BMW 323i (2001) manuel d'utilisation

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Un bon manuel d’utilisation

Les règles imposent au revendeur l'obligation de fournir à l'acheteur, avec des marchandises, le manuel d’utilisation BMW 323i (2001). Le manque du manuel d’utilisation ou les informations incorrectes fournies au consommateur sont à la base d'une plainte pour non-conformité du dispositif avec le contrat. Conformément à la loi, l’inclusion du manuel d’utilisation sous une forme autre que le papier est autorisée, ce qui est souvent utilisé récemment, en incluant la forme graphique ou électronique du manuel BMW 323i (2001) ou les vidéos d'instruction pour les utilisateurs. La condition est son caractère lisible et compréhensible.

Qu'est ce que le manuel d’utilisation?

Le mot vient du latin "Instructio", à savoir organiser. Ainsi, le manuel d’utilisation BMW 323i (2001) décrit les étapes de la procédure. Le but du manuel d’utilisation est d’instruire, de faciliter le démarrage, l'utilisation de l'équipement ou l'exécution des actions spécifiques. Le manuel d’utilisation est une collection d'informations sur l'objet/service, une indice.

Malheureusement, peu d'utilisateurs prennent le temps de lire le manuel d’utilisation, et un bon manuel permet non seulement d’apprendre à connaître un certain nombre de fonctionnalités supplémentaires du dispositif acheté, mais aussi éviter la majorité des défaillances.

Donc, ce qui devrait contenir le manuel parfait?

Tout d'abord, le manuel d’utilisation BMW 323i (2001) devrait contenir:
- informations sur les caractéristiques techniques du dispositif BMW 323i (2001)
- nom du fabricant et année de fabrication BMW 323i (2001)
- instructions d'utilisation, de réglage et d’entretien de l'équipement BMW 323i (2001)
- signes de sécurité et attestations confirmant la conformité avec les normes pertinentes

Pourquoi nous ne lisons pas les manuels d’utilisation?

Habituellement, cela est dû au manque de temps et de certitude quant à la fonctionnalité spécifique de l'équipement acheté. Malheureusement, la connexion et le démarrage BMW 323i (2001) ne suffisent pas. Le manuel d’utilisation contient un certain nombre de lignes directrices concernant les fonctionnalités spécifiques, la sécurité, les méthodes d'entretien (même les moyens qui doivent être utilisés), les défauts possibles BMW 323i (2001) et les moyens de résoudre des problèmes communs lors de l'utilisation. Enfin, le manuel contient les coordonnées du service BMW en l'absence de l'efficacité des solutions proposées. Actuellement, les manuels d’utilisation sous la forme d'animations intéressantes et de vidéos pédagogiques qui sont meilleurs que la brochure, sont très populaires. Ce type de manuel permet à l'utilisateur de voir toute la vidéo d'instruction sans sauter les spécifications et les descriptions techniques compliquées BMW 323i (2001), comme c’est le cas pour la version papier.

Pourquoi lire le manuel d’utilisation?

Tout d'abord, il contient la réponse sur la structure, les possibilités du dispositif BMW 323i (2001), l'utilisation de divers accessoires et une gamme d'informations pour profiter pleinement de toutes les fonctionnalités et commodités.

Après un achat réussi de l’équipement/dispositif, prenez un moment pour vous familiariser avec toutes les parties du manuel d'utilisation BMW 323i (2001). À l'heure actuelle, ils sont soigneusement préparés et traduits pour qu'ils soient non seulement compréhensibles pour les utilisateurs, mais pour qu’ils remplissent leur fonction de base de l'information et d’aide.

Table des matières du manuel d’utilisation

  • Page 1

    [...]

  • Page 2

    010-2 How to Us e T h i s M a n u a l WA RN I NG! Yo ur co mmo n sense and go od judg ment are cru cial to sa fe and su cc es sfu l se rvice wo rk . Re ad pro cedu res t hro ug h b efo re start in g them. T h in k abo u t w hether the co nd it ion of yo ur ca r, yo ur l ev el of me chani ca l skill, o r yo ur leve l of re adi n g co mprehensio n mi[...]

  • Page 3

    ELE EL ECT RI CA L WIR I NG DI A GRA M S OBD O N BOA RD DI A G NOST I CS 0 GENERA L DA T A A ND M A I NT ENA NC E cov ers g en era l v eh icl e inf orma t ion (Re p ai r G rou p 010 ) as well as th e recomme n d ed maint enan ce sch edu l es and serv ice procedu r es to p erform BM W sch ed u l ed mai n ten an ce wo rk (Repair G roup 020 ) . T h e [...]

