2/25/2009 10:35 PM 

connections before 

disconnecting. 


battery. 

CAUTION! 



cautions given at front of this manual 

on page viii. 

- Using a clean syringe, empty 


WARNING! 




- 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 fasteners (B).

Brakes 


3 of 4 2/25/2009 10:35 PM 


connectors at left footwell trim panel 

and remove panel: 

Unplug connector at footwell 

interior light (A), if equipped. 

Slide lock at OBD II connector (B) 

in direction of arrow. 

Unplug connector at speaker (C). 

Remove clip (A) and slide brake 

booster pushrod off brake pedal pin. 

Remove brake booster mounting nuts 

(B). 

- Working in engine compartment, 

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 


- Installation is reverse of removal 


Make sure all nuts, fluid 

couplings, thread bores and 

mating surfaces are clean. 

Replace brake booster self-locking

Brakes 


4 of 4 2/25/2009 10:35 PM 

mounting nuts. 


master cylinder and brake 

booster. 

Bleed brake system as described 

earlier. 

CAUTION! 

Do not over-torque the master 

cylinder mounting bolts. This could 

damage the brake booster and 

prevent proper vacuum build-up. 


Brake master 


booster 

Brake booster to 

bulkhead 

Brake fluid line to 

master cylinder or 


26 Nm (19 ft-lb) 

22 Nm (16 ft-lb) 

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.

Brakes 


1 of 6 2/25/2009 10:35 PM 

Parking brake 

340-6 

The parking brake is a brake drum 

system integrated into the rear brake 

rotors. 

The parking brake can be adjusted 

with the wheels installed, although the 

rear wheels will have to be raised off 

the ground. 

Adjusting the parking brake becomes 

necessary under the following 

circumstances: 

Replacing parking brake shoes 

Replacing rear brake rotors 

Excessive 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! 




beneath a structural chassis point.

Brakes 


2 of 6 2/25/2009 10:35 PM 

Do not place jack stands under 


- Remove one lug bolt from each 

rear wheel. Turn road wheel until 

lug bolt hole lines up with parking 

brake adjuster (approximately 65° 

to rear of wheel centerline). 

Use flat-bladed screwdriver to turn 

adjuster. On left wheel, turn adjuster in 

direction 1 to expand shoes. On right 

wheel, turn adjuster in direction 2 to 

expand shoes. 

- Using a screwdriver, turn adjuster 

to expand brake shoes until road 

wheel can no longer turn, then 

back 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. 

- Turn on ignition. Pull up parking 

brake lever 1 notch and make sure 

that light comes. 

- Pull parking brake lever up one 

more notch and check that rear 

wheels do not move and parking

Brakes 


3 of 6 2/25/2009 10:35 PM 

brake warning light stays lit. If 

parking brake light goes out, 

contact switch must be adjusted. 

- Install parking brake lever boot. 

Install road wheel lug bolts. 


Road wheel to 

hub 

100 ± 10 Nm 

(74 ± 7 ft-lb) 

Parking brake shoes, removing 


- Raise rear of car and remove road 

wheels. 

- Without disconnecting brake fluid 

hose, remove rear brake calipers 

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 

out. 

- Inspect shoe expander to make 

sure it functions properly. Apply a

Brakes 


4 of 6 2/25/2009 10:35 PM 

thin coat of grease to sliding parts 

and pins. 


Be sure to adjust parking brake 

cables as described earlier. 

Parking brake cable, replacing 

The parking brake is actuated by two 

separate Bowden cables between the 

parking brake handle and the parking 

brake shoe actuators at the rear brake 

backing plates. Each cable can be 

replaced separately. 

To replace a cable it is not necessary 

to remove the rear wheel or to 

disassemble the brakes. However, it is 

necessary to remove the 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. 


equivalent deep 10 mm socket to 

remove parking brake cable lock nuts 

(A) at base of parking brake handle. 

- Raise rear of car. 

WARNING! 




beneath a structural chassis point. 


suspension parts.

Brakes 


5 of 6 2/25/2009 10:35 PM 

- 

Remove complete exhaust system 

as described in 180 Exhaust 

System. 

- Remove center tunnel heat shield. 

Pull parking brake cable out of body 

guide tube (arrows) and detach from 

routing brackets, noting correct routing 

for reinstallation. 

Remove one lug bolt from rear wheel. 

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 


6 of 6 2/25/2009 10:35 PM 

Pull cable out of back of backing 

plate. 

- To reinstall: 

Push new cable housing into hole 

in back of backing plate. 

Push free (parking brake handle) 

end of cable into housing until 

end of cable snaps audibly into 

holder inside brake drum. 

Reroute new cable under car, attaching 

to brackets (arrows). 


reverse of removal noting the 

following: 

Adjust parking brake as described 

earlier. 


Brakes 


1 of 11 2/25/2009 10:35 PM 

ABS Component 

Replacement 

340-7 

CAUTION! 

If the tires on the car are of 

different makes, the ASC system 

may over-react. Only fit tires of 

the same make and tread 

pattern. 

In adverse conditions, such as 

trying to rock the car out of deep 

snow or another soft surface, or 

when snow chains are fitted, it 

is advisable to switch off ASC 

and allow the car's driveline to 

operate conventionally. 

All E46 vehicles are equipped with an 

Antilock Braking System (ABS). Early 

production models featured ABS with 

Automatic Stability Control (ABS/ASC). 

Later models came equipped with ABS 

and Dynamic Stability Control 

(ABS/DSC). 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 & Hall effect wheel 

speed sensors can be interchanged 

physically in the rear wheels, but 

function is not similar. 

- Raise applicable end of car.

Brakes 


2 of 11 2/25/2009 10:35 PM 

WARNING! 




beneath a structural chassis point. 



Front sensor: Unscrew mounting bolt 

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 


3 of 11 2/25/2009 10:35 PM 

of Molykote® Longterm 2 or an 

equivalent grease to impulse 

sensor and housing. 



ABS wheel speed 

sensor to steering 

arm / trailing arm 

8 Nm (6 ft-lb) 

ABS impulse wheel 

ABS impulse wheel replacement may 

be needed in case of damage or 

impulse teeth corrosion. 

Front impulse wheel 

- Rear wheel drive models: 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: Impulse wheel is 

pressed on outer CV joint, but it is

Brakes 


4 of 11 2/25/2009 10:35 PM 

not replaceable separately. 

See 331 Rear Axle Final Drive for CV 

joint and drive axle replacement 

procedures. 

DSC lateral acceleration 


Rear wheel drive cars: The lateral 

accleration sensor is located on the left 

side driver's footwell, under the panel 

trim on rear wheel drive vehicles. 

All wheel drive cars: The lateral 

acceleration sensor is combined into 

one unit with the rotational rate (yaw) 

sensor. It is mounted under 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. 


connector. Remove mounting 

screw and nut. Remove lateral 

accleration sensor. 


DSC rotational rate (yaw) 


Rear wheel drive cars: The DSC

Brakes 


5 of 11 2/25/2009 10:35 PM 

rotational rate sensor is located on the 

left side of the car, under the driver's 

seat. 

All wheel drive cars: The rotational rate 

sensor is combined into one unit with 

the lateral acceleration sensor. It is 

mounted under the driver's seat, in 

front of the left seat rail. 

- Remove driver's seat. See 520 

Seats. 

- Remove plastic trim as necessary. 

Lift carpet for driver's footwell and 

fold toward center console. Move 

insulation forward to gain access 

to sensor. 

- Remove sensor bracket mounting 

screws. 


connector at sensor. 

- Remove sensor to bracket 

mounting screws. Lift sensor away 

from bracket. 


CAUTION! 

Be sure to tighten rotational rate 

sensor and mounting bracket to 

specified torques. The sensor is 

vibration sensitive and subject to 

cause DSC malfunctions if installed 

improperly. 


Rotational rate 

sensor to bracket 

8 Nm (6 ft-lb)

Brakes 


6 of 11 2/25/2009 10:35 PM 


Sensor bracket to 

body 


DSC steering angle sensor 

Vehicles equipped with DSC have a 

steering angle sensor (arrow) mounted 

to the steering column right above the 

pedal cluster. Replacement of this 

component requires special tools to 

properly align the steering column and 

sensor. 

After removal or replacement the 

steering angle sensor requires 

calibration using BMW scan tools DIS 

or MoDiC. Once calibrated, the sensor 

sends a confirmation ID code to the 

DSC control module to indicate proper 

calibration. 

For steering column removal see 


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. 


Pressure sensor to 


Pressure sensor to 


19 Nm (14 ft-lb) 

15 + 4 Nm 

(11 + 3 ft-lb) 

Hydraulic unit/control module,

Brakes 


7 of 11 2/25/2009 10:35 PM 


CAUTION! 



the brakes. Removal of the hydraulic 

unit is not recommended unless this 

equipment is available. For safety 

reasons, the brake system on cars 

with ABS must be bled using the 

procedures described in this repair 

group. 

Note: 

Before starting this procedure, 

read any fault codes from control 

module memory and print out 

diagnostic record. 

After completing 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 



connector at hydraulic unit/control 

module. 

Mark brake lines in relation to their 

placement on hydraulic unit. (Teves 

MK 20 ASC hydraulic unit shown.) 

A - Front from master cylinder 

B - Left front

Brakes 


8 of 11 2/25/2009 10:35 PM 

C - Right front 

D - Rear from master cylinder 

E - Right rear 

F - Left rear 

Remove brake fluid input and 

output lines. 

Seal open brake fluid lines and 

bores with suitable plugs to 

prevent contamination. 

- Carefully remove brake lines from 

any retainers or grommets that 

may be in the way of hydraulic 

unit/control module removal. 

CAUTION! 

Make sure not 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. 



Check rubber mount for hydraulic 

unit/control module. Replace if 

damaged. 

Make sure all nuts, fluid 

couplings, thread bores and 

mating surfaces are clean.

Brakes 


9 of 11 2/25/2009 10:35 PM 

Make sure brake lines are 

securely seated in grommets 

before installing brake lines in 

hydraulic unit bores. 

Bleed brakes as described earlier. 


Brake lines to 


Brake master 


booster 

Hydraulic unit to 

body 


to hydraulic unit 

18 Nm (13 ft-lb) 

26 Nm (19 ft-lb) 



DSC precharge pump, 


CAUTION! 



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. 

The precharge pump is mounted below 

the brake master cylinder on the left 

side of the engine compartment.

Brakes 


10 of 11 2/25/2009 10:35 PM 

- 

Using a clean syringe, empty 


WARNING! 





housing. 


microfilter. 


remove wires. 



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 reservoir. 

Remove brake fluid intake and

Brakes 


11 of 11 2/25/2009 10:35 PM 

output lines from pump. 

Remove electrical harness 

connector. 

Lift pump to release from lower 

mounting pad. 

Slide pump out of retaining ring. 



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.

Body - General 


1 of 1 2/25/2009 10:37 PM 

General 

400-1 

This section covers system descriptions 

and general information for the repair 

groups found in 4 Body and 5 Body 

Equipment. 

E46 Sedan 




1 of 8 2/25/2009 10:37 PM 

Body Assembly 

400-2 

The body styles of E46 cars covered by 

this manual are the 4-door Sedan, 

4-door Sport Wagon, 2-door Coupe 

and 2-door Convertible. Body 

dimensions vary slightly among 

models. Dimensions are given in 

inches. 

E46 Sedan 

E46 Sport Wagon



2 of 8 2/25/2009 10:37 PM 

E46 convertible 

E46 Coupe



3 of 8 2/25/2009 10:37 PM 

Body shell 

The BMW 3 Series chassis is a unibody 

design constructed of high strength 

steel. Attaching parts, such as the front 

fenders, rear quarter panels, doors, 

trunk lid and hood are also constructed 

of steel. 

Computer aided design (CAD) 

techniques have been used in refining 

E46 body models to reduce vehicle 

weight while retaining strength and 

increasing 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 

resists corrosion and maintains body 

strength over time.



4 of 8 2/25/2009 10:37 PM 

The E46 body shell was designed so 

that the vibrations of torsional twisting 

and bending are separated into discrete 

components and in the inaudible range. 

The current Sedan design ensures that 

the body twists at 29 hertz and bends at 

26 hertz. 

Exterior and aerodynamics 

With its traditional styling features, such 

as the kidney grille, circular headlights 

behind a glass cover (for reasons of 

streamlining), and the "kick" in the 

rearmost roof pillar (C-pillar), the E46 

can be immediately recognized as a 

BMW. 

Wind resistance. Windows bonded flush 

to the body and the guided flow of 

cooling air into the engine compartment 

provide a good coefficient of drag (C d ). 

E46 cars have been designed for 

balanced aerodynamics but not 

necessarily an extremely low C d . 

A low coefficient of lift (C l ) promotes 

stability at high speeds. The current 

design has a front C l of 0.08 and a 

rear C l of 0.10. 

Windshield wipers are designed for 

effectiveness at speeds up to and 

beyond 200 kph (124 mph). 

Body, window and exterior mirror 

shapes have been refined for lower 

wind noise and reduced soiling of 

mirrors and windows. The Coupe's 

side mirrors are specially shaped 

and include five ribs (arrows) on 

the top edge for further wind noise 

reduction. 

All this has resulted in a C d of



5 of 8 2/25/2009 10:37 PM 

approximately 0.31 for the Sedan and 

0.32 for the Coupe models. 

Fenders. The exterior panels are 

corrosion-resistant zinc coated 

(galvanized) steel. The front fenders are 

bolted on. For front fender replacement 

information, see 410 Fenders, Engine 

Hood. 

Bumpers. The front and rear bumpers 

are clad in high quality deformable 

plastic and provide protection with 

virtually no damage to the bumper or the 

vehicle at solid barrier impact speeds of 

4 kph (2.5 mph). In addition to hydraulic 

dampeners, which absorb the initial 

impact energy, these bumpers are 

backed by compressible tubes. These 

deform in a controlled manner at impact 

speeds greater than that for which 

bumpers 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 

end, a flatter hood line with air slits, and 

a roof 2.7 cm (1.1 in.) lower. Additional 

differences include wider doors with 

frameless windows, glass-covered 

door-posts (B pillars) and a shorter and 

lower trunk lid in the Coupe. 

Convertible models 

The E46 Convertible is an all-season 

vehicle with a high level of functionality, 

excellent interior comfort and acoustic



6 of 8 2/25/2009 10:37 PM 

refinement. Interior materials and colors, 

the soft top and the light-alloy wheels 

have been carefully matched. 

Although the automatic Convertible roof 

is standard, a hard-top in body color with 

heated rear window is available as an 

option for the cold season. 

The Convertible body structure includes 

many passive safety refinements over its 

fixed-top counterparts. 

Note: 

To achieve a more rigid underbody, 

an aluminum reinforcement plate 

(arrow) is bolted to the front 

undercarriage and reinforcing struts 

are bolted to the rear undercarriage. 

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. 

There are tubular door 

reinforcements. 

The rollover protection system is 

tripped into position in a fraction of 

second. With this feature, two bars 

fully independent of each other 

come up behind each rear-seat



7 of 8 2/25/2009 10:37 PM 

backrest when the vehicle is in 

danger of turning over. 

A Convertible body normally flexes and 

vibrates, transferring oscillations to the 

passenger compartment. In the E46 

Convertible, BMW utilizes a unique 

battery tray in the trunk as a vibration 

dampening system to counteract this 

oscillation. 

CAUTION! 

The E46 Convertible requires a special 

battery which is designed for constant 

vibration. 

Information for the Convertible top and 

its related mechanisms 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 rear bumper 

Roof rails (optional equipment) 

Structural, safety and comfort features in 

the Sport Wagon are comparable to the 

E46 Sedan and Coupe.



8 of 8 2/25/2009 10:37 PM 

Sport Wagon capacities 

Cargo capacity: 

Rear seat backrest 

up 

Rear seat backrest 

folded down 

Load capacity: 

In cargo 

compartment 

On roof 

435 liters (15.4 

cu. ft.) 

1345 liters 

(47.5 cu. ft.) 

540 Kg (1191 lb.) 

75 Kg (165 lb.) 




1 of 5 2/25/2009 10:38 PM 

Safety and Security 

Features 

400-3 

A large number of new or improved 

safety and security features are 

incorporated in E46 cars. 

Safety cage 

The body safety cage is a continuation 

of an established BMW concept for 

passenger protection. Tubular impact 

structures built into the body provide 

protection against passenger injury 

during front or rear impacts. 

Door anchoring system 

Each door is reinforced 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 and door handles 

The bow type door handles allow easy 

door opening, but are secure in 

accidents.



2 of 5 2/25/2009 10:38 PM 

Electrical components in the locks are 

fully encapsulated and cannot be 

picked easily. The new door handles, 

latches and lock assemblies offer 

improved reliability and security against 

theft. 

Door position and lock condition are 

detected by hall sensors. 

Roof padding 

In addition to the side and head 

protection airbags, there is 

supplementary padding at the roof 

pillars and along the roof above the 

doors. This is positioned to present 

energy absorbing surfaces to 

passengers thrown around by side 

impact forces. 

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 force limiter puts an upper limit on 

the amount of force each belt can exert 

on the passenger. 

The Convertible seat belts are 

integrated into the seat, but otherwise 

have features similar to the other 

models.



3 of 5 2/25/2009 10:38 PM 

Airbags 

As many as 8 airbags are installed in 

E46 cars, depending on model. 

The front airbags operate without 

sodium azide propellant, widely 

considered an irritant when an airbag is 

deployed. 

Starting with 2000 models, "smart" 

front passenger and driver airbags 

were installed. These are of the 

dual-threshold, dual stage design, 

including a sensor to help prevent the 

unnecessary deployment of the 

passenger side airbag if the seat is 

unoccupied. 

Depending on options chosen, one 

airbag may be installed in each door of 

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 

explosive device. Handled 

improperly or without adequate 

safeguards, airbag units can be 

very dangerous. Special 

precautions must be observed 

prior to any work at or near any 

of the airbags. See 721 Airbag 

System (SRS).



4 of 5 2/25/2009 10:38 PM 

Always disconnect the battery 

and cover the negative (-) 

battery terminal with an 

insulator before starting 

diagnostic, troubleshooting or 

service work on cars fitted with 

SRS, and before doing any 

welding on the car. 

Battery safety terminal (BST) 

A pyrotechnic (explosive charge) device 

automatically disconnects the battery 

positive terminal during impacts or 

collisions. 

The seatbelt system, airbag system 

and battery safety terminal are 

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 unless the correct coded 

ignition key is used. 

Note: 

Electronic immobilization is sometimes 

referred to as the driveaway protection



5 of 5 2/25/2009 10:38 PM 

system. 

Anti-theft alarm (DWA). This is a 

dealer-installed option for which the 

E46 vehicles are factory-wired. When 

armed, the system monitors door lock 

contacts and trunk and engine hood 

locks and sounds a siren if it detects 

tampering. 

Tilt sensor. Located in the right side of 

the trunk above the battery, the tilt 

sensor monitors the vehicle parked 

angle when DWA is armed. The siren is 

activated if the vehicle angle is 

changed. This helps prevent theft of 

the car using a ramp truck. 

Ultrasonic interior protection (UIS). An 

interior ultrasonic emitter/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, see 515 Central Locking 

and Anti-theft. 

Emergency location 


If emergency assistance is needed, the 

on-board navigation system (if 

equipped) uses GPS technology to 

pinpoint the location of the vehicle.



1 of 7 2/25/2009 10:39 PM 

Interior Features 

400-4 

E46 interiors have a unique character, 

with a combination of sporty features 

and innovative design. All body 

versions were made in a wide choice of 

interior and exterior colors. New colors 

with matching leather or leatherette 

upholstery were introduced for each 

model year, including light-alloy wheels 

in new designs. 

Driving comfort is enhanced by power 

steering, tilt steering wheel, heightadjustable 

front seats, and electrically 

adjustable and heated rear-view 

mirrors. Inside the car there 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 

constructed from polyurethane foam 

containing areas or "zones" of different 

firmness. They offer good lateral 

support without constricting the 

occupant. 

Driving comfort is enhanced by power 

steering, tilt steering wheel, height-



2 of 7 2/25/2009 10:39 PM 

adjustable front seats, and electrically 

adjustable and heated rear-view 

mirrors. Inside the car there are reading 

lights at four seating positions. 

The seats have a passive internal 

ventilation system: Cylindrical cavities 

within the cushions and backrests 

generate a pumping effect as the car's 

ride motions cause occupant motion. 

This helps remove moisture and feeds 

fresh air into the seats. 

Other features of the seating system: 

The seat bases have steel springs 

for added support and strength. 

The seat 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 

forward and lowers the headrest 

to prevent it from contacting the 

sun visor. The seat and headrest 

are then returned to memorized 

positions. These functions are 

controlled by the seat memory 

module(s).



3 of 7 2/25/2009 10:39 PM 

For security reasons, the release 

lever to fold the rear seat backrest 

forward is installed in the trunk. 

In Sport Wagon models: Rear seat 

backs are split 60/40 with the 

center arm rest on the left seat 

back. The center arm rest 

incorporates a non adjustable 

headrest. When folded down, the 

arm rest opens out with 

cup-holders and a storage 

compartment. 

See 

520 Seats for more details. 

Instruments and controls 

Everything in the interior passenger 

compartment essential to the driver is 

logically grouped and easy to reach. All 

instruments and controls have 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 and the ventilation 

and heating system. 

Instrument cluster uses large 

easy-to-read analog instruments and is 

removable as a unit without removing 

the dashboard. On-board computer 

and Check Control functions are 

integrated into the instrument cluster



4 of 7 2/25/2009 10:39 PM 

displays. 

Service Interval Display calculates 

vehicle service needs, based on 

current driving patterns, and indicates 

to the driver when the car requires 

service. 

Integrated on-board navigation system, 

based on Global Positioning System 

(GPS) technology, is optionally 

available on E46 cars. When installed, 

a multi-function monitor is included in 

the center of the dash above the radio. 

In addition to displaying navigation 

system information, this monitor 

accesses to On-Board Computer 

functions, audio system controls, 

mobile phone dialling and memory, 

and automatic ventilation. 

Park Distance Control (PDC) is an 

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 systems into a 

single control module minimizes power 

requirements and the incorporation of 

the diagnostic link results in more 

efficient and accurate troubleshooting. 

ZKE V directly controls the following 

functions: 

Windshield wiper/washer system, 

with optional Rain Sensor 

Interface. See 611 Wipers and



5 of 7 2/25/2009 10:39 PM 

Washers. 

Central locking with power trunk 

release. See 515 Central 

Locking and Anti-theft. 

Keyless entry (FZV) 

Power window control. See 512 

Door Windows. 

Car/key memory 

Interior lighting 

Alarm system (DWA) 

Electronic consumer sleep mode. 

See 600 Electrical System– 

General. 

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.



6 of 7 2/25/2009 10:39 PM 

Note: 

All 1999 models and cars 

produced through June 2000 are 

equipped with the DLC socket in 

the rear right corner of the engine 

compartment. 

In cars produced after June 2000, 

the DLC socket in the engine 

compartment has been 

discontinued. All scan tool codes 

can now be accessed through the 

OBD II interface socket on the 

driver's side of the dashboard, left 

and below the instrument 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 covered in 

640 Heating and Air Conditioning. 

Heating and air conditioning vent diagram



7 of 7 2/25/2009 10:39 PM 


Sport Wagon interior features 

Child seats. There are three child seat 

hold down anchors behind the rear seat 

back rest. Plastic trim covers are used to 

hide the anchors. 

Cargo area. There is a spring-loaded 

blind and a cargo safety net installed 

behind the rear seat. 

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.

Fenders, Engine Hood 


1 of 1 2/25/2009 10:39 PM 

General 

410-1 

This repair group covers replacement 

of the front fenders and removal and 

installation of the engine hood. 

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. 

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 




1 of 3 2/25/2009 10:39 PM 

Front Fenders 

410-2 

Front fender, removing and 

installing 

- Raise hood. Raise and safely 

support front of vehicle. 

WARNING! 








body damage. 






- 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 corner of side 

trim panel cover out from side of 

fender. Gently lift panel cover upwards



2 of 3 2/25/2009 10:39 PM 

and remove retaining screw (arrow). 

Remove lower fender attaching bolts 

(arrows) at rear of wheel housing. 

With door open remove upper fender to 

door post attaching bolt (arrow). 

Remove screw (arrow) at front of 

fender.



3 of 3 2/25/2009 10:39 PM 

Remove bolts (arrows) along top edge 

of fender. 

- Carefully remove fender from 

body. 



Before installing new fender, clean 

old sealant and protective coating 

from mounting surfaces. 

Position new fender and 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.) 




1 of 6 2/25/2009 10:40 PM 

Engine Hood 

410-3 

Hood, raising to service 

position 

CAUTION! 

Do not switch on the windshield 

wipers with the engine hood 

raised. As a precaution, remove 

the wiper motor fuse. See 610 

Electrical Component Locations. 

The hood is heavy. Before 

removing the hood supports, be 

sure to have an assistant help 

support the hood. 

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, disconnect



2 of 6 2/25/2009 10:40 PM 

electrical harness connector (B) 

from heated nozzles. 

- Detach gas-charged hood 

supports from hood. 

CAUTION! 

The hood is heavy. Before removing 

the hood supports or hood retaining 

bolts, be sure to have an assistant 

help support the hood. 

Loosen upper hood hinge bolts (A). 

Remove ground strap (B) and remove 

lower hinge bolts (C). Lift hood off 

carefully. 




Note: 

Check hood alignment as 

described next. 

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 paint. 

The hood should be aligned so that 

gap (arrows) to fender is as even as 

possible.



3 of 6 2/25/2009 10:40 PM 

Clearance specification 

Hood edges to 

adjoining body 

panel (gap) 

5.5 mm (0.216 

in.) 

If height adjustment at rear of hood 

cannot be completed using upper 

hinge, loosen lower hinge bolts 

(arrows) and reposition as necessary. 

Plastic coating on top of hinge stop 

screw must not be damaged or 

missing. 

Stop disk for front of hood (arrow) is 

eccentric, and is marked 0-10. Initial 

setting is with the 0 setting forward, for



4 of 6 2/25/2009 10:40 PM 

minimal clearance. Turn stop disk to 

move hood front stop further out. 

- Height at front of hood is set using 

spring pins and rubber stop 

buffers. 

Hood release cable and spring 

pins, adjusting 

Before adjusting hood pins, be sure 

the hood is aligned evenly to fenders 

and front panel. 

- Make sure bowden cable, which 

connects both hood locks 

together, is seated in lock guide 

on both left and 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 when alignment is 

correct. 

- Remove one screw from each 

side, clean and coat with



5 of 6 2/25/2009 10:40 PM 

Loctite®270 or equivalent, and 

reinstall. 

- Unscrew rubber stop buffers 

above headlight assemblies until 

they support hood when closed 

without movement. 

- Test hood for correct closure and 

opening. If hood does not spring 

open, lengthen spring pins. 

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



6 of 6 2/25/2009 10:40 PM 

8 - Stop buffer 

9 - Spring pin 

10 - Lower hood 

lock 

11 - Saucer head 

screw 

12 - Eccentric wheel 

13 - Hex nut with 

plate 

14 - Hood catch 

15 - Bowden cable, 

center 


http://ebahn.bentleypublishers.com/header.jsp 

1 of 1 2/25/2009 10:40 PM 

BMW > 328 > 2000 > 2.5L L6 (M52) 

Welcome tethoma@gmail.com 

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1 of 1 2/25/2009 10:40 PM 

Vehicle 

Tech Info 

Enter Vehicle Indentification Number (VIN): 

Search 

411-1 

General 

Choose vehicle: 

DTC Xpress TM 

Choose Diagnostic Trouble Code (DTC): 

This repair 

group covers 

front and 

rear door 

repair 

information. 

It includes 

removal and 

installation 

of interior 

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. 

Copyright © 

2008. All 

Subscription Status | FAQs | Contact Us | Help

Doors 


1 of 6 2/25/2009 10:40 PM 

Doors 

411-2 

WARNING! 

E46 cars are fitted with side-impact 

airbags in the front doors. When 

servicing doors on cars with front 

side-impact airbags, always 

disconnect the negative (-) battery 

terminal. See 721 Airbag System 

(SRS) for cautions and procedures 

relating to the airbag system. 

Front or rear door, removing 


- If working on a door with 

side-impact airbag, disconnect 

negative (-) battery cable. 

CAUTION! 





Remove harness connector mounting 

bolt (arrow) at door pillar. 

Pull up on locking clip and separate 

connector.

Doors 


2 of 6 2/25/2009 10:40 PM 

With door fully open, remove pin bolts 

(arrow) from top and bottom door 

hinges. 

Remove door check mounting bolt 

(arrow). 

- Remove door by lifting up off 

lower hinge halves. 

CAUTION! 

Be careful not to damage door or 

other painted body surfaces. Make 

sure no load is placed on wiring 

harness. 


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 


3 of 6 2/25/2009 10:40 PM 

Adjust door striker so that trailing 

edge of front door is slightly 

higher (1 mm / 0.04 in.) than 

leading edge of rear door. See 

515 Central Locking and 

Anti-theft. 



CAUTION! 

In 2-door models, removing and 

installing the door may upset the 

adjustment and alignment of the 

window. Window adjustment, as 

described in 512 Door Windows, 

must be carried out after installation 

to prevent damaging the glass. 

Door adjustment 

Front fender to 

front door gap 

approx. 

Front door to rear 

door gap approx. 

Rear door to rear 

fender approx. 

Permissible 

deviation from 

parallel 

4.25 mm ± 0.25 

mm 

(0.17 ± 0.01 in.) 

4.5 mm ± 0.25 

mm 

(0.18 ± 0.01 in.) 

4.0 mm ± 0.25 

mm 

(0.16 ± 0.01 in.) 

1.0 mm (0.04 

in.) 


Door hinge to door 

20 Nm (15 ft-lb) 

Door check, replacing 

WARNING! 

E46 cars are fitted with side-impact

Doors 


4 of 6 2/25/2009 10:40 PM 

airbags in the front doors and as an 

option on 4-door models. When 







- Close door window completely. 


cable. 

CAUTION! 





- Remove interior door panel as 


- 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 check from inside 

door.

Doors 


5 of 6 2/25/2009 10:40 PM 

- 


Lubricate door check before 

installing. 

Use new mounting bolts when 

reinstalling the side-impact airbag 

to the door (where applicable). 


Door check to 

door 

24 Nm (16 ft-lb) 

Door hinge adjustment 

If the installed door is uneven or out of 

parallel, shims can be used to correct 

its position. 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 


6 of 6 2/25/2009 10:40 PM 


Door hinge to door 

20 Nm (15 ft-lb) 


Doors 


1 of 6 2/25/2009 10:41 PM 

Door Panels 

411-3 

WARNING! 


airbags in the front doors and as an 

option on 4-door models. When 







Door trim panel, removing and 

installing 


cable. 

CAUTION! 





Gently pry off door panel trim strip. 

Carefully pry out mirror adjustment 

switch and disconnect harness 

connector from switch.

Doors 


2 of 6 2/25/2009 10:41 PM 

- 

For rear trim panel: Pry out 

window switch at top of armrest. 

Pry off concealing plugs (arrows) from 

under armrest. 

Remove door panel retaining screws 

(arrows). 

Unclip door panel from door perimeter 

using a trim panel tool. Pull panel 

retaining clips off one at a time.

Doors 


3 of 6 2/25/2009 10:41 PM 

Pry off inside door release Bowden 

cable at end of clip (arrow). 

Pull off panel: Detach cable from 

interior door release lever. 

- Disconnect radio speaker harness 

connector. 



Replace any damaged plastic 

parts or clips. 

Renew vapor barrier if it is 

damaged. 


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 


4 of 6 2/25/2009 10:41 PM 

Rear side trim panel, removing 

and installing (Coupe model) 

- Remove rear seat cushion. 

Remove rear backrest side 

section. See 520 Seats. 

Using a trim tool, gently pry up door 

threshold trim. Starting at A-pillar, 

press radius of trim downwards while 

sliding trim forward off trim clips. 

Remove clips from body using pliers. 

Save for installation. 

- Remove trim plugs on armrest. 

Remove panel mounting screws. 

- Gently pry off panel using trim 

tool. 


connectors as necessary. Remove 

side panel by lifting up and toward 

interior. 


Replace any damaged plastic 

parts or clips. 

Rear side trim panels, 


(Convertible model) 

- Remove rear seat cushion. 

Remove rear backrest side 

section. See 520 Seats. 

- Lower side windows; open 

convertible roof. 

- Remove side panel insert:

Doors 


5 of 6 2/25/2009 10:41 PM 

Remove trim plugs on side panel 

armrest. 

Remove insert panel retaining 

screws. 

Gently pry side panel insert from 

upper and lower side panels. 


connectors as necessary. 

- Remove upper side trim panel: 

Remove trim retaining rivet from 

upper corner at door. Pull trim cap 

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.

Doors 


6 of 6 2/25/2009 10:41 PM 

- 


Make sure to replace any broken 

trim clips. 


Trunk Lid, Tailgate 


1 of 1 2/25/2009 10:41 PM 

General 

412-1 

This repair group covers trunk lid and 

tailgate removal and installation. Also 

included here are replacement 

procedures for the gas-charged 

support struts that hold the trunk lid or 

tailgate in the open position. 

Note: 


The body is painted at the factory after 

assembly. Realignment of body panels 

may expose unpainted metal. Paint all 

exposed metal once the work is 

complete.



1 of 6 2/25/2009 10:41 PM 

Trunk Lid 

412-2 

Trunk lid, removing and 

installing 

Raise trunk lid. 

Open tool kit and remove screws 

attaching tool kit to trunk lid 

(white arrows). 

Unclip retaining strap at trunk lid 

and remove tool kit. 

Remove insulating liner expansion 

rivets (black arrows), by prying 

upper portion out (inset). 

Remove trunk liner. 


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 


- Installation is reverse of removal. If 

necessary, align trunk lid to body 

as described next.



2 of 6 2/25/2009 10:41 PM 

Trunk lid, aligning 

Raise trunk lid. Working at lower 

corners of trunk lid, unscrew out rubber 

buffers (arrows) on left and right sides. 

Inspect pads (arrows) on each side of 

latch assembly for damage or wear and 

replace if necessary. 

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



3 of 6 2/25/2009 10:41 PM 

screw and protective cap. 

If stop screw has removable 

protective cap (arrow) remove 

protective cap from stop screw. 

Adjust stop screw so that head is set to 

(A) 10 mm (0.40 in.) above bore height. 

To adjust trunk lid gap at rear fender: 

Loosen bolts retaining trunk hinge 

to trunk 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.



4 of 6 2/25/2009 10:41 PM 

To adjust trunk lid at lock: 

Remove protective caps from trim 

panel and loosen screws retaining 

latch assembly until it can just be 

moved. 

Inspect pads (arrows) on each 

side of latch assembly for damage 

or wear and replace if necessary. 

Insert key in trunk lock, and hold 

key in unlock position to prevent 

lock from closing. Close trunk lid 

to center latch assembly. 

Open trunk lid and tighten screws 

retaining latch. Replace protective 

caps on trim panel. 

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. 

- To adjust stop screw at trunk lid 

hinge: 

Working at trunk lid hinge, set 

stop screw to a height of 10 mm 

(0.40 in.). Place a strip of paper on



5 of 6 2/25/2009 10:41 PM 

top of stop screw, and gently 

close trunk lid. 

Adjust height of stop screw until 

paper strip can be removed with 

slight resistance. Once stop screw 

height has been adjusted, lower 

adjusted height of stop screw 2.5 

mm (0.1 in.) to accommodate for 

stop screw protective cap. 

Fit protective cap on stop screw. 

Check that trunk lid is in correct 

position, adjust 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) 

Trunk lid / rear 

fender (B) 

5 ± 1.5 mm 

(0.2 ± 0.06 in.) 

4.25 ± 0.75 mm 

(0.17 ± 0.03 in.) 

Trunk lid support strut, 


WARNING! 

Make sure to support trunk lid before 

removing strut. 

Open trunk lid and support in open 

position. Remove spring clips (arrows) 

from support strut ends.



6 of 6 2/25/2009 10:41 PM 

- 

Remove strut from trunk lid. 


Replace retaining clips damaged 

during removal. 




1 of 8 2/25/2009 10:41 PM 

Tailgate (Sport wagon 

models) 

412-3 

Tailgate, removing and 

installing 

- Raise complete tailgate. Remove 

interior trim and disconnect wiring 

harnesses. 

- Disconnect left and right support 

struts as detailed below. 

- While supporting tailgate, remove 

hinge bolts for tailgate on left and 

right sides. 

CAUTION! 

The tailgate is very heavy. Use 

assistance to properly support both 

sides prior to removal of the hinge 

bolts. 

- Installation is the reverse of 

removal. Follow alignment 

procedures as shown below. 


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 opening of the latch in



2 of 8 2/25/2009 10:41 PM 

case of an electrical failure. The 

release is located in the rear cargo 

area, along the lower edge of the rear 

apron behind a small access cover. 

- Working inside car, at base of 

tailgate: 

Remove release cover. 

Push lever toward driver's side 

(arrow). 

Tailgate support strut, 


Open tailgate fully. Support tailgate 

and remove retaining 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. 


Replace retaining clips if damaged 

during removal. 

Rear spoiler, removing and 

installing



3 of 8 2/25/2009 10:41 PM 

Raise rear window. Remove inner trim 

from glass panel by releasing clips on 

trim from retainers (arrows). For clarity, 

trim is removed in photo. 

Note: 

Use two plastic prying wedge tools to 

release each pin retaining trim. 

Release spoiler mounting bolts 

(arrows). Disconnect wiring to brake 

light and AM radio antenna and release 

washer hose. Remove spoiler. (Window 

shown in place). 


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 grounds (A) and rubber 

grommets (B, C) at both hinges.



4 of 8 2/25/2009 10:41 PM 

Support window in open position. 

Working at top of tailgate, loosen 

screws (arrows) on each window 

hinge. Note positions of any spacers 

for reinstallation. 

CAUTION! 

Rear window is heavy. Use a second 

person to support window prior to 

releasing from hinges. 

- Remove screws and lift off 

window, taking care to release 

wiring to rear defroster/antenna. 


removal. Replace waterproofing 

sheeting where disturbed. Align 

window as described below. 


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 disturbed 

during repair adjust fit of tailgate 

to body. Then adjust fit of rear 

window to hatch.



5 of 8 2/25/2009 10:41 PM 

Clearance of the rear window is 

adjusted by adding or removing 

shims between hinge bracket and 

rear window (maximum of three 

shims). 

Adjust spoiler gap to body last. 

Height of spoiler is set by 

alignment of the rear hatch. Gap 

of spoiler to body is set by 

adjusting spoiler attachment bolts. 

Seam clearance specification 

Rear spoiler to roof 

(A) 

Max. deviation 

from parallel 

4.25 - 5 mm 

(0.167 - 0.197 

in.) 

0.5 mm (0.019 

in.) 

Lateral and vertical 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) 

Rear window / side 

panel (B) 

Tailgate / side 

panel (C) 


panel (height) (D) 

Tailgate light / 

corner light (D) 

Tailgate / rear 

bumper (E) 

3.75 ± 1.3 mm 

(0.15 ± 0.05 in.) 

3.5 ± 1.4 mm 

(0.14 ± 0.06 in.) 

3.6 ± 0.75 mm 

(0.14 ± 0.03 in.) 

flush to 2 mm 

(0.08 in.) lower 

4.25 ± 0.75 mm 

(0.17 ± 0.03 in.) 

5 ± 1 mm 

(0.2 ± 0.04 in.)



6 of 8 2/25/2009 10:41 PM 



Rear window / 

tailgate (F) 

Rear window / 

tailgate (G) 

4 ± 1 mm 

(0.16 ± 0.04 in.) 

5.4 ± 1 mm 

(0.21 ± 0.04 in.) 

To adjust fit of tailgate to body: 

Close tailgate and open rear 

window. 

Tailgate hinge bolts (A, behind 

trim) should be centered both 

vertically and horizontally within 

their adjustment range. When 

centered, tighten bolts. 

Loosen screws (B) on left and 

right to adjust horizontal location 

(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. 

Initially adjust buffers to just 

contact tailgate when closed, then 

tighten buffers one turn. Tighten 

lock nut.



7 of 8 2/25/2009 10:41 PM 


Lock nut for stop 

buffer (M8) 

15 Nm (11 ft-lb) 

Loosen screws (arrows) and reposition 

rear latch to further adjust gap 

between tailgate and body at sides, 

and to assure smooth operation. 

- To adjust striker position: 

Close tailgate slowly, allowing 

striker to center itself on lock. 

Striker must not touch lock 

housing. 

Note: 

Tighten striker mounting bolts, 

then check tailgate to body gaps 

as shown below. 

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.



8 of 8 2/25/2009 10:41 PM 

Retighten lock nut when window 

latch operates smoothly. 

To adjust rear window lock position, 

initially loosen lock mounting bolts 

(arrows). 

Close window slowly, allowing 

lock to center itself on striker. 

Tighten mounting bolts, then 

check rear window to body gaps 

as shown above. 


Exterior Trim, Bumpers 


1 of 1 2/25/2009 10:43 PM 

General 

510-1 


This repair group includes repair 

information for the outside rear view 

mirror, front and rear bumpers, and the 

easily removable exterior trim parts.



1 of 4 2/25/2009 10:43 PM 

Outside Rear View 

Mirrors 

510-2 

Many of the mirror components are 

separately available from an authorized 

BMW dealer, including the glass and 

outside plastic housing. 

Outside mirror glass, replacing 

CAUTION! 

Mirror should be at or above room 

temperature before removal. 

Otherwise, small plastic parts or 

glass may break. 

- Insert thin pry tool (wooden or 

tape-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, 


- Remove mirror glass as described



2 of 4 2/25/2009 10:43 PM 

above. 

Remove housing retaining screws 

(arrows) and lift off rear housing. 

Tilt mirror housing forward and 

compress plastic retainers (arrows) 

and lift off front housing. 

Note: 

The front mirror housing is retained by 

either three or four clips, depending on 

model. 


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).



3 of 4 2/25/2009 10:43 PM 

Gently pry off door inner trim panel 

from retaining clips (arrows). 


connectors for window anti-trapping 

protection and speaker (arrows), if 

equipped. 

Remove inner door panel trim. On 

sedan models, trim strip extends 

around window to door latch area. 

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.



4 of 4 2/25/2009 10:43 PM 

Check mirror function before 

installing covering parts. 


Outside mirror to 

door (M6) 

6 Nm (4.5 ft-lb) 




1 of 8 2/25/2009 10:44 PM 

Bumpers 

510-3 

Front bumper 

assembly 

1 - Impact absorber 

2 - Spacer 

3 - Cap 

4 - Support bracket 

5 - Bumper bracket 

bolt 


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 


ft-lb) 

13 - Mounting sleeve



2 of 8 2/25/2009 10:44 PM 

Front bumper, removing and 

installing 

- Raise and properly support vehicle. 

WARNING! 







- Working underneath car, remove 

screws from left 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 at



3 of 8 2/25/2009 10:44 PM 

outside temperature sensor at rear 

of left side of bumper and 

temperature switch at rear of right 

side of bumper. 

- Slide bumper straight off side 

brackets. 



Slide side brackets on bumper and 

body carefully together. 

Make sure gap between body and 

bumper is set to specifications, 

adjust height as necessary. See 

Bumper height, adjusting. 


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 compound such as 

Loctite®270 or equivalent.



4 of 8 2/25/2009 10:44 PM 

Rear bumper 

assembly 

1 - Cap 

2 - Casket 

3 - Impact absorber 

4 - Carrier bumper 

5 - Support bracket 

6 - Bracket 

7 - Protective 

rubber strip 

8 - Bumper cover 

9 - Lower part 

cover 

10 - Tow eye cover 

11 - ASA bolt 


ft-lb) 

12 - Bumper bracket 

bolt 


ft-lb) 

Rear bumper, removing and 

installing 

- Raise and properly support vehicle.



5 of 8 2/25/2009 10:44 PM 

WARNING! 







Remove bumper support bolts using 

special BMW tool 00 2 150. 

Remove nut from bumper cover retaining 

bracket at 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. 


Note:



6 of 8 2/25/2009 10:44 PM 

Install the bumper bracket bolt with 

thread locking compound such as 

Loctite®270 or equivalent. 


Bumper bracket to 

impact absorber 

(M10 bolt) 41 Nm (30 ft-lb) 

Rear bumper impact absorber, 

replacing 

- Remove bumper as described 

above. 

- Remove luggage 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. 


Replace body seal and protective 

cap if necessary. Make sure to 

check bumper height. See



7 of 8 2/25/2009 10:44 PM 

Bumper height, adjusting. 


Bumper bracket to 

impact absorber 

(M10 bolt) 41 Nm (30 ft-lb) 

Impact absorber to 

chassis (M8 nut) 

22 Nm (16 ft-lb) 

Bumper height, adjusting 

The adjustment procedure applies to 

either front or rear bumpers. A 14 mm 

allen socket is needed to make 

adjustments. 

- Raise and properly support vehicle. 

WARNING! 







- 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 mounting



8 of 8 2/25/2009 10:44 PM 

bolt at impact absorber. 

Using a 12-inch extension and a 14 mm 

Allen socket, turn adjusting collar 

clockwise or counterclockwise as needed 

to change height of adjusting collar. 

- Reinstall mounting bolts and check 

bumper height. Refit front bumper. 


Front bumper to 

bumper bracket 

(M8 nut) 22 Nm (16 ft-lb) 

Front bumper 

bracket to impact 

absorber (M10 bolt) 

Rear bumper 

bracket to impact 

absorber (M10 bolt) 

55 Nm (41 ft-lb) 

42 Nm (31 ft-lb) 




1 of 3 2/25/2009 10:44 PM 

Exterior Trim 

510-4 

Exterior trim is retained to the body by 

plastic clips and fasteners that may be 

damaged during removal. Be sure to 

have necessary fasteners on hand 

when reinstalling exterior trim pieces. 

BMW emblem, removing and 

installing 

The procedure given below applies to 

both front and rear emblems. 

- Wrap end of a screwdriver with 

tape. 

CAUTION! 

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. 


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 


Body side molding, replacing 

To remove body side moldings, 

carefully pry moldings straight off.



2 of 3 2/25/2009 10:44 PM 


Replace any clips or clip covering 

boots damaged during removal. 

Radiator grill, removing and 

installing 

- Open hood. 

Gently pry out tab on left or right side 

of grill trim ring (A), as well as tabs on 

bottom. 

- Feed grill out through opening. Be 

careful of 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.



3 of 3 2/25/2009 10:44 PM 

Headlight housing trim panel, 


- Open hood. 

- Remove spray nozzle of vehicles 

equipped with headlight cleaning 

systems. See 611 Wipers and 

Washers. 

Unclip inner tab at radiator support. 

- Press pane downward, out of 

retaining brackets. Feed out 

retaining hook at fender. 



Door Windows 


1 of 8 2/25/2009 10:44 PM 

General 

512-1 

This repair group covers door glass, 

window regulator and power window 

motor repair information. 

CAUTION! 

All E46 models are equipped with 

side-impact airbags in the front 

doors. Some models are also 

equipped with airbags in the rear 

doors. Be sure to read the airbag 

warnings and cautions in 721 

Airbag System (SRS). 

Electric window switch replacement 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 adjustment tool BMW 

41 6 120 

Window height gauge BMW 51 3 080

Door Windows 


2 of 8 2/25/2009 10:44 PM 

Power windows 

Power window features in E46 models 

include: 

Control of the front and rear door 

window motors is carried out 

directly by the General Module 

(GM V). 

One-touch operation in both 

directions on all four windows, 


Cable type window regulator used 

for all door windows. 

Anti-trap protection is provided by 

the pressure sensitive 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 FZV remote key. 

FZV operation can be owner

Door Windows 


3 of 8 2/25/2009 10:44 PM 

customized with the Car Memory 

function. See 515 Central 

Locking and Anti-theft. 

After the ignition is switched off, 

electric windows can be operated 

until a door is opened or until 16 

minutes has elapsed. 

The GM V bases window motor 

end position on current draw 

(load). 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 


4 of 8 2/25/2009 10:44 PM 

Window switches 

The push-pull type window switch 

provides the GM V with a coded ground 

signal. Holding a switch at the first 

detent provides a single ground signal 

on one wire requesting the GM V to 

open the window. When released, the 

ground signal is removed and the 

window motor stops. 

Momentarily pushing the switch to the 

second detent and releasing provides 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 covered in 612 Switches. 

Rear window child lockout 

switch

Door Windows 


5 of 8 2/25/2009 10:44 PM 

In 4-door models, the rear window child 

lockout switch (arrow) is incorporated in 

the driver's window switch block to the 

left of the shifter. When activated, it 

provides a constant ground signal to the 

GM V, preventing the windows from 

being operated from the rear door 

switches. 

The lockout switch ground signal is 

overridden by the GM V if a passive 

safety system (MRS) crash signal is 

received. 

Note: 

In Convertible models the four-window 

control switch is in the position occupied 

by the rear window lockout switch in 

4-door models. 

Power window motors 

The window motors are mounted on 

cable regulators. The 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 provides the convenience 

open/close feature, providing control of 

the power windows (and sunroof) from 

outside the vehicle with the key in the 

driver's door lock. The FZV (remote key) 

provides the same function for window 

opening only. 

Anti-trap protection is active during 

convenience closing from the driver's

Door Windows 


6 of 8 2/25/2009 10:44 PM 

door lock. 

If the GM receives a request to operate 

convenience closing or opening for more 

than 110 seconds, the function is 

deactivated and a fault code is stored. 

Window anti-trap protection 

In 4-door models, a rubber pressure 

guard located at the top edge of each 

door frame consists of two contact strips 

that close when subjected to pressure. 

When the contact strip closes (for 

example, a hand is trapped between the 

top of the window and the door frame), 

an anti-trap signal is sent to the GM V. 

The window immediately (within 10 

milliseconds) reverses direction. This 

feature does not require initialization. 

The E46 pressure sensor 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. 

Window motor limit stop 

function 

If repeated window activation (up/down 

cycles) exceeds one minute, the GM V 

deactivates the internal relays and 

disregards any further up/down 

requests. The GM V provides motor 

activation after a short duration but not 

for the full one minute monitoring cycle. 

The GM V monitors the number of times

Door Windows 


7 of 8 2/25/2009 10:44 PM 

a window motor is activated. It counts 

each cycle and stores the number in 

memory. After the stop function limit is 

reached and the window motor is 

deactivated, the GM V slowly reverses 

the stored count of activation until the 

stored number equals 0, thus allowing 

the window motor to cool down. 

Convertible windows 

A central power window switch is located 

in the Convertible console between the 

left side window switches. This switch 

allows all four windows to be opened 

with one-touch operation and closed if 

the switch is held. 

The Convertible is not supplied 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 working with 

broken glass. 

If a window is broken, all of the 

glass bits should be vacuumed 

out of the door cavity. Use a blunt 

screwdriver to clean out any 

remaining glass pieces from the 

window guide rails. 

When servicing the door 

windows, the harness connector

Door Windows 


8 of 8 2/25/2009 10:44 PM 


to the window regulator should 

always be disconnected to 

prevent pinching fingers in the 

moving window mechanism.

Door Windows 


1 of 8 2/25/2009 10:45 PM 

Window Service, 4-door 

Models 

Sedan and Sport Wagon doors are 

similar. Use the following procedures 

for window service on these models. 

WARNING! 

512-2 

E46 cars are fitted with 


doors. Some are equipped with 

airbags in the rear doors as well. 


windows on cars with 


disconnect the negative (-) 

battery cable. See 721 Airbag 

System (SRS) for cautions and 

procedures relating to the airbag 

system. 





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. 

Insert wooden block or other soft 

object between glass and upper 

door frame.

Door Windows 


2 of 8 2/25/2009 10:45 PM 

Note: 

Window should contact block, 

then immediately reverse direction 

and lower by approx. 25 mm (1 

in.). 

Anti-trap strip is integrated into the 

molding strip of the door window frame. 

Front window anti-trap strip, 

removing 

- Remove front door panel and 

vapor barrier as described in 

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 blackwhite. 

If replacing molding with new one, 

transfer mounting clips and foam 

insulation as necessary.

Door Windows 


3 of 8 2/25/2009 10:45 PM 

1 - Window frame molding 

2 - Clip 

3 - Door corner speaker cover 

4 - Foam insulation 

5 - Mounting clip 

- After installation, recheck anti-trap 

protection. 

Rear window anti-trap strip, 

removing 

- Remove rear door panel and vapor 

barrier as described in 411 

Doors. 

Detach window frame molding strip, 

peeling it off fixed window partition 

(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 blackwhite. 

- 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 squarely and should seat

Door Windows 


4 of 8 2/25/2009 10:45 PM 

against the window seal uniformly. 

Note: 

If the window does not contact the 

window seal uniformly, wind noise or 

water infiltration may result. 

- Remove front door panel as 

described in 411 Doors. 


battery. Then remove airbag unit 

and vapor barrier from door. See 

721 Airbag System (SRS). 

WARNING! 





- 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. 


Window regulator 

guide rail to door 

9 Nm (80 in-lb) 

Front door window, removing 

and installing (4-door models)

Door Windows 


5 of 8 2/25/2009 10:45 PM 

- 

Remove front door panel as 






WARNING! 





Detach 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. 

Detach plastic window retainers from 

glass: 

Push expander nut (1) out of 

plastic retainer. 

Note: 

Squeeze retainer tabs (2) and 

remove from glass. 

BMW recommends replacing the plastic

Door Windows 


6 of 8 2/25/2009 10:45 PM 

window retainers every time the glass is 

removed from the door. 

Turn window glass carefully inside door 

cavity and lift out of door. 


Replace plastic window retainers 

once glass is inside door. 



door. 

Adjust window as described 

earlier. 


Side-impact airbag 

to door 

Window to 

regulator guide 

8.5 Nm (75 

in-lb) 

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 



rail: 

If applicable, reattach battery. 

Move window to approx. 115 mm

Door Windows 


7 of 8 2/25/2009 10:45 PM 

(4.5 in.) from bottom. 

Remove window retaining screw 

(inset) at window regulator rail. 

WARNING! 




to prevent accidental operation of 

the window. 

Detach plastic window retainer from 

glass: 

Push expander nut (1) out of 

plastic retainer. 

Note: 

Squeeze retainer tabs (2) and 

remove from glass. 

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. 


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 need 

adjustment.

Door Windows 


8 of 8 2/25/2009 10:45 PM 



to door 

Window to 

regulator guide 

8.5 Nm (75 

in-lb) 

8 Nm (71 in-lb) 


Door Windows 


1 of 13 2/25/2009 10:45 PM 

Window Service, 2-door 

Models 

512-3 

2-door models are equipped with the 

"close with door shut" feature. In this 

mode, the window glass moves down 

slightly when the door latch is 

activated, then jams up tightly against 

the weather-strip when the door is fully 

closed. 

WARNING! 



doors. When servicing the door 







system. 





viii. 

Front door window, adjusting 


The "close with door shut" feature of 

2-door cars with frameless windows 

makes window adjustment critical. 

CAUTION! 

There is risk of window glass 

breakage if correct adjustment 

procedures are not used. If in doubt, 

this procedure should be left to a 

trained BMW technician.

Door Windows 


2 of 13 2/25/2009 10:45 PM 

The following adjustments can be 

made to the window: 

Longitudinal adjustment 

Pretension (or window rake) 

Parallelism (or window tilt) 

Vertical adjustment (or retraction 

depth) 

Glass protrusion (when open) 

Distance between side window 

and door window 

Emergency operation 

Adjusting the "close with door shut" 

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 Windows 


3 of 13 2/25/2009 10:45 PM 

Close door as far as possible without 

forcing. 

Coupe models: Top edge of glass 

must rest on door seal (A). 

Note: 

Convertible models: Gap between 

door and B-pillar (B) must be 25 

mm (1 in.). 

Window must seal with water drain at 

mirror triangle 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 


Longitudinal adjustment

Door Windows 


4 of 13 2/25/2009 10:45 PM 

Position window approx. 155 mm (6.1 

in.) above dead bottom. 

Working carefully with a plastic prying 

tool, detach outside trim strip from 

door. 

Reach through door bores (A) using 

Torx driver E7 on extension with ratchet 

wrench (BMW special tool 41 6 120 or 

equivalent). Loosen but do not remove 

longitudinal adjustment screws. 

Raise glass to top. Move glass fore or 

aft to attain correct adjustment. 

Coupe models: When fully closed, 

rear edge of window must 

protrude by distance A from edge

Door Windows 


5 of 13 2/25/2009 10:45 PM 

of window outer sealing lip. 

If necessary, replace side window 

trim. 

Window longitudinal adjustment 

Dimension A 

Door window rear 

edge to side 

window seal 

(Coupe) 

1 - 2 mm 

(0.04 - 0.08 in.) 

6 ± 0.75 mm 

(0.24 ± 0.03 in.) 

Convertible models: When all the way 

up, measure door window gap 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. 


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 


6 of 13 2/25/2009 10:45 PM 

- 

Remove outer door trim strip as 


Latch door to first catch of door lock 

(A). Check that top of window rests on 

rubber door seal (B). 

Reach through rear bore in door with 


equivalent ratchet wrench. 

Loosen window 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. 



8 Nm (71 in-lb) 

Vertical adjustments 

Note:

Door Windows 


7 of 13 2/25/2009 10:45 PM 

Adjusting the depth that the window 

retracts into the door seal insures that 

wind noise and water leakage past 

window is kept to a minimum. 

Parallelism. Top edge of door window 

must be parallel to contour of water 

drain in roof. 

Note: 

Window parallelism is also referred to 

as window tilt. 

Retraction depth. With door closed, 

raise window to top. 


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.

Door Windows 


8 of 13 2/25/2009 10:45 PM 

Pry out rubber plugs at base of 

door. 

Note: 

Starting at rear of door, reach 

through bore in door to turn Torx 

screw (A). 

Torx screw size is T20. 

Repeat at front bore. 

Raise window and check for 

parallelism and correct depth of 

retraction. 

Repeat as necessary. 

Reinsert rubber plugs. 

Front door window, removing 

and installing (2-door models) 

- Remove interior door panel. See 

411 Doors. 





WARNING! 





Detach door corner rubber seal 

mounting clips (arrows). Remove seal 

by pulling up in direction of curved

Door Windows 


9 of 13 2/25/2009 10:45 PM 

arrow. 

Lift off window inner lip seal. 

If necessary, replace any defective 

retaining clip (arrow). 

Position door window approximately 80 

mm (3.15 in.) below roofline. If 

necessary, temporarily reconnect 

battery cable. 

WARNING! 

Once the window is lowered, 

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 


10 of 13 2/25/2009 10:45 PM 

Window rear mounting hardware 

will stay with glass. 

- Tilt rear edge of window glass up 

and out of door. 

- If glass is being replaced, transfer 

window rear mounting hardware 

(mounting shim, threaded sleeve 

and clamping retainer) from lower 

rear corner of glass to new 

window. 


Note: 

Install window rear mounting 

screw with adjusting sleeve 

through guide rail and threaded 

sleeve in glass. 

Window mounting screws have 

left-hand thread. 



door. 

Adjust window as described 

earlier. 



to door 


8.5 Nm (75 

in-lb) 

8 Nm (71 in-lb) 

Rear vent window or vent latch, 

(Coupe models)

Door Windows 


11 of 13 2/25/2009 10:45 PM 

Refer to accompanying illustration 

when removing Coupe rear vent 

window or vent latch mechanism. 

1 - Vent window drive 

2 - Inner cap 

3 - Retainer 

4 - Washer 

5 - Washer 

6 - Shim 

7 - Glass support 

When installing, make sure 

U-shaped opening in glass 

support points to rear of car. 

To access rear vent hinges, 

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 

Rear of window to 

water drain 

Top of window to 

water drain 

up to 6 mm (0.24 

in.) 

up to 1.8 mm 

(0.07 in.) 

1 mm (0.04 in.) 


Vent window to 

body (M6 nut) 

6.2 Nm (55 in-lb) 

Rear side window (Convertible

Door Windows 


12 of 13 2/25/2009 10:45 PM 

models) 

Refer to accompanying illustration 

when removing Convertible rear 

window or window motor. 

1 - Window motor 

2 - Window regulator assembly 

3 - Window glass 

4 - Insert 

5 - Inner seal 

6 - Outer seal 

CAUTION! 

Convertible rear window removal, 

installation and adjustment is 

complex. If the final adjustment is 

incorrect glass breakage may result. 

This job is best left to be done by a 

trained technician at a qualified 

BMW repair facility. 

Rear side window, adjusting 

(Convertible models) 

The Convertible rear side window 

shares a version of "close with door 

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 correct 

adjustment of the folding top and of 

the front window glass. 


when adjusting Convertible side

Door Windows 


13 of 13 2/25/2009 10:45 PM 

window. 

Distance to front door window 

(longitudinal adjustment) (A) must 

be set by loosening Torx bolt 

through bore in outer shell of car, 

after removing exterior side trim 

strip. 

To set retraction depth 

(submersion) into top rubber seal 

(B), rear interior side trim panel 

must be removed to access 

adjustment screws. 

To set window centering (C), rear 

interior side trim panel must be 

removed to access adjustment 

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 

B 

C 

D 

23 - 25 mm (0.9 - 1.0 in.) 

Window must run into 

convertible top seal 

when top is closed. With 

top open, glass must 

rest firmly against 

window seal. 

With convertible top 

open, window must be 

centered in channel 

up to 1 mm (0.04 in.) 

toward inside of car 


Door Windows 


1 of 6 2/25/2009 10:45 PM 

Window Regulator 


512-4 

WARNING! 












system. 





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 door panel and 

vapor barrier 

Detach window motor electrical

Door Windows 


2 of 6 2/25/2009 10:45 PM 

harness connector (A). 

Remove motor mounting bolts (B). 

Twist motor slightly (arrows) to 

clear window regulator mounting 

tabs. 

- When reinstalling: 

Make sure window has not 

travelled fully downward. 

Manipulate spring-loaded window 

control cable (C) to engage motor 

teeth to regulator gears. 

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 


3 of 6 2/25/2009 10:45 PM 

Window regulator and motor, 

removing and installing (4-door 

models) 

Sedan and Sport Wagon doors are 

similar. There are two window rails in 

each front window regulator, only one in 

the rear. Otherwise the front and rear 

regulators are similar. 

Note: 

BMW recommends removing the window 

regulator and motor as one unit, then 

separating the two on the bench. 

- Remove door panel as described in 

411 Doors. 

- Disconnect battery negative cable 

and remove side impact air bag, if 

applicable. See 721 Airbag 

System (SRS). 

WARNING! 





When servicing the door windows 

on cars with side-impact airbags, 

always disconnect the negative (-) 




system. 





viii.

Door Windows 


4 of 6 2/25/2009 10:45 PM 

- 

Remove vapor barrier. 

- Detach window from window 

regulator as described earlier. Do 

not remove window from door. Push 

window up and use wedge to hold 

in position. 

Detach window regulator from door: 


connector (A) to power window 

motor. 

Remove regulator mounting nuts 

(arrows). 

- Remove window regulator through 

opening in bottom of door, checking 

for any wiring harnesses that might 

become snagged during 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. 


Window motor to 

regulator 


to door 




8 Nm (71 in-lb)

Door Windows 


5 of 6 2/25/2009 10:45 PM 

Door window regulator and 

motor, removing and installing, 


- Remove door panel as described in 

411 Doors. 





- Remove door glass as described 

earlier. 

- Lower window regulator completely. 

WARNING! 

Once the window regulator is 

positioned correctly, 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 


connector to power window motor. 

Remove regulator mounting nuts. 

- Remove window regulator through 

opening in bottom of door, checking 

for any wiring harnesses that might 

become snagged during regulator

Door Windows 


6 of 6 2/25/2009 10:45 PM 

removal. 



Inspect rubber insulators. Replace if 

brittle. 

After inserting window regulator into 

door cavity, install and tighten down 

mounting nuts on rear window rail. 

Install front window rail mounting 

nuts but do not tighten. 

Install glass. See Front door 

window, removing and installing 


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). 


Window motor to 

regulator 


to door 




8 Nm (71 in-lb) 


Interior Trim 


1 of 3 2/25/2009 10:46 PM 

General 

513-1 

This repair group covers interior trim 

removal and installation procedures. 

Refer to the following repair groups for 

additional information: 

250 Gearshift Linkage 

411 Doors (interior 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 


2 of 3 2/25/2009 10:46 PM 

Interior trim and finish panels are 

clipped or screwed into place. Many of 

the trim retaining clips are designed to 

be used only once. When removing 

trim that is held in place with clips, it is 

a good idea to have spares on hand 

before beginning the job. 

Note: 

The BMW E46 is equipped with SRS 

airbags mounted in the steering wheel, 

the dashboard on the passenger side, 

the front doors, the A-pillars, and as an 

option in rear doors on four door 

models. See warnings and cautions on 

below and in 721 Airbag System 

(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 


Before performing any work 

involving airbags, disconnect 

the negative (-) battery cable. 

See 721 Airbag System (SRS). 

Airbags contain a back-up 

power supply within the SRS 

control module. A 5 second 

discharge period should be 

allowed after the battery cable 

has been disconnected.

Interior Trim 


3 of 3 2/25/2009 10:46 PM 

CAUTION! 

When working on electrical 

switches or lights, always 

disconnect the negative (-) cable 

from the battery and insulate the 

cable end to prevent accidental 

reconnection. 





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.

Interior Trim 


1 of 2 2/25/2009 10:46 PM 

Center Console 

513-2 

The console between the two front 

seats starts behind the shifter housing. 

It houses the parking brake handle, 

optional telephone and oddments 

storage tray. The rear portion of the 

console houses the ashtray and covers 

the emergency brake cable ends. 

The optional front seat armrest is part 

of this console. 

Center console, removing and 

installing 

Press rolling cover of rear 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 

transmission selector. On 

automatic transmission vehicles, 

unplug connector for gear 

indicator light.

Interior Trim 


2 of 2 2/25/2009 10:46 PM 

Remove trim panel retaining screws 

(arrows) under transmission selector 

boot/trim. 

Slide center console back and lift up. 


connector from hazard light and central 

locking switch. 

If applicable disconnect wiring for 

factory installed cellular telephone. To 

release phone connector, press catch 

(A) and slide lock (B) forward. 

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. 



Make sure to securely fasten all 

electrical harness connectors 

during reassembly.

Interior Trim 


1 of 10 2/25/2009 10:46 PM 

Dashboard 

513-3 

The E46 dashboard assembly includes 

the instrument cluster, passenger side 

airbag, glove compartment, fuse and 

relay panel, radio, IHKA control panel 

or on-board monitor (if equipped with 

GPS), front ashtray, shifter assembly, 

and window control switches. 

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 


2 of 10 2/25/2009 10:46 PM 

11 - Glove 

compartment 

hinge 


cover 

13 - Left glove 

compartment 

(optional) 

14 - Center knee 

protector 


knee protector 

16 - Left footwell 

(pedal cluster) 

trim panel 

17 - Footwell light 

cover 

18 - Footwell light 

socket 

19 - Left knee 

protector 

Glove compartment and right 

footwell trim panel, removing 


- 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 


3 of 10 2/25/2009 10:46 PM 

right side strap. 

Pull out pin from bottom of left side 

dampening rod. 

Remove glove compartment hinge 

mounting bracket screws (arrows). Lift 

glove compartment over mounting rod to 

remove. 

Remove glove compartment housing: 

Remove insert mounting screws 

(arrows). 

If necessary, release mounting pin 

(A) at right side of housing. 

Note: 

Pull glove compartment housing 

down. 

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 


4 of 10 2/25/2009 10:46 PM 

Steering column trim, removing 


- Remove steering wheel as 


Fully lower and extend (arrows) 

adjustable steering column. 

- Remove retaining screw from top of 

steering column upper trim cover. 

Push in sides of upper trim cover 

(arrow) to release from lower trim. 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 


5 of 10 2/25/2009 10:46 PM 

to release. Pull down on trim. 


Replace any broken or missing 

fasteners. 

Left footwell (pedal cluster) trim 

panel, removing and installing 

- Move steering column to maximum 

extended position. 

Working at trim panel, remove screws 

(arrows) and expansion rivets (A). 

Clips (inset) 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. 


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 Trim 


6 of 10 2/25/2009 10:46 PM 

Dashboard/shifter console 

assembly, removing and 

installing 


battery and cover terminal with 

insulating material. 

CAUTION! 





Using a plastic trim tool pry gently to 

remove left, center and right dashboard 

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 


- Remove upper and lower steering 

column trim. Detach steering 

column stalk switch electrical 

connectors and remove stalk 

switch. See 612 Switches.

Interior Trim 


7 of 10 2/25/2009 10:46 PM 

Remove shifter knob by pulling straight 

up. 

Note: 

Apply approx. 90 lb. of force to pull off 

knob from shift rod. 

- Lift up and remove shifter bezel by 

prying gently. 

- Unclip bottom of shifter boot from 

center console trim by pushing 

forward. Pull boot up around shifter. 

- Remove center console as 


- Lift off switch carrier and detach 

electrical harness connectors to 

window switches. 

- Remove glove compartment as 


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 use sharp

Interior Trim 


8 of 10 2/25/2009 10:46 PM 

instruments to remove trim or finisher 

strip 

- Remove screws beneath finishing 

strip. 

Carefully pull away A-pillar trim. 

- Remove headlight switch. See 

612 Switches. 

- Remove instrument cluster. See 

620 Instruments. 

- Remove IHKA control panel and 

module. See 640 Heating and Air 

Conditioning. 

- If applicable: Reach through IHKA 

control panel opening and 

disconnect solar sensor harness 

connector. 

- Remove radio. See 650 Radio. 

- Remove front passenger airbag. 

See 721 Airbag System (SRS). 



Remove right footwell trim panel (arrow) 

by pulling backward to detach from 

mounting points. 

Note: 


from panel while removing. 

Remove dashboard mounting screw or 

expansion rivet (arrow) in lower right

Interior Trim 


9 of 10 2/25/2009 10:46 PM 

dashboard. 

- Similarly, remove left side 

dashboard mounting screw or 

expansion rivet. 

Remove dashboard mounting nut 

(arrow) at shifter console. 

Remove mounting nuts and screw 

(arrows) at dashboard face. 

- To remove dashboard: 

Pull up parking brake fully. 

Push seats fully back. 

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 


10 of 10 2/25/2009 10:46 PM 

tightening fasteners. 


Central Locking and Anti-Theft 


1 of 2 2/25/2009 10:47 PM 

General 

515-1 

This section covers repair information 

for door, trunk and cargo compartment 

locks and central locking. Also covered 

are Electronic Immobilization System 

(EWS) and anti-theft alarm (DWA). 

Keep in mind that E46 cars are 

equipped with sophisticated and 

self-diagnostic electrical systems. 

When experiencing malfunctions 

relating to central locking or anti-theft 

systems, it is recommended that the 

system 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 


Note: 

Additional general electrical information 

can be found in 610 Electrical 

Component Locations and Electrical 


Special tools 

A few special tools may be necessary 

for repairs in this section. 

Ring antenna removal tool BMW 61 3 

300 

Front door lock adjustment tool 4 mm 

Allen wrench



2 of 2 2/25/2009 10:47 PM 




1 of 14 2/25/2009 10:53 PM 

Central Locking 

515-2 

Note: 

There is a door lock key cylinder on the 

driver's door only 

Central locking in E46 vehicles controls 

the door locks, trunk or cargo 

compartment lock and fuel filler flap 

lock. The Central Body Electronics 

(ZKE V) control module, known as the 

General Module (GM V), controls 

central locking. 

The door lock actuators are sealed, self 

contained units with no replaceable 

parts. The actuators use Hall effect 

sensors in place of pin contacts and 

microswitches to provide door 

OPEN/CLOSED status signal. Each 

door lock-button only affects the 

actuator it controls. There is no effect 

on the central lock control of other 

doors. 

The 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 control all of 

the central locking system functions. 

The outside locks (driver's door and 

trunk) incorporate an overrunning lock 

cylinder that breaks away and 

freewheels if an attempt is made to 

destroy either with a screwdriver or 

dent puller. 

The rear doors are equipped with the 

child lock-out lever preventing the door



2 of 14 2/25/2009 10:53 PM 

from being opened from the inside 

regardless of lock-button position. 

The General Module (GM V) and 

Electronic Immobilization (EWS 3.3) 

interface via the K-bus to monitor 

double lock status and to initiate 

double lock override. This feature 

allows the doors to be opened from the 

inside if a key accepted by EWS is 

switched on in the ignition when the 

doors 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 system (MRS). 

Central locking system



3 of 14 2/25/2009 10:53 PM 

Central locking switch 

The central locking switch is housed in a 

combined housing with the hazard 

flasher switch. The central switch locks 

all vehicle locks except for the fuel filler 

flap. 

The switch provides a momentary 

ground input signal to the GM V. This 

input single locks 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.



4 of 14 2/25/2009 10:53 PM 

Single lock and double lock 

function 

Each door lock actuator incorporates two 

motors: 

Single lock motor controls the 

mechanical lock mechanism when the 

central lock switch is pressed to single 

lock the vehicle. The lock mechanism is 

fully locked at this point but can still be 

opened from the interior by pulling the 

appropriate interior door handle twice or 

by pressing the central lock switch 

again. When single lock function is 

activated, the fuel filler flap actuator is 

not locked. 

Double lock motor, also known as 

central arrest, is activated only when the 

vehicle is locked from the outside at the 

driver's door lock with a key or when the 

General Module (GM V) receives a lock 

request from the remote 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. 

Trunk lock 

The trunk lock can be operated with the 

key but does not lock or unlock the 

entire vehicle. When unlocked, the trunk 

can be opened by pressing the trunk 

release switch pad located above the 

license plate or from the remote trunk 

button in the left kick panel. 

The trunk can also be opened from 

inside the vehicle by pressing the remote 

trunk lid release button in driver's



5 of 14 2/25/2009 10:53 PM 

footwell area. The button provides the 

GM V with a ground signal when 

pressed. 

The vehicle must be unlocked or single 

locked from the central lock switch for 

the remote unlock to work. The remote 

trunk release is locked out when the 

trunk is locked in the valet setting or 

when the GM V detects a vehicle speed 

over 4 mph via the K-bus. 

Pressing the trunk release button on an 

FZV key also opens the trunk. 

The trunk lid position (open/closed) and 

trunk lock key positions are input signals 

to the General Module (GM V). The trunk 

lid OPEN/CLOSED signals come from 

the trunk lid switch contact located in the 

trunk lock motor. When closed, the trunk 

contact provides a 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: 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 release button preventing the 

trunk from being opened. 

DWA cancel switch: When the trunk 

is opened with the key, this switch 


preventing the DWA alarm system 

from activating, if armed.



6 of 14 2/25/2009 10:53 PM 

Remote entry (FZV) 

The E46 remote (keyless) entry system 

(usually called FZV) uses a tiny radio 

transmitter in the vehicle key to lock and 

unlock the doors and the trunk by 

remote control. 