  • Page 4

    the w o rk or b y in cr eas ed risk o f ac cid ent or me chani ca l failure wh i le drivin g . CA UTI ON! A cau tion calls attention to impor tant prec au tions to b e o b ser ved d u rin g the repair wor k th at wi l l h elp p re vent ac cid entally dama ging the car or i ts parts . No te: A note con t ains helpful i nformation, ti ps that w i l l[...]

  • Page 5

    sho rts, spark s, b u rns, or dama ge to the elec trical sy stem wh en acc id entally co ntacting the b atte ry or ot her elec trical ter min als. Disc onnect the b atter y n eg ative (–) ca b l e wh enev er w o rking o n o r n ear the f u el sys tem o r anythin g th at is elec trically power ed. A ccidental elec t rica l co ntact ma y dama ge th[...]

  • Page 6

    and any o p en flame away fro m the top of the b atte ry . Hy dro gen g as em i tted by th e battery is hi g hl y flamm ab le. A ny n ea rby so u rc e of i g n i tion may ca us e th e batter y to ex p l o d e. Ne ver l ay too l s o r p ar ts in the eng i ne co mpar tme n t o r o n top o f the batter y. T hey ma y fall in to co nfi n ed space s and [...]

  • Page 7

    010-3 Getti n g Sta rted M ost of th e n ece ssary mai n t enan ce and minor repair th at an au t omo b ile will n ee d can b e d on e wi t h ord inary t oo l s. Below is some import ant in f orma t ion on h ow t o wo rk safel y, a d iscu ssion of what t ools will b e n eeded an d h ow to u se th em. Sa fety A l th oug h an aut omobile p resents ma[...]

  • Page 8

    points. Watch th e jack clos ely. Mak e su re i t stay s sta b le and doe s not shift o r til t. A s th e ca r i s ra ised, it ma y ro ll slightly and t he j ac k ma y shi ft. Raising car safely - Park car on f l at, l ev el su rf ace . - I f ch ang ing a t ire , l oo sen l u g b olt s b efore rasing car. S ee Chang in g a t ire . Pl ace j ack in t[...]

  • Page 9

    Work ing under c a r s a fely - Di scon n ect n eg ativ e (–) cab l e f rom b attery so t h at n o on e can start car. Let oth ers kn ow what you will b e d oing . CA UTI ON! Prio r to di sco nn ect in g the b atte ry, re ad th e batter y d isco n nectio n ca utio n s give n at the fro nt o f th is ma n u al on p ag e vii i . - Ra ise car sl owly[...]

  • Page 10

    - Lo wer car sl ow l y u n t il its wei g h t is fu l l y su p p orted b y j ack stan d s. Watch t o make su re t h at th e j ack stand s d o n ot t ip or l ea n as t h e car settl es on th em. - Ob serv e all j acki n g p reca u t io n s again when rai sin g car to remov e j ack stan d s. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s [...]

  • Page 11

    010-4 A dv i ce f or th e Begi n n er T h e tip s in th e p aragraph s th at f oll ow are g eneral advi ce t o h el p any d o-it-yoursel f BM W owner p erform rep air s an d mai n ten ance t asks more ea sil y an d more p rofessi onal l y. P l anning a hea d T o p rev ent g etting in too d eep, kn ow what th e whol e j ob req u ires bef ore st arti[...]

  • Page 12

    M an y f asteners u sed on t h e cars cov er ed b y th is manu al mu st b e re p l aced wi th n ew ones once t h ey are remo v ed. These incl u d e b u t are n ot l imited to: b ol t s, n u t s ( self -l ocking , n yl ock, etc. ), cotter p ins, st u d s, b rake fitt in g s, rol l p in s, cl ip s an d wa sh ers. G en u in e BM W p arts sh ou l d b e[...]

  • Page 13

    va lue s l i ste d i n th e tabl e ar e not in tended to b e u se d as a su b stitu te for t o rqu es spec i fi ca l l y ca l l ed ou t i n t he tex t. No te: Metri c bol t cl asse s or gra des are marke d on the bo l t hea d. Do not con f use w ren ch si z e w i th bolt diameter. F or a l i sti ng of t he common w re nch es use d on various bo l t[...]