1 Press once: 

unlock driver'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:



7 of 14 2/25/2009 10:53 PM 

panic mode (alarm if 

equipped) 

There are a number of other features 

incorporated in FZV: 

Locking/unlocking of fuel filler lid 

Selective unlocking of driver's door 

(as with key in lock) 

Arming/disarming of DWA alarm 

system (if equipped) 

Remote unlocking of the trunk only 

Comfort opening of windows, 

sunroof, and convertible top. 

Interior 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 required.



8 of 14 2/25/2009 10:53 PM 

Key incorporates an LED that 

signals operator of signal 

transmitting, key initialization status 

and key self-test indication 

Note: 

Keys delivered with four different 

colored labels. This is helpful to 

differentiate FZV keys during 

initialization, preventing possibility 

of misassigning key ID which would 

change coded Key Memory 

functions. 

A single unlock request from the 

driver's door with the FZV key 

unlocks the driver's door only. A 

second unlock request unlocks the 

remaining doors and trunk. This 

feature can be modified for 

individual users with the Key 

Memory capabilities to activate all 

lock actuators simultaneously. Car 

Memory/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 the GM V for 

processing. The GM V then carries out 

all remote lock system, window/sunroof 

convenience closing features and DWA 

arming/disarming functions. The 

frequency of the FZV key radio signal to 

the antenna amplifier is 315 MHz. The 

system is also used to convey the key 

identification number being used to



9 of 14 2/25/2009 10:53 PM 

lock/unlock the vehicle. This is a 

requirement of the Key Memory feature, 

covered below. 

Car Memory/Key Memory 

A number of features and functions can 

be customized to the driver(s) 

preference. The identity of the vehicle 

user is provided by a signal from the 

keyless entry system (FZV). 

Car Memory and Key Memory are 

actually two separate functions, 

although they are marketed as a 

combined feature. 

Car Memory 

The owner is provided with a list of 

systems that can be customized. Prior to 

vehicle delivery, the BMW scan tool DIS 

or MoDiC is used to code the driver 

preferences into the appropriate control 

modules. Thereafter these choices 

cannot be changed without recoding 

with a BMW scan tool. 

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 

Interior light activation when central 

locking is used 

Convenience opening of 

windows/sunroof 

Interior and external lighting 

preferences



10 of 14 2/25/2009 10:53 PM 

Heating/A/C preferences (IHKA) 

Seat and mirror preferences 

(triggered by Key Memory) 

Instrument cluster display units (for 

example: km vs. miles) 

Key Memory 

Whenever one of the FZV keys is used 

to lock or unlock the car, the user is 

identified by the GM V. A maximum of 

four keys can be programmed with the 

Key Memory feature. The use of the 

personalized key then triggers Car 

Memory functions such as heating/A/C 

(IHKA) settings or memory seat position 

adjustment. 

Most programming of Key Memory 

requires the use of BMW scan tools DIS 

or MoDiC. However, features such as 

IHKA blower speed and temperature 

store automatically without the use of 

scan tools. 

Available Key Memory functions vary 

based on vehicle equipment. The 

functions that can be set include: 

Automatic locking after start off 

Selective locking 

Note: 

Heating/A/C blower speed, heated 

or cooled air distribution, automatic 

blower setting. 

Key Memory is only activated when using 

keyless entry. If the driver's door is 

unlocked manually, no electronic input is



11 of 14 2/25/2009 10:53 PM 

received at the GM V. Therefore Car 

Memory/Key Memory features will not be 

activated. 

Remote key initialization 

Initialization of FZV keys is required to 

establish lock/unlock signal 

synchronization with the GM V. The 

initialization procedure provides the GM 

V with a key identification number and a 

"rolling code" for each key. If initialization 

is not performed, the GM V will not 

respond to the key signals. 

Up to 4 remote keys can be initialized. 

They must be initialized at the same 

time. Key initialization 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 buttons. 

Note: 

The Key Memory function of the GM 

responds to the key identification number 

of each key. If the keys are not initialized 

in the same order prior to initialization,



12 of 14 2/25/2009 10:53 PM 

the key memory functions activated by 

the keys will not be assigned correctly. 

Always initialize the keys in the same 

order. 

Convertible central locking 

In Convertible models, the glove 

compartment lock is integrated into 

central locking functions. An additional 

lock actuator is positioned above the 

glove compartment lock, locking it 

whenever central locking is activated. 

A microswitch on the glove compartment 

lock cylinder signals the GM V to lock 

the trunk electrically. This is the 

equivalent of valet key position. 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 whenever the trunk is OPEN. 

The FZV antenna for the Convertible is 

incorporated into the rear view mirror. 

Tailgate and rear window 

locking 

The Sport Wagon tailgate can be 

opened from: 

Remote key (FZV)



13 of 14 2/25/2009 10:53 PM 

Interior tailgate release button at 

driver's kickpanel 

Unlock microswitch above rear 

license plate 

Any of these input requests to the GM V 

activate the tailgate latch motor. The GM 

V will also switch on the interior lights 

with a tailgate unlock request. 

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



14 of 14 2/25/2009 10:53 PM 




1 of 22 2/25/2009 10:59 PM 

515-3 

Door Handles and Locks 

Any time a door lock is removed and 

reinstalled, be sure to check and reset: 

Unlocking of rotary latch 

Outside door handle overtravel 

These adjustments and measurements 

must be made by closing the door lock 

rotary latch with a screwdriver, then 

attempting to open it with the outside 

door handle. Both adjustment 

procedures are described below, 

under 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 handle 

assembly 

1 - Inside door lock 

release 

2 - Inside door



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release Bowden 

cable 

3 - Lock button and 

rod 

4 - 9/2000 and later 

models: 

Bowden cable 

bracket 

5 - 9/2000 and later 

models: Door 

handle inner 

mechanism 

5a 

- Models to 

9/2000: 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) 


in-lb) 

12 - Gasket 

13 - Outer door 

handle 

14 - Driver’s door: 

Door lock



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cylinder and 

cover 

14a - Rear or right 

door: Outer 

handle rear 

anchor 

15 - Door striker 

cover 

16 - Torx bolt M8 


ft-lb) 

17 - Door lock striker 

18 - Lock plate 

Rotary latch unlocking, 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



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adjustment screw, then retighten. 

Note: 

Carry out check again. 

The right side latch adjusting screw is 

threaded left-handed. 


Door lock 

adjustment screw 

3 + 2 Nm 

(27 + 18 in-lb) 

Outside handle overtravel, resetting 

- With door open, close rotary latch 

with a screwdriver. 

- Open rotary latch with outside door 

handle. 

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.)



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Door lock, removing and 

installing 

The front and rear door locks for all E46 

models are similar. Early production 

cars, up to 9/2000, use a lock actuator 

with an external lever which couples with 

the outside door handle mechanism. 

Cars produced from 9/2000 use a 

Bowden cable to attach the outside door 

handle to the lock release mechanism. 

- Remove front door tim panel, air 

bag, and vapor barrier as described 

in 411 Doors and 721 Airbag 

System (SRS). 


rails: 

Reattach battery. Move window to 

approx. 140 mm (5.5 in.) from 

bottom. 

Remove window retaining screws 

(insets) at window regulator rails. 

WARNING! 




to prevent accidental operation of the 

window. 

Note: 

Be prepared to retrieve the captured nut 

corresponding to the retaining screw on 

the back side of the window rail. It may 

fall to the bottom of the door. 

Be sure to separate plastic lug at 

base of window from rail.



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Raise window to top. 

CAUTION! 

Guide the window up manually in 

order to avoid binding. 

Remove window regulator rear rail: 

Remove top and bottom rail 

mounting fasteners (arrows). 

Slide rail down, allowing it to hang 

to the side out of the way. 

WARNING! 


airbags in the front doors. When 

servicing the door locks on cars with 

front side-impact airbags, always 





- 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 connector from 

lock assembly. 

- Remove lock assembly, complete 

with lock-button linkage.



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- 



Insert lock button up through inner 

door plate, taking care to avoid 

bending linkage. 

On models produced to 9/2000: Tilt 

lock assembly outward while lifting 

it into position inside the door. This 

is done to make sure lock lever is 

inserted between outside door 

handle pawl and outer door skin. 

Use new door lock mounting bolts. 

Use new self-locking mounting 

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 


Check function of window 

mechanism before reinstalling vapor 

barrier and inner door panel. 


Airbag to door 

(replace screws) 

Door lock to door 


replace) 

Window guide to 

door 

8.5 Nm (75 in-lb) 

9 Nm (80 in-lb) 

9 Nm (80 in-lb)



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8 Nm (71 in-lb) 

Driver's door lock cylinder, 


Only the driver's door is equipped with a 

lock cylinder. The procedure for 

removing the door handle rear anchor on 

the other three doors is similar to that for 

removing the driver's door lock cylinder. 

Open door and remove plastic plug 

(Sedan or Sport Wagon shown in 

illustration) or rubber covering (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 

off cylinder gently to avoid breaking 

tabs. 




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On Sedan or Sport Wagon: 

Replace cylinder mounting bolt 

access hole trim cover if necessary. 

Door handle, removing and 

installing (to production date 

9/2000) 

- On driver's door: Remove door lock 

cylinder as described earlier. 

- Other doors: Remove door handle 

rear anchor. Procedure is similar to 

removing driver's door lock cylinder 


Pull handle out as far as it will go, then 

backward approx. 2 mm (0.08 in.). 

- Push handle in slightly (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 check unlocking of rotary 



under Rotary latch adjustments.



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Door handle, removing and 

installing (from production date 

9/2000) 

- On driver's door: Remove door lock 

cylinder as described earlier. 

- On other doors: Remove door 

handle rear anchor. Procedure is 

similar to removing driver's door 

lock cylinder described earlier. 

Pull outside door handle out and wedge 

BMW special tool 00 9 322 under 

handle. 

- Working in lock cylinder mounting 

bolt access hole, tighten down 

screw (counterclockwise direction). 

Lock is now in "installation position". 

Remove special tool 00 9 322. 


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 

"installation position" as described 

earlier: 

Distance between inner door handle 

lever and outer door skin must not



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exceed measurement A. 

If measurement exceeds 

specification, pull lever outward with 

fingers until measurement is 

correct. 

Installation distance: inner door 

handle lever to door 

Measurement A 

less than 8 mm 

(0.32 in.) 

Note: 

Insert handle and snap into place. 

Take care that the door handle base 

gasket is not deformed when the handle 

is installed. 

- Be sure to check unlocking of rotary 




Door handle inner mechanism, 

removing and installing (to 

production date 9/2000) 

- Remove door lock and outside door 

handle as described earlier. 




System (SRS). 

- Remove outside handle base seals. 

Loosen inner handle mounting bolt 

(arrow).



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- 

Working inside door opening, slide 

inner handle toward front and 

remove. 


Note: 

Inspect mounting bolt and replace if 

necessary. 

Door handle inner mechanism, 

removing and installing (from 

production date 9/2000) 

- Remove outside door handle as 


- Remove outside handle base seals. 




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 


- On Coupe or Convertible: Remove 

inner door guide (plastic) to gain 

access to Bowden cable. 

Note:



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Take care to not damage inner door 

guide during removal and installation. 

- Loosen handle mounting bolt. 

- Working inside door opening, slide 

inner handle toward front and 

remove. 


Note: 

Inspect handle mounting bolt and 

replace if necessary. 

Bowden cable end must be correctly 

fitted in lock actuator. 

Door striker, 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 fingertight. 

Position striker bar approx. 90° to inside 

edge of door frame. Leave striker 

mounting bolts finger-tight.



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Set position of striker: 

When closed, rear edge of front 

door must be even with front edge 

of rear door (Sedan or Sport 

Wagon) or with rear quarter panel 

(Coupe or Convertible). Maximum 

deviation allowed measured at A. 

When closed, shoulder of front door 

must be flush to shoulder of rear 

door (Sedan or Sport Wagon) or 

with top of rear quarter panel 

(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 


Striker plate to 

24 Nm (18 ft-lb)



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body pillar 

Trunk locking mechanism 

Trunk lock assembly 

1 - Trunk release microswitch 

2 - Connecting rod 

3 - Lock with microswitch 

4 - Torx screw M6 

5 - Striker plate 

6 - Trim screw 

7 - Lock cover 


9 - Lock 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



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license plate light strip 

The trunk lock cylinder does not actuate 

central locking control. 

- To remove the trunk lock 

microswitch: 

Remove licence plate light strip. 

Separate electrical harness 

connector from strip. 

Separate microswitch from strip. 

To access trunk lock cylinder or lock: 

Raise trunk lid. 

Open tool kit and remove screws 

attaching tool kit to trunk lid (white 

arrows). Unclip retaining strap at 

trunk lid and remove tool kit. 

Remove insulating liner expansion 

rivets (black arrows). 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 from trunk 

lid.



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Note: 

Remove lock cylinder cover 

mounting screws (arrows). Slide 

cover to right to remove. 

On Convertible models: Remove 

third brake light to access trunk lock 

mechanism. 

Use new self-tapping screws to 

reinstall trunk lock cylinder. 

Pry out rear trunk edge trim caps 

(arrows) to access mounting screws to 

remove 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) 

Trunk lid / rear 

fender (B) 

5 ± 1.5 mm 

(0.2 ± 0.06 in.) 

4.25 ± 0.75 mm 

(0.17 ± 0.03 in.)



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Note: 


grease. 

Tailgate lock, emergency 

release 

The Sport Wagon tailgate can be 

unlocked using the central locking 

switch, the left door key or the FZV 

remote entry system. The tailgate can be 

opened by pushing the tailgate release 

button in the left front kickpanel or by 

pressing the microswitch in the center of 

the license plate light strip. There is no 

key lock 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 


2 - Rear window lock 

3 - Rear window lock cover 

4 - Nut M6 

5 - Rear window striker mounting 

bracket and wiper pivot



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6 - Rear window lock striker 

7 - Tailgate lock 


9 - Tailgate lock striker 

10 - Lock plate 

11 - Tailgate release microswitch 

12 - Tailgate grip 

13 - Tailgate grip gasket 

14 - Tailgate 

To remove tailgate lock microswitch: 

Remove license plate light strip. 

Separate electrical harness 

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.



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To remove tailgate lock striker: 

Open tailgate and pry out lock 

striker trim from bottom of tailgate. 

Remove one striker mounting screw 

(arrows). 

Thread in M8 stud to keep striker 

lock plate from falling inside door. 

Remove second screw and striker. 

Reinstall striker bolts finger tight. 

Adjust striker position before 

tightening bolts. 

- To adjust striker position: 

Close tailgate slowly, allowing 

striker to center itself on lock. 

Striker must not touch lock housing. 

Note: 

Tighten striker mounting bolts, then 

check tailgate to body gaps as 

shown below. 


grease. 

To remove rear window lock striker: 

Adjust striker height by loosening 

lock nut A, then turning striker in or 

out. 

Retighten lock nut.



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To remove rear window lock: 

Open tailgate. Remove tailgate trim 

panel. 

Detach window lock electrical 

harness connector (A). 

Remove lock mounting screws 

(arrows). 

Slide lock out from under rear 

window wiper motor. 

Reinstall lock mounting bolts finger 

tight. Adjust lock position before 

tightening bolts. 

- To adjust lock position: 

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.



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Rear spoiler / side 

panel (A) 

Rear window / side 

panel (B) 


panel (C) 


panel (height) 

Tailgate light / 

corner light (D) 

Tailgate / rear 

bumper (E) 

Rear window / 

tailgate (F) 

Rear window / 

tailgate (G) 

3.75 ± 1.3 mm 

(0.15 ± 0.05 in.) 

3.5 ± 1.4 mm 

(0.14 ± 0.06 in.) 

3.6 mm ± 0.75 

mm 

(0.14 ± 0.03 in.) 

flush to 2 mm 

(0.08 in.) lower 

4.25 ± 0.75 mm 

(0.17 ± 0.03 in.) 

5 ± 1 mm 

(0.2 ± 0.04 in.) 

4 ± 1 mm 

(0.16 ± 0.04 in.) 

5.4 ± 1 mm 

(0.21 ± 0.04 in.) 




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Electronic 

Immobilization (EWS) 

515-4 

E46 cars are equipped with a passive 

theft-prevention system. The Electronic 

Immobilization System (EWS 3.3) 

makes it impossible to start the engine 

using any means other than the special 

keys furnished with the vehicle. 

Note: 

EWS is sometimes also referred to 

as Driveaway Protection. 

If a vehicle key is lost or stolen, 

the electronic authorization for that 

key can be cancelled using the 

BMW scan and diagnostic tools 

DIS or MoDiC. 

Force applied to a key can 

damage the electronic circuitry. A 

damaged key will not start the 

engine. 

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 the key code 

and EWS control module code do not 

match, the engine management control 

module and the starter are disabled. 

EWS ignition keys cannot be 

duplicated. 

The system is designed to have up to



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ten keys. Only an authorized BMW 

dealer can provide replacement keys. 

Note: 

It is possible to damage the 

electronic circuitry in the key, 

rendering it unusable. In that case, 

a new key should be purchased 

and initialized by an authorized 


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. 

EWS control module, replacing 


battery. 

CAUTION! 





Lower left footwell (pedal cluster) trim 

panel. 


Remove fasteners (B).



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connectors at left footwell trim panel 

and remove panel: 

Unplug connector at footwell 

interior light (A), if equipped. 

Slide lock at OBD II connector (B) 

in direction of arrow. 

Unplug connector at speaker if 

equipped (C). 

Remove EWS control module harness 


- Remove module mounting screws. 

Remove module. 

Note: 

The EWS module should be identified 

with EWS markings. 


Ring antenna 

To remove the ring antenna using 

BMW special tool 61 3 300, it is 


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 cylinder out. 

- Detach ring antenna harness 

connector.



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- 


cylinder. 




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Anti-Theft Alarm (DWA) 

515-5 

The DWA anti-theft system is a dealer 

installed accessory option. All E46 

vehicles are factory prepared to provide 

the DWA function. This means that the 

vehicle is prewired and the General 

Module (GM V) is preprogrammed for 

the system. However, once the DWA 

system components are installed the 

GM V must be coded, using the DIS or 

MoDiC, 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 

Siren in cowl area next to IHKA 

housing



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Anti-theft and alarm system (DWA) (Sedan models) 

DWA alarm arming/disarming 

The DWA alarm is armed every time the 

vehicle is locked from the outside with 

the door lock cylinder or FZV key. 

The LED in the rear view mirror flashes 

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



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an activation component. If after 3 

seconds any input signal not in CLOSED 

status is excluded (this is acknowledged 

by the DWA LED) preventing false alarm 

activation. 

If the DWA is armed a second time 

within 10 seconds, the tilt sensor and 

interior protection sensor are also 

excluded as alarm activation 

components. This function is useful for 

preventing false alarm activation if the 

vehicle is transported on a train or flat 

bed truck. 

While armed the trunk can be opened 

without the alarm being triggered as 

follows: 

If opened with the trunk remote 

button via the FZV, the GM V 

prevents the alarm from activating. 

(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 seconds. At the same 

time the headlight low beams and 

hazard lights will flash for 5 minutes. 

The GM V signals the Light Center 

Switch (LSZ) via the K-bus to flash the 

lights. Following an alarm trigger, the 

system will reset and trigger again if 

further tampering is done to the vehicle.



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Door contacts 

The door lock Hall effect sensors provide 

status of door OPEN/CLOSED: 

When the door latch is CLOSED, 

current flow through the sensor is 

12 mA. 

With the DWA armed, the GM V will 

activate the siren if it receives a door 

OPEN signal. 

Trunk lid switch contact 

The trunk switch contact is located in the 

trunk lock assembly. When closed, the 

trunk contact provides a ground 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 


V. The GM V locks out the interior 

trunk release button preventing the 

trunk from being opened. 

DWA deactivation switch. When the 

trunk is opened mechanically with



5 of 11 2/25/2009 11:00 PM 

the key, this switch provides a 

ground signal to the GM V 

preventing the DWA from activating 

if armed. 

Hood contact switch 

Located on the right side engine 

compartment, the hood contact switch 

(arrow) provides a ground signal to the 

GM V signifying an open hood. The 

plunger of this switch can be pulled up 

past a detent causing the switch contact 

to open. This feature can be used to 

simulate a CLOSED hood with the hood 

open when diagnosing 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 

summarized in Table a. 

Table a. DWA LED status 

DWA status 

Disarmed 

Armed 

DWA LED 

condition 

OFF 

Continual slow 

flash



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Table a. DWA LED status 

DWA status 

Armed with one or 

more monitored 

inputs not in 

CLOSED position 

(trunk not closed, 

etc.) 

DWA LED 

condition 

Rapid flash for 10 

seconds, then 

continual slow 

flash 

Alarm activated Rapid flash for 5 

minutes, then 

continual slow 

flash 

Rearmed in less 

than 10 seconds 

Disarmed after 

activated alarm 

ON for 1 second 

Rapid flash for 10 

seconds, then 

OFF 

Tilt sensor 

Located in the right trunk area above the 

battery, the solid state tilt 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 

signal provided to the GM V. This 

signal is used for two purposes: a. 

As a momentary acknowledgment 

that the tilt sensor received STDWA



7 of 11 2/25/2009 11:00 PM 

and is currently monitoring the 

vehicle angle. b. If the tilt sensor 

detects a change in the vehicle 

angle when DWA is armed, the NG 

signal is switched to inform the GM 

V to activate the siren. 

When the tilt sensor receives the 

STDWA signal from the GM V, the angle 

of the vehicle is memorized and 

monitored by the solid state electronics. 

Once armed, if the angle changes, the 

tilt sensor provides a switched ground 

signal to the GM V to activate DWA. 

Interior protection (UIS) 

The combined ultrasonic transmitter and 

receiver in UIS monitors the vehicle 

interior for motion. 

The UIS is mounted 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 emits ultrasonic 

waves in a programmed timed cycle. It 

receives echoes of the emitted signals. 

The UIS amplifies the received sound 

wave signals and compares them with 

the transmitted waves. The UIS also 

checks the incoming echoes for 

background hiss (wind noise through a



8 of 11 2/25/2009 11:00 PM 

partially open window) and adapts for 

this. 

If the echoes are consistently similar, no 

movement is detected. If the echoes are 

altered or inconsistent, the UIS changes 

to a constant cycle and the echo is 

compared again. If the inconsistency is 

still present the UIS sends the activate 

siren signal (INRS) to the GM V. 

As with the tilt sensor, the UIS is also 

switched OFF when the vehicle is locked 

two times within ten seconds. This 

allows the sensor to be switched OFF for 

transportation purposes. 

Convertible interior protection 

(SDR) 

In Convertible models, the interior motion 

detector for the alarm system is a short 

distance radar (SDR) detector located on 

the center tunnel, 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 field in a hemispherical 

pattern within the vehicle interior. The 

monitoring radius is preset in the 

module. The receiving antenna monitors 

reflected signals from the interior. The 

module evaluates these signals as a 

base line for vehicle security. Any 

objects that come into this monitoring 

radius will be detected and evaluated by 

the SDR module.



9 of 11 2/25/2009 11:00 PM 

The module operates in pulse mode. 

The radar unit transmits a signal, then 

pauses for the reflected signals to be 

received by the module. 

The detection range of the radar is 

adjusted by rapid switching when the 

system is armed. This allows the sensor 

to adjust its range to either the 

windshield with the top lowered or to the 

soft top when it is raised. 

The module will signal the GM V to 

trigger the alarm if a new object is 

detected within its sensing hemisphere. 

However, false alarms may be triggered 

by objects falling into the interior when 

the system is armed with the top 

lowered. Also, large metal objects, such 

as the seat backrests, will shield the 

microwave pulse and create 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 

alarm is triggered. The siren also 

contains a rechargeable battery that is 

used to power the siren when the alarm 

is triggered. The rechargeable battery 

will allow the siren to sound if it or the 

vehicle battery is disconnected. The 

siren battery is recharged from the 

vehicle battery when DWA is not in the 

armed state. 

The siren has four wires connecting it to



10 of 11 2/25/2009 11:00 PM 

the alarm system: 

KL 30 (power) 

KL 31 (ground) 

STDWA signal (arm/disarm signal 

from GM V) 

NG signal (activate siren output 

signal to the GM V) 

The arm/disarm output signal from the 

GM V (STDWA) is provided to the tilt 

sensor, UIS sensor and the siren 

simultaneously. The arm/disarm signal is 

a switched ground that signals the 

components of DWA armed/disarmed 

status. 

The activate the siren, the NG signal is 

high whether DWA is armed or 

disarmed. If a monitored input activates 

the alarm, the high signal to the siren is 

switched 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 

mode is functional with either an armed 

or disarmed DWA system. 

Emergency disarming 

Emergency disarming occurs 

automatically if a key is used to turn the 

ignition switch ON and EWS accepts it.



11 of 11 2/25/2009 11:00 PM 


The EWS signals the GM V to unlock the 

doors and to deactivate the DWA.

Seats 


1 of 5 2/25/2009 11:03 PM 

General 

520-1 


installation of the front and rear seats. 

Seat design and upholstery 

The front seats installed in E46 cars 

come in either manual or powered 

versions. They offer firm support and 

comfort. Their internal construction is 

engineered to work together with the 

vehicle suspension to absorb vibration. 

The internal ventilation system of the 

seats adds to the built-in comfort 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, E46 seats 

offer the following minimum 

adjustments, with manual (photo) or 

power controls (below): 

Fore-aft position 

Backrest angle

Seats 


2 of 5 2/25/2009 11:03 PM 

Cushion height 

Head restraints. 

Seat memory system 

In cars with seat memory, the driver's 

front seat incorporates two control 

modules: One in the seat adjusting 

switch (arrow) and the second under 

the seat cushion. The two modules 

process the following: 

Seat adjustments 

Comfort entry aid switch (2-door 

models) 

Seat backrest lock microswitch 


Seat belt fastened 

K-bus communication with the 

General Module (GM 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 the seat 

cushion control module. Seat positions 

are recognized through the use of Hall 

sensors in the motors. All components

Seats 


3 of 5 2/25/2009 11:03 PM 

of the seat memory system are 

monitored for faults. Access the fault 

codes using BMW scan tool DIS or 

MoDiC. 

In Coupe and Convertible models, the 

easy entry feature facilitates access to 

the rear seats. When a front backrest is 

folded over, the entire seat moves 

forward 90 mm (3.54 in.) to facilitate 

rear entry. In models with seat memory, 

the seat control module 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 the passenger seat on these 

models. 

Driver seat memory module

Seats 


4 of 5 2/25/2009 11:03 PM 

Passenger seat memory module

Seats 


5 of 5 2/25/2009 11:03 PM 

Rear seat configuration 

Split rear folding seats are optional in 

the Sedan and standard in the Sport 

Wagon and Coupe. They are split 1/3 

right to 2/3 left with a folding center 

armrest in the left portion. The armrest, 

when folded down, is equipped with a 

storage compartment and cupholders. 


Seats 


1 of 4 2/25/2009 11:03 PM 

Front Seats 

520-2 

Seat removal and installation is similar 

for all versions. Seat disassembly 

differs in detail among the many 

models of seats. 

Seat repair and component 

replacement is possible once the seat 

has been removed from the vehicle. 

Front seat, removing and 

installing 

WARNING! 

The front seats are equipped 

with pyrotechnic seat belt 

tensioners. These tensioners are 

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 replace them. 

Never treat pyrotechnic 

components with cleaning 

agents or grease.

Seats 


2 of 4 2/25/2009 11:03 PM 

Do not expose pyrotechnic 

components to temperatures 

above 75°C (167°F). 

Pyrotechnic components can 

only be tested electrically when 

installed, using BMW service 

tester DIS, MoDiC or equivalent 

scan tool. 

Do not fire a pyrotechnic gas 

generator prior to disposal. It 

must be fired by a special 

disposal company or shipped 

back to BMW in the packaging 

of the new components. 

During body straightening and 

welding with an electric arc 

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 seat to its rear most position, 

keeping it raised.

Seats 


3 of 4 2/25/2009 11:03 PM 

Remove plastic caps over front seat 

mounting nuts, then remove mounting 

nuts (arrows). 


battery. 

CAUTION! 





Tilt seat back to access electrical 

harness connectors. Slide lock to 

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. 


Use wire ties or equivalent means 

to keep seat harness wiring from 

fraying. 


Front seat to floor 

Seat belt end to 

seat 

45 Nm (33 ft-lb) 

48 Nm (35 ft-lb)

Seats 


4 of 4 2/25/2009 11:03 PM 


Seats 


1 of 2 2/25/2009 11:04 PM 

Rear Seats 

520-3 

Rear seat cushion and 

backrest, removing and 

installing (fixed seat back 

models) 

- Pull front of rear seat cushion up 

to release clips. While holding 

front of cushion up, pull cushion 

forward to remove. 

Remove rear seat backrest: 

Pull top outer corners of backrest 

forward (A) to detach from top 

retainers. 

Pull entire backrest up (B) to 

detach from bottom hooks. 

Note: 

Slide backrest to side to clear seat 

belts. 

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 back 

models)

Seats 


2 of 2 2/25/2009 11:04 PM 

- 

Pull front of rear seat cushion up 

and out of clips. While holding 

front of cushion up, pull cushion 

forward to remove. 

- Tilt backrests forward. 

Note: 

Remove rear headrests, if equipped, by 

pulling straight up. 

Remove backrest side section by 

pulling out (A) and up (B). 

- 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). 


Sunroof 


1 of 5 2/25/2009 11:04 PM 

General 

540-1 

This repair group covers the slide-tilt 

sunroof assembly. 

Component locations, initialization, 

sunroof panel replacement, and 

sunroof height adjustment are covered. 

Replacement of the cable assembly or 

frame require that the headliner be 

removed. Removal and repair of the 

sunroof assembly and other 

components inside the roof cavity is 

beyond the scope of this manual. 

Sunroof electronic 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 the mechanical 

end positions of the sunroof are 

detected and stored by the General 

Module (GM V).

Sunroof 


2 of 5 2/25/2009 11:04 PM 

Press and hold sunroof switch in "lift" 

direction. 

After reaching end position, keep 

switch pressed for approximately 

20 seconds longer. 

The sunroof motor will briefly jerk 

upwards, signalling normalization 

is complete. 

Characteristic curve 

The characteristic resistance curve of 

the E46 sunroof is learned using 

coding software. This resets the safety 

(anti-trapping) feature. See your BMW 

dealer service department. 

Sunroof panel, emergency 

closing 

Remove access panel from below 

sunroof motor by gently prying at the 

rearmost edge with a plastic tool. 

Disconnect the electrical connections 

and lay switch panel aside.

Sunroof 


3 of 5 2/25/2009 11:04 PM 

Insert hex key into drive in sunroof 

motor, and turn hex key to manually 

close sunroof. 

Note: 

The hex key for manually (emergency) 

closing the sunroof can be found in the 

tool kit located in the trunk lid (sedan, 

coupe and convertible) or under the 

cargo area floor panel (Sport Wagon). 

Sunroof panel, adjusting 

Note: 

Be sure to check drains 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 noise at high speeds 

(sunroof closed)

Sunroof 


4 of 5 2/25/2009 11:04 PM 

Sunroof has been removed 

Whenever the top of the closed sunroof 

becomes misaligned with the roof of 

the car, if it does not close squarely, if 

there are wind noises at speed, if there 

are water leaks, or if the sunroof has 

been removed. 

Correct sunroof alignment: 

Sunroof must be fully closed. 

Note: 

Gap must be even all around 

edge of sunroof. 

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.) is 

exposed.

Sunroof 


5 of 5 2/25/2009 11:04 PM 

The sunroof panel is retained by three 

Torx screws (arrows) on each side. To 

adjust sunroof height: 

Loosen Torx screws until sunroof 

can just be moved. 

Push sunroof panel forward. 

Push sunroof panel up or down 

until correct height is achieved. 

Tighten screws. Recheck height. 

Check sunroof function.nothing 

Sunroof height adjustment 


Rear 

Front 

flush/1 mm higher than 

roof top 

flush/1 mm lower than roof 

top 


Sunroof panel to 

roof (Torx) 

4.5 Nm (40 in-lb) 


Sunroof 


1 of 4 2/25/2009 11:04 PM 

Sunroof Components 

540-2 

Sunroof assembly removal and 

installation involves headliner removal, 

and is not covered in this manual. After 

sunroof repairs be sure to follow 

initialization and adjustment 

procedures given earlier. 

Sunroof assembly 


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 


tighten to 3.5 Nm

Sunroof 


2 of 4 2/25/2009 11:04 PM 

(31 in-lb) 

16 - Emergency 

operation crank 

handle 

17 - Hex bolt with 

washer 


Sunroof panel, removing and 

installing 

To remove sunroof panel, open sunroof 

and 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. 


Sunroof 


3 of 4 2/25/2009 11:04 PM 

Adjust sunroof height and gap as 



Wind blocker to 

roof (Torx) 


roof (Torx) 

1 Nm (9 in-lb) 

4.5 Nm (40 in-lb) 

Sunroof panel gasket, replacing 

- Remove sunroof panel as shown 

above. 

Pull old seal from panel. 

Coat new seal and channel in 

sunroof panel with soapy water. 

Starting at back center of panel, 

install new seal, taking care to not 

pull seal too tightly around four 

corners of panel. 


Adjust sunroof height and gap as 

shown earlier in this repair group. 


Wind blocker to 

roof (Torx) 


roof (Torx) 

1 Nm (9 in-lb) 

4.5 Nm (40 in-lb) 

Sunroof motor, replacing 

Remove access panel from below 

sunroof motor by gently prying at the

Sunroof 


4 of 4 2/25/2009 11:04 PM 

rearmost edge with a plastic tool. 

Remove sunroof motor mounting screws 

(arrows). 


removal. Perform intitialization 

procedure as described earlier. 


Sunroof motor to 

sunroof carrier 

2.8 Nm (25 in-lb) 


Convertible Top 


1 of 11 2/25/2009 11:05 PM 

General 

541-1 

This repair group covers the automatic 

electro-hydraulic convertible top. 

Information on the Rollover Protection 

System is also included here. 

Note: 

The convertible top control module 

(CVM II) is located behind the left 

rear side trim panel. For the 

location of other convertible top 

electric components see 610 


The glass rear window in the 

Convertible is not replaceable 

separately. 

Convertible top controls



2 of 11 2/25/2009 11:05 PM 

Convertible battery 

BMW has designed a special battery tray 

for the Convertible which serves to 

dampen Convertible body flexing and 

vibration. 

CAUTION! 

The E46 Convertible requires a special 

battery which is designed for constant 

vibration. A battery not designed for 

this will fail much earlier. 

Convertible 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



3 of 11 2/25/2009 11:05 PM 

Top monitoring during operation 

using Hall sensors and angle Hall 

sensors 

Emergency operation 

- Manually unlock top storage cover: 

Remove center arm rest. 

Lift seat upholstery below ski bag. 

Press button on motor assembly to 

release motor from gear linkage. 

Use hand crank (stored on 

assembly cover) to turn linkage 

assembly through 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 storage cover is 

closed.



4 of 11 2/25/2009 11:05 PM 

- 

Working in trunk, remove trunk trim 

liner and soundproofing. If 

necessary, partially remove 

hydraulic unit to gain view of fill 

plug and fluid reference mark 

(circle). DO NOT detach hydraulic 

lines. 

To check: 

Level must be between MAX and 

MIN marks. 

Reference mark is circle in 

translucent reservoir. 

- 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.



5 of 11 2/25/2009 11:05 PM 

Convertible top fluid 

Hydraulic fluid 

Aral Vitamol 


Filler plug to 


Hydraulic unit to 

body 

10 + 1 Nm 

(89 + 9 in-lb) 

10 Nm (89 in-lb) 

Note: 

The convertible top hydraulic fluid is 

supplied in the spare parts kit. To restock 

fluid, check with an authorized BMW 

dealer parts department. 

Convertible top switch 

The convertible top switch assembly is in 

the center console below the IHKA 

control panel. Two push buttons, one for 

each direction of travel, provide ground 

input signals to the Convertible 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 in this group. 

The top ceases moving once the switch 

is released. The hydraulics hold the top 

in position and remain under pressure 

for approximately 20 minutes if the 

ignition key is left in the ON position.



6 of 11 2/25/2009 11:05 PM 

Convertible Top Module (CVM II) 

The CVM II is installed in the left rear of 

the car behind the side trim (next to the 

seat). It contains the processing, 

controlling and monitoring electronics for 

top operation. 

The CVM II communicates 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)



7 of 11 2/25/2009 11:05 PM 

Fault memory storage 

Convertible Top Module (CVM II) fault 

memory is stored in NVRAM. Up to 16 

fault codes can be stored in order of 

occurrence. A distinction is made 

between permanent and sporadic faults. 

If a fault occurs during raising or 

lowering the top, all top movement will 

cease and a fault code will be stored in 

memory. Then the emergency closing 

procedure must be followed. 

Depending on the location and type of 

the fault, it may be possible to raise or 

lower the top fully by pressing the switch 

in the opposite direction. 

If the top switch is held 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 have time-out limits 

preset in CVM II. If a time-out occurs 

before the end position is reached, 

movement will be switched off to prevent 

damage to any of the top components. 

Note: 

The temperature sensor in the 

convertible top system signals CVM II to



8 of 11 2/25/2009 11:05 PM 

cease operation if the hydraulic fluid 

temperature exceeds 95°C (203°F). 

However, any functions that have been 

started will be completed before the 

system is switched off. If the temperature 

exceeds 105°C (221°F) the system is 

immediately switched off. Close the top 

using the emergency closing procedure. 

Automatic operation can be resumed 

when the fluid temperature drops below 

95°C. 

Comfort operation 

Comfort closing of the top is possible by 

using the key in the driver door lock 

cylinder. Holding the key in the locking 

position the will raise the top and close 

the windows. 

Comfort opening 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. Flexible drive shafts are used to 

activate the lock assemblies and drive 

the tension link rods. 

Convertible top sensor operation 

Three Hall sensors detect the position of 

the top frame are located on the left lock 

drive assembly. All three sensors receive 

power and ground from CVM II.



9 of 11 2/25/2009 11:05 PM 

Windshield lock sensor provides low 

signal when top frame is unlocked from 

windshield. LED in convertible top switch 

will flash. 

Tension point position sensor provides 

high signal when top frame is raised 

past tension point. The angle sensor 

provides a linear voltage signal input to 

CVM II (approx. 0.5 - 3.5 volts) as 

tension bow moves from a vertical to a 

horizontal position. 

Main pillar Hall angle sensor is similar in 

function and output to tension point 

position sensor. It is mounted on left 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 this input as a 

switching signal: 

For activating tension bow solenoid 

during top lowering 

For activating main pillar solenoid 

during top raising. 

Top storage compartment cover 

lock motor



10 of 11 2/25/2009 11:05 PM 

The convertible top storage compartment 

cover lock motor is on driveshaft tunnel 

under rear seat. It consists of a motor 

with Hall sensor, gear assembly and two 

bowden cables connected to cover locks 

on two sides of cover. The Hall sensor 

detects locked/unlocked position of 

cover. 

During convertible top operation (raising 

or lowering) CVM II signals General 

Module (GM V) over K-bus to unlock 

storage compartment. The lock motor 

runs 180° to unlock cover latches. The 

motor always turns in same direction to 

lock or unlock. 

Once motor has turned 180°, the Hall 

sensor will signal GM V to switch off 

motor. At the same 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 Hall sensors 

send a signal to CVM II which signals 

GM V to relock storage cover. 

Top storage compartment floor 

The trunk of the E46 Convertible offers 

the variable convertible top storage 

compartment floor. This feature allows 

the luggage storage area to be enlarged 

by approximately 40 liters (1.5 cu. ft.)



11 of 11 2/25/2009 11:05 PM 

when soft top is raised or removed for 

hard top installation. 

The plastic variable compartment floor is 

hinged at four point so that it can 

articulate and be rotated up into top 

storage space. 

A lever on right side of variable floor 

actuates and locks floor into position. 

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. 




1 of 8 2/25/2009 11:05 PM 


Components 

541-2 

Mechanical top components 

The metal folding frame of the top is 

bolted to the sides of the car behind 

the door pillars (B-pillars). 

The three layer soft top consists of: 

Fabric outer layer 

Middle fleece liner 

Inner liner 


for mechanical component locations. 

Convertible top 

mechanical 

components 

1 - Folding top 

2 - Folding top 

frame 

3 - Base plate 

4 - Windshield 

frame lock 

microswitch 


frame lock drive 

motor 

6 - Windshield



2 of 8 2/25/2009 11:05 PM 

frame cover 

7 - Emergency 

mechanism 

cover 

8 - Emergency 

operation crank 

9 - Tension rope 

Insulation 

10 - Tension bow 

11 - Hall sensor 

12 - Gas pressurized 

spring 

13 - Main pillar Hall 

sensor 

14 - Console 


latch (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.



3 of 8 2/25/2009 11:05 PM 

Once hydraulic lines have been 

disconnected from hydraulic 

components, top must not be 

moved. Fluid will leak from 

separated coupling. 

Avoid scratching hydraulic piston 

rods. Even paint mist and welding 

spots are harmful. 

When working around hydraulic 

cylinders, cover with a protective 

cloth. 

Working in the trunk at the convertible 

top hydraulic unit, disconnect the supply 

and return lines and connect them to 

each other (short circuit). The system is 

thus closed and the couplings 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 hydraulic 

system repair are listed in Table b. 

Convertible top hydraulic system repair 

procedures. 


hydraulic components 

1 - Tension bow 

(rear of top) 

hydraulic



4 of 8 2/25/2009 11:05 PM 

cylinders: 

Operate on top 

frame linkage to 

raise and lower bow 

Located on two 

sides of tension 

bow, at sides of rear 

window 

Angle Hall sensor 

on left tension bow 

linkage detects bow 

position 

Hydraulic lines for 

right 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



5 of 8 2/25/2009 11:05 PM 

3 - Top storage 

compartment 

cover hydraulic 

cylinders: 

Open and close 

storage 

compartment cover 

Located in trunk 

Left cylinder 

equipped with Hall 

sensor to detect 

fully opened 

position of cover 

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:



6 of 8 2/25/2009 11:05 PM 

In left side of trunk 

behind trim 

Mounted on rubber 

bushings and 

covered by sound 

insulation 

Unit consists of: 

Hydraulic motor and 

pump, Storage 

cover solenoid 

valve, Drain 

solenoid valve, 

Hydraulic fluid 

reservoir, Hydraulic 

fluid temperature 

sensor 

Operates at 

pressures of up to 

200 bar (2900 

lb/in 2 ). 

Convertible top hydraulic electronics



7 of 8 2/25/2009 11:05 PM 

Table a. Definition of hydraulic system terms 

Term Action Notes 

Hydraulic system at zero 

pressure 

Untensioned state 

Turn ignition to 0 position. 

Wait 15 seconds. 

Hydraulic system has no or 

very low pressure. 

Mechanical (emergency) 

actuation 

Open or close top by hand. See Emergency operation 

Closed system All hydraulic lines connected. Even short-circuiting of lines 

is possible. 

Function test 

Short circuit 

Open and close top several 

times (min. 3 times). 

Check hydraulic unit fluid 

level and top up if necessary. 

Unfasten quick release 

coupling. 

Connect supply and return 

lines to each other. 

Refer to Operating 

Instructions. 

Hydraulic system cannot 

build up pressure. 

Convertible top can be 

moved. 

Table b. Convertible top hydraulic system repair procedures 

Operation 

Mechanical (manual) 

operation of top 

Procedures 

Ignition must be turned off 

Hydraulic lines must be disconnected. (Reconnect 

when finished) 

After repeated actuation, system fluid is pumped into 

supply tank of hydraulic unit. If hydraulic components 

are replaced, there will be too much fluid in system. 

Fluid level check 

Stow convertible top and close storage compartment



8 of 8 2/25/2009 11:05 PM 

Operation 

Fluid topping up or draining 

Procedures 

lid. 

Follow directions in Hydraulic fluid level, checking or 

filling, earlier in this group. 




1 of 2 2/25/2009 11:05 PM 

Rollover Protection 

System 

541-3 

Two spring-loaded rollbar cassettes are 

mounted behind the rear seat. The 

cassettes are bolted into the reinforced 

carrier behind the seat backs. When 

retracted they are covered by the rear 

headrest which incorporates a flap at 

the back, that will open when the 

rollbars deploy. 

A rollover sensor, mounted in the rear 

behind the left rear seat back on the 

rollbar cassette, contains the 

electronics for rollover detection and 

deployment final stage for triggering 

the rollover bar solenoids. Two 

capacitors are installed for rollbar 

deployment in case of a power failure 

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: 

Diagnosis of convertible top and 

Rollover Protection System are beyond 

scope of this book. Your authorized 

BMW dealer has proper diagnostic 

equipment and tools to carry out these 

tasks. 

After deployment, the detent pawl in a 

rollover protection cassette can be 

retracted by pulling the reset lever



2 of 2 2/25/2009 11:05 PM 

forward so that rollbar can be pushed 

down and locked into the solenoids. 

WARNING! 

Ensure that area above and adjacent 

to rollover bars remains clear and 

unobstructed at all times. 

CAUTION! 

It is not possible to close 

convertible top with rollover 

bars extended. 


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.

Electrical System - General 


1 of 2 2/25/2009 11:07 PM 

General 

600-1 

A brief description of the principal parts 

of the electrical system is presented 

here. Also covered here are basic 

electrical system troubleshooting tips. 

See also 

Starter. 

121 Battery, Alternator, 

Electrical test equipment 

Many electrical tests described in this 

manual call for measuring voltage, 

current, or resistance using a digital 

multimeter. Digital meters are preferred 

for precise measurements and for 

electronics work because they are 

generally more accurate than analog 

meters. An analog meter (swingneedle) 

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 self-diagnostic 

capabilities. The quickest way to 

diagnose many problems is to start out 

with a scan tool read out of Diagnostic 

Trouble Codes (DTCs). See OBD 

On Board Diagnostics at rear of 

manual. 

Special Tools



2 of 2 2/25/2009 11:07 PM 

Automotive digital multimeter Fluke 87 

LED tester with thin spade probes 

Baum 1115 (Source: Baum Tools 

Unlimited) 

Scan tools BMW DIS/MoDiC 

Aftermarket scan tool Baum CS2000 

(Source: Baum Tools Unlimited) 




1 of 10 2/25/2009 11:07 PM 

E46 Electrical System 

600-2 

E46 cars are electrically complex. Many 

vehicle systems and subsystems are 

interconnected or integrated. In 

addition, the requirements of second 

generation On-Board Diagnostics (OBD 

II) are such that there are now many 

more circuits and wires in the vehicle 

than ever before. The components 

must exchange large volumes of data 

with one another in order to perform 

their various functions. 

The use of dedicated data lines for 

each link in the system has reached 

the limits of its capabilities. On the one 

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 

K-bus 

Circuits covered 

Driver information 

systems (instrument 

cluster, Check Control, 

on-board computer) 

Central Body 

Electronics (ZKE V) 

General Module (GM 

V) 

Seat memory (SM) 

Sunroof (SHD) 

Rain sensor (AIC) 

Telephone and sound 

system 

Headlight module 

(LSZ)



2 of 10 2/25/2009 11:07 PM 

Table a. E46 busses 

Bus 

M-bus 

CAN-bus 

D-bus 

Circuits covered 

Coded anti-theft (EWS 

III) and anti-theft (DWA) 

Remote entry (FZV) 

Park distance control 

(PDC) 

Heating and air 

conditioning (IHKA) 

components 

Engine management 

system (DME) 

Transmission control 

(AGS) 

Antilock brakes (ABS) 

Traction control (ASC) 

Dynamic stability 

control (DSC) 

Data link connector 

(DLC) 

OBD II connector 

Multiple restraint 

system (MRS II) 

1999 E46 bus system, diagram



3 of 10 2/25/2009 11:07 PM 

Voltage and polarity 

The vehicle electrical system is a 12-volt 

direct current (DC) negative-ground 

system. A voltage regulator controls 

system voltage at approximately 12-volts. 

All circuits are grounded by direct or 

indirect connection to the negative (-) 

terminal of the battery. A number of 

ground connections throughout the car 

connect the wiring harness to chassis 

ground. These circuits are completed by 

the battery cable or 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 from the ignition switch or the 

battery through the main relay panel in 

back of the glove compartment or the



4 of 10 2/25/2009 11:07 PM 

main fuse box (arrow) above the glove 

compartment. Fuses are color coded to 

indicate current capacities. 

The relays and control modules are 

mounted in various places throughout 

the vehicle. See 610 Electrical 

Component Locations. 

Central Body Electronics (ZKE 

V) 

E46 vehicles are equipped with an 

integrated complex of electronic modules 

connected mostly via K-bus. This 

system, called ZKE V, is primarily 

controlled by the General 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 system (DWA). See 515 

Central Locking and Anti-theft. 

Electronic consumer sleep mode, 

described later in this section



5 of 10 2/25/2009 11:07 PM 

Other functions are not directly 

controlled by the GM V but 

interconnected: 

Rain sensor (AIC). See 611 

Wipers and Washers. 

Sunroof operation (SHD). See 

540 Sunroof. 

Seat memory (SM) and electrical 

operation. See 520 Seats. 

Outside rear-view mirror control and 

heating. See 510 Exterior Trim, 

Bumpers. 

Windshield washer jet heating. See 

611 Wipers and Washers. 

Redundant data storage 

The following vehicle information 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 dot 

(arrow) in the mileage display will be 

illuminated. Under certain circumstances



6 of 10 2/25/2009 11:07 PM 

a fault code (DTC) will be set. 

Resetting and resynchronizing of codes 

and data requires the use of BMW scan 

tools DIS or MoDiC. 


A number of features and functions can 

be customized to the driver(s) 

preference. The identity of the vehicle 

user is provided by a signal from the 

keyless entry system (FZV). 

Car Memory and Key Memory are 

actually two separate functions, 

although they are marketed as a 

combined feature. See 515 Central 

Locking and Anti-theft for further 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 sleep mode, the 

16 minute cycle starts again. Once the 

vehicle is in sleep mode, the GM V will 

"wake up" if it receives a change of 

signal from one of the following sensors:



7 of 10 2/25/2009 11:07 PM 

K-bus 

Door jamb sensors 

Trunk lid lock cylinder microswitch 

Interior trunk lid release 

push-button microswitch 

Central locking button 

Engine hood latch microswitch 

Trunk key position switch 

Interior light switch 

Internal motion sensor 

Tilt sensor 

Note: 

Driver's door lock sensors 

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!



8 of 10 2/25/2009 11:07 PM 

An airbag unit houses an 

explosive powerful charge. 

Making repairs without the proper 

knowledge and special test 

equipment may cause serious 

personal injury. See 721 Airbag 

System (SRS). 

The ignition system of the car 

operates at lethal voltages. 

People with pacemakers or weak 

hearts should not expose 

themselves to the ignition system 

electric currents. Extra caution 

must be taken when working on 

the ignition system or when 

servicing the engine while it is 

running or the key is on. See 

120 Ignition System 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 


from the battery before removing 

any electrical components. 




for fault codes using special BMW 

diagnostic equipment. 



disconnection cautions given at



9 of 10 2/25/2009 11:07 PM 


viii. 

Connect and disconnect ignition 

system wires, multiple 

connectors and ignition test 


ignition is off. 

Do not disconnect the battery 

with the engine running. 

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 

boosting cables attached. Wait at 

least one minute before boosting 

the battery 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 

relay terminals. 

Always switch a digital 

multimeter to the appropriate 

function and range before making 

test connections.



10 of 10 2/25/2009 11:07 PM 

Do not try to start the engine of a 

car which has been heated above 

176F/80C, (for example, in a paint 

drying booth). Allow it to cool to 

normal temperature. 

Disconnect the battery before 

doing any electric welding on the 

car. 

Do not wash the engine while it is 

running, or anytime the ignition is 

switched on. 

Choose test equipment carefully. 

Use a digital multimeter with at 

least 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 circuit.



1 of 5 2/25/2009 11:08 PM 

Wiring Diagrams 

600-3 

The wiring diagrams shown in 

Electrical Wiring Diagrams have been 

specially designed to enable quick and 

efficient diagnosis and troubleshooting 

of electrical malfunctions. 

Wiring codes and 

abbreviations 

A lot of information is included in each 

wiring diagram if you know how to read 

them. Wire colors in the diagrams are 

abbreviated. Combined color codes 

indicate a multi-colored wire. For 

example the code BLU/RED indicates a 

blue 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 


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 

connects to the proper terminals. 

Table b. Wire color codes 

German 

code 

English 

code 

Color 

SW BLK Black 

BL BLU Blue 

BR BRN Brown 

GN GRN Green



2 of 5 2/25/2009 11:08 PM 

Table b. Wire color codes 

German 

code 

English 

code 

Color 

GR GRY Grey 

ORG 

Orange 

RT RED Red 

VI VIO Violet 

WS WHT White 

GE YEL Yellow 

Most terminals are identified by 

numbers on components and harness 

connectors. Terminal numbers for 

major electrical connections are shown 

in the diagrams. Though many terminal 

numbers appear only once, several 

other numbers appear in numerous 

places throughout 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 


when ignition switch is 

in RUN or START 

position



3 of 5 2/25/2009 11:08 PM 

Table c. Terminal and circuit 

numbers 

Number 

Circuit description 

30 Battery positive (+) 

voltage. Supplies 

power whenever 

battery is connected. 

(Not dependent on 

ignition switch position, 

unfused) 

31 Ground, battery 

negative (-) terminal 

50 Supplies power from 

battery to starter 

solenoid when ignition 

switch is in START 

position only 

+54 Originates at ignition 


when ignition 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 position 

A/C air conditioning LDP fuel tank leak diagnosis 

pump (DME MS 42.0)



4 of 5 2/25/2009 11:08 PM 


ADB, ADB-X automatic differential lock LEV low emission vehicle 

AGS adaptive transmission control LSZ light switch module 

AIC rain sensor MAF mass air flow sensor 

ASC traction control MBC maximum braking control 

AUC automatic air recirculation MFL multifunction steering wheel 

BST Battery safety terminal MRS multiple restraint system 

CAN 

Controller Area Network 

(BUS) 

NLEV 

national low emission 

vehicle program 

CBC cornering brake control NTC negative temperature 

coefficient resistor 

DBC dynamic brake control OBC on board computer 

DK throttle valve OBD II second generation on-board 

diagnostics 

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 

electronics box under engine 

hood 

RXD 

receive data line 

ECM engine control module SBE front passenger seat sensor 

EGS 

electronic transmission 

control 

SGS 

seat integrated belt system 

EPROM 

erasable/programmable 

read-only memory 

SHD 

sunroof module 

EWS electronic immobilizer SII service interval indicator 

FZV keyless entry SM seat memory module



5 of 5 2/25/2009 11:08 PM 


GM general module (see ZKE) SRS supplemental restraint 

system-airbag 

HPS head protection system TCM transmission control module 

IHKA 

automatic heating and air 

conditioning system 

TDC 

top dead center 

IHKR 

manual heating and air 

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 




1 of 8 2/25/2009 11:08 PM 

Electrical 


600-4 

Four things are required for current to 

flow in any electrical circuit: a voltage 

source, wires or connections to 

transport the voltage, a load or device 

that uses the electricity, and a 

connection to ground. 

Most problems can be found using a 

digital multimeter (volt/ohm/amp meter) 

to check the following: 

Voltage supply 

Breaks in the wiring (infinite 

resistance/no continuity) 

A path to ground that completes 

the circuit. 

Electric current is logical in its flow, 

always moving from the voltage source 

toward ground. Electrical faults 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 circuit works by following the 

circuit from ground back to the power 

source. 

When making test connections at 

connectors and components, use care 

to avoid spreading or damaging the 

connectors or terminals. Some tests 

may require jumper wires to bypass



2 of 8 2/25/2009 11:08 PM 

components or connections in the 

wiring harness. When connecting 

jumper wires, use blade connectors at 

the wire ends that match the size of the 

terminal being tested. The small 

internal contacts are easily spread 

apart, and this can cause intermittent 

or faulty connections that can lead to 

more problems. 

Voltage and voltage drops 

Wires, connectors, and switches that 

carry current are designed with very 

low resistance so that current flows 

with a minimum loss of voltage. A 

voltage drop is caused by higher than 

normal resistance in a circuit. This 

additional resistance actually 

decreases or stops the flow of current. 

A voltage drop can be noticed by 

problems ranging from 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 faulty switch. Normally, there should 

be less than 1 volt drop across most 

wires or closed switches. A voltage 

drop across a connector or short cable 

should not exceed 0.5 volts. 

Note: 

A voltage drop test is generally 

more accurate than a simple 

resistance check because the 

resistances involved are often too 

small to measure with most 

ohmmeters. For example, a



3 of 8 2/25/2009 11:08 PM 

resistance as small as 0.02 ohms 

would results in a 3 volt drop in a 

typical 150 amp starter circuit. 

(150 amps x 0.02 ohms =3 volts). 

Keep in mind that voltage with the 

key on and voltage with the engine 

running are not the same. With the 

ignition on and the engine off 

(battery voltage), voltage should 

be approximately 12.6 volts. With 

the engine running (charging 

voltage), voltage should be 

approximately 14.0 volts. Measure 

voltage at the battery with the 

ignition 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. 

Note: 

If a reading is obtained, current is 

flowing through circuit. 

The voltage reading should not deviate 

more than 1 volt from voltage at the 

battery. If voltage drop is more than 

this, check for a corroded connector or 

loose ground wire.



4 of 8 2/25/2009 11:08 PM 

Voltage drop, testing 

Voltage drop can only be checked 

when there is a load on the circuit, 

such as when operating the starter 

motor or turning on the headlights. A 

digital multimeter should be used to 

ensure accurate readings. 

Connect digital multimeter positive lead 

to positive (+) battery terminal or a 

positive power supply close to battery 

source. 

- Connect digital multimeter 

negative lead to other end of cable 

or switch being tested. 

- With power on and circuit working, 

meter shows voltage drop 

(difference between two points). 

This value should not exceed 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 usually indicates a 

problem. 

Continuity, checking 

Continuity tests can be used to check a 

circuit or switch. Because most 

automotive circuits are designed to 

have little or no resistance, a circuit or 

part of a circuit can be easily checked



5 of 8 2/25/2009 11:08 PM 

for faults using an ohmmeter. An open 

circuit or a circuit with high resistance 

will not allow current to flow. A circuit 

with little or no resistance allows 

current to flow easily. 

When checking continuity, the ignition 

should be off. On circuits that are 

powered at all times, the battery should 

be disconnected. Using the appropriate 

wiring diagram, a circuit can be easily 

tested for faulty connections, wires, 

switches, relays and engine sensors by 

checking for continuity. 

For example, to test brake 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 away and the metal wire is 

exposed. When the wire rubs against a 

metal part of the car or other ground 

source, the circuit is shorted to ground. 

If the exposed wire is live (positive



6 of 8 2/25/2009 11:08 PM 

battery voltage), a fuse will blow and 

the circuit may possibly be damaged. 

Shorts to ground can be located with a 

digital multimeter. Short circuits are 

often difficult to locate and may vary in 

nature. Short circuits can be found 

using a logical approach based on 

current path. 

CAUTION! 

On circuits protected with high 

rating fuses (25 amp and 

greater), wires or circuit 

components may be damaged 

before the fuse blows. Always 

check for damage before 

replacing fuses of this rating. 

When 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) and the 

other test lead to ground. 

- If there is continuity to ground, 

there is a short to ground. 

- If there is no continuity, work from 

wire harness nearest to fuse/relay



7 of 8 2/25/2009 11:08 PM 

panel and move or wiggle wires 

while observing meter. Continue to 

move down harness until meter 

displays a reading. This is the 

location of short to ground. 

- Visually inspect wire harness at 

this point for any faults. If no faults 

are visible, carefully slice open 

harness cover or wire insulation 

for further inspection. Repair any 

faults found. 

Short circuit, testing with 

voltmeter 

- Remove blown fuse from circuit. 

Disconnect harness connector 

from circuit load or consumer. 

Note: 

Most 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 wires 

while observing meter. Continue to 

move down harness until meter 

displays a reading. This is the 

location of short to ground. 

- Visually inspect wire harness at



8 of 8 2/25/2009 11:08 PM 


this point for any faults. If no faults 

are visible, carefully slice open 

harness cover or wire insulation 

for further inspection. Repair any 

faults found.

Electrical Component Locations 


1 of 3 2/25/2009 11:08 PM 

General 

610-1 

This repair group covers fuse, relay 

and control module location 

information. Ground points and other 

component locations are also covered, 

primarily via photos or illustrations. 

For additional E46 electrical system 

information, see: 

600 Electrical System– 

General. 

Electrical Wiring Diagrams 

Fuses, relays and control 

modules 

The complex nature of E46 electrical 

systems requires a very large number 

of fuses and electrical components. 

Locating this array of equipment is 

always 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 has been 

identified by using the electrical wiring 

diagrams at the back of this manual. 

Electrical system safety 

precautions 

Please read the following warnings and



2 of 3 2/25/2009 11:08 PM 

cautions before doing any work on your 

electrical system. 

WARNING! 

The battery safety terminal, 

pyrotechnic seat belt tensioners, and 

airbags utilize explosive devices and 

must be handled with extreme care. 

Refer to the warnings and cautions 

in 121 Battery, Alternator, Starter; 

720 Seat Belts; and 721 Airbag 

System (SRS). 

CAUTION! 





viii. 

Relay and fuse positions are 

subject to change and may vary 

from car to car. If questions 

arise, an authorized BMW dealer 

is the best source for the most 

accurate and up-to-date 

information. 

A good way to verify a relay 

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 removing 

any electrical components. 

Connect and disconnect ignition 

system wires, multiple 

connectors, and ignition test 


ignition is switched off.



3 of 3 2/25/2009 11:08 PM 



electrical tests.



1 of 14 2/25/2009 11:09 PM 

Fuse Positions 

610-2 

There are three locations for fuses in 

E46 cars: 

Main harness fuse in trunk 

Fuse panel above glove 

compartment 

Note: 

E-box in engine compartment left 

side 

In BMW repair information, fuses 

are numbered F1 through F108. 

There are two fuses with the same 

designation: F5 in the main fuse 

panel is rated 5A and protects the 

horn circuit. 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 trunk, 

remove trim liner clips.



2 of 14 2/25/2009 11:09 PM 

Peel back liner to access F108 

(200 amp) fuse (arrow) in main 

power distribution circuit. 

Electronics box (E-box) fuse 

carrier 

Fig. 2 Engine electronics fuse pack in 

E-box: 

Working in left rear of engine 

compartment, remove E-box 

plastic cover. 

Push on hold-down lock clip (A) to 

release fuse pack carrier. 

Pull up on fuse pack lock clip (B) 

to 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) 


(2001 models) 

Ignition coils



3 of 14 2/25/2009 11:09 PM 

Table a. E-box fuse pack 


circuits 

(2001 models) 

2 30A DME control 

module (ECM) 

Evaporative 

emissions valve 

Fuel injectors 

Idle speed control 

valve 

Resonance valve, 

intake manifold 

Secondary air 


Suction jet pump 

valve, LDP system 

Vanos solenoids 

3 20A A/C compressor 

clutch relay 

Camshaft position 

sensors 

Crankshaft 



Fuel pump relay 

Leakage 

diagnosis pump 

(fuel tank) 

Mass air flow 

sensor 

Secondary air 


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)



4 of 14 2/25/2009 11:09 PM 

Main fuse panel 

Fig. 3 Fuse panel above glove 

compartment: 

Open glove compartment door. 

Working inside compartment, twist 

each plastic lock tab (arrows) at 

top of compartment 90°. 

Note: 

Pull down on fuse panel to swing 

it down. 

When the fuse box is up in locked 

position, the plastic tabs should 

point toward each other. When 

unlocked, they point to the back of 

the car. 

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 positions. 

Additional high amperage fuses are



5 of 14 2/25/2009 11:09 PM 

found on top of the glove compartment 

fuse panel beneath an access panel. 

Lower glove compartment fuse panel 

fully. 

Slide harness connector block off 

top of panel (curved arrow). 

Detach access panel by 

squeezing retaining clips 

(arrows). 

Fig. 4 High amperage fuses above 

main fuse panel: 

Fuses F101 through F107 are 

mounted in this location. 

Table b. High amperage fuse 

positions 


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 


(TCM) 

103 80A not used 

104 100A Preheater relay 

105 50A Ignition switch 

DLC



6 of 14 2/25/2009 11:09 PM 

Table b. High amperage fuse 

positions 

Fuse Rating Protected circuits 

106 50A Light switching 

center control 

module 

107 50A Light switching 

center 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 

2 

3 

not used 

4 

5 5A Horn (see also fuse 55) 

6 5A Make-up mirror light



7 of 14 2/25/2009 11:09 PM 


7 5A Navigation (see also fuse 41) 

On-board monitor (see also fuse 41) 

Radio (see also fuse 41) 

Telephone (see also fuse 39) 

8 not used 

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 


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 

17 

18 

19 

20 

not used 

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



8 of 14 2/25/2009 11:09 PM 


28 5A Heater-A/C (see also fuses 62, 63) 

Heater-A/C blower (see also fuse 37) 

29 5A Engine control (see also fuse 30) 

30 7.5A Engine control (see also fuse 29) 

OBD II system 

31 5A Outside mirror 

Tire pressure control (see also fuse 69) 

32 5A Light module (see also fuse 9) 

33 5A ABS/ASC (see also fuses 53, 56) 

ABS/DSC (see also fuses 40, 53, 56, 61) 


35 not used 

36 50A Secondary air pump 

37 50A Heater-A/C blower (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) 



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 outlet 

48 30A Window, front (see also fuse 49) 

49 5A Anti-theft (see also fuse 67) 

Central locking system (see also fuse 60) 

Interior light (see also fuse 52)



9 of 14 2/25/2009 11:09 PM 


50 25A Seat heating 

Power window, front (see also fuse 48) 

Windshield washer system (see also fuses 52, 

59) 

51 30A Headlight cleaning system 

52 30A Central locking system, trunk 

Glove box light 

Interior light (see also fuse 49) 

Passenger compartment/trunk lighting 


59) 



54 15A Fuel pump 




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 


Electrochromic rear view mirror (see also fuse 

24) 

Electronic immobilizer (EWS) (see also fuse 14) 

68 30A Heated rear window 

69 5A Tire pressure control (see also fuse 31)



10 of 14 2/25/2009 11:09 PM 


70 30A Passenger seat adjustment 

71 30A 

(10A Coupe) 

Hinged window (Coupe) 

Window, rear 

Table d. 2000-2001 fuse positions 


1 

2 

3 

not used 

4 


6 5A Make-up mirror light 

Power top (Convertible, see also fuses 12, 35, 

42, 46) 

7 5A Heated rear window (Convertible, see also fuse 

68) 

Navigation system (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 


11 5A 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) 

Manual top (Convertible, see also fuses 42, 46) 

Power top (Convertible, see also fuses 6, 35, 42,



11 of 14 2/25/2009 11:09 PM 


46) 

Seat heating (see also fuse 42) 

Roller sun blind (see also fuse 42) 

Tire pressure control (see also fuses 31, 42, 69) 

13 7.5A Roll-over protection system (Convertible) 

14 5A Electronic immobilizer (EWS) (see also fuse 67) 

Starter interlock 

15 5A Rain sensor 

Rear wiper (Sport Wagon, see also fuse 45) 

16 

17 

18 

19 

not used 

20 

21 

22 5A Engine control (M3, see also fuses 29, 30) 

Sequential transmission (M3, see also fuse 22) 

23 5A Heater (see also fuses 28, 62) 

24 5A Electrochromic rear view mirror (see also fuse 

67) 


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) 

Engine control (M3, see also fuses 22, 30) 

30 7.5A Engine control (see also fuses 27, 29) 

Engine control (M3, see also fuses 22, 29) 

OBD II system (see also fuse 43)



12 of 14 2/25/2009 11:09 PM 


31 5A Outside mirror (see also fuse 57) 


32 5A Light module (see also fuse 9) 

33 5A ABS/ASC (see also fuses 12, 42, 53, 56) 



40, 42, 53) 


35 50A Power top (Convertible, see also fuses 6, 12, 42, 

46) 


40, 42, 53) 

36 50A Secondary air pump 

37 50A Engine cooling fan 

38 10A 

(15A) 

Front foglights 

39 5A Telephone (see also fuse 7) 

40 5A ABS/DSC (see also fuses 12, 33, 42, 53, 56, 61) 


35, 42, 53) 

Shift gate illumination 

41 30A Navigation system (see also fuse 7) 






35, 40, 53) 


Power top (Convertible, see also fuses 6, 12, 35, 

46) 

Seat heating (see also fuse 12) 

Roller sun blind (see also fuse 12) 



OBD II system (see also fuse 30) 

44 20A Trailer module 

45 20A Rear wiper (Sport Wagon, see also fuse 15)



13 of 14 2/25/2009 11:09 PM 


46 30A 

(20A convertible) 

47 15A 

(20A) 

Power top (Convertible, see also fuses 6, 12, 35, 

42) 


Sunroof 

Cigarette lighter / power outlet (Australia, see 

also fuse 26) 

48 30A Power window, front (see also fuse 49) 


Central locking system (see also fuses 52, 60, 

Sport Wagon, see fuse 58) 

Interior light (see also fuse 52) 


59) 

Window, front (see also fuse 48) 

50 40A Heater-A/C blower (see also fuse 28) 

51 30A Headlight washer system 

52 30A 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 


59) 




35, 40, 42) 

54 15A Fuel pump 




57 5A Outside mirror (see also fuse 31) 

58 7.5 Central locking (Sport Wagon, see also fuses 

49, 52, 60) 

59 30A Windshield washer system (see also fuses 49, 

52)



14 of 14 2/25/2009 11:09 PM 


60 25A Central locking (see also fuses 49, 52, Sport 

Wagon, see fuse 58) 

61 30A ABS/DSC (see also fuses 12, 33, 40, 42, 53, 56, 

61) 

62 7.5A Heater-A/C (see also fuses 28, 63) 

Heater (see also fuses 23, 28) 

63 7.5A Heater-A/C (see also fuses 28, 62) 

64 not used 

65 30A Driver seat adjustment 

66 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 




1 of 3 2/25/2009 11:09 PM 

Ground Locations 

610-3 

Grounds are widely distributed 

throughout the vehicle body. Several 

are found under the interior carpets. 

Lugs and connectors attached to 

ground are susceptible to damage and 

corrosion. Clean or renew them as 

necessary. 

Fig. 5 Left front engine compartment, 

behind left headlight 

1 - Ground X165 

Fig. 6 Right front engine compartment, 

behind right headlight 


Fig. 7 On bulkhead behind E-box 

1 - Ground X6454



2 of 3 2/25/2009 11:09 PM 

Fig. 8 Under left front carpet on door 

sill 

1 - Ground connector X173 

Fig. 9 On door sill, under driver seat 

carpet 


2 - Side impact airbag crash sensor 

Fig. 10 Under right front carpet on door 

sill 


Fig. 11 Behind right rear seat backrest 

1 - Ground X494



3 of 3 2/25/2009 11:09 PM 

Fig. 12 Right side trunk, behind trim 


Fig. 13 Left side trunk, behind trim 

1 - Ground X13016 




1 of 40 2/25/2009 11:09 PM 

Component Locations 

610-4 

On the following pages are photos and 

illustrations showing the location of 

major electrical components in E46 

vehicles. 

Note: 

Every component is not installed in 

every car. 

Due to changes in production, 

component locations may vary 

from what is illustrated. Consult 

your BMW dealer for the latest 

information. 

The automatic transmission range 

switch is also sometimes referred 

to as the gear-position switch. 

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 glove compartment (no 

headlight cleaning system)



2 of 40 2/25/2009 11:09 PM 

1 - A/C relay 

2 - Secondary air pump relay 

3 - Fuel pump relay 

4 - A/C relay 

5 - Foglight relay 

6 - Horn relay 

7 - General module (GM V) 

Fig. 15 Behind glove compartment 

(with headlight cleaning system) 

1 - Headlight 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.



3 of 40 2/25/2009 11:09 PM 

Fig. 16 E-box 

1 - Engine control module (ECM) 

2 - Automatic transmission control 

module (TCM) 

3 - DME main relay 

4 - Windshield washer double relay 

5 - E-box temperature sensor 

6 - B+ connector 

7 - Engine electronics fuse pack 

8 - 1999 - 2000 models: Unloader 

relay 2001 models: fuel injector 

relay 

9 - Back-up light relay (automatic 

transmission only) 

Component location table 

Table e. E46 component locations is 

a cross-referenced 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 model 

applications are given in the 

component location table and the 

illustrations.