  • Page 14

    Some g askets—su ch as h ea d g askets—a re d irectio n al . M ake su re t h at th ese are inst al l ed corre ct l y. This same l ogic ap p l ies to any p art u sed f or sea l ing , incl u d in g ru b b er O-rin g s and cop p er sealin g wash ers. I n p l ace s w h ere a sh aft mu st p ass th roug h a h ousin g , fl ex ib l e l ip sea l s are u[...]

  • Page 15

    swi tch is “open ” wh en th e circuit is int erru p ted , an d “cl osed” when t h e circu it is compl eted . See 60 0 El ectrica l Syst em– Gen eral for el ectrica l trou b l esh oo tin g . W ire re pa irs Re p air s t o a wir ing h arn ess req u ire specia l care t o make t h e rep ai r p ermanen t . The wi re end s mu st b e cl ean. If [...]

  • Page 16

    010-5 Bu yi n g Pa rts M any of t h e ma in ten ance an d repair tasks in t h is man u al cal l for th e inst all at io n of n ew part s, or th e u se of n ew g aske t s an d oth er materia l s wh en rei n st al l in g p arts. M ost oft en, t h e p art s th at wi l l b e n ee d ed sh ou l d b e on h an d b efore b eginn in g t h e j ob . Rea d th e[...]

  • Page 17

    BM W is con stan tl y u p d atin g an d improv ing t h eir ca rs, oft en making improv eme n ts d u ring a g iv en model yea r. BM W may recomme n d a newe r, improv ed p art as a repl ace m ent, and your aut h orize d d ealer’s p arts d epartmen t will kn ow abou t it and p rov id e it. The BM W p arts organ izatio n is b est eq u ip p ed t o d [...]

  • Page 18

    of th e wa rrant y reca l l s are ap p l icabl e t o your car. The l abel on th e d riv er’s d oor b elow th e d oo r l at ch will sp ecify th e mont h an d year th at th e car wa s b u il t . V ehicl e Iden tificatio n Nu mb er (V IN ). T h is is a combin atio n of l ett ers an d n u mb ers t h at iden t ify t h e p articu l ar car. T h e V I N [...]

  • Page 19

    010-7 T ool s M ost maint en ance can b e acco mp l ished wi t h a smal l selection of th e rig h t tools. To ol s rang e in q u al ity from in ex p ensiv e j u n k, wh ich may b rea k at f i rst u se, t o v ery ex pen siv e and well -mad e tools f or th e p rofessi onal. The b est tools for most d o-i t -you rself BM W owners l ie some wh ere in b[...]

  • Page 20

    h t tp : / /www . sp tool.com Zel end a M ach ine an d Too l Cor p . 65 -60 A u st in St ree t, Forest Hill s, NY 11 37 4-46 95 71 8-8 96-2 288 h t tp : / /www . zel end a. com B a sic tool re quirem ents T h e b asi c h and t oo l s d escri b ed b el ow can b e u sed t o accom p l ish most of th e simpl e maint en ance an d repair tasks. Screw d r[...]

  • Page 21

    Socke t s. Sockets are u sed wi th a ratch et h and l e for sp eed and conv en ience and can b e combin ed with ex t ension s and u n iv ersa l j oi n t s (swi ve l s) to rea ch f asteners more ea sil y. The most commo n d riv e sizes are 1/4 in. , 3/8 in . , and 1/2 in . Socke t s come in 6-p oi n t and 12 -p oi n t styl es. The 6-poin t offers a [...]

  • Page 22

    h old ing irregu l ar obj ects, b end ing , or crimpin g . Some h av e sp eci al app l ica tions. Ne ed l en ose p l ie rs are u sed f or g rip p ing small an d p oo rl y acce ssib l e ob j ects, and are u sefu l for w iri n g and oth er electrical wo rk. Lo cking p l ie rs su ch as th e V ise-Grip® are u sefu l b eca u se of th eir tig h t g rip.[...]

  • Page 23

    to su p port th e car fo r a long p er iod. A l w ay s us e jack stands to s u p p or t a ra i sed ve hi cle. Jack stan d s are av ai l ab l e in sev eral styl es. The b est ones are made of h ea v y materia l f or st reng th , h av e a wi d e b ase f or stab il ity, and are equ ip p ed t o p ositiv el y l ock in t h eir rai sed p osi tions. G et t[...]