4 of 40 2/25/2009 11:09 PM 

Table e. E46 component locations 

Component Year, model Location Refer to 

12 volt auxiliary 

power socket 

see Power socket, 12-volt 

3/2-way valve 1999 - 2000 Under car ahead of fuel filter, under 

protective cover 

A/C blower final 

stage (resistor pack) 

1999 - 2001 Right side of IHKA housing below 

glove compartment 

Fig. 40 

A/C blower relay 1999 - 2001 Main relay panel behind glove 

compartment 

Fig. 14, 

Fig. 15 

A/C blower 1999 - 2001 Behind engine compartment rear 

bulkhead 

A/C compressor 1999 - 2001 Right front lower engine 

compartment 

A/C compressor 

clutch relay 

1999 - 2001 Main relay panel behind glove 

compartment 

Fig. 14, 

Fig. 15 

A/C control module 1999 - 2001 Center of dashboard 

A/C evaporator 


1999 - 2001 Left side of IHKA housing below 


Fig. 39 

A/C pressure sensor 1999 - 2001 Behind right headlight on top of 

receiver/drier 

Fig. 32 


sensor connector, 

front (right/left) 



rear (right/left) 

1999 -2001 In wheel housing (right/left) Fig. 62 

1999 - 2001 Ahead of rear wheel housing 

(right/left) 


sensor, front 

(right/left) 


sensor, rear 

(right/left) 

ABS/ASC control 

module/hydraulic 

unit 

1999 - 2001 In front wheel bearing 

housing(right/left) 

1999 - 2001 In rear wheel bearing housing 

(right/left) 

1999 Left rear engine compartment, below 

brake master cylinder 

Fig. 60 

Fig. 61



5 of 40 2/25/2009 11:09 PM 


ABS/ASC/DSC 

warning lights 

1999 - 2001 In instrument cluster 

ABS/DSC charge 

pressure sensor 

ABS/DSC charge 

pressure sensor 

ABS/DSC control 


unit 

ABS/DSC control 


unit 

ABS/DSC lateral 

acceleration sensor 

ABS/DSC lateral 


1999 - 200 

rear wheel drive 

with DSC 

2001 


1999 - 2000; 

2001 

all wheel drive 

2001 


1999 - 2001 


200 

all wheel drive 

Base of master cylinder, left side Fig. 18 

In ABS/DSC hydraulic unit, right rear 


Right rear of engine compartment Fig. 19 

Left rear of engine compartment 

Behind driver kickpanel 

Combined with rotational rate (yaw) 

sensor under driver side carpet 

ABS/DSC precharge 

pump 

ABS/DSC rotational 

rate (yaw) sensor 

1999 - 2001 Left rear engine compartment, below 

brake master cylinder 

1999 - 2001 Under driver side carpet 

Fig. 18 

ABS/DSC steering 

angle sensor 

ABS/DSC switch 

Accelerator pedal 

sensor (PWG) 

Accelerator pedal 

sensor (PWG) 

AGS (adaptive 

transmission control) 

Air distribution 

motors 

Air flow sensor 

Air quality sensor 

(AUC) (for automatic 

1999 -2001 Base of upper steering column Fig. 35 

see ASC/DSC switch 

1999 - 2000 At throttle housing 

2001 Above accelerator pedal 

see Automatic transmission control 

module 

1999 - 2001 In IHKA housing under dashboard 

(see 640 Heating and Air 

Conditioning) 

see Mass air flow sensor 

2000 - 2001 Right side of radiator Fig. 17, 

Fig. 29



6 of 40 2/25/2009 11:09 PM 


recirculation system) 

Airbag connector, 

passenger side 

1999 - 2001 Right side dashboard support Fig. 41 

Airbag connector, 

steering wheel 

1999 - 2001 Under steering wheel airbag Fig. 34 

Airbag control 

module (MRS 

module) 

Airbag crash sensor, 

side-impact airbag 

(left/right) 

1999 - 2001 Under parking brake lever console, 

under carpet 

1999 - 2001 Front seat crossmember under 

carpet (left/right) 

Fig. 9 

Airbag warning light 1999 - 2001 In instrument cluster 

Airbag, driver side 1999 - 2001 Steering wheel center pad 

Airbag, head 

protection (HPS), 


(left/right) 

1999 - 2001 At bottom of windshield pillar (A 

pillar) behind dashboard (left/right) 

Fig. 42 

Airbag, passenger 

side 

Airbag, side-impact 

(left/right front/rear) 

Alarm control module 

(DWA) 

Alarm indicator LED 

(DWA) 

1999 - 2001 Right side dashboard Fig. 41 

1999 - 2001 Inside door (left/right, front/rear) 

1999 - 2001 Above main fuse box behind glove 

box 

1999 - 2001 Attached to rear view mirror 

Alarm siren (DWA) 1999 - 2001 Right side rear of engine 

compartment near wipers 

Alarm siren battery 

(DWA) 

All season traction 

(AST) 

Alternator 

(generator) 

1999 - 2001 Inside alarm siren 

see ABS/ASC entries 

1999 -2001 Left front of cylinder block 

Amplifier, radio 1999 - 2001 Left side trunk or cargo compartment 

behind trim panel 

Fig. 54, 

Fig. 57



7 of 40 2/25/2009 11:09 PM 


Antenna amplifier, 

diversity 

Convertible 

On convertible top storage cover 


diversity 

Sport Wagon 

Behind left side cargo area storage 

cover 

Fig. 57 


main 

Convertible 

Below mast antenna in trunk 


main 

Sedan, Coupe 

Behind left rear roof pillar (C-pillar) 

trim panel 

Fig. 44 


main 

Sport Wagon 

Below rear spoiler 

Antenna diversity 

switching module 

Convertible 

Below mast antenna in trunk 

Antenna, AM Sport Wagon In rear spoiler 

Antenna, diversity Convertible In convertible top storage cover 

Antenna, diversity Sport Wagon Left rear side window 

Antenna, FZV 

(keyless entry) 

Antenna, FZV 


Antenna, FZV 


Convertible 

Sedan, Coupe 

Sport Wagon 

Interior rear view mirror 

Rear window, lower antenna grid 

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 Convertible Wound around mast antenna 

Antenna, telephone 

Anti-slip (traction) 

Anti-slip (traction) 


Anti-theft 

ASC 

ASC+T 

Coupe, Sedan, 

Sport Wagon 

In roof above rear window 



see Alarm entries 


see ABS/ASC entries



8 of 40 2/25/2009 11:09 PM 


ASC/DSC switch 1999 - 2001 Bottom of center console, left of 

shifter 

AST 

Automatic climate 

control (IHKA) 

Automatic 

transmission control 

module (TCM) 


see A/C entries 

1999 - 2001 Left rear engine compartment in 

E-box 

Fig. 16 

Automatic 

transmission range 

switch (gear 

position/neutral 

safety switch) 

GM trans. 

Left side of transmission, inside 

transmission case 

Automatic 


switch (gear 

position/neutral 

safety switch) 

Automatic 


switch harness 

connector 

ZF trans. Left side of transmission Fig. 64 

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) 

Back-up light switch 

(manual 

transmission) 

Back-up light relay 

(automatic 

transmission) 

see Automatic transmission range 

switch 

1999 - 2000 Top left side of transmission housing 

1999 - 2001 Left rear engine compartment, in 

E-box 

Fig. 16 

Battery 1999 - 2001 Right side trunk or cargo 

compartment, under tray 

Battery safety 

terminal (BST) 

1999 - 2001 On positive battery terminal



9 of 40 2/25/2009 11:09 PM 


Blower 

Body electronics 


Brake fluid level 

sensor 

Brake fluid pressure 

sensor 

see A/C blower 

see General module (GM V) 

1999 - 2001 Top of brake fluid reservoir, left rear 


see ABS/DSC charge pressure 

sensor 

Fig. 17, 

Fig. 18 

Brake light switch 1999 -2001 At pedal cluster Fig. 37 

Brake pad sensor, 

left front 

Brake pad sensor, 

right rear 

Brake pad wear 


left front 

Brake pad wear 


right rear 

Camshaft actuator 

(VANOS) 


sensor, exhaust 


sensor, intake 

Carbon canister 

valve 

1999 - 2001 Left front brake pad 

1999 - 2001 Right rear brake pad 

1999 - 2001 In left front wheel housing Fig. 62 

1999 - 2001 Ahead of right rear wheel housing 

see VANOS 

1999 - 2001 Right front of cylinder head Fig. 29 

1999 - 2001 Left front of cylinder head Fig. 28 

1999 - 2000 Right side of spare tire well under 

floor pan 

CD changer 1999 - 2001 Left side of trunk 

Center brake light Sedan, Coupe Rear of headliner 

Central locking 

switch 

Changeover valve, 


Changeover valve, 

running losses 

see Hazard warning/central locking 

switch 

see Resonance valve, intake 

manifold 

see 3/2-way valve



10 of 40 2/25/2009 11:09 PM 


Charge pressure 

sensor 

Child protection 

window control 

Chime module, park 

distance control 

(PDC) 

see ABS/DSC charge pressure 

sensor 

see Window lock-out switch, rear 

1999 - 2001 In left footwell top trim 

Clock 1999 - 2001 In on-board computer display of 


Clutch pedal position 

switch 

Combination (stalk) 

switch 

1999 - 2001 On pedal cluster 

see Turn-signal/headlight dimmer 

switch (stalk switch) 

see also Wiper/washer switch (stalk 

switch) 


control module (CVM 

II) 

Convertible 

Left rear quarter panel behind trim 

panel 

Fig. 66 


hydraulic motor 

Convertible top main 

pillar Hall sensor 

Convertible In left side of trunk behind trim cover Fig. 66 

Convertible Behind rear seat in C pillar position Fig. 66 


solenoid valves 

Convertible 

Left and right rear main pillar, behind 

quarter panel windows 

Fig. 66 


storage compartment 

floor microswitch 

Convertible 

Right side storage compartment 

hinge in trunk 

Fig. 66 


storage cover Hall 

sensor 

Convertible Left rear of convertible top cover Fig. 66 


storage cover lock 

Hall sensor 

Convertible 

Center of cover, between rear seat 

backrests 

Fig. 66 


storage cover lock 

motor Hall sensor 

Convertible 


backrests 

Fig. 66 


storage cover motor 

Convertible 


backrests 

Fig. 66



11 of 40 2/25/2009 11:09 PM 



switch 

Convertible 

Bottom of center console, ahead of 

shifter 

Fig. 66 


tension bow Hall 

sensor 

Convertible top visor 

latch Hall sensor 

Convertible Top rear of convertible top Fig. 66 

Convertible Top of windshield Fig. 66 

Coolant level sensor 1999 - 2001 At bottom of coolant expansion tank 

Coolant temperature 

sensor, radiator 

outlet 

Coolant temperature 

sensor 

1999 - 2001 In lower radiator hose, right front of 

engine 

see Engine coolant temperature 

(ECT) sensor 

Fig. 31 

Coolant thermostat 1999 - 2001 Front of cylinder head 

Cooling fan 

Crankshaft position 

sensor 

see Engine cooling fan entries 

1999 - 2001 Left rear of engine block, under 

starter motor 

Fig. 22 

Cruise control cut-off 

switch 

Cruise controls 

(steering wheel) 

1999 -2001 At pedal cluster Fig. 37 

1999 - 2001 Steering wheel right side keypad 

Data link connector 

(20-pin DLC) 

Diagnosis module 

tank leakage (DMTL) 

Digital motor 

electronics control 

module 

Directional switch 

(stalk switch) 

DLC 

DME control module 

1999 - 2000 Right rear engine compartment (see 

also OBD II connector) 

2001 see Fuel tank leakage diagnosis 

pump (LDP or DMTL) 

see Engine control module (ECM) 

see Turn signal/headlight dimmer 


see Data link connector 

see also OBD II connector 

see Engine control module (ECM) 

Fig. 17 

DME main relay 1999 - 2001 Left rear engine compartment in 

E-box 

Fig. 16



12 of 40 2/25/2009 11:09 PM 


DMTL 2001 see Fuel tank leakage diagnosis 


Door lock 1999 - 2001 In door 

Door lock Hall sensor 1999 - 2001 In door lock mechanism 

Door lock 

microswitch 

Drive-away 

protection 

DSC 

DSC switch 

DWA 

Dynamic stability 

control 

1999 - 2001 In door lock mechanism 

see EWS 

see ABS/DSC entries 


see Alarm entries 

see ABS/DSC entries 

E-box 1999 - 2001 Left rear engine compartment, under 

plastic cover 

Fig. 16 

E-box cooling fan 1999 - 2001 Bottom rear of E-box 

E-box temperature 

sensor 

ECT sensor 

Electric coolant 

thermostat 

Electronic 

immobilizer 

Electronics box 


light switch 

1999 - 2001 Rear of E-box Fig. 16 

see Engine coolant temperature 

(ECT) sensor 

see Coolant thermostat 

see EWS entries 

see E-box entries 

see Engine hood contact switch 

Engine control 

module (ECM) 

Engine coolant 

temperature (ECT) 

sensor 

Engine cooling fan 

(electric) 


E-box 

1999 - 2001 Under rear of intake manifold at rear 

of cylinder block 

1999 - 2001 Models with automatic transmission: 

In front of radiator 

Fig. 16 

Fig. 21 

Fig. 17



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Engine cooling fan 

final stage (resistor) 

Models with standard transmission: 

In back of radiator 

1999 - 2001 In engine cooling fan housing 

Engine electronics 

fuse pack 

Engine hood contact 

switch 

Evaporative control 

valve 

Evaporator 


see Fuses, engine electronics 

1999 - 2001 Right rear engine compartment Fig. 19 

1999 - 2001 Left front of engine mounted on 


see A/C evaporator temperature 

sensor 

EWS control module 1999 - 2001 On passenger compartment 

bulkhead, above pedal cluster 

Fig. 38 

EWS ring antenna 1999 - 2001 Around ignition switch Fig. 36 

EWS transmitter 

module 




VANOS solenoid 

1999 - 2001 In ignition key 

1999 - 2001 Right front of engine, top Fig. 29 

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 

Fresh air distribution 

motor 

Fuel filler door lock 

motor 

see Air distribution motors 

1999 - 2001 In right side of trunk or cargo 

compartment, behind trim 

Fuel injector relay 2001 Left rear engine compartment in 

E-box 

Fig. 16 

Fuel injectors 

electrical harness 

1999 - 2001 Top of engine, under plastic cover



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Fuel level sensor, 

left 

Fuel level sensor, 

right 

1999 - 2001 Top of fuel tank, under left rear seat 

cushion 

1999 - 2001 Top of fuel tank, under right rear 

seat cushion, combined with fuel 

pump 

Fig. 52 

Fig. 52 

Fuel pump 1999 - 2001 Top of fuel tank, under right rear 

seat cushion, combined with right 

fuel level sensor 

Fuel pump relay 1999 - 2001 Main relay panel behind glove 

compartment 

Fig. 52 

Fig. 14, 

Fig. 15 

Fuel tank leakage 

diagnosis pump 

(LDP or DMTL) 

Fuel tank vent valve 

1999 - 2001 Under right rear of vehicle, right side 

of trunk, under protective cover 

see Evaporative control valve 

Fig. 65 

Fuse for main 

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 

FZV antenna 

Gas generator, 

airbag 


E-box 

see Antenna, FZV (keyless entry) 

see Airbag entries 

Fig. 2 

Gear position 

indicator light 

Gear position/neutral 

safety switch 

1999 - 2001 Under shifter bezel Fig. 47 


switch 

General module (GM 

V) 

Generator 

Glove compartment 

lock motor 


compartment 

see Alternator (generator) 

Above glove compartment lock 

Fig. 14 

GM V see General module (GM V)



15 of 40 2/25/2009 11:09 PM 


GPS receiver module 1999 - 2001 In trunk, mounted behind left rear 

well 

Ground jumper 

connection 

1999 - 2001 Right rear engine compartment Fig. 19 

Grounds: 

X1108 1999 - 2001 Under driver seat carpet on door sill Fig. 9 

X13016 1999 - 2001 Left side trunk Fig. 13, 

Fig. 54 

X165 1999 - 2001 Left front, engine compartment Fig. 5 

X166 1999 - 2001 Right front, engine compartment Fig. 6 

X173 1999 - 2001 Under left front carpet on door sill Fig. 8 

X217 1999 - 2001 Under right side dashboard 

X218 1999 - 2001 Under right side 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 

Head protection 

airbag (HPS) 

Headlight dimmer 

relay 

Headlight flasher 

Headlight vertical 

aim actuator 

(left/right) (models 

with xenon 

headlights) 

1999 - 2001 On center console, behind shifter 

see Airbag listings 

1999 - 2001 In light control center (LSZ) 

see Turn-signal/headlight dimmer 


1999 - 2001 In headlight assembly (left/right)



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aim load sensor, 

front 


aim load sensor, rear 

Headlight washer 

pump 

Heater blower 

Heater core 


Heater recirculation 

distribution motor 

Heater regulator air 

distribution motor 

1999 - 2001 Front subframe, right side Fig. 59 

1999 - 2001 Rear subframe, right side 

1999 - 2001 Front of washer tank, right front 


see A/C blower entries 

1999 - 2001 Behind center console below radio Fig. 45 



Heater valve 

assembly 

Heating-A/C 

High beam switch 

Hood switch 

1999 - 2001 Mounted on inner side of left strut 

tower 

see A/C entries 

see Turn signal/headlight dimmer 


see Engine hood security switch 

Fig. 27 

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 

Idle speed control 

valve 

see Mass air flow sensor 

1999 - 2001 Under intake manifold Fig. 23 

Ignition coils 1999 - 2001 Top of cylinder head, under plastic 

cover 

Fig. 25 

Ignition relay 

see Unloader relay 

Ignition switch 1999 - 2001 Right side steering column 

IHKA 

see A/C entries



17 of 40 2/25/2009 11:09 PM 


Individual control 

intake system valve 

Inflator assembly, 

airbag 

Instrument cluster 

control unit 

Intake air 

temperature (IAT) 

sensor 

Intake manifold 

resonance valve 


manifold 


1999 - 2001 In instrument cluster 

1999 - 2001 Center top of engine, between intake 

manifold and cylinder head 


manifold 

Fig. 25 

Interior protection 


(SDR) 

Interior protection 

control module (UIS) 

Convertible 

Sedan, Coupe, 

Sport Wagon 

On center tunnel below console 

In headliner 

Interior temperature 

intake fan 

Keyless entry 

antenna 

Kickdown switch, 

automatic 

transmission 

1999 - 2001 In A/C control module in center 

console 

see Antenna, FZV (keyless entry) 

see Accelerator pedal sensor (PWG) 

Knock sensors 1999 - 2001 Under intake manifold Fig. 24 

Lateral acceleration 

sensor 

LDP 

Leakage diagnosis 

pump (LDP) 

see ABS/DSC lateral acceleration 

sensor entries 

see Fuel tank leakage diagnosis 


see Fuel tank leakage diagnosis 


Light control module 1999 -2001 In light switch center (LSZ) 

Light switch 

assembly 

Light switch center 

(LSZ) 

Load-reduction relay 

1999 - 2001 In light switch center (LSZ) 

1999 - 2001 In dashboard, left of steering wheel 

see Unloader relay



18 of 40 2/25/2009 11:09 PM 


Lumbar support air 

compressor 

Lumbar support 


Lumbar support 

switch 

Main fuse panel 

Main relay panel 

Main harness fuse 

1999 - 2001 Under each seat equipped with 

support system 

1999 - 2001 Below seat base trim 

1999 - 2001 Four-way toggle switch at base of 

seat, near seat control switches 

see Fuse panel, main 

see Relay panel, main 

see Fuse for main harness F108 

(200 amp) 

Mass air flow sensor 1999 - 2001 Left side engine compartment Fig. 17 

Mixing actuators 

MRS module 


see Airbag control module 

Multi-function clock 1999 - 2001 In dash cluster below speedometer 

and tachometer 

Multiple restraint 

system (MRS) 

module 

see Airbag control module 

Navigation computer 1999 - 2001 Left side of trunk 

Neutral safety switch 

OBD II connector 

(16-pin DLC) 


switch 

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 temperature 

sensor 

1999 - 2001 Left front of engine at oil filter 

housing 

Fig. 26 

On-board computer 1999 - 2001 In instrument cluster 

On-board monitor 1999 - 2001 In center of dashboard 

Outside air 


Outside mirror 


1999 - 2001 Under left side of front bumper 

1999 - 2001 On left front door arm rest



19 of 40 2/25/2009 11:09 PM 


Oxygen sensor 

connector, 

post-catalyst 

Oxygen sensor 

connector, 

precatalyst 

Oxygen sensor, 

post-catalyst 

1999 - 2001 Top of engine, between intake 

manifold and cylinder head cover 

1999 - 2001 Top of engine, between exhaust 

manifold and cylinder head cover 

1999 - 2001 Bottom of exhaust manifold (access 

from below) 

Fig. 25 

Fig. 25 

Fig. 58 

Oxygen sensor, 

precatalyst 

1999 - 2001 Top of exhaust manifold Fig. 25 

Park angle/tilt sensor 1999 - 2001 In right side trunk behind trim 


(PDC) module 


sensors 


warning speaker 

1999 -2001 In right side trunk above battery 

1999 - 2001 Rear bumper trim strip Fig. 67 

1999 - 2001 Right rear speaker, rear parcel shelf 

Parking brake 

warning switch 

Pedal position 

sensor 

Pinch protection, 

window 

1999 -2001 Under center console, rear of 

parking brake handle 


see Window anti-trap strip 

Fig. 49 

Power socket, 12-volt Sport Wagon Cargo compartment behind left rear 

seat 

Fig. 57 

Power window 

motors 

Power window 

switches 

Pressure sensitive 

finger guard 

Radiator fan 

Radio antenna 

Radio controls 


see Window motors 

see Window switches 

see Window anti-trap strip 

see Engine cooling fan (electric) 

see Antenna entries 

1999 - 2001 On steering wheel left keypad



20 of 40 2/25/2009 11:09 PM 


Radio speaker: front 

tweeter (left/right) 

Radio/cassette/CD 

player 

1999 - 2001 Front door window frame (left/right) Fig. 33 

1999 - 2001 Center of dashboard 

Rain sensor 1999 - 2001 Top center of interior windshield 

surface, directly ahead of rear view 

mirror 

Rain sensor control 

module (AIC) 

Rear power window 

lock-out switch 

1999 - 2001 Attached to rain sensor at top of 

windshield 

see Window lock-out switch, rear 

Rear window 

defogger relay 

Convertible 

Right rear quarter panel behind trim 

panel 

Rear window 


Sedan, Coupe Right trunk wall, behind trim liner Fig. 53 

Rear window 


Sport 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, 


Reversing light 

switch 

Ride level sensor 

Ring antenna (EWS) 

1999 - 2001 Left of intake manifold Fig. 17 

see Back-up light entries 

see Headlight vertical aim sensor 

entries 

see EWS ring antenna 

Rollover cassette Convertible Rear seat headrest 

Rollover sensor Convertible Rear seat headrest 

Rotational rate (yaw) 

sensor 

see ABS/DSC rotational rate (yaw) 

sensor 

Seat backrest motor 1999 -2001 Bottom of seat backrest Fig. 51 

Seat control switch 

module 

1999 - 2001 At base of seat, on side of seat 

cushion 

Fig. 50



21 of 40 2/25/2009 11:09 PM 


Seat cushion tilt 

motor 

Seat forward-back 

motor 

1999 - 2001 Bottom of seat cushion Fig. 50 

1999 -2001 Bottom of seat cushion Fig. 50 

Seat headrest motor 1999 - 2001 Top of front seat backrest Fig. 51 

Seat heater 1999 - 2001 In front seat cushion and backrest 

Seat heater switch 1999 - 2001 Center console, below IHKA control 

panel 

Seat heater 


1999 - 2001 Front of front seat cushion 

Seat height motor 1999 - 2001 Back of seat cushion Fig. 50 

Seat load sensor 2000 - 2001 Under passenger seat cushion 

Seat memory module 

(SM) 

Seat belt lock Hall 

sensor 

Seat belt tensioner, 

pyrotechnic 

(left/right) 

1999 - 2001 Front of seat cushion Fig. 50 

1999 - 2001 In seat belt lock 

1999 - 2001 Base of seat belt lock (left/right) 

Secondary air 


Secondary air 

injection pump relay 

1999 - 2001 Right side engine compartment, 

above exhaust manifold 


compartment 

Fig. 17, 

Fig. 30 

Fig. 14, 

Fig. 15 

Secondary air 

injection pump valve 

1999 - 2001 Left front of engine Fig. 30 

Shift interlock cable 1999 - 2001 Under shifter bezel Fig. 46 

Shiftlock solenoid 1999 - 2001 Under shifter bezel 


Slip control 

Socket, 12 volt 


see ABS/ASC or ABS/DSC entries 

see Power socket, 12-volt 

Solar sensor 2000 - 2001 Right defroster outlet at base of 

windshield 

Sound system 

amplifier 

see Amplifier, radio



22 of 40 2/25/2009 11:09 PM 


Speed sensor 

Spiral spring 

see ABS wheel speed sensor entries 

see Volute spring 

Starter 1999 - 2001 Left rear of engine, under intake 

manifold 

Starter 

immobilization switch 

(manual 

transmission) 

Starter terminals 30, 

50 

Steering angle 

sensor 

Stepper motors 

On clutch pedal 

1999 - 2001 Left rear of engine, under intake 

manifold 

see ABS/DSC steering angle sensor 


Fig. 22 

Steptronic switch 2000 - 2001 Under shifter bezel 

Stop light switch 

see Brake light switch 

Sunroof motor 1999 - 2001 In headliner Fig. 43 

Sunroof/sunshade 

switch 

Supplemental 

restraint system 

(SRS) 

1999 - 2001 In center console ahead of shifter 


Tailgate lock (central 

locking) 

Tailgate emergency 

release actuator 

Tailgate unlock 

switch, exterior 

Tailgate unlock 

switch, interior 

Sport Wagon 

Sport Wagon 

Sport Wagon 

Sport Wagon 

In tailgate lock 

Rear deck sill, under trim panel, 

integrated with lock mechanism 

Above license plate 

Left kick panel 

Telephone connector 1999 - 2001 Under center console Fig. 48 

Telephone antenna 

Telephone controls 


see Antenna entries 

1999 - 2001 Steering wheel left keypad 

Telephone speaker 1999 - 2001 In left footwell top trim



23 of 40 2/25/2009 11:09 PM 


Telephone 

transceiver 

Thermostat, 

characteristic map 

cooling 

Sedan, Coupe 

In trunk below parcel shelf 

see Coolant thermostat 

Throttle housing 

(MDK/EDK) 


sensor 

Tilt sensor 

Tire pressure control 

system (RDC) 

control unit 

Toroidal coil 

Traction control 

1999 - 2001 Under intake manifold Fig. 23 


see Park angle/tilt sensor 

1999 - 2001 Behind glove compartment 

see EWS ring antenna 

see ABS/ASC or ABS/DSC entries 

Trailer module 1999 - 2001 Right side trunk 

Transmission control 

module 

Transmission range 

switch 

Transverse 


Trunk lid microswitch 

Trunk light switch 

Trunk lock (central 

locking) 

Sedan, Coupe, 

Convertible 

Sedan, Coupe, 

Convertible 

Sedan, Coupe, 

Convertible 

see Automatic transmission module 


switch 

see ABS/DSC lateral acceleration 

sensor entries 

In trunk lid lock 



Turn-signal/headlight 

dimmer switch (stalk 

switch) 

1999 - 2001 Left side of steering column 

Ultrasonic sensor 

(motion detector) 

(UIS) 

Coupe, Sedan, 

Sport Wagon 

In headliner 

Unloader relay 1999 - 2001 Left rear engine compartment in 

E-box, 

Fig. 16



24 of 40 2/25/2009 11:09 PM 


Valet position switch 1999 - 2001 On trunk lock cylinder 

VANOS solenoid, 

exhaust side 

VANOS solenoid, 

intake side 

Variable camshaft 

control 

1999 - 2001 Right front of cylinder head Fig. 29 

1999 - 2001 Left front of cylinder head Fig. 17 

see VANOS 

Volute spring 1999 - 2001 In center of steering wheel under 

driver airbag 

Washer fluid level 

sensor 

Wheel speed sensor 

1999 - 2001 Bottom of windshield washer tank 

see ABS wheel speed sensor entries 

Window anti-trap 

strip 

Window lock-out 

switch, rear 

Sedan, Sport 

Wagon 

Sedan, Sport 

Wagon 

Top of window frame in door 

Left side shifter bezel 

Window motors 1999 - 2001 Inside doors 

Window switches 1999 - 2001 On shifter bezel 

Windshield washer 

nozzle heaters 


pump 


relay 

1999 - 2001 In nozzles at rear of engine hood 

1999 - 2001 At rear of washer tank, right front 



E-box 

Fig. 16 

Wiper motor 1999 - 2001 Rear of engine compartment, behind 

bulkhead 

Fig. 20 

Wiper/washer switch 

(stalk) 

Yaw sensor 

ZKE V control 

module 

1999 - 2001 Right side steering column 

see ABS/DSC rotational rate (yaw) 

sensor 

see General Module (GM V)



25 of 40 2/25/2009 11:09 PM 

Engine compartment electrical 

components 

Fig. 17 Engine compartment (1999 323i) 

1 - Data link connector (DLC) (1999 - 

mid-2000 models) 

2 - Hood contact switch 

3 - B+ jumper connector 

4 - DSC control module/hydraulic unit 

5 - Secondary air pump 

6 - Interior microfilter housing 

7 - Resonance valve, intake manifold 

(changeover valve) 


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



26 of 40 2/25/2009 11:09 PM 

Fig. 19 Right rear corner of engine 

compartment (Teves DSC MK 20/60) 

1 - DSC hydraulic unit 

2 - Ground jumper connection 

3 - Hood contact switch 

4 - B+ jumper connection 

5 - DSC control module 

Fig. 20 Rear of engine compartment, 

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 


1 - Starter motor terminal 50 

2 - Starter motor terminal 30 

3 - Crankshaft position sensor



27 of 40 2/25/2009 11:09 PM 

4 - Bore hole for crankshaft locking tool 

Fig. 23 Under intake manifold 

1 - Idle speed control valve 

2 - Throttle housing (MDK/EDK) 

Fig. 24 Under intake manifold, at 

cylinder head 

1 - Knock sensor cylinder 1 - 3 

2 - Knock sensor harness connector 

3 - Knock sensor 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



28 of 40 2/25/2009 11:09 PM 

Fig. 27 Left side of engine compartment 

1 - Heater control valve 

Fig. 28 Cylinder head, left front 

1 - Intake camshaft 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)



29 of 40 2/25/2009 11:09 PM 

Fig. 30 Right front of engine 

1 - Secondary air injection pump 

2 - Secondary air injection pump valve 

Fig. 31 Right front of engine, low 

1 - Exhaust camshaft 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



30 of 40 2/25/2009 11:09 PM 

Fig. 34 Underneath horn pad at steering 

wheel 

1 - Airbag connector 

Fig. 35 Left side of steering column, 

below dashboard 

1 - Steering angle sensor 

Fig. 36 At ignition switch 

1 - EWS (electronic immobilizer) ring 

antenna



31 of 40 2/25/2009 11:09 PM 

Fig. 37 At pedal cluster 

1 - Cruise control cut-off switch (if 

equipped) 

2 - Brake light switch 

Fig. 38 Above pedal cluster 

1 - EWS control module 

Fig. 39 Left side IHKA housing, below 


1 - A/C evaporator temperature sensor 

Fig. 40 Right side IHKA housing, below 

glove compartment 

1 - Blower motor resistor pack



32 of 40 2/25/2009 11:09 PM 

Fig. 41 Right side dashboard 

1 - Passenger airbag 

2 - Passenger airbag connector 

Fig. 42 In windshield pillar (A-pillar) 

1 - Head protection airbag (HPS) 


Fig. 43 In headliner 

1 - Sunroof motor



33 of 40 2/25/2009 11:09 PM 

Fig. 44 In left rear roof pillar (C pillar) 

1 - Antenna amplifier 

Fig. 45 Behind center 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



34 of 40 2/25/2009 11:09 PM 

Fig. 48 Under center console 

1 - Telephone connector 

Fig. 49 Under center console, rear of 

parking brake 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



35 of 40 2/25/2009 11:09 PM 

5 - Seat height motor 

Fig. 51 Passenger seat (Convertible seat 

rear view) 

1 - Headrest motor 

2 - Comfort entry switch 

3 - Backrest motor 

Fig. 52 Below rear seat cushion, under 

access covers (top of fuel tank) 

1 - Right 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)



36 of 40 2/25/2009 11:09 PM 


Fig. 54 Left side trunk 

1 - Sound system amplifier 

2 - Ground X13016 

Fig. 55 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)



37 of 40 2/25/2009 11:09 PM 

1 - Antenna diversity amplifier 

2 - Sound system components 

3 - Power socket, 12 volt 

Electrical components 

underneath car 

Fig. 58 Underneath 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)



38 of 40 2/25/2009 11:09 PM 

1 - ABS wheel speed sensor, front 

Note: 

Left front wheel speed sensor is similar. 

Fig. 61 Right rear wheel bearing housing 

(1999 rear wheel drive model shown) 

ABS wheel speed sensor, rear 

Note: 

Left rear wheel speed sensor is 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)



39 of 40 2/25/2009 11:09 PM 

1 - Transmission control (AGS) 

connector 

Fig. 64 Left side of automatic 

transmission (ZF) 

1 - Transmission range switch/back-up 

light switch harness connector 

2 - Transmission range switch/back-up 

light 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



40 of 40 2/25/2009 11:09 PM 

5 - Convertible top module (CVM II) 

6 - Hydraulic motor 

7 - General module (GM V) 

8 - Top storage cover lock motor 

9 - Rear window defogger relays 

10 - Storage cover lock hall sensor 

11 - Roll-over cassettes and sensors 

12 - Storage compartment floor 

microswitch 

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 


Wipers and Washers 


1 of 11 2/25/2009 11:10 PM 

General 

611-1 

This repair group covers repair 

information for windshield, headlight 

(optional) and rear window (Sport 

Wagon) wiper and washer systems. 

Replacement of the wiper/washer stalk 

switch assembly is covered in 612 

Switches. Electrical wiring diagrams 

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 


Rear wiper drive aligning tool BMW 61 

1 330 

Wiper arm removal tool BMW 61 6 060



2 of 11 2/25/2009 11:10 PM 

Wiper and washer system 

The wiper and washer functions in E46 

vehicles are controlled by the ZKE V 

general module (GM V). Driver input to 

the system is via the multi-function 

stalk switch to the right of the steering 

column. 

Operational faults in the wiper/washer 

system will set Diagnostic Trouble 

Codes (DTCs) which can be accessed 

through BMW scan tools DIS or MoDiC. 

The components of the wiper/washer 

system are described 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 stopped.) 

In "interval" setting, wiping intervals are 

dependent on road speed. See 

Table a. Wiper interval (seconds).



3 of 11 2/25/2009 11:10 PM 

The windshield washer system is 

activated by pulling the stalk switch 

toward the driver. 

In Sport Wagon models with rear 

wiper/washer, pushing the stalk switch 

one detent away from the driver 

activates the interval rear wiper. 

Pushing the stalk further forward 

activates the rear window washer. 

Windshield wiper double relay is in 

E-box, left rear of engine compartment 

(arrow) under plastic cover. 

Rain sensor (optional). 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 tank. 

Windshield washer nozzle jets are 

located on the engine hood. With the 

ignition ON, the washer jets are



4 of 11 2/25/2009 11:10 PM 

automatically heated. The nozzle 

heaters, being of the positive 

temperature coefficient (PTC) design, 

increase resistance as they heat up 

and automatically cut back on current 

consumption. 

Headlight washer system (optional). 

Headlight washer nozzles are on top of 

the front bumper. The headlight 

washer pump uses fluid from the front 

washer tank. If headlights are on, they 

will be cleaned every fifth time the 

windshield washers are activated. 

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 

position 

Vehicle speed (mph) 

87 

1 26 19 17 15 15 13 

2 17 12 11 10 9 7 

3 10 6 6 5 4 3 

4 5 3 3 2 2 2



5 of 11 2/25/2009 11:10 PM 

Windshield wiper/washer system



6 of 11 2/25/2009 11:10 PM 

Rain sensor system (optional) 

The optional rain sensor system uses an 

infrared sensor, located at the top of the 

windshield in front of the rear view 

mirror, to detect the presence of water 

drops (or dirt) on the windshield. The 

signal from the sensor is communicated 

to the GM V, which activates the interval 

wipe cycle if the wiper stalk switch 

knurled knob (interval control) is in one 

of the four interval settings. 

The rain sensor functions by aiming a 

beam of infrared light through the 

windshield 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. 


An optical prism body attached to 

the top of the windshield 

Infrared emitter and detector diodes 

Optics heater (to prevent 

condensation from forming on 

diodes and prism)



7 of 11 2/25/2009 11:10 PM 

Control module (connected to GM V 

via K-bus) 

The rain sensor is on-line as soon as it 

receives KL R (ignition on) operating 

power. 

When the windshield wiper stalk 

switch is placed in the intermittent 

position, the GM V signals the rain 

sensor control module via the K-bus 

of the request for intermittent wiping 

and the position of the knurled 

wheel (sensitivity). 

As an acknowledgment, the rain 

sensor sends a command via the 

K-bus to activate the wiper motor. 

If more than 12 seconds pass 

before the GM V receives the 

acknowledgment, it concludes the 

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 knurled wheel position signal (1 - 4) 

via the K-bus informs the rain sensor of 

the selected level of sensitivity: 

Position 1 (least sensitive) delays 

the wiper activation signal. 

Position 4 (most sensitive) sends 

the wiper activation signal to the



8 of 11 2/25/2009 11:10 PM 

GM V sooner. 

Depending on the intensity of the rain 

the wipers can be operated continuously 

as if set in the normal wiper stalk switch 

position regardless of the knurled wheel 

setting. For this reason, the vehicle 

speed signal on the K-bus is not utilized 

on rain sensor equipped wiper systems. 

If the ignition switch is turned off with the 

wiper switch in the intermittent position, 

the rain sensor will only become active 

after the ignition is switched back on and 

one of the following occurs: 

The stalk switch is moved from the 

intermittent position and then back. 

The knurled 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 control module adapts for loss 

of light based on the intensity of the 

detected infrared light with a 

cleared windshield. Therefore, rain 

sensor function is not adversely 

affected due to windshield aging. 

Dirty windows: The rain sensor 

adaptation reacts less sensitively to



9 of 11 2/25/2009 11:10 PM 

a dirty windshield (dirt, road salt, 

wax residue) after a completed wipe 

cycle. A dirty windshield has a film 

on it that diminishes the ability of 

infrared to refract into water 

droplets that are present. This 

causes a delay in the rain sensor 

detection capabilities 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



10 of 11 2/25/2009 11:10 PM 

Rear window wiper/washer 

system (Sport Wagon) 

The rear wiper motor assembly in Sport 

Wagon models is mounted in the tailgate 

through a sound-insulating rubber 

bushing. 

The rear wiper/washer is controlled by 

the wiper/washer steering column stalk 

switch via the ZKE V system. The 

functions of the system are: 

Normal interval wipe 

Programmed interval wipe 

Continuous wipe 

Washing 

Normal operation is a timed interval of 

approx. 7 seconds. 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 programmed 

interval, up to approx. 30 seconds. 

Continuous wiping is activated any time 

the rear wiper is on and the transmission



11 of 11 2/25/2009 11:10 PM 

is in reverse. The signal is provided by 

the back-up light switch via the LSZ (light 

control module). 

Rear window washing is activated when 

the stalk switch is pushed forward past 

the first detent: 

Wash cycle 1. Washer pump ON for 

1.5 seconds. Wiper ON 1 second 

later. 


0.5 second after 0.8 second delay. 

Wiper continues. 

Note: 


0.5 second after 0.8 second delay. 

Wiper ON for two wipe-dry cycles. 

After washing, the rear wiper will remain 

in interval (normal) wiping mode until 

switched OFF. 

Rear wiper/washer system 




1 of 5 2/25/2009 11:11 PM 

Wiper Blades 

611-2 

Wiper blade cleaning problems 

Common cleaning problems with the 

wipers include streaking or sheeting, 

water drops after wiping, and blade 

chatter. 

CAUTION! 

Never turn on the wiper blades while 

the hood is open. Damage to the 

wiper system and hood may occur. 

To ensure safety during wiper 

system repair procedures, remove 

the windshield wiper fuse. See 

610 Electrical Component Locations. 

Streaking is usually caused when wiper 

blades are coated with road film or car 

wash wax. Clean the blades using 

soapy water. If cleaning does not cure 

the problem, the blades 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 out of 

alignment. Clean the blades and 

windshield as described above. Adjust 

the wiper arm so that there is even 

pressure along the blade, and so that 

the blade at rest is perpendicular to the 

windshield. If problems persist, the 

blades and wiper arms should be 

replaced.



2 of 5 2/25/2009 11:11 PM 

Note: 

BMW has available a special 

tool/gauge (BMW special tool 00 9 210) 

to align the angle of the wiper arm to 

the windshield glass. 

The wiper blades can be renewed in 

one of two ways: 

Complete blade replacement 

Rubber insert replacement 

Insert replacement is the most 

economical method, although over time 

the wiper blade itself will become worn. 

One rule of thumb would be to 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. 

Note: 


Install wiper blade to wiper arm 

until retaining tab can be heard to 

click into position. 

Some wiper blade versions may have 

two retaining tabs.



3 of 5 2/25/2009 11:11 PM 

Wiper blade inserts, replacing 

To replace wiper inserts: 

Remove wiper blade as described 

earlier. 

Unhook wiper blade insert from 

wiper arm guide. If necessary, 

guide slightly using needle nose 

pliers. 

Pull old insert from wiper arm 

guides, noting installation position. 

Remove metal support strips from 

old insert and install into slots in 

new insert, noting installation 

direction of cutouts in support 

strips. 

Note: 

Slide new insert through wiper 

blade guides. Lock insert in place 

at end guides. 

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 front 

wiper arms.



4 of 5 2/25/2009 11:11 PM 

It may be necessary to raise the 

engine hood to the service position 

to access the front wiper arm 

fasteners. See 410 Fenders, 

Engine Hood. 

CAUTION! 

Make sure wipers are parked 

(stalk switch in OFF position) 

and the ignition is also OFF. 

Use fender cover to protect 

windshield. 

- With engine hood in closed 

position, 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: 


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



5 of 5 2/25/2009 11:11 PM 


Front wiper arm to 

wiper shaft 

Rear wiper arm to 

wiper shaft 

30 Nm (22 ft-lb) 

9.5 Nm (7 ft-lb) 

- Check to make sure blades are 

positioned correctly Front wiper 

arms should be installed with tips 

to the right (passenger) side of the 

vehicle. Measure distance 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 

Left blade 

Rear wiper blade 

tip distance from 

rear window gasket 

24 mm (1 in.) 

44 mm (1.7 in.) 

12 mm (1/2 in.) 




1 of 6 2/25/2009 11:11 PM 

Wiper Assemblies 

611-3 

Windshield wiper assembly, 


The windshield wiper assembly 

(linkage and motor) is removed as a 

single unit. Once the assembly is 

removed, the wiper motor and other 

linkage parts can be repaired or 

replaced. 

1 - Wiper assembly mounting nut 

-tighten to 10 Nm (88 in-lb) 

2 - Washer 

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 OFF.



2 of 6 2/25/2009 11:11 PM 

Use fender cover to protect 

windshield. 

To avoid damaging the wiper 

arms and pivots, do not 

manually slide or force the wiper 

arms across the windshield. 

- Remove wiper arms as described 

earlier. 




microfilter. 


remove wires. 







mounting lip. 




Detach wiper assembly inside cowl: 

Remove assembly center 

mounting bolt (A). 


connector (B).



3 of 6 2/25/2009 11:11 PM 

Remove right side wiper rod (arrow) 

from transmission arm. 

- Release retaining clips and 

remove windshield base trim tray. 

Remove large nuts (arrow) at base of 

wiper arm shafts in cowl panel. 

Remove assembly. 

Note: 

Cover inside edges of cowl panel sheet 

metal with thick tape to prevent damage 

during wiper assembly removal. 



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.



4 of 6 2/25/2009 11:11 PM 

Next, install wiper arms but not 

blades. 

Close hood and fit wiper blades. 

Recheck wiper blade position as 

described earlier under Wiper 

arms, removing and installing. 

Check all electrical harness 

fittings and sealing grommets for 

correct reinstallation. Replace any 

wire ties cut off during removal. 


Center wiper 

assembly mount to 

cowl 

Wiper arm to wiper 

shaft 

Wiper shaft nut at 

cowl 

10 Nm (88 in-lb) 

30 Nm (22 ft-lb) 

10 Nm (88 in-lb) 

Rear window wiper motor, 

removing and installing (Sport 

Wagon) 

- Remove rear deck interior trim 

panel. 


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 ft-lb) 

4 - Mechanical coupling



5 of 6 2/25/2009 11:11 PM 

5 - Wiper motor assembly 

6 - Torx bolt M6 -tighten to 9.5 Nm (7 

ft-lb) 

7 - Damper ring 

8 - Mounting sleeve 

9 - Rear wiper motor assembly 

- To install: 

Remove rear window lock 

assembly from rear deck. 

Install wiper motor assembly and 

thread mounting bolts finger tight. 

Place BMW special tool 61 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. 


Wiper motor to 

rear deck (Torx) 

9.5 Nm (7 ft-lb) 

Rear window wiper shaft, 

removing and installing (Sport



6 of 6 2/25/2009 11:11 PM 

Wagon) 

- Remove rear wiper arm. 

- Lift rear window and remove wiper 

shaft housing plastic trim covers. 

- Remove housing mounting nuts. 

Remove housing. 

- Slacken rear window lift nut. 

Remove wiper shaft assembly 

mounting nut (arrow). Pull shaft and 

bearing out of housing. 


Adjust wiper arm position as 



Rear window 

button to rear 

window 

Wiper arm to wiper 

shaft 

Wiper shaft 

housing to rear 

window 

9.5 Nm (7 ft-lb) 

9.5 Nm (7 ft-lb) 

9.5 Nm (7 ft-lb) 




1 of 6 2/25/2009 11:11 PM 

Washer Systems 

611-4 

The windshield washer system 

includes the heated spray nozzles in 

the engine hood, the washer fluid 

pump, and the washer fluid reservoir in 

the front passenger side of the engine 

compartment. 

The headlight washer system (optional) 

consists of the front washer fluid tank 

(shared with the windshield washer 

system), a separate washer pump and 

spray nozzles in the front bumper. 

The rear window washer system (Sport 

Wagon 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, 


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 for nozzle heater. 

Installation is reverse of removal: 

Check and adjust nozzles before 

driving. Use diagram. 

1a - 265 mm (10.4 in)



2 of 6 2/25/2009 11:11 PM 

1b - 445 mm (17.5 in.) 

2a - 400 mm (15.7 in.) 

2b - 270 mm (10.6 in.) 

3a - 260 mm (10.2 in.) 

3b - 550 mm (21.7 in.) 

4a - 500 mm (19.6 in.) 

4b - 350 mm (13.8 in.) 

Note: 

The windshield spray nozzles can be 

aimed by using a sewing needle or a 

similar diameter stiff piece of wire. 

Headlight washer spray nozzle, 


Note: 

Headlight nozzles are marked L or R 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 

equivalent, adjust headlight washers



3 of 6 2/25/2009 11:11 PM 

so that spray jets strike approximately 

in center of each beam (arrows). 

Note: 

To turn on headlight washer jets, turn 

on ignition, lights and windshield 

washer system. To repeat spray 

procedure, turn off ignition, then back 

on again. Otherwise the headlight 

washers are disabled for 3 minutes. 

Front washer fluid reservoir 

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.



4 of 6 2/25/2009 11:11 PM 

To remove windshield washer pump 

(arrow) and headlight washer pump if 

equipped: 

Disconnect electrical connection at 

pump. 

Twist pump clockwise. 

Pull pump out of reservoir. 



Twist washer fluid level sensor 

clockwise to remove from base 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



5 of 6 2/25/2009 11:11 PM 

(arrow) clockwise to remove from 

base of reservoir. 


Rear window spray nozzle, 

removing and installing (Sport 

Wagon) 

- Use plastic prying tool to lever 

nozzle out of rubber strip at top of 

rear window. 

- Push new nozzle into rubber strip. 

Adjust nozzle spray pattern using 

alignment specifications. 

Rear window spray nozzle 

alignment specifications 

A 

B 

100 mm (3.9 in.) 

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.



6 of 6 2/25/2009 11:11 PM 

To remove tank: 

Detach filling and pressure hoses 

(A). 

Remove washer pump electrical 

harness connector (B). 

Loosen mounting nuts at bottom 

of tank (C) slightly. 

Remove top mounting nut (D) and 

remove reservoir. 

- 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. 


Switches 


1 of 2 2/25/2009 11:12 PM 

General 

612-1 

This section covers replacement of 

electrical switches at the steering 

wheel, steering column, dashboard, 

pedal cluster, center console and other 

locations. 

See also the following sections: 

119 Lubrication System for 

information on testing the oil 

pressure switch 

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 


2 of 2 2/25/2009 11:12 PM 

the repairs detailed in this section. 


Ignition cylinder removal tool BMW 32 3 

110 

Ring antenna removal tool BMW 61 3 

300 

CAUTION! 

When working on electrical 

switches or lights, always 


from the battery and insulate the 

cable end to prevent accidental 

reconnection. 





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.

Switches 


1 of 3 2/25/2009 11:12 PM 

612-2 

Steering Wheel Switches 

E46 vehicles are equipped with either 

the multi-function (MFL) steering wheel 

or the sports steering wheel. 

Incorporated into each steering wheel 

are an SRS airbag, horn contacts, 

selected cellular phone and radio 

controls and cruise control buttons. 

To replace the steering wheel switches, 

remove the airbag first. See 721 


WARNING! 

Improper handling of the airbag 

could cause serious injury. Store the 

airbag with the horn pad facing up. If 


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 

the fault memory has been cleared. 

Multi-function (MFL) steering 

wheel switches, accessing 

Remove airbag.

Switches 


2 of 3 2/25/2009 11:12 PM 

Detach electrical harness connectors 

1 - Cruise control/radio/telephone 


2 - Horn button electrical harness 

3 - Airbag electrical harness 

4 - Radio/telephone control switch set 

5 - Airbag 

6 - Cruise control switch set 

- Remove small screws on back 

side of airbag pad to release left 

or right 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 


3 - Airbag 

4 - Lower cover

Switches 


3 of 3 2/25/2009 11:12 PM 

5 - Horn button and airbag electrical 

harness 

- Pull switch carrier and trim down 

to detach from steering wheel. 


connector. 

- Separate bottom trim piece from 

switch carrier. 

Note: 


BMW does not provide the horn contact 

switch as a separate part.

Switches 


1 of 5 2/25/2009 11:12 PM 

Steering Column 

Switches 

612-3 

To remove any of the steering column 

switches, it is necessary to first remove 

the upper and lower column trim 

pieces. See 513 Interior Trim. 

CAUTION! 

To prevent marring interior trim, 

work with plastic prying tools or 

wrap the tips of screwdrivers and 

pliers with tape before prying out 

switches or electrical accessories. 

Ignition lock cylinder, 


To remove the EWS ring antenna prior 

to removing ignition lock cylinder, it is 


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. 


cylinder. 

Reinstallation is reverse of 

removal.

Switches 


2 of 5 2/25/2009 11:12 PM 

Steering column stalk switch 

assembly, removing and 

installing 

To replace either the 

directional/headlight dimmer stalk 

switch or the wiper/washer stalk switch, 

you must first remove the entire stalk 

switch assembly from the steering 

column. 

CAUTION! 

To prevent marring interior trim, 

work with plastic prying tools or 

wrap the tips of screwdrivers and 

pliers with tape before prying out 

switches or electrical accessories. 


battery and cover terminal with 

insulating material. 

CAUTION! 





- 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 BMW dealer. Making 

repairs without the proper 

knowledge and special test 

equipment may cause serious 

personal injury. See 721 Airbag 

System (SRS)

Switches 


3 of 5 2/25/2009 11:12 PM 

- 

With front wheels pointed straight 

ahead, remove steering wheel. 


Alignment. 

Note: 

To help with reassembly, mark steering 

wheel and spindle shaft 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 


4 of 5 2/25/2009 11:12 PM 

Detach airbag electrical harness 


Remove stalk switch housing retaining 

screws (arrows). Slide switch housing 

off steering column. 



Place turn signal indicator in 

center position before installing. 

Ensure that self cancelling cams 

on turn signal switch are not 

damaged during installation. 


Steering wheel to 

steering column 

spindle shaft 

63 Nm (46 ft-lb) 

Turn signal/headlight dimmer 

switch/ wiper switch removing 


- After removing steering column 

stalk switch assembly, as

Switches 


5 of 5 2/25/2009 11:12 PM 

described above, turn switch 

assembly face-down on work 

bench. 

Squeeze locking tabs (arrows) on 

sides of switch and slide switch out of 

assembly holder. 

- Push in new switch until it 

positively snaps into switch 

housing. 


Switches 


1 of 2 2/25/2009 11:13 PM 

Pedal Cluster Switches 

612-4 

To access either the brake pedal or the 

clutch pedal switch, remove the left 

footwell trim (above pedals). See 

513 Interior Trim. 

Brake light switch, replacing 

Working at pedal cluster: 


connector (arrow) from brake light 

switch. 

Note: 

Slide switch out of holder (toward 

rear of car). 

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 electrical harness

Switches 


2 of 2 2/25/2009 11:13 PM 

connector from switch. 

Squeeze together retaining clips 

at front of switch. Slide switch out 

of holder (toward rear of car). 


- Install new switch, then allow 

clutch pedal to spring back slowly, 

automatically adjusting switch 

position.

Switches 


1 of 5 2/25/2009 11:13 PM 

Other Interior Switches 

Many of the remaining electrical 

switches are housed at the bottom 

center of the dashboard, or in the 

center console. 

612-5 

The ASC or DCS switch is ahead of the 

shifter console at the bottom of the 

center dashboard. When equipped, 

seat heater switches are in the same 

location. 

The right front and right rear window 

switches are ganged into one unit on 

the right side of the shifter. The left 

front and left rear window switches are 

ganged with the child safety rear 

window lockout 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/console 

switches, replacing 

- Remove shift knob by pulling knob 

straight off the gearshift lever. 

Note: 

Removal of the shift knob will require 

about 90 lbs. of force. Do not twist knob 

or locating key can be damaged.

Switches 


2 of 5 2/25/2009 11:13 PM 

- 

Pry up on rear of shift boot/bezel 

to unclip, then remove boot from 

front retainers. 

Remove retaining screws (arrows) 

under transmission selector boot/trim. 

Power window switches, replacing 

- To remove left or right ganged 

window switches: 

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. 


connector (B) from switches. 


Switches 


3 of 5 2/25/2009 11:13 PM 

ASC/DSC/seat heater switches, 

replacing 

Either the ASC or DSC switch is 

located in the storage 

compartment/ash tray housing. Seat 

heater switches are also located here, 

if equipped. 

This procedure can be skipped in order 

to access center console switches. 

Remove storage compartment below 



Push upward in center of 

compartment, then 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. 


Central locking/hazard warning 

switches, replacing 

Working at rear of center console, 

press rolling cover of rear ashtray 

down. Depress cover fully to pop 

ashtray out of console. Remove

Switches 


4 of 5 2/25/2009 11:13 PM 

ashtray. 

- Remove retaining screws and 

storage tray housing. Disconnect 

electrical harness connector for 

storage tray courtesy light. 

- Remove screws at base of storage 

tray compartment in console. 

Unclip trim boot for parking brake lever 

and pull boot and handle forward off 

brake lever. 

- Slide center 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. 


Outside mirror switch, 

replacing 

Carefully pry outside mirror switch from 

door arm rest. 

- Disconnect harness connector

Switches 


5 of 5 2/25/2009 11:13 PM 

from switch. 



Instruments 


1 of 1 2/25/2009 11:13 PM 

General 

620-1 


installation of the instrument cluster. 

Instrument cluster self-test procedures 

are also included. 

Special tools 

Individual instrument cluster 

components are not available. Since 

instrument clusters are only available 

as complete units, BMW recommends 

no special tools. 

Würth 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.

Instruments 


1 of 9 2/25/2009 11:14 PM 

Instrument Cluster 

620-2 

The dashboard mounted instrument 

cluster is the control and information 

center of the E46 cars. It is connected 

to most of the systems and sensors in 

the car through the use of "bus" 

networks: 

K-bus connects to Central Body 

Electronics (ZKE V) functions, 

heating/A/C (IHKA), rain sensor 

system, exterior and interior lights, 

Multiple Restraint System (MRS 

III), and Driveway Protection (EWS 

III). 

CAN-bus connects 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 switch brings up on the cluster 

information of interest to the driver: 

Time 

Outside temperature 

Average fuel consumption

Instruments 


2 of 9 2/25/2009 11:14 PM 

Cruising range 

Average vehicle speed 

These functions are more fully 

explained in the Owner's Manual. 

The cluster also stores important 

vehicle memory functions such as total 

mileage and service interval data. 

Instrument cluster replacement must 

be followed by special procedures, 

using BMW scan tools DIS or MoDiC or 

equivalent, to synchronize vehicle 

memory and mileage with the new 

cluster unit. 

Note: 

Specific 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 directional 

3 - Tachometer 

4 - Alternator warning light 

5 - High beam warning 

6 - Oil warning light 

7 - Speedometer

Instruments 


3 of 9 2/25/2009 11:14 PM 

8 - Right directional 

9 - Temperature gauge 

10 - Warning lights (Check Engine, 

etc.) 

11 - Left reset button 

(odometer/service interval) 

12 - Check Control LCD 

13 - Odometer/On-Board Computer 

LCD 

14 - ASC/DSC warning light 

15 - Fuel economy gauge 

16 - Transmission range/ program LCD 

(includes transmission fault 

indicator) 

17 - Right reset button (clock) 

18 - Warning lights (brakes, 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 sealed unit 

and contains no serviceable 

components.

Instruments 


4 of 9 2/25/2009 11:14 PM 

E46 instrument cluster

Instruments 


5 of 9 2/25/2009 11:14 PM 

Instrument cluster, self-testing 

In addition to the storing diagnostic 

trouble codes (DTCs) and 

communicating through the diagnostic 

link, the instrument cluster is 

programmed with a series of test menus 

that can be accessed to check various 

functions and values. The 

odometer/On-Board Computer LCD 

block is used to display the test menus 

and results. 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 cluster left 

button. This signals cluster to

Instruments 


6 of 9 2/25/2009 11:14 PM 

Note: 

display submenus or continue on to 

next main test menu. 

Tests 1 and 2 are always unlocked. 

Tests 3 - 21 are only accessible 

after unlocking the test function. 

Test 19 is the unlock function for 

accessing the displays. 

If adjustment is necessary, enter 

into Test 20 using the cluster button. 

The correction factor number is 

changed by using the sub-menus for 

the 1s, 10s and 100s of the factor 

number. The digits will 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 version of cluster 

(hardware = 04, software = 6.00) 

3_1.6 415_06 Injection status, number of 

cylinders, engine factor 

1.7

Instruments 


7 of 9 2/25/2009 11:14 PM 


output 

Meaning 

Test 2: Cluster system test - activates gauge drivers, indicators and LEDs to confirm function 

(see Note) 

Test 3: SI data 3.0 1500 Liters 

3.1 0 Periodic inspection days (not 

applicable for US) 

Test 4: Fuel 

consumption data 

(current) 

Test 5: Fuel 

consumed/distance 

traveled 

Test 6: Fuel level 

sensor input in 

liters 

4.0 0267 26.7 liters/1000km 

4.1 0073 7.3 liters/hour 

5.0 0195 9.5 liters/100 km 

5.1 226 Distance left to go (226 km) 

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 Engine speed = 5,283 RPM 

7.3 058 Vehicle speed = 58 km/h 

Test 8: Input 

values in HEX code 

8.0 - 8.3 XXX HEX code, instrument cluster inputs

Instruments 


8 of 9 2/25/2009 11:14 PM 


output 

Meaning 

Test 9: Battery 

voltage 

Test 10: Country 

coding 

Test 11: Cluster 

code 

9.0 125 12.5 volts 

10.0 02 US (= 02) 

11.0 000003 Cluster code 

Test 12: Not used 

Test 13: Gong test 13.0 "Gong" Activate gong by pressing button 

(gong response is delayed). 

Test 14 Fault memory (not for diagnosis) 

Tests 15 - 18: Not used 

Test 19: 

Lock/unlock (see 

Note) 

L-ON 

19.0 L-OFF 

Display changes from L-ON to 

L-OFF every second. To unlock test 

functions, press cluster button 

immediately when it changes to 

L-OFF. Tests are automatically 

locked when exiting test functions. 

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 


20.2 12XX Press button when correct 100s 


Test 21: Software 

reset 

21.0 reset Reset software 

Instrument cluster, removing 


Remove instrument cluster retaining 

screws (arrows).

Instruments 


9 of 9 2/25/2009 11:14 PM 

Place a towel over steering column. 

Carefully tilt top of cluster out of dash 

panel. Unlock and disconnect harness 

connectors (arrows) from back of 

cluster. 

Note: 

Steering wheel does not need to be 

removed to remove instrument cluster. 

If it is necessary to replace cluster, 

detach trim by unlocking plastic clips 

(arrows) and pushing through slots. 



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.

Lights 


1 of 6 2/25/2009 11:14 PM 

General 

630-1 

This repair group covers interior and 

exterior lighting, including repairs to the 

light switch assembly. 

Special tools 

Some special tools may be necessary 

to install or adjust lights and 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 

Low beam 

(Halogen) 

H7 12V 55W 

H7 12 V 55 W

Lights 


2 of 6 2/25/2009 11:14 PM 

Table a. E46 bulb applications 

Location 

Low bean (Xenon) 

Type & rating 

D2-S 

Foglights 

Front 

Rear (Euro only) 

HB4 

12V 21W 

Turn signal and taillight 

Back-up 

Brake 

12V 21W 

12V 21W 

Brake/taillight 12V 21/4W 

Licence plate 

Side turn signal 

Third brake light 

Turn signal (front 

or rear) 

12V 5W 

W5W 

LED 

12V 21W 

Interior lights 

Footwell 


Passenger 

compartment, front 

or rear 

Reading, front or 

rear 

Trunk or tailgate 

Visor vanity 

Softlite 5W 

Softlite 5 W 

Softlite 5W 

6W 

Softlite 10W 

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 


3 of 6 2/25/2009 11:14 PM 

Headlight/taillight/running light 


Foglight switch 

Instrument dimmer control 

Light control module 

In addition to normal light control, the 

LSZ provides the following functions: 

Hot and cold monitoring of the 

exterior 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 


4 of 6 2/25/2009 11:14 PM 

Parking lights 

Side marker lights 

License plate lights 

Hot and cold monitoring of light bulbs 

allows the LSZ to detect defective 

bulbs. Hot monitoring checks the 

continuity of circuits while the lights are 

switched on. Cold monitoring consists 

of a brief pulse of current which is too 

short for the lights to illuminate.t If the 

module detects a defective bulb, a 

signal is sent to the instrument cluster 

and Check Control is illuminated with 

the appropriate warning. 

Home lighting 

This convenience feature provides 

lighting for the driver and passengers 

to leave 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 vehicle 

identification, encoded on the 

assembly line. In addition the total 

mileage and service interval data are 

also stored in the light control module. 

If either the instrument cluster or light 

control module has to be replaced, the 

data is taken from the remaining

Lights 


5 of 6 2/25/2009 11:14 PM 

module and transferred to the 

replacement unit. 

Emergency (fail safe) lighting 

The light control module provides 

emergency lighting in the event of an 

electronic module failure. Back up 

hardware allows the following lighting 

circuits to function: 

Low beam headlights 

Taillights 

Brake lights 

The headlights and taillights come on 

as soon as the ignition is switched ON. 

The brake light operates when the 

brake pedal is pressed. 

WARNING! 

When working on electrical systems, 

remove the fuse protecting the 

circuit under repair. See 610 


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 alcohol. 

Use only original equipment 

replacement bulbs. Non-original 

equipment bulbs may cause 

false failure readings on the

Lights 


6 of 6 2/25/2009 11:14 PM 

Check Control display. 


To avoid marring car paint or 

trim, work with plastic prying 

tools or wrap the tips of tools 

with tape.

Lights 


1 of 2 2/25/2009 11:14 PM 

Light Switch 

630-2 

Light switch assembly, 


Pry gently at left dashboard trim to 

remove. 

CAUTION! 



Remove light switch mounting screws 

(arrows). 

- Lift switch slightly and withdraw 

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 


2 of 2 2/25/2009 11:14 PM 

Swing latch backward (arrow). 

Pull electrical harness connector 

off switch assembly. 


Light control module, 

separating 

- Remove light switch assembly as 


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. 


Lights 


1 of 10 2/25/2009 11:15 PM 

Headlights 

630-3 

E46 cars are equipped with Halogen 

headlights as standard equipment. 

Halogen bulb replacement is 

performed from the back (engine) side 

of the headlight assembly. The front 

face of each headlight assembly is a 

removable plastic cover. 

Optional Xenon low-beam headlights 

illuminate the road ahead and to the 

sides in greater detail than 

conventional headlights. Sometimes 

referred to as High Intensity Discharge 

(HID) lights, Xenon lights use less 

energy and last longer than other 

headlight 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 lb) in 

driver seat. 

Use 6 mm Allen wrench, phillips head 

screwdriver, or hand to adjust 

headlight by turning adjusting knobs. 

A is primarily for lateral 

adjustment. 

B is primarily for vertical 

adjustment.

Lights 


2 of 10 2/25/2009 11:15 PM 

Note: 

When adjusting headlights with 

automatic adjuster system (LWR), wait 

at least 30 seconds for the LWR to 

cycle and adjust to its calculated 

position. 

Halogen headlight 

assembly 

1 - Mounting screw 

2 - Expanding nut 

3 - High beam 

cover 

4 - 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 


3 of 10 2/25/2009 11:15 PM 

1 - Automatic 

headlight 

adjustment 

(LWR) stepper 

motor 

2 - Electrical 

harness 

connector 

3 - Expanding nut 

4 - Mounting screw 

5 - Xenon bulb 


6 - Control module 

bracket 

7 - High beam 

cover 



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 


4 of 10 2/25/2009 11:15 PM 

18 - Cover lock strip 

Headlight bulb (Halogen), 

replacing 

Working in back of headlight assembly: 

Rotate headlight bulb retaining ring 

(arrows) counterclockwise. 

Pull bulb socket and bulb out of 

headlight assembly. 

Disconnect harness connector from 

socket. 

Gently wiggle bulb and pull straight 

out of socket. 

Replace bulb by pushing firmly into 

socket. Headlight bulb applications 

are listed below. 

Note: 


To remove left side high beam bulb, 

remove air filter housing cover. See 


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 


5 of 10 2/25/2009 11:15 PM 

replacing 

- Working in back of headlight 

assembly: 

Remove low beam (Xenon) cover. 

Twist Xenon ignition element 

counterclockwise and remove. 

Rotate headlight bulb retaining ring 

counterclockwise. Pull bulb out of 

headlight assembly. 


Headlight bulb applications are 

listed 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) 

Low bean (Xenon) 

High beam 

H7 12V 55W 

D2-S 

H7 12V 55W 

Headlight assembly, removing 


CAUTION! 

Following headlight assembly work, 

headlight beam aim must be adjusted 

using special equipment. 

- Disconnect harness connectors

Lights 


6 of 10 2/25/2009 11:15 PM 

from headlight assembly. 

- If necessary, remove headlight 

washer spray nozzles. See 611 


- Remove front turn signal assembly 


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 


7 of 10 2/25/2009 11:15 PM 

Close engine hood and check to 

make sure that gap between hood 

and headlight assembly (A) is 

correct. See specification below. 

Open hood and tighten down 

mounting screws. 

Remainder of assembly is reverse 

of removal. 

Headlight to hood gap 

Dimension 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 


- Remove front turn signal assembly 


group. 

Use plastic prying tool to detach and 

remove trim piece below headlight 

assembly.

Lights 


8 of 10 2/25/2009 11:15 PM 

Unclip sealing gasket (arrows) and 

remove. 

Release clips (arrows) retaining front 

lens. 

Pull lens forward to remove. 


Replace gasket between lens and 

body of light if necessary. 

Automatic headlight adjustment 

(LWR) 

Vehicles 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 


9 of 10 2/25/2009 11:15 PM 

angle changes. 

LWR monitors vehicle load via two hall 

effect sensors mounted to the front and 

rear suspension members. When an 

adjustment to the angle of the headlight 

beams is necessary, LWR 

simultaneously activates two stepper 

motors (one in each headlight 

assembly). The stepper motors drive a 

threaded rod that moves the lower edge 

of the headlight carrier plates. The 

pivoting movement adjusts the vertical 

position 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 components 

1 - Bolt M5 

2 - Right front ride 

height sensor 

mounting 

bracket 


M6 

4 - Front ride 

height sensor

Lights 


10 of 10 2/25/2009 11:15 PM 

5 - Front ride 

height sensor 

link 


M8 

7 - Bolt M5 

8 - Right rear ride 

height sensor 

mounting 

bracket 

9 - Bolt M6 

10 - Rear ride height 

sensor 


M6 

12 - Rear ride height 

sensor link 

13 - Extension 

14 - Bracket 

15 - Bolt M6 


Lights 


1 of 3 2/25/2009 11:15 PM 

Front Foglights 

630-4 

Foglight aim, adjusting 

Sedan or Sport Wagon: Use 4 mm 

Allen wrench to turn plastic adjuster 

(arrow) on 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 


2 of 3 2/25/2009 11:15 PM 

Foglight assembly, removing 


Sedan or Sport Wagon: 

Use plastic prying tool to lever out 

foglight assembly. 


connector. 

- Coupe or Convertible: 

Gently remove lower bumper trim. 

Working at foglight, detach grille 

and loosen mounting screws. 

Remove foglight assembly with 

grille attached. 


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 


3 of 3 2/25/2009 11:15 PM 

- 



Sedan/Sport Wagon: Foglight 

must be snapped firmly into 

bumper retainers. 

Coupe/Convertible: Keep 

ventilation grommets unkinked 

and firmly seated. 

Adjust foglight aim as described 

earlier. 

Foglight bulb, replacing 

- Remove foglight assembly as 


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. 


Check electrical connector for 

corrosion. Spray with contact 

cleaner, if necessary. 

Foglight application 

Front foglight bulb 

HB4 


Lights 


1 of 6 2/25/2009 11:15 PM 

Turn Signals, Taillights 

630-5 

Front turn signal assembly, 


The procedure below also includes 

turn signal bulb replacement. 

With engine hood open, use a 

screwdriver to press turn signal 

assembly retaining clip down to 

disengage from retaining tab on 

headlight 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. 


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 


2 of 6 2/25/2009 11:15 PM 

Before reinstalling, make sure rubber 

seal on wrap-around trim (underneath 

headlights) is firmly glued to trim. 

Reglue if necessary. 

Front turn signal 

Turn signal bulb 

12V 21W 

Side turn signal assembly 

The yellow marker lights on the sides 

of the front fenders are turn signals. 

Use plastic prying tool to gently lever 

assembly out of fender. 

Side turn signal 

Side light bulb 

12V 5W 

Taillight assembly, removing 


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 


3 of 6 2/25/2009 11:15 PM 

In E46 cars, taillight functions are split. 

The corner bulb carrier on each side 

contains: 

Taillight bulb 


Brake light bulb 

Trunk light bulb 

The bulb carrier on each side of the 

trunk or tailgate contains: 

Back-up light 

Rear foglight (European models 

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. 


connector. 

- Replace bulbs as necessary. 

CAUTION! 


hands. If necessary wipe bulb using

Lights 


4 of 6 2/25/2009 11:15 PM 


alcohol. 

To access trunk lid taillight bulbs: 

Partially remove trunk lid trim panel by 

removing plastic expansion rivets 

(arrows). Expansion rivets are released 

by prying upper portion out (inset), 

then pulling off trunk lid. 

- To access tailgate taillight bulbs: 

Remove tailgate inside trim panel. 

See 412 Trunk Lid, Tailgate. 

Unlatch bulb carrier retainer (arrow), 

then pull carrier off. 


connector. 

- Replace bulb(s) as necessary. 

CAUTION! 


hands. If necessary wipe bulb using 


alcohol. 

- Installation of either bulb carrier is 


Taillight applications 

Backup light bulb 

Brake light bulb 

12V 21W 

12V 21W 

Brake light/taillight 

bulb 12V 21/4W 

Rear foglight 

(European only) 


12V 21W 

12 V 21W 

Center brake light

Lights 


5 of 6 2/25/2009 11:15 PM 

The center brake light in all models is 

an LED unit. There are no replaceable 

bulbs. 

Sedan or Coupe: Working from rear 

seat in passenger compartment, gently 

pull off trim cover over third brake light 

(at top of rear glass). 


connector (A). 

Remove retaining clips (B) on 

either side and remove assembly. 

- Convertible: Remove inner trunk 

lid trim adjacent to license plate 

light assembly. 


connector 

Push center brake light out. 

Sport Wagon: Open rear window. 

Carefully detach rear window 

hinge cover. 

Remove rear spoiler mounting 

bolts (arrows). 


connector and rear washer hose 

from spoiler. 

Remove mounting screws and 

remove third brake light assembly 

from spoiler. 

When installing, be sure electrical 

harness and rear window washer

Lights 


6 of 6 2/25/2009 11:15 PM 

Note: 

hose are not damaged or kinked. 

Replace sealing plastic and grommets 

as necessary during reassembly. 

TIghtening torque 

Rear spoiler to 

rear glass 


License plate light, removing 


Using a flat tipped screw driver, pry 

gently on right side 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 



Lights 


1 of 5 2/25/2009 11:15 PM 

Interior Lights 

630-6 

The ZKE V general module (GM V) 

controls the interior lighting 

automatically using input from several 

monitors. The lighting can also be 

manually controlled. 

Each door lock actuator contains a hall 

effect sensor for the purpose of 

monitoring door open/closed status. 

The hall effect sensor is located 

directly behind the rotary latch plate 

encased in the lock actuator. The 

sensor is activated by the rotary latch 

plate position. 

Door closed: Rotary latch plate in 

latched position. Current flow 

through hall sensor 12 mA. 

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 light on (if off) 

or turn the light off (if on). 

If the switch is held for more than 3 

seconds, the GM V interprets the 

continuous ground signal as a request 

to turn the interior light circuit off 

(workshop mode). Workshop mode is 

stored in memory: Even if the GM V is 

removed from the power supply and 

reconnected, the lights do not come

Lights 


2 of 5 2/25/2009 11:15 PM 

back on unless the switch is pressed 

again. 

There are two reading/map lights 

located in the front interior light 

assembly. Each is mechanically 

controlled by 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 


3 of 5 2/25/2009 11:15 PM 

Interior light automatic controls 

The GM V provides 12 volts to the 

interior lighting circuit when the status of 

one of the following input signals 

changes: 

Door contact hall sensor active 

(door open) 

"Unlock" request received from 

driver door key lock hall sensor 

(ignition switch OFF) 

"Unlock" request from FZV keyless 

entry system received via K bus 

(ignition switch OFF) 

Vehicle exterior lights on for 

minimum of 2 minutes when ignition 

switch is OFF 

Active crash signal from MRS II 


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 remain on for 20 

seconds, then go to soft off. 

After interior search function is

Lights 


4 of 5 2/25/2009 11:15 PM 

activated, lights automatically turn 

off (soft off) after 8 seconds. 

After 16 minutes with door contact 

active (open door) and key off, 

lights are switched off (consumer 

cutoff function). 

The component activation function of 

DIS also has the ability to switch the 

lights. 

Interior light, footwell light, or 

cargo compartment light (Sport 

Wagon), replacing bulb 

Pry interior light fixture gently to remove. 


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. 


Bulb types and specifications for 

various interior lamps are listed 

below. 

Interior light applications 

Footwell light bulb 


light bulb 

Passenger 

compartment bulb, 

Softlite 5W 

Softlite 5W 

Softlite 5W

Lights 


5 of 5 2/25/2009 11:15 PM 

Interior light applications 

front or rear 

Reading bulb, front 

or rear 

Tailgate courtesy 

light bulb 

Visor vanity light 

bulb 

6W 

Softlite 10W 

Softlite 10W 

Trunk light bulb, replacing 

The trunk lights are integrated with the 

taillight assembly. 

Pry trunk light cover (arrow) gently to 

remove from taillight corner bulb carrier. 

Remove bulb and replace. 


Trunk light application 

Trunk light bulb 

Softlite 10W 


Heating and Air Conditioning 


1 of 22 2/25/2009 11:16 PM 

General 

640-1 

The repair information given under this 

heading applies to the heating and air 

conditioning system. Many of the 

procedures require that the A/C 

refrigerant charge be evacuated. See 

A/C system warnings and cautions 

later in this repair group. 

For information on the engine cooling 

system, see 170 Radiator and 

Cooling 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 


IHKA control panel removal tools BMW 

64 1 010 

A/C line plug kit BMW 64 5 100 

Note: 

A/C system recharging procedures are



2 of 22 2/25/2009 11:16 PM 

beyond the scope of this manual. 

Integrated heating and cooling 

system (IHKA) 

The E46 integrated automatic climate 

control system (IHKA) offers powerful 

cooling and heating, effective 

ventilation, and smooth operation in 

A/C mode. 

The E46 IHKA design includes the 

following: 

Use of R134a refrigerant only 

Single heater core for temperature 

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 

compressor



3 of 22 2/25/2009 11:16 PM 

Heater control personalization via 


E46 IHKA control



4 of 22 2/25/2009 11:16 PM 

Control panel and module 

Heating and air conditioning functions 

are programmed via the center console 

mounted control panel. The control 

panel has large, easy to use soft-touch 

controls, an LED display and a single 

temperature setting. 

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



5 of 22 2/25/2009 11:16 PM 

the front panel, includes an EEPROM 

chip for storage of Diagnostic Trouble 

Codes (DTCs). Inputs to the module 

include: 

Heater core temperature sensor 

A/C evaporator temperature sensor 

Other programmed functions from 

Car Memory (such as rear window 

defrost timing). 

The module can go into "sleep mode" to 

reduce power consumption when the 

ignition is switched OFF but still retain 

control panel settings and DTC 

information. If the 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 signal 

Ambient temperature signal 

Heater core temperature sensor 

signal 

Evaporator temperature signal



6 of 22 2/25/2009 11:16 PM 

Solar sensor input (if applicable) 

A rocker switch is used to select the 

desired cabin temperature, shown in the 

display matrix of the control panel. The 

range for temperature display is from 15° 

to 32°C (60° to 90°F). 

A "service station" feature is integrated 

into the E46 IHKA. This prevents the 

heater core from being flooded with hot 

coolant when refueling the vehicle. 

Blower control 

The blower rocker switch on the IHKA 

control 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 and the IHKA control panel 

continues to signal the heater water 

valve for heat. 

Regulated A/C compressor



7 of 22 2/25/2009 11:16 PM 

The operation of the A/C compressor is 

modulated, eliminating noticeable on/off 

cycling. In order to reduce fuel 

consumption and improve vehicle 

performance, the system default is with 

the compressor OFF. 

The A/C system uses a variable 

displacement compressor. The swash 

plate of the compressor is hinged so that 

is can vary piston travel based on output 

requirements of the system. 

A/C compressor function is controlled by 

the Engine Control Module (ECM) based 

on inputs from the IHKA control panel. 

Pressing the "snowflake" button is a 

request for A/C activation. As long as the 

evaporator temperature is above 2°C 

(36°F), the IHKA signals the ECM to 

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 pressure sensor 

provides a linear voltage input signal (0 - 

5 volts) to the IHKA control module. The 

module processes this signal and 

determines the load torque of the system 

(0 to 30 Nm with a variable displacement 

compressor). The higher the pressure in 

the system, the higher the voltage input 

signal to the IHKA module. The output



8 of 22 2/25/2009 11:16 PM 

signal to the ECM enables the ECM to 

modify the idle speed, timing and fuel 

injection amount based on the load that 

is imposed when the compressor is 

activated. 

Regulated engine cooling fan 

operation 

The engine cooling fan (arrow) operates 

at variable speeds (15 stages) based on 

cooling system load. The ECM activates 

the 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



9 of 22 2/25/2009 11:16 PM 

Maximum defrosting 

Pressing the defrost button turns on 

maximum defrost functions: 

Fresh air distribution valves are 

opened. 

Recirculation valves are closed. 

Windshield defrost vents are 

opened. 

All other air distribution vents are 

closed. 

Blower runs at maximum speed. 

Note: 

Rear window defroster is switched 

on. 

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



10 of 22 2/25/2009 11:16 PM 

2 - Defrost 

3 - Footwell 

4 - Recirculation 

5 - Fresh air 

Two different types of air distribution 

motors are used in the system. Fast 

acting motors (A) are used for the fresh 

air/recirculation flaps. (Right side 

shown.) 

- Slower acting motors (B) are used 

for the other operations. 

The center dashboard air outlet 

distribution 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.



11 of 22 2/25/2009 11:16 PM 

IHKA personalization 

Car Memory/Key Memory allows various 

functions and features of IHKA control to 

be tailored to the driver's wishes. The 

functions of IHKA that can be 

programmed by the driver include: 

Automatic activation of recirculation 

when the vehicle is started 

Blower speed adjustment (8-speed 

blower) 

Automatic opening of ventilation 

flaps with warm coolant 

Automatic 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 Anti-theft 

for an explanation of Car Memory/Key 

Memory.



12 of 22 2/25/2009 11:16 PM 

Automatic air recirculation 

As of model year 2000, automatic 

recirculation control is available. This 

system uses an air quality sensor (AUC) 

(arrow), located at the top right corner of 

the radiator, to detect high levels of air 

pollution and automatically switch the 

IHKA to recirculation of interior air. The 

recirculation button on the IHKA control 

panel can be toggled to allow automatic, 

manual or no recirculation. 

Once recirculation is turned on, it runs 

until it is turned off using the button. 

Once the ignition is turned off, the 

recirculation setting is saved 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 can be 

serviced by releasing three-quick release 

screws and removing a plastic cover. 


The heating system is part of the engine 

cooling system and is sealed. The only 

required service is periodic coolant 

flushing. See 170 Radiator and



13 of 22 2/25/2009 11:16 PM 


Servicing the A/C system requires the 

use of specialized equipment. Follow the 

equipment manufacturer's instructions. 

Rear window defogger 

The electric rear window defogger switch 

is integrated in the IHKA control panel. 

Pressing the rear window defogger 

button activates the rear window heating 

element for about 17 minutes, although 

this can be changed through Car 

Memory settings. Pressing the button 

again activates a cycle of 40 seconds 

on/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 located on the right side rear 

quarter panel behind the interior trim 

cover. 

Rear defogger operation is controlled by 

the IHKA control module.



14 of 22 2/25/2009 11:16 PM 

On hard top: 

Rear relay is energized. 

Power to hard top window is 

supplied through connector strip on 

hard top lock. 

On convertible top: 

Rear relay is energized. It powers 

front relay. 

If convertible top control module 

(CVM) signals that convertible top is 

locked to windshield frame, front 

relay powers rear window heater 

grid. 

If convertible top is lowered, a 

signal from CVM to front relay 

prevents heated top operation. 

Front relay also signals 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 the right 

defroster outlet and a short harness. 

The solar sensor receives power (5 volts) 

and ground from the IHKA control



15 of 22 2/25/2009 11:16 PM 

module. The module then calculates 

voltage drop across the photoresistor 

and determines the degree of solar 

heating based on the change in voltage. 

Voltage drop across the photoresistor 

increases as solar radiation increases. 

The IHKA control module processes the 

photoresistor input every 10 seconds 

and also checks it for plausibility based 

on mapped values. Values outside the 

limit indicate a malfunction and the solar 

sensor signal is ignored by the module. 

The IHKA module regulates interior 

climate settings using the following: 

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 the dashboard vents. 


Trouble with the heating and A/C system 

can be broken down into one or more of 

the following categories. 

Mechanical problems 

Control head malfunction 

Blower motor malfunction



16 of 22 2/25/2009 11:16 PM 

Noisy or seized compressor 

Noisy compressor clutch 

Malfunctioning belt 

Diagnosis of noisy engine compartment 

components is covered in 100 

Engine–General. A/C belt replacement is 

covered in 020 Maintenance. 

Cooling system problems 

Coolant problems 

Cooling fan problems 

Cooling system pressure testing and 

other diagnosis is covered in 170 


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 described later in this repair group.



17 of 22 2/25/2009 11:16 PM 

- 

Poke a spray wand through IHKA 

housing opening and spray 

commercially available cleaning 

agent on evaporator. Move wand 

back and forth to cover evaporator 

fins with liquid. 

- Allow 5 minutes for liquid to drip 

through evaporator drain. 

- Start car and run heater and A/C at 

maximum power for 5 minutes to 

dry out evaporator. 

Functional problems 

IHKA self diagnostics monitors the inputs 

and outputs of the system. If a fault is 

detected, a Diagnostic Trouble Code 

(DTC) is initially entered in RAM and 

then in the EEPROM when the ignition is 

switched off. A maximum of six DTCs 

can 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 settings 

should be performed prior to 

condemning a component as faulty. 

Substitute value operation 

If an input potentiometer, sensor or 

circuit fails or the signal from it is not 

plausible, the control module ignores the 

faulty signal and substitutes a



18 of 22 2/25/2009 11:16 PM 

programmed substitute value. See 

Table a. 

Table a. Substitute programmed 

values for IHKA component inputs 

Input 

Heat 

exchanger 

sensor 

Evaporator 

sensor 

Interior 

temperature 

sensor 

Exterior 

temperature 

Working 

range 

5° to 

124°C 

(41° to 

255°F) 

-10° to 

30°C (14° 

to 86°F) 

10° to 

40°C (50° 

to 104°F) 

K-bus 

Substitute 

value 

55°C 

(131°F) 

0°C (32°F) 

20°C (68°F) 

0°C (32°F) 

Coolant 

temperature 

K -bus 100°C 

(212°F) 

Specified 

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 at 25°C (77°F) 

Sensor Resistance Fault 

limit 

Heater core 9 k ± 2% Temp >



19 of 22 2/25/2009 11:16 PM 

Table b. Temperature sensor 

resistance values at 25°C (77°F) 

Sensor Resistance Fault 

limit 

125°C 

(257°F) 

Evaporator 9 k ± 2% Temp > 

120°C 

(248°F) 

Interior 10 k ± 2% Temp ≤ 

-46°C 

(-51°F) 

Table c lists A/C evaporator 

temperature-dependent resistance 

values. 

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



20 of 22 2/25/2009 11:16 PM 

Table d. Expansion valve pressure 

values 

Inlet pressure 

Outlet pressure 

Leak test with 

detector pressure 

14 bar (203 psi) 

1.8 bar (26 psi) 

1 - 2 bar 

(14.5 - 29 psi) 

A/C system warnings and 

cautions 

WARNING! 

Always wear hand and eye 

protection (gloves and goggles) 

when working around the A/C 

system. If refrigerant does come 

in contact with your skin or eyes: 

do not rub skin or eyes; 

immediately flush skin or eyes 

with cool 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. Poisonous gas is 

produced if it burns. Do not 

smoke near refrigerant gases for 

the same reason.



21 of 22 2/25/2009 11:16 PM 

The A/C system is filled with 

refrigerant gas which is under 

pressure. Pressurized refrigerant 

in the presence of oxygen may 

form a combustible mixture. 

Never introduce compressed air 

into any refrigerant container (full 

or empty). 

Electric welding near refrigerant 

hoses causes R-134a to 

decompose. Discharge system 

before welding. 

CAUTION! 

As of January 1, 1992, any person 

who services a motor vehicle air 

conditioner must, by law, be 

properly trained and certified, 

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 partially charged 

refrigerant system. Discharge 

system, evacuate and then 

recharge system. 

Do not use R-12 refrigerant, 

refrigerant oils or system



22 of 22 2/25/2009 11:16 PM 

components in R-134a system. 

Component damage and system 

contamination results. 

The mixture of refrigerant oil 

(PAG oil) and refrigerant R-134a 

attacks some metals and alloys 

(for example, copper) and breaks 

down certain hose materials. Use 

only hoses 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.



1 of 6 2/25/2009 11:17 PM 

Vents and Ducts 

640-2 

The IHKA air distribution system 

includes 5 air distribution motors 

(stepper motors), right and left footwell 

ducts, dashboard mounted defroster 

vents, and three sets of face level 

vents. 

Removal of at least one of the stepper 

motors (right footwell vent) involves 

removal of the passenger side airbag in 

the dashboard. 

WARNING! 

Airbags are inflated by an explosive 

device. Handled improperly or 

without adequate safeguards, the 

system can be very dangerous. 

Special precautions 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 trim panel or the left footwell 

(pedal cluster) trim panel as described 

below. 

Each motor can be removed after its 

electrical wiring harness connector has 

been removed.



2 of 6 2/25/2009 11:17 PM 

Squeeze plastic clip (arrow) to 

release motor. 

Tilt motor out of housing. 

- During installation, be sure to 

align air distribution flap and 

motor drive (A). 

Right side air distribution 

motors, accessing 

Four of the air distribution motors are 

under the right side of the dashboard: 

Right side fresh air/recirculation 

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. 


cable in trunk. 

CAUTION! 




manual on page viii.



3 of 6 2/25/2009 11:17 PM 

Right side fresh air/recirculation motor 

(arrow): 

For access, remove right footwell 

duct as described below. 

Unhook linkage, then remove 

motor. 

Defroster air distribution 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).



4 of 6 2/25/2009 11:17 PM 

Unhook linkage, then remove 

motor. 

Left side air distribution motor, 

accessing 

The fresh air distribution motor is under 

the left side of the dashboard. Remove 

the left footwell (pedal cluster) trim 

panel for access. 

CAUTION! 

Disassemble interior trim carefully to 

avoid damage. 

- Move steering column to maximum 

extended 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. 


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).



5 of 6 2/25/2009 11:17 PM 

Right footwell duct, removing 



described in 513 Interior Trim. 

- Remove IHKA control panel or 

GPS On-Board Monitor, as 

applicable (described below). 

Reach through control panel opening 

to detach air duct locking clip (arrow) 

from heater/evaporator housing. 

- Separate bottom of air duct from 

rear compartment duct. 

- Pull forward and down to remove. 


Dashboard vent, removing and 

installing 

Pry gently at dashboard trim to remove. 

CAUTION! 


with a plastic prying tool.



6 of 6 2/25/2009 11:17 PM 

Remove air vent mounting screws 

(arrows). 

- Lift vent slightly and withdraw from 

dashboard. 


Note: 

Removal of right or center 

dashboard 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.



1 of 4 2/25/2009 11:17 PM 

Heating and A/C 

Controls 

640-3 

The IHKA control module is integrated 

with the control panel in the center 

console below the radio. There is a 

built-in interior temperature sensor and 

fan. 

Models with GPS navigation are 

equipped with a center consolemounted 

On-Board Monitor. This 

combines sound system control 

functions, GPS monitoring and 

heating/A/C control functions. 

IHKA control panel, removing 

If BMW special 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 



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 shifter trim (window switch 

carrier) by pushing forward. Pull 

boot up around shifter, but do not



2 of 4 2/25/2009 11:17 PM 

remove. 

Remove screws (arrows) at rear of 

shifter trim (window switch carrier). Lift 

trim at back to unhook from front. 

Remove screws (arrows) at front and 

rear of ashtray carrier. Lift up ashtray 

carrier. 

- Reach up through opening and 

push IHKA control module and 

panel out. 


connectors. 

- Disassemble panel from module 

using an anti-static mat as a 

working surface. 

CAUTION! 

Do not touch circuit boards with bare 

fingers. 


On-Board Monitor, removing 

- Remove dashboard center vent as 

described earlier.



3 of 4 2/25/2009 11:17 PM 

- 

Pull off menu button on face of 

monitor. Reach through apertures 

with screwdriver to twist catches. 

This releases monitor from 

console. 

- Pull out monitor and detach 

electrical harness connectors in 

back. 

Heater core temperature 

sensor, removing and installing 

- Remove IHKA control panel or 

On-Board Monitor as described 

earlier. 

Reach through dashboard opening and 

detach heater core temperature sensor 

electrical harness connector (arrow). 

- Pull sensor out of IHKA housing. 


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



4 of 4 2/25/2009 11:17 PM 

pipes. 




1 of 4 2/25/2009 11:17 PM 

Blower Components 

640-4 

Blower motor, removing and 

installing 


microfilter. 


microfilter. 


remove wires. 


lower housing. 

Remove heater bulkhead cover: 


trim panel. Turn locking clips (A) 

and slide trim panel up. 



off bulkhead. 



(arrows). 


and lift off cover.



2 of 4 2/25/2009 11:17 PM 

Working inside right side of cowl, pull 

up on lever (arrow) and detach right air 

intake flap from blower housing. 

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).



3 of 4 2/25/2009 11:17 PM 

Pry off blower motor retaining strap. 

- Pull blower motor forward to 

remove. 

- Installation is reverse of removal: 

Align slot in blower motor with 

mounting tab in blower motor 

housing. 

Blower motor resistor pack, 

replacing 

Note: 

The blower motor resistor pack is also 

referred to as the final stage unit. 

- Remove right footwell air duct as 


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



4 of 4 2/25/2009 11:17 PM 

(arrows). 


connector. 

Press retaining clip away from 

switch to release switch. 


Make sure electrical harness is 

routed as before. 


Align guides and clips correctly.



1 of 9 2/25/2009 11:17 PM 

Heater Components 

640-5 

The heater valve is located in the left 

side of the engine compartment, 

attached to the left strut tower. The 

solenoid operated valve controls 

coolant flow through the heater core. 

The IHKA housing, located underneath 

the center of the dashboard, houses 

the heater core, the A/C evaporator, the 

heating and A/C blower and associated 

sensors and air distribution motors. 

CAUTION! 

Removal of either the heater core or 

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 


Heater valve, replacing 

- Drain engine coolant. See 170 


WARNING! 




Disconnect hoses (A) and electrical 

harness connector (B) at heater valve 

on left inner fender. 

- Carefully pull heater valve out of 

rubber mounting and pull up and 

out of engine compartment.



2 of 9 2/25/2009 11:17 PM 

- 


Inspect hoses and rubber mounts. 

Replace as necessary. 

Use new hose clamps. 


Coolant hose 

clamp 

32 - 48 mm 

(2 1/4 - 4 in.) 2.5 Nm (22 in-lb) 

Heater core, replacing 


microfilter. 


microfilter. 


remove wires. 



- Remove center console and 

dashboard. See 513 Interior 

Trim. 



WARNING! 



cooling system.



3 of 9 2/25/2009 11:17 PM 

Working at rear engine compartment 

bulkhead, loosen hose clamps 

(arrows) and detach heater hoses. 

- Blow out excess coolant from 

heater core using compressed air 

at coolant lines. 

- Release right air duct from IHKA 

housing. 

Working inside passenger 

compartment at IHKA 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



4 of 9 2/25/2009 11:17 PM 

(arrows) to detach pipes. 

Tilt heater core to remove from 

housing. 


Fit lugs in back of housing cover 

in heater housing slots. 

Use new sealing O-rings and coat 

with anti-seize agent. 

Fill and bleed cooling system. 


System. 

CAUTION! 

Replace coolant flange O-rings and 

tighten fasteners to specified 

torques. 


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



5 of 9 2/25/2009 11:17 PM 

motor vehicle air conditioner 

must, by law, be properly 

trained and certified, and use 

approved refrigerant recycling 

equipment. Technicians must 

complete an EPA-approved 

recycling course to be certified 


microfilter. 


microfilter. 


remove wires. 



Remove heater bulkhead cover: 






off bulkhead. 



WARNING! 




Working at rear engine compartment 

bulkhead, loosen hose clamps 

(arrows) and detach heater hoses.



6 of 9 2/25/2009 11:17 PM 

- 

Blow out excess coolant from 

heater core using compressed air 

at coolant lines. 

- Following manufacturer's 

instructions, connect approved 

refrigerant recovery/recycling 

/recharging unit to A/C system 

and discharge system. 

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. 

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 


- 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 and 

dashboard. See 513 Interior 

Trim.



7 of 9 2/25/2009 11:17 PM 

- 

Working inside passenger 

compartment below steering 

column, drill out steering column 

shear bolt. See 320 Steering 

and Wheel Alignment. 

Remove steering column 


Lower column. 

Under dash attachments 

1 - Bulkhead 

2 - Left A-pillar 

3 - Head protection airbag 


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.



8 of 9 2/25/2009 11:17 PM 

Working at right side of dash: 

Cut wire tie (A) at dashboard 

reinforcement support for relay 

panel. 

Turn fuse panel lock tabs (B) 90° 

and swing fuse panel down. 

Detach fuse panel pivots (C) from 

dashboard reinforcement. 

- Lift off dashboard reinforcement, 

making sure all electrical 

harnesses and hoses are free. 

- Remove IHKA housing, making 

sure all electrical harnesses and 

hoses are free. 


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. 


System. 

CAUTION!



9 of 9 2/25/2009 11:17 PM 

Replace heater and A/C flange 

O-rings and tighten fasteners to 

specified torques. 


Coolant hose clamp 

32 - 48 mm 

(2 1/4 - 4 in.) 


dashboard 

reinforcement 

2.5 Nm (22 

in-lb) 

22 Nm (16 ft-lb) 




1 of 11 2/25/2009 11:18 PM 

Air Conditioning 

Components 

640-6 

This section covers removal and 

installation of air conditioning 

refrigerant components. A/C testing 

and diagnosis, refrigerant discharge, 

evacuation and recharge are not 

covered here. 

The A/C condenser, compressor, 

receiver dryer, pressure sensor, 

refrigerant lines and expansion valve 

are either installed in the engine 

compartment or accessible from the 


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 pressure 

line 



3 - Receiver-dryer 

4 - Condenser



2 of 11 2/25/2009 11:18 PM 

5 - Compressor 

6 - Low pressure 

line 

7 - Access port 

8 - Double pipe 

9 - Expansion valve 

10 - Evaporator 

11 - Access port 

12 - Pressure sensor 

A/C compressor, replacing 


instructions, connect an approved 


/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. 


engine. 

- Mark A/C drive belt with direction of 

rotation. 

Release tension on A/C belt: 


tensioner pulley release lug (A) 

clockwise (against spring tension).



3 of 11 2/25/2009 11:18 PM 

Remove drive belt. 

- Detach and set aside front washer 

fluid reservoir. See 611 Wipers 

and Washers. 


connector from compressor. 

Remove A/C pressure hose and suction 

hose flange bolts (arrows) from 

compressor. Plug hoses immediately. 

- All-wheel-drive model: Unbolt and 

lower front stabilizer bar. See 

310 Front Suspension. 

Support compressor while removing 

compressor mounting bolts (arrows). 

Remove compressor. 


CAUTION! 

Always replace O-rings when 

reconnecting refrigerant lines. 

When installing a new 

compressor always replace 

receiver/drier unit. 


A/C line to A/C 

compressor 

20 Nm (15 ft-lb)



4 of 11 2/25/2009 11:18 PM 

- 

Recharge system following 

equipment manufacturer's 

instructions. See Table e for A/C 

system fluid specifications. 

Table e. A/C system fluid 


Fluid 

R-134a refrigerant 

Refrigerant oil 

Quantity 

740 ± 25 g 

(2 lb ± 1 oz.) 

PAG oil 

A/C condenser, replacing 

The A/C condenser is located in front of 

the radiator. 






WARNING! 







(A). 



(B). 


(C).



5 of 11 2/25/2009 11:18 PM 


screws (D). 

Detach air duct connections (E) and 

lift complete air filter housing out of 

engine compartment, pulling it 

forward away from mass air flow 

sensor. 

- Remove intake hood, cooling fan 

and shroud, and radiator, as 

described in 170 Radiator and 


Detach A/C lines from upper right corner 

of condenser. Plug lines immediately. 

- Remove 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. 


CAUTION! 



When installing a new condenser 

always replace receiver/drier unit. 

- Recharge system following 


instructions.



6 of 11 2/25/2009 11:18 PM 

A/C system fluid specifications 

Fluid 



Quantity 

740 ± 25 g 

(2 lb ± 1 oz.) 

PAG oil 

A/C receiver/drier, replacing 

The receiver/drier is mounted in the front 

right corner of the engine compartment 

behind and below the headlight 

assembly. 






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 assembly. 

See 630 Lights.



7 of 11 2/25/2009 11:18 PM 

Remove refrigerant pressure line 

mounting bolts (A) from receiver/drier. 

Plug lines immediately. 

Disconnect high pressure switch 

harness connector (B). 

- Working beneath right front of car, 

remove splash shield retaining 

screws. Remove splash shield. 

- Loosen receiver/drier mounting 

strap bolts and slide receiver/dryer 

down and out. 


CAUTION! 





instructions. 


Fluid 



Quantity 

740 ± 25 g 

(2 lb ± 1 oz.) 

PAG oil 

A/C expansion valve, removing 






discharge system.



8 of 11 2/25/2009 11:18 PM 

WARNING! 






microfilter. 

Remove upper cover and microfilter. 


remove wires. 



To remove heater bulkhead 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.



9 of 11 2/25/2009 11:18 PM 

Working inside right side of cowl, pull up 

on lever (arrow) and detach right air 


- 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 expansion valve mounting 

bolts and remove valve. 


CAUTION! 





instructions. 


Fluid 



Quantity 

740 ± 25 g 

(2 lb ± 1 oz.) 

PAG oil 

A/C evaporator, removing and 

installing 





discharge system.



10 of 11 2/25/2009 11:18 PM 



- Remove complete IHKA housing as 


- Remove heater core as described 

earlier. 

- Working on left side of IHKA 

housing: 

Detach evaporator temperature 

sensor electrical harness connector 

and pull out sensor. 

Detach wiring 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.



11 of 11 2/25/2009 11:18 PM 

Remove double coolant pipe. 

- Pry off evaporator housing retaining 

clips and remove cover. Pull 

evaporator and expansion valve out 

of bottom of housing. 

- If installing new evaporator, switch 

over expansion valve. Use new 

sealing O-rings. 

CAUTION! 

Do not bend cooling fins on 

evaporator. If necessary, straighten 

with fin comb. 


Make sure electrical harnesses are 

routed as before. 

Align guides and clips correctly. 

Recharge system following 


instructions. 


Fluid 



Quantity 

740 ± 25 g 

(2 lb ± 1 oz.) 

PAG oil 


Radio 


1 of 3 2/25/2009 11:18 PM 

General 

650-1 

This section covers the BMW factoryinstalled 

sound system, including 

radio, amplifier and speaker removal. 

Radio antenna information is also 

included. 

Special tools 


equivalent plastic prying tool to pry out 

plastic interior parts without damage or 

marring. 


General 

A tag on the bottom of the radio 

contains the serial number (A) and 

model number (B). 

Sound system

Radio 


2 of 3 2/25/2009 11:18 PM 

The standard E46 radio features a 

cassette player. The optional radio has 

a single in-dash CD player. Both radios 

are prewired for the optional CD 

changer that mounts in the trunk. 

Another option, the On-Board Monitor, 

integrates GPS navigation with radio 

and IHKA controls. Basic radio controls 

are also incorporated in the steering 

wheel. 

Sound system components are 

interconnected via K-bus. Theft 

proofing of the radio by code is no 

longer required as the radio will not 

function without the K-bus connection 

and a valid signal 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 which the information 

is transmitted inaudibly with the audio 

programs. The name of the station is 

displayed in the radio when the RDS 

system is active. Program identification, 

program service name and RDS quality 

are also displayed.

Radio 


3 of 3 2/25/2009 11:18 PM 


Although electronic radio and sound 

system troubleshooting is beyond the 

scope of this manual, there are number 

of self-tests that are possible with the 

standard BMW radio installed in E46 

cars. 

Radio test functions are activated by 

pressing the M button within 8 seconds 

of switching the radio on. Hold it 

pressed in for 8 seconds to start the 

tests. 

The test functions include: 

Radio serial number 

Software 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 value falls below 

10, radio stations can not be 

listened to in stereo.

Radio 


1 of 2 2/25/2009 11:19 PM 

Radio and Audio 

Accessories 

650-2 

Radio, removing and installing 

CAUTION! 

Before beginning work on the 

radio or sound system, verify 

that the radio is an original 

equipment BMW radio and that 

the wiring harness has not been 

modified. 

Note: 

Servicing of aftermarket sound 

equipment should be referred to 

an authorized agent of the 

equipment's manufacturer. 

On-Board Monitor removal is covered 

in 640 Heating and Air Conditioning. 

- Prying gently, remove right 

dashboard trim, then center 

dashboard trim. 

CAUTION! 



Remove radio mounting screws 

(arrows). 

- Pull radio out of instrument panel 

opening. Detach electrical harness 

connector and antenna lead. 


Radio 


2 of 2 2/25/2009 11:19 PM 

Amplifier 

In all models the sound system 

amplifier is installed behind the trim on 

the left side of the car. 

- Sedan or Coupe: To access 

amplifier, carefully remove trunk 

trim clips on left side and peel 

back trim. 

Sport Wagon: Remove left cargo 

compartment trim cover. Sound system 

amplifier (arrow) is behind sound 

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.

Radio 


1 of 4 2/25/2009 11:19 PM 

Speakers 

650-3 

Each model in the E46 model line-up 

features a slightly different speaker 

setup. Speaker and other component 

locations also vary depending on the 

type of sound system installed. Some 

of the common speaker installations 

are covered in this section. 

Sedan and Sport Wagon: The standard 

installation is six speakers, one in each 

door and two in the rear. The rear 

speakers in the Sedan are in the parcel 

shelf. The rear speakers in the Sport 

Wagon are mounted on the left and 

right wheel housings behind trim 

covers. 

Coupe: A tweeter and a mid-range 

speaker are installed in one housing 

unit in each front door panel. Another 

speaker pair is in 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 amplifier. 

In the Convertible, the subwoofer is 

installed in the ski bag cover. It is 

hinged so that it can be swung aside 

when the ski bag is used. A magnet on 

the subwoofer cover holds it inplace 

against the rear bulkhead while the ski 

bag is used. The subwoofer functions 

in either position. 

Also in the Convertible, the sound 

system receives a signal from the rear

Radio 


2 of 4 2/25/2009 11:19 PM 

window defroster relay when the top is 

lowered. This switches off the 

stereophonic function. 

Door mounted speaker, 

removing 

WARNING! 

All E46 cars are equipped with front 

door airbags. Rear door airbags are 

optional. Before performing any work 

involving airbags, disconnect the 

negative (-) battery cable. See 721 


CAUTION! 





- Remove interior door panel as 


Detach electrical harness connector (A) 

and remove speaker mounting screws 

(B). 

- Remove speaker. 

Rear side panel speaker, 

removing 

- Disconnect battery negative 

terminal. 

CAUTION!

Radio 


3 of 4 2/25/2009 11:19 PM 





- Remove lower section of rear seat 

side trim. 

- If necessary, remove convertible 

top module. See 541 

Convertible Top (left side only). 

- Speaker is attached to side wall. 

Rear speaker, removing and 

installing 

Working at rear parcel shelf, pry 

speaker cover by inner edge and 

remove. 

CAUTION! 



- 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 mounting

Radio 


4 of 4 2/25/2009 11:19 PM 

screws. 

Unhook and pull subwoofer down. 


connector. 

- Convertible: 

Working in trunk, unhook and 

swing out subwoofer. 

Squeeze plastic harness cover 

and remove. 


connector. 


Using plastic pry tool, gently pry 

subwoofer at bottom left and pull 

out.

Radio 


1 of 5 2/25/2009 11:19 PM 

Antenna 

650-4 

Antenna and diversity 

The antenna used for the radio, 

telephone and FZV remote entry 

system is integrated with the rear 

window defogger in the Sedan and 

Coupe models. 

Convertible and Sport Wagon models 

feature a diversity antenna system to 

provide the strongest possible radio 

station signal to the sound system. 

In this system there are two (or more) 

antennas. Both the main 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 antenna in rear window 

(center) 

FM3 antenna in left rear side 

window 

AM antenna in rear spoiler

Radio 


2 of 5 2/25/2009 11:19 PM 

FZV (keyless entry) antenna 

combined with FM2 antenna 

The FM1/FM2 antenna amplifier is 

located beneath the rear spoiler. The 

signal from this amplifier is transmitted 

to the diversity module in the cargo 

compartment behind the left trim panel. 

1 - Suppression filter 

2 - Antenna amplifier 

3 - AM antenna 

4 - Diversity module 

The FM3 antenna has a separate 

amplifier integrated into the diversity 

module. The module 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 antenna mast 

Auxiliary antenna amplifier, 

mounted on convertible top 

storage cover and powered 

through antenna lead

Radio 


3 of 5 2/25/2009 11:19 PM 

Diversity switching module, 

mounted below antenna mast in 

trunk 

More information on the rear window 

defogger/antenna system is in 640 

Heating and Air Conditioning. 

Note: 

The telephone antenna is wound around 

the main antenna mast. 

Antenna, removing 

(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 


4 of 5 2/25/2009 11:19 PM 

Place antenna base down on 

bracket. 

Remove antenna head from above 

fender. 

- To remove base, slide toward rear 

of car, then detach cable 

connections. 

- When installing, make sure the 

offset of antenna head points 

toward back of car. 

Antenna amplifier, accessing 

- Convertible main antenna 

amplifier: 

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 


5 of 5 2/25/2009 11:19 PM 

- 

Sedan or Coupe antenna 

suppressor: 

Remove right roof pillar (C-pillar) 

trim panel to access suppressor. 

Sport Wagon FM3 antenna/diversity 

module: 

Remove 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.

Seat Belts 


1 of 5 2/25/2009 11:20 PM 

General 

720-1 

This section covers repairs to the seat 

belts. 

Multiple Restraint System (MRS II) 

electronics integrate seat belt 

operations and airbag deployment. 

Airbag repair information is covered in 


All E46 models are equipped with 

3-point shoulder belts at four seating 

positions. 

Sport Wagon models are 

equipped with an 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 plastic cover (arrow) to access 

safety anchor eye.

Seat Belts 


2 of 5 2/25/2009 11:20 PM 


The seat belt reel should lock when 

driving quickly through curves, during 

severe braking or in case of a collision. 

The automatic reel does not require 

any servicing and should never be 

opened. 

In case of an accident, follow the seat 

belt troubleshooting procedures 

presented in Table a. 

Troubleshooting the automatic seat 

belt system. 

Note: 

The rear bench seat belt strap may not 

retract fully due to increased friction 

between 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 

webbing. Webbing that is 

severely faded or re-dyed will 

not meet the strength 

requirements of a collision and 

must be replaced. Clean belts

Seat Belts 


3 of 5 2/25/2009 11:20 PM 

with a luke-warm soap solution 

only. 

Seat belts should be 

periodically inspected for 

webbing defects such as cuts or 

pulled threads. 

Immediately after replacing a 

damaged or worn seat belt, 

destroy the old belt to prevent it 

from being used again. 

Table a. Troubleshooting the automatic seat belt system 

Problem Probable cause Repairs 

Damage to seat belt: 

Accident in which bumper 

impact absorbers were 

permanently deformed 

Replace complete automatic 

seat belt. Also check and 

replace, if necessary: 

Seat belt mounting on 

car body 

Belt creased, unraveled, 

pinched, cut or melted 

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 automatic reel does 

not lock when pulled out 

suddenly. 

Seat belt automatic reel jams 

when pulled out. 

Seat belts aged or worn 

Seat belt lock mechanism 

worn or damaged 

Automatic reel defective 

Automatic reel loose 

Return spring broken inside 

reel 

Seat belt mounting on 

seat runner 


seat belt. 

Replace seat belt lock. 

Replace reel assembly. 

Tighten reel mounting bolt. 

Replace reel assembly.

Seat Belts 


4 of 5 2/25/2009 11:20 PM 

Problem Probable cause Repairs 

Seat belt does not retract 

automatically. (See note.) 

Automatic belt squeaks when 

belt fastened or unfastened. 

Seat belt pyrotechnic 

tensioner triggered 

Convertible models only: 

Front seat back requires 

excessive force to lock or 

unlock 

Seat back lock warning lamp 

on when seat back is locked; 

or warning lamp lights up 

when seat back is shaken 

Contact surface of inertia reel 

warped 

Seat back warped or 

deformed 

Head restraint carrier not 

parallel 

Seat movement sticky or 

sluggish at some point in its 

range; unusual noises 

Front seat shows evidence of 

contact with body structural 

part (e.g., door) 

Front seat shows evidence of 

contact with external objects 



reel 

Excessive friction in belt 

guides 



reel 

Accident triggered 

pyrotechnic deployment 

Accident damage to seat via 

seat belt 

Seat back lock microswitch 

defective 

Microswitch electrical harness 

connectors loose or defective 

Seat back lock is damaged 

Accident damage 



Accident damage (side) 

Accident damage (side) 

Accident damage (rollover) 







seat belt. Also check 

retaining bracket of belt 

tensioner for twist. 

Replace front seat. 

Replace microswitch 

Repair electrical leads. 

If fault persists, replace front 

seat. 

Replace front seat.

Seat Belts 


5 of 5 2/25/2009 11:20 PM 


Seat Belts 


1 of 10 2/25/2009 11:20 PM 

Front Seat Belt 

Assembly 

720-2 

Front seat belt tensioner, 


The front seat belt locks are equipped 

with pyrotechnic (explosive charge) 

automatic tensioners. These tensioners 

are designed to automatically retract 

and tension the seat belt by 55 mm 

(approximately 2 inches) in the event of 

an accident. 

WARNING! 

Pyrotechnic seat belt tensioners 

are powerful 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. 

Never treat pyrotechnic 

components with cleaning 

agents or grease.

Seat Belts 


2 of 10 2/25/2009 11:20 PM 

Do not expose pyrotechnic 

components to temperatures 

above 75°C (167°F). 

Pyrotechnic components can 

only be tested electrically when 

installed, using BMW service 

tester DIS, MoDiC or equivalent 

scan tool. 

Do not fire a pyrotechnic gas 

generator prior to disposal. It 

must be fired by a special 

disposal company or shipped 

back to BMW in the packaging 

of the new components. 

During body straightening and 

welding with an electric arc 

welder, always disconnect the 

battery and the connection to 

the pyrotechnic gas generators. 

- Detach battery negative (-) cable 

in luggage compartment. 

CAUTION! 





- Remove front seat as described in 

520 Seats. 

Remove pyrotechnic belt tensioner: 

Detach tensioner harness 

connector from seat rail by cutting 

wire tie (A).

Seat Belts 


3 of 10 2/25/2009 11:20 PM 

Detach harness connection (B). 

Remove tensioner mounting bolt 

(C). 

Check tensioner mounting bracket 

(arrow) for damage or bending. 


CAUTION! 

A bent tensioner mounting bracket 

may make it impossible to adjust 

seat height. 

When reinstalling: 

Replace wire ties to relieve tension 

on the pyrotechnic belt tensioner 

harness connector. 

Make sure tensioner harness 

connector mounting bracket 

(arrow) is installed correctly. 



(M10 fastener) 45 Nm (33 ft-lb) 

Seat belt to seat 

Tensioner 

mounting bracket 

to seat rail 

Tensioner to 

mounting bracket 

48 Nm (35 ft-lb) 

24 Nm (18 ft-lb) 

48 Nm (35 ft-lb) 

Front seat belt

Seat Belts 


4 of 10 2/25/2009 11:20 PM 

assembly (Sedan, 

Coupe, Sport Wagon) 

1 - Seat belt buckle 

2 - Tensioner 

mounting bolt 


ft-lb) 

3 - Seat belt lock 

with 

pyrotechnic 

tensioner 

4 - Seat belt stop 

button 

5 - Seat belt anchor 

bolt 


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 


ft-lb) 

11 - Spring washer

Seat Belts 


5 of 10 2/25/2009 11:20 PM 

12 - Spacer 

13 - Seat belt anchor 

bar (Coupe 

only) 

14 - Cap 

15 - Grommet 

16 - Seat belt reel 

mounting bolt 

M10 


ft-lb) 

17 - Seat belt height 

adjuster 

Front seat belt reel, removing 

and installing (Sedan, Coupe or 

Sport Wagon models) 

- Detach battery negative (-) cable in 

luggage compartment. 

CAUTION! 





- 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 


6 of 10 2/25/2009 11:20 PM 

Note: 

Remove anchor bar bolt and slip off 

end of seat belt from bar. 

Replace anchor bar if it is bent. 

Prying gently upward, remove plastic 

door sill protector strip. 

Sedan or Sport Wagon models: Remove 

lower B-pillar (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 


7 of 10 2/25/2009 11:20 PM 

Pull B-pillar upper trim down to remove. 

Remove automatic reel from B-pillar: 

Remove upper seat belt anchor bolt 

(A). 

Remove cross-brace mounting bolts 

(B). 

Remove sound insulation 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. 


Install automatic reel housing to

Seat Belts 


8 of 10 2/25/2009 11:20 PM 

B-pillar by sliding tab into locating 

slot. 



(M10 fastener) 45 Nm (33 ft-lb) 

Seat belt anchor 

bar to door sill 

Seat belt to seat 

Seat belt to B-pillar 

sliding anchor 

Seat belt reel to 

B-pillar bottom 

Sliding seat height 

adjuster to B-pillar 

31 Nm (23 ft-lb) 

48 Nm (35 ft-lb) 

31 Nm (23 ft-lb) 

31 Nm (23 ft-lb) 

24 Nm (18 ft-lb) 

Seat-integrated seat belt system 

(SGS) (Convertible models) 

The front seats of E46 Convertible 

models are designed with integrated 

seat belts. In this way, the forces acting 

on a 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 seat 

frame. The upper seat belt guide is 

attached to the headrest. In this way the 

belt is optimally positioned regardless of 

headrest position. 

The inertia reel is attached to the inside 

of the seat backrest. The mechanism is

Seat Belts 


9 of 10 2/25/2009 11:20 PM 

connected to the backrest hinge through 

a lever and a cable drive (coupler 

mechanism). As the angle of the 

backrest is adjusted, the cable drive will 

change the angle of the inertia lock. In 

this way the reel is in the proper position 

for locking at any seat back angle. 

The seat belt lock and tensioner on the 

SGS system is a pyrotechnic device 

similar to that on other E46 models. 

When working on SGS belts, be sure to 

read the warnings 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-integrated seat 

belt system (SGS) 

(Convertible) 

1 - Coupler 

mechanism 

2 - Self-tapping 

screw M4.2 


(22 in-lb) 

3 - Threaded pin

Seat Belts 


10 of 10 2/25/2009 11:20 PM 

4 - Front seat 

backrest 

5 - Support 

6 - SGS belt reel 

mounting nut 

M10 


ft-lb) 

7 - SGS inertia reel 

assembly 



(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 (selflocking, 

always 

replace) 


ft-lb) 


Seat Belts 


1 of 5 2/25/2009 11:20 PM 

720-3 

Rear Seat Belt Assembly 

Rear seat belts (Sedan or 

Coupe models) 

- Remove rear parcel shelf to 

access shoulder belt assembly 


- Remove rear seat cushion to 

access rear seat belt lock 

mounting bolts. See 520 Seats. 

- The accompanying illustration 

provides information 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 


2 of 5 2/25/2009 11:20 PM 

equipped) 

2 - Right shoulder 

belt lock 

3 - Lap-belt 

assembly 

4 - Left shoulder 

belt lock 

5 - Bolt M10 


ft-lb) 

6 - Left shoulder 

belt reel 

assembly 

7 - Center shoulder 

belt lock (if 

equipped) 

8 - Bolt M12 


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 


3 of 5 2/25/2009 11:20 PM 

Note: 

Remove shoulder belt reel 

mounting bolt inside backrest. 

Remove bowden cable from backrest 

brackets and unhook from backrest 

release latch. Center seat belt reel can 

be then be removed. 

- Outboard shoulder belt: 

Remove roof-pillar (C-pillar) trim. 

Remove center shoulder belt. 

- Lift up rear seat cushion(s) to 

access rear seat belt lock mounting 

bolt(s). 

The accompanying illustration provides 

information on rear seat belt component 

locations and fastener torques. 


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 


- When installing seat belt lock 

straps: 

Install right belt lock strap (which is 

shorter) underneath center belt lock

Seat Belts 


4 of 5 2/25/2009 11:20 PM 

strap. 

Install left belt lock strap 

underneath center lap belt strap. 

Metal strap ends must rest against 

stop on floor underneath seat. 

Rear seat belts (Convertible 

models) 

- Access shoulder belt or seat belt 

lock mounting bolts: 

Remove center armrest. 

Push shoulder belts toward sides 

and feed out of 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 Belts 


5 of 5 2/25/2009 11:20 PM 

The accompanying illustration provides 

information on rear seat belt component 

locations and fastener torques. 


2 - Left shoulder belt reel assembly. 

3 - Seat belt stop button 

4 - Left belt lock 





1 of 8 2/25/2009 11:21 PM 

General 

721-1 

This repair group covers airbag 

components. Airbag system repair and 

fault diagnosis is not covered here. 

Diagnostics, component testing, and 

airbag system repair should be carried 

out by trained BMW service 

technicians. 

Note: 

Airbags are also known as the 

Supplemental Restraint System 

(SRS). In the E46 cars the 

occupant safety system is called 

the Multiple Restraint System 

(MRS). 

Special test equipment is required 

to retrieve airbag fault codes, 

diagnose system faults, 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 normal shop tools. Use 


equivalent plastic prying tool to pry out 

plastic interior parts without damage or 

marring. 

Plastic prying tool BMW 00 9 321



2 of 8 2/25/2009 11:21 PM 

Airbag system 

The E46 airbag system consists of the 

following: 

Driver airbag in the center of the 

steering wheel hub 

Passenger airbag in the right side 

of the dashboard 

Front side-impact airbags, one in 

each front door 

Head Protection System (HPS) 

airbags, one in each 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



3 of 8 2/25/2009 11:21 PM 

2 - Passenger 

airbag 

3 - Head Protection 

System (HPS) 

airbag 

4 - Front door 

side-impact 

airbag 

5 - Rear door 

side-impact 

airbag (optional) 

2-stage airbag 

Beginning in the 2000 model year 

(9/1999 production) the front airbags 

were changed to a 2-stage style airbag. 

This ensures that the force of airbag 

inflation is not greater than necessary to 

provide protection. The 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 and front roof rail and 

concealed by interior trim.



4 of 8 2/25/2009 11:21 PM 

Upon severe side impact, a gas 

generator unit fills the Head Protection 

System (HPS) tube with inert gas. The 

expanding tube pops out of the trim to 

form a straight tube 5.1 inches in 

diameter and stretched in a straight line 

from the lower windshield pillar to above 

the rear door. The inflated tube is 

located to prevent the front occupant's 

head from contacting the A-pillar, the 

B-pillar, or side window. The tube's 

sloping position allows protection for 

both short and tall people. The inflated 

tube is stiff enough to retain much of its 

effectiveness even if the window is 

broken. The HPS tube remains inflated 

for approximately 7 to 8 seconds to 

extend protection time in case the 

vehicle 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 

using either DIS or MoDiC BMW scan 

tools. 

MRS deployment logic 

Main sensing and triggering functions for 

the front-impact airbags and seat belt 

tensioners are combined into a single 

MRS control module located above the 

center tunnel, under the rug, beneath 

the parking brake handle. 

Side-impact and head protection airbags 

are controlled by separate sensors, one 

for each side of the vehicle.



5 of 8 2/25/2009 11:21 PM 

MRS deployment logic provides two 

thresholds for the activation of the safety 

system, depending upon the severity of 

impact and whether or not occupants 

have fastened their seat belts: 

Belts fastened, low impact speed: 

Lower deployment 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



6 of 8 2/25/2009 11:21 PM 

Airbag indicator light 

The MRS control module detects and 

stores system status. 

The airbag indicator light in the 

instrument cluster displays the status of 

the airbag system when the ignition key 

is in "accessory" or ON positions. 

System normal: Indicator light 

comes on briefly, then goes out. 

System malfunction: Indicator light 

fails to come on. 

System malfunction: 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 

accident. Be sure to have the 

system inspected and repaired



7 of 8 2/25/2009 11:21 PM 

immediately. 

Airbag(s) are inflated by an 

explosive device. Handled 

improperly or without adequate 

safeguards, the system can be 

very dangerous. Special 

precautions must be observed 

prior to any work at or near the 

airbags. 

The airbag is a vehicle safety 

system. Serious injury may result 

if system service is attempted by 

persons unfamiliar with the BMW 

MRS II and its approved service 

procedures. BMW advises that all 

inspection and service be 

performed by an authorized BMW 

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 components be 

replaced. For more information on 

post-collision airbag service, see 

an authorized BMW dealer. 

Do not fire an airbag unit prior to 

disposal. It must be fired by a



8 of 8 2/25/2009 11:21 PM 

special disposal company or 

shipped back to BMW in the 

packaging of the new 

components. 

When removing a fired airbag unit, 

avoid contact with the skin; wear 

gloves. In case of skin contact, 

wash with water. 

Do not allow airbag system 

components to come in contact 

with cleaning solutions or grease. 

Never subject airbag components 

to temperatures 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.



1 of 3 2/25/2009 11:21 PM 

Airbag Electronics 

721-2 

Airbag harnesses and 

connectors 

If airbag connection harnesses show 

visible signs of wear or damage, they 

must be replaced or repaired. 

- To repair airbag harness: 

Disconnect negative (-) cable from 

battery and cover negative 

terminal with insulating material. 

Disconnect harness connector at 

airbag module 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 



terminal with insulating material.



2 of 3 2/25/2009 11:21 PM 

CAUTION! 





- Remove center utility tray between 

front seats. See 513 Interior 

Trim. 

Cut open carpet on top of center tunnel 

to access MRS II module. 

- Remove module mounting nuts 

and lift up control module. Detach 

electrical harness connector. 


Be sure that MRS module ground 

cable is attached to the module 

mounting stud. 

Side-impact crash sensor, 


- 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 floor level 

heater duct.



3 of 3 2/25/2009 11:21 PM 

Remove electrical harness connector 

from crash sensor (A). Remove sensor 

retaining screws (B) and remove 

sensor. Note direction of sensor arrow 

before removing. 


Note: 

Arrow on sensor must point to door sill. 




1 of 8 2/25/2009 11:21 PM 

Airbags 

721-3 

Driver airbag, removing and 

installing 




WARNING! 

After disconnecting the battery, wait 

5 seconds before beginning work on 

airbag components. 

CAUTION! 





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.



2 of 8 2/25/2009 11:21 PM 

Sport steering wheel: 

Insert screwdriver through 

opening in rear of steering wheel 

and push against spring tension 

to release airbag unit lock. 

Repeat procedure on other side of 

steering wheel. 

Lift off airbag unit and detach 

electrical harness connectors. 

WARNING! 

Store the removed airbag unit 

with the horn pad facing up. If 


deployment 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 check that the 

airbag indicator light goes out. If



3 of 8 2/25/2009 11:21 PM 

the indicator light stays on, the 

airbag system will not function 

as designed. Have the system 

diagnosed and repaired by an 



MFL steering wheel: Torque 

airbag using specification listed 

below. 

Sport steering wheel: Press airbag 

unit mounting pins into spring 

locks in steering wheel until they 

snap in firmly. 

CAUTION! 

Do not pinch airbag harness in 

center of steering wheel when 

installing airbag. 


Airbag to steering 

wheel (MFL) 

8 Nm (71 in-lb) 

Passenger airbag, removing 





WARNING! 

After disconnecting the battery, wait 

5 seconds before beginning work on 

airbag components. 

CAUTION! 


read the battery disconnection



4 of 8 2/25/2009 11:21 PM 



Pry gently at right dashboard trim to 

remove. 

CAUTION! 



- Remove right dashboard fresh air 

outlet mounting screws and pull 

outlet out of dash. 

Lift cover from top of passenger side 

airbag on dashboard. 

Remove cover strap retaining bolts 

(arrows) to detach cover 

completely from 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 air, 

causing injury. 

Early E46 cars (through production 

date 9/1999) were equipped with a



5 of 8 2/25/2009 11:21 PM 

single stage airbag, identified by 

having only one wire loom in the 

harness connector. Later production 

two stage airbags are supplied by two 

wire looms in the connector plug. The 

two kinds of airbags are NOT 

interchangeable. 


Make sure wiring harness is not 

pinched when installing airbag 

unit in dashboard. 


Airbag cover strap 

to dashboard (M6) 

Passenger air bag 

to dashboard (M8) 


22 Nm (16 ft-lb) 

Door mounted side-impact 

airbag, removing and installing 




CAUTION! 





- Remove inside door panel as 


Front door airbag: 

Remove airbag mounting bolts 

(arrows). 

Turn over airbag unit and cut off 

electrical harness wire tie.



6 of 8 2/25/2009 11:21 PM 

Detach harness connector. 

CAUTION! 

When removing and installing the 

airbag unit, pay attention to the 

routing of the electrical harness to 

avoid kinks or breaks in the wire. 

- Rear door airbag: 


connector. 

Remove mounting bolts and 

remove airbag from door. 


Route electrical harnesses as they 

were before. 

Use new wire ties as necessary. 

Use new self-locking mounting 

bolts. 



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:



7 of 8 2/25/2009 11:21 PM 

Complete dashboard 

Complete headliner 

Windshield pillar (A-pillar) trim 

Door pillar (B-pillar) trim 

- Before starting work on the HPS 

airbag, disconnect negative (-) 

cable from battery and cover 

negative terminal with insulating 

material. 

CAUTION! 






HPS airbag to body 

HPS airbag 

mounting bracket to 

A or B-pillar 

HPS gas generator 

to dashboard 

reinforcement M6 

self-tapping screw 

11 Nm (8 ft-lb) 

2.5 Nm (22 

in-lb) 

4 Nm (35 in-lb) 

Head protection airbag 

(HPS) 

1 - B-pillar 

deflection plate 

2 - Head protection 

airbag



8 of 8 2/25/2009 11:21 PM 

3 - Cable holder 

4 - Gas generator 

5 - Self-tapping 

screw M6 


in-lb) 




1 of 11 2/25/2009 11:22 PM 


(OBD II) 

OBD-2 

OBD II is an acronym for On-Board 

Diagnostics II, the second generation of 

on-board self-diagnostic equipment 

requirements. These standards were 

originally mandated for California 

vehicles. Since 1996 they have been 

applied to all passenger vehicles sold 

in the United States. 

On-board diagnostic capabilities are 

incorporated into the hardware and 

software of the engine control module 

(ECM) to monitor virtually every 

component that can affect vehicle 

emissions. OBD II works to ensure that 

the vehicles remain as clean as 

possible over their 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 information about the 

detected malfunction so that a repair 

technician can accurately find and fix 

the problem. 

Note: 

Specialized OBD II scan tool 

equipment is needed to access the 

fault memory and OBD II data. 

The OBD II fault memory 

(including the MIL) can only be



2 of 11 2/25/2009 11:22 PM 

reset using the special scan tool. 

Removing the connector from the 

ECM or disconnecting the battery 

will not erase the fault memory. 

The extra hardware needed to operate 

the OBD II system consists mainly of 


Additional oxygen sensors 

downstream of the catalytic 

converters 

Fuel tank pressure sensor and 

device to pressurize fuel storage 

system 

Several engine and performance 

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: 




Service Engine Soon.



3 of 11 2/25/2009 11:22 PM 

The MIL will come on under the 

following conditions. 

An engine management system 

fault is detected for two 

consecutive OBD II drive cycles. 

A catalyst damaging fault. 

A component malfunction (such 

as catalyst deterioration) causes 

emissions to exceed 1.5 times 

OBD II standards. 

Manufacturer-defined 

specifications are exceeded. 

An implausible 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. 


fails to enter closed-loop operation 

within specified time. 


or automatic transmission control 

module (TCM) enters "limp home" 

operation mode. 

Key is in "ignition on" position 

before cranking (bulb check 

function).



4 of 11 2/25/2009 11:22 PM 

Additional information, MIL: 

A fault code is stored within the 

ECM upon the first occurrence of 

a fault in the system being 

checked. 

Two complete consecutive drive 

cycles with the fault present 

illuminate the MIL. The exception 

to the two-fault requirement is a 

catalyst damaging fault, which will 

turn the light on immediately. 

If the second drive cycle was not 

complete and the specific function 

was not checked as shown in the 

example, the ECM counts the third 

drive cycle as the next consecutive 

drive cycle. The 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. 

Note: 

The fault code will be cleared from 

memory automatically if the 

specific function is checked 

through 40 consecutive drive 

cycles without the fault being 

detected. 

In order to automatically clear a catalyst 

damaging fault from memory, the 

condition under which the fault occurred 

must be evaluated for 80 consecutive 

drive cycles without the fault 

reoccurring.



5 of 11 2/25/2009 11:22 PM 

With the use of a universal or 'generic' 

scan tool connected to the DLC 

(Diagnostic Link Connector), diagnostic 

trouble codes (DTCs) can be obtained, 

along with the conditions associated 

with the illumination of the engine 

service light. Using a more advanced or 

BMW-dedicated scan tool, additional 

'proprietary' information is normally 

available. 

Scan tool and scan tool display 

Owing to the advanced nature of OBD 

II adaptive strategies, all diagnostics 

need to start with a scan tool. The 

aftermarket scan tools can be 

connected to either the 16-pin OBD II 

Data Link Connector (DLC) or the BMW 

20-pin DLC in the engine compartment. 

Data from the OBD II DLC may be 

limited, depending on scan tool and 

vehicle. 

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 the engine 

compartment has been deleted. All 

diagnostic, coding and programming 

functions are incorporated into the 

OBD II diagnostic port, located under 

left side of dashboard. 

Note: 

On cars built up 06-2000: when 

accessing emissions related DTCs 

through the 16-pin OBD II DLC, the 

BMW 20-pin DLC cap must be



6 of 11 2/25/2009 11:22 PM 

installed. 






BMW-specific tools. The CS2000 


Retriever from Assenmacher 


from Snap-On Tools are examples 


In addition to the professional line 

of scan tools, inexpensive 


programs and handheld units are 

readily available. These tools do 

have limited capabilities, but they 

are 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 diagnostic monitor is an operating 

strategy that runs internal tests and 

checks a specific system, component 

or function. This is similar to computer 

self tests. 

Completion of a drive cycle ensures 

that all monitors have completed their



7 of 11 2/25/2009 11:22 PM 

required tests. The ECM must 

recognize the loss or impairment of the 

signal or component and determine if a 

signal or sensor is faulty based on 3 

conditions: 


ground 


B+ 

Signal or component missing 

(open circuit) 

The OBD II system must monitor all 

emission control systems that are 

on-board. Not all vehicles have a full 

complement of emission 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 using DME input 

sensors and output accouters based 

on preprogrammed data sets. If the



8 of 11 2/25/2009 11:22 PM 

ECM cannot determine the 

environment or engine operating 

conditions due to missing or faulty 

signals it will set a fault code and, 

depending on conditions, illuminate the 

MIL. 

Oxygen sensor monitoring: When drive 

conditions allow, response rate and 

switching time of each oxygen sensor 

is monitored. In addition, the heater 

function is also monitored. The OBD II 

"diagnostic executive" knows the 

difference between upstream and 

downstream oxygen sensors and reads 

each one individually. 

All oxygen sensors are monitored 

separately. In order for the oxygen 

sensor to be effectively monitored, the 

system must be in closed loop 

operation. 

Catalyst monitoring: This 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 

monitors crankshaft speed fluctuations 

and determines if a misfire occurs by 

variations in speed between each 

crankshaft sensor trigger point. This 

strategy is so finely tuned that it can 

even determine the severity of the 

misfire. 

The diagnostic executive must 

determine if misfire is occurring, as well 

as other pertinent misfire information.



9 of 11 2/25/2009 11:22 PM 

Specific cylinder(s) 

Severity of the misfire event 

Emissions relevant or catalyst 

damaging 

Misfire detection is an on-going 

monitoring process that is only 

disabled under certain limited 

conditions. 

Secondary air injection monitoring: 

Secondary air injection is used to 

reduce HC and CO emissions during 

engine warm up. Immediately following 

a cold engine start (-10 to 40ï¿½C), 

fresh air/oxygen is pumped directly into 

the exhaust manifold. By injecting 

oxygen into the exhaust manifold, 

catalyst warm-up time is reduced. 


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, the 

signal at the oxygen sensor will reflect 

a lean condition. If the oxygen sensor 

signal does not change, a fault will be



10 of 11 2/25/2009 11:22 PM 

set and identify the faulty bank(s). If 

after completing the next cold start a 

fault is again present, the MIL will be 

illuminated. 

Fuel system monitoring: This monitors 

receives high priority. It looks at the 

fuel delivery needed (long/short term 

fuel trim) for proper engine operation 

based on programmed data. If too 

much or not enough fuel is delivered 

over a predetermined time, a DTC is 

set and the MIL is turned on. 

Note: 

Fuel trim refers to adjustments to base 

fuel schedule. Long-term fuel trim 

refers to gradual adjustments to the fuel 

calibration adjustment as compared to 

short term fuel trim. Long term fuel trim 

adjustments compensate for gradual 

changes that occur over 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. 

Evaporative system monitoring: This 

monitor checks the sealed integrity of 

the fuel storage system and related 

fuel lines. 

This monitor has the ability to detect 

very small leaks anywhere in the 

system. A pressure test is be 

performed on the EVAP system on a 

continuous basis as the drive cycle 

allows. 

On MS 42.0 cars, a leak detection 

pump (LDP) is used to pressurize and



11 of 11 2/25/2009 11:22 PM 

check system integrity. On MS 43.0 

cars, a more sophisticated DMTL 

(Diagnostic Module - Leak Detection) 

pump is used. 

Drive cycle 

The OBD II drive cycle is an important 

concept in understanding OBD II 

requirements. The purpose of the drive 

cycle is to run all of the emissionrelated 

on-board diagnostics over on a 

broad range of driving conditions. 

The drive cycle is considered 

completed when all of the diagnostic 

monitors have run their tests without 

interruption. For a drive cycle to be 

initiated, the vehicle must be started 

cold and brought up to 160ï¿½F and at 

least 40ï¿½F 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 determine if 

on-board diagnosis is complete as well 

as the status of the I/M codes. All 

required tests must be completed 

before the I/M readiness codes will be 

set to "Yes". 

Readiness codes



1 of 20 2/25/2009 11:23 PM 

BMW Fault Codes 

(DTCs) 

OBD-3 

Below is a comprehensive listing of 

BMW DTCs and the corresponding 

SAE P-codes. 

Table a. Diagnostic trouble codes (DTCs) 


code 

P-code 


function 


range 

Explanation 












occurred. 






occurred. 






occurred. 


2 


1 



low) 



low) 






exists. 






exists.



2 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

8 P0101 Mass air flow 

circuit range/perf. 

10 Engine coolant 

temp. circuit 

range/perf. 

11 Coolant temp. 

coolant outlet 

14 P0111 Intake air temp. 

range/performance 

18 P1397 Exhaust cam 


malfunction 


activation, exhaust 


activation, intake 


3 


range 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

phase shift (0-5V) 



low) 



low) 



low) 

Explanation 



limits. 




operations. 




operations. 




operations. 

Internal check of phase shift 

from camshaft sensor - 

should change during every 

crankshaft revolution.Phase 

shift occurs due to 2:1 

relationship between 

camshafts. 






exists. 






exists. 






exists.



3 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


6 


4 



(Bank1) 


closing coil 


range 



low) 



low) 



low) 



low) 

Explanation 






exists. 






exists. 






exists. 






exists. 












occurred. 






occurred. 






occurred.



4 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


5 



36 MS 43 Main relay 

malfunction 

38 MS 43 Clutch switch 

faulty 


and brake light 



pedal sensor 




redundant code 





range 



low) 



Input analog 

(0-12V) 

Input digital 

(0-12V) 

Input digital 

(0-12V) 


analog (0-12V / 

0-5V) 

Input binary 


Input binary 


Explanation 






exists. 

TDME final stage will set flag 





exists. 

Signal range check between 

DME ignition analog input 

and main relay power circuit 

analog input. 

Plausibility check of clutch 

switch and DME internal 

values such as load and 

engine speed. 

When brake light switch is 

active, brake light test switch 

must be also active. If not, 


If pedal sensor is showing 

angle greater than "limp 

home angle" and additionally 

brake light switch is active, 


Every signal from cruise 

control switch is transferred 

redundantly. A fault is set 

whenever two redundant 

information paths are showing 

a different status. 

When status from cruise 

control showing 

set/accelerate and 

deceleration are same time, 

fault is set.



5 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 



toggle-bit 

47 MS 43 Torque monitoring 

level 1 

48 MS 43 Internal control 

module 


range 

Input binary 


DME internal 


DME HW test 

memory 

Explanation 

Every 0.5 sec. a message that 

includes a toggle bit (toggles 

between 0->1 and 1->0) is 

transmitted. Change bit is 

monitored to indicate proper 

function. 

49 ECU internal test DME HW test 

50 P1145 

MS 42 

Running losses 

valve (3/2), final 

stage 








exists. 

MS 43 ECU internal test DME HW test 

51 MS 43 ECU internal test DME HW test 

52 Rear exhaust valve 

flap 


opening coil 



(Bank 2) 


interruption at 


steady (active low) 



low) 



low) 

Input analog (32V) 






exists. 






exists. 






exists. 


voltage. If voltage is 32V



6 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

shunt resistor 









(Bank 2) 


injection system 

switching valve 

65 P0340 Intake cam position 

sensor, 

malfunction 

68 EVAP system, 

purge control valve 

circuit 


range 

Input analog 

amplitude 

(13-19kHz) 

Input analog 

amplitude 

(13-19kHz) 



low) 



Input analog 

phase shift 0-5V 



low) 

Explanation 

(limitation voltage) then 

secondary ignition voltage is 

detected and shunt resistor 

may be faulty. 





values. 





values. 






exists. 






exists. 






exists. 






exists. 

69 Relay fuel pump Output digital 





disconnection between output



7 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

74 AC compressor 

relay 



(Bank 1) 

83 P0335 Crankshaft position 

sensor, 

malfunction 

100 P0601 Internal control 

module, memory 

check sum or 

communication 



intake 



exhaust 




(Bank 2) exhaust 


pulse width not 

plausible 


range 





low) 

Input digital 

(0-12V) 

DME internal 


DME internal 


DME internal 


DME internal 

values 

DME internal 

values 


pulse width 

(0-12V) 

Explanation 


exists. 






exists. 






exists. 

Checks for correct signal 

pattern and correct number of 

expected flywheel teeth. 

Internal hardware test of 

RAM, ROM, and Flash Prom. 












limit. 




limit. 

Throttle position control 

algorithm checks for problems 

with mechanical coupling



8 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 



111 P1542 Pedal Sensor 

Potentiometer 2 


range 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Explanation 

spring within motor throttle 

body. 



limits. 



limits. 

112 P0120 

MS 42 



Input analog 

(0-5V) 



limits. 

MS 43 


sensor 1 

Input analog 

(0-5V) 



limits. 



Input analog 

(0-5V) 



limits. 

114 P1580 

MS 42 


final stage 


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 


If pedal sensor malfunction is 

determined, followed by a 

second malfunction, a signal 

is sent. 

115 P1623 

MS 42 

Output voltage 5V 

for potentiometer 

operation 1 





voltage limit. 

MS 43 

Range check for 


adaptation 

Input analog 

(0-5V) 

Range check for closed 

position of throttle sensors. 

116 P1623 Output voltage for 

potentiometer 

operation 2 





voltage limit.



9 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


potentiometer 

plausibility 


range 

Input analog 

(0-5V) 

Explanation 





set. 

118 P0120 

MS 42 

Motor throttle 

feedback 

potentiometer 

plausibility 

Input analog 

(0-5V) 





set. 

MS 43 


sensor 1; 




DME internal 

values 





meter. 

119 P1580 

MS 42 

MDK, throttle 

mechanical 

sticking 


Throttle doesn't reach desired 

opening angle within a 

specified time. 

MS 43 


sensor 2; 




DME internal 

values 





meter. 

120 P1542 

MS 42 

Pedal sensor/ 

motor throttle valve 

potentiometer not 

plausible 

DME internal 


motor 



equal signal from pedal 

sensor potentiometer plus 

any adaptive values. 

MS 43 

Plausibility check 

between brake 

switch and pedal 

sensor 


analog 


constant pedal value and 

brake switch. First pedal 

value must be constant and 

for next step brake switch 

must be active. 

122 P1101 Oil temp. sensor 

malfunction 

123 P1622 Electric thermostat 

control, final stage 

Input analog 

(0-5V) 





limits and calculated 

temperature. 



short to battery voltage or a



10 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


range 

124 P1593 DISA, range/perf. Output digital 


Explanation 



exists. 






exists. 

125 Coolant fan, final 

stage 








exists. 

126 P1470 

MS 42 

LDP-magnetic 

valve 








exists. 

MS 43 DMTL valve Output digital 


127 Fuel pump Output digital 







exists. 






exists. 

128 EWS signal not 

present or faulty 


(ASC1) 

Input binary 


(0-12V) 

Input binary 


(0-12V) 

During time out check no 

signal was present within 

specific time or faulty 

information from serial 

interface (parity, overrun, 

etc.). 



expected time.



11 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


2) 


3) 


(ASC3) 

135 MS 43 Limp home 

position adaptation 

necessary 

136 MS 43 Motor throttle valve 

open / closing test 

failed 

140 P1475 LDP reed-switch 

not closed 

140 MS 43 DMTL pump final 

stage 




close 




close 


range 

Input binary 


(0-12V) 

Input binary 


(0-12V) 

Input binary 


(0-12V) 

DME internal 


DME internal 



(0-12V) 




(0-12V) 


(0-12V) 

Explanation 










Limp home position must be 

in specified range. If range is 

exceeded, a fault is set. 

From limp home mode 

position, throttle valve will be 

open, afterwards it must fall 

back into limp home position. 

If fall back position is not in 

specified range, fault is set. 

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. 






exists. 




from low to high or LDP reed 






from low to high or LDP reed



12 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


range 

142 MS 43 DMTL module fault DME internal 


Explanation 



143 P1476 EVAP: clamped 

tube check 





sensors 





sensors 

149 P1140 Motor throttle 

feedback 

potentiometer and 

air mass sensor 

signal not 

plausible 




volt. 






disconnection 

Input digital 



analog 


analog 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Frequency of LDP pumps 

reed switch is lower then 

predetermined limit. Volume 

of leak is determined to be too 

small (i.e. pinched or 

restricted hose) 



range. 



range. 



suitable to signal from air 

mass sensor. A fault is set if 

difference exceeds specified 

limit. 




line. Voltage signal has to be 


(0.1V -1V) or a fault will set. 









electrical disconnection exist



13 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 




volt. 

154 P0150 Oxygen 

sensorpre-cat 

(Bank 2), short to 

ground 



disconnection 




volt. 







volt. 





range 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Explanation 









































(0.1V -1V) or fault will set.



14 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 








position, throttle 

sticking 

169 MDK final stage 

shut off 

171 P0601 System has been 

shut down due to 

safety controller 


potentiometer 

short between two 

potentiometer 

paths 


potentiometer 

contact short 


potentiometer 

adaptation of idle 

end position 

175 Pedal sensor 









range 

DME internal 


DME internal 


DME internal 



calculated 



DME internal 

check 

Rationality check 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Explanation 

This fault indicates problem 

on pedal sensor, throttle 

potentiometer or throttle. A 

separately stored fault code 

indicates problem. 

Safety controller has shut 

down motor throttle valve 

function due to not plausible 

MDK input values. 

5 volts for potentiometers are 

switched on within a specific 

time pattern. 


potentiometer 




set. 




set. 




set.



15 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 



(Bank 1), 

insufficient 



(Bank 2), 

insufficient 

190 P1186 Oxygen sensorheater, 

post-cat 

(Bank 1), 

insufficient 


heater, post-cat 

(Bank 2), 

insufficient 


range 



low) 



low) 



low) 



low) 

Explanation 




limits. 




limits. 




limits. 




limits. 

197 MS 43 Signal range check DME internal 

analog input 



203 P0173 Fuel Trim (Bank 2), 


204 P0505 Idle control 

system, idle speed 

not plausible 

208 EWS, engine 

speed check not 

ok 

209 EWS, content of 

message 


faulty (>2 

cylinders) 

DME internal 


DME internal 


DME internal 



Input binary 


(0-12V) 

Input analog 






Functional check between 

actual engine speed (RPM) 

and predetermined RPM 

exceeds maximum deviation 

of +200/-100 RPM. 

Engine speed signal is 

transferred by EWS to DME. 

Fault is set if transferred 

signal is not reflecting engine 

speed due to input problem in 

EWS. 

Content of binary message 

received from EWS invalid. 


timing after each ignition has 

been initiated by feedback



16 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


stuck 

214 P0500 Vehicle speed 

sensor 



disconnection 



disconnection 

217 P0505 CAN time out 

(EGS1) 


range 

DME internal 


Input digital 


Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input digital binary 

information(0-12V) 

Explanation 

signal. If more than two 

ignition signals are not 

recognized than there might 

be a problem in feedback line. 

Functional check against a 

calculated value by 

monitoring flow though air 

mass meter to determine if 

idle valve is mechanically 

stuck open. Tested during 

closed throttle. 



limits. No vehicle speed is 

observed after specific time 

when compared to engine 

speed and load equivalent to 

moving vehicle. 










DME/EGS was not received 

within expected time. 

219 CAN-chip, bus off Input digital binary 

information (0-12V) 

Hardware test determines if 

CAN bus is off line. Data 

transmission is disturbed. 














too long in either, fault will 

set. 




too long in either fault will set.



17 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 

222 P0125 Insufficient coolant 

temp. to permit 

closed loop 

operation 









control 



control 


O2 control 



O2 control 



pre-cat (Bank 1, 








slow 


range 

Input analog 

(0-5V) 





Input analog 

(0-5V) 

Input analog 

(0-5V) 

DME internal 


DME internal 








Explanation 

Comparison of actual coolant 

temperature against 

calculated DME value which 

varies with load signal. 





set. 





set. 








values. 


values. 





set. 


oxygen sensor stays in its rich 

or lean state. If it remains 

there too long in either fault 

will set. 




versa. If it takes too long to



18 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 




slow 



threshold 



threshold 


(Bank 1):trim 

control 


(Bank 2):trim 

control 


detected 


detected 


range 



Input analog 

(0-5V) 

Input analog 

(0-5V) 





DME internal 


DME internal 


Explanation 





versa. If it takes too long to 
























Crankshaft 







will set. 

Crankshaft 





against avg. of others. If time



19 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 


detected 


detected 


detected 


detected 

244 Segment timing 

faulty, flywheel 

adaptation 


range 

DME internal 


DME internal 


DME internal 


DME internal 


Input analog 

(0-5V) 

Explanation 


will set. 

Crankshaft 







will set. 

Crankshaft 







will set. 

Crankshaft 







will set. 

Crankshaft 







will set. 

Flywheel segments are 

monitored during deceleration 

to establish baseline for 

misfire calculation. If 

segments are too long/short 

(bad flywheel) and exceed 

limit, fault will be set.



20 of 20 2/25/2009 11:23 PM 


code 

P-code 


function 



flow too low 



flow too low 


valve stuck open 



phase not 




phase not 


250 P0440 Functional check 

purge valve 


range 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Input analog 

(0-5V) 

Explanation 

























after decel 




after decel 

This functional check looks 

for reaction of oxygen sensor 

signal during canister 

purging. Oxygen sensor, air 

flow meter and RPM values 

must react to purging of 

canister.

BMW 3 Series Service Manual (E46)

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