  • Page 24

    repair pr oce d u res in t h is man u al incl u d e BM W -sp eci fied t orqu e v alu es in Ne wton -meters (Nm) and t h e equ iv alen t v alu es in f oot-p oun d s (ft -l b ) . Sev eral typ es of t orq u e wrench es are av ailab l e. A n inex p en siv e b ea m-typ e (top ) is ad equ ate b u t m u st b e read v isual l y. A ra t ch et-typ e (b ottom[...]

  • Page 25

    CA UTI ON! Vehicle electr onic sys tems may be dama ge d by th e h igh cu rrent draw of a tes t li ght w it h a nor ma l in ca nd es ce n t b ulb. A s a ge n era l ru le, u se a hi gh i mpedance d igital mu lti met er or an LED test li ght for all elec trical testing. B M W s pe c ia l tools M any repairs cov er ed in t h is man u al call for th e [...]

  • Page 26

    010-8 Em ergen c i es Changing a tire - Stop car on as fl at a su rf ace as p ossi b l e, in a p l ace where you can b e ea sily see n b y oth er d riv er s. A v oi d stop p in g j u st ov er t h e crest of a h il l . - T u r n on eme rg ency f l ash ers, an d set ou t fl are s or emergen cy marke rs we l l b eh ind car. Ch ock wheel ( wheel ch ock[...]

  • Page 27

    remo v e whee l n u t s and wh ee l . - I n stal l sp are whee l . Inst all wh eel n u t s an d tig h t en th em h an d tig h t u sing l u g n u t w rench . - Lo wer car. W ith all wh eels on g roun d , f u l l y t igh t en n u t s in a crisscro ss p att ern. T orqu e wh eel n u t s wh en in stal l in g wheel. Check inf l atio n p ressure of sp are[...]

  • Page 28

    th e rear of t h is man u al f or d ia g n ostic code rea d in g p roce d u res. J um p st arting Ca rs with d isch arg ed or d ead b atteries can b e j u m p -started u sing t h e g ood b attery f rom an oth er car. W h en j u mp -st arting th e en g ine, al wa ys n ote th e f ol l ow ing warning s. WA RN I NG! B atter y a cid (electr olyte ) can [...]

  • Page 29

    other. - T u rn off en g in e of car with g ood b at tery. - T u rn off ig n ition switch of car wi th d isch arg ed b attery. Co n n ect on e end of p ositiv e (+) cabl e to p ositiv e (+) p ost of g oo d b attery. Re mov e cov er from t h e p ositiv e (+) j u n ct ion p ost ( A ) i n eng ine compartmen t and con n ect oth er en d of th e p osi t [...]

  • Page 30

    M any of t h e v ehicl e syst ems a re self -monitored b oth st atica l l y an d d yn amica l l y wh il e d riv ing . Gen era l l y, a red wa rn in g l amp th at comes on d u rin g d riv ing sh ou l d b e consid ered seri ous. I f you can n ot immediately d etermine th e seri ou sn ess of th e wa rn ing l ig h t , st op th e v eh icl e in a safe p [...]

  • Page 31

    b u mp er. No te: A t ow i ng eye i s pro vi ded i n t he l ugg ag e comp artment t ool ki t. T he tow i ng eye can be scre w e d i nto the front or rea r bu mper. I n stal l towi n g eye in to t h readed h ol e. - Stan d ard t ransmission: A max imu m towi n g d istance of 20 miles is accept abl e wi t h th e rea r wheels on th e g roun d and t h [...]

  • Page 32

    ATF dra i ni ng an d f i l l i ng i s covere d i n 24 0 Au t oma t i c Transmissi on . Be sure t o rea d t he fi l l i ng and dra i ni ng pro cedu r e, as special service eq ui pmen t i s req ui red to che ck the fl uid l eve l . Drivesha f t remova l i s covere d i n 260 Dri vesh aft . Spare parts k it Ca rryin g a b asic set of sp are p arts can [...]

  • Page 33

    Spare p art s kit – add iti o nal contents Ex t eri or l igh t in g b u l b s (h ea d l ig h t , b rake l igh t, tu r n sign al, an d taill ig h t) Wip er b l ad es Brake f l u id (n ew u n open ed b ottl e, D O T 4 sp ecifica t ion) M ai n relay f or DM E syst em Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Gen eral h t[...]

  • Page 34

    020-1 Gen era l T h e inf orma tion g iv en in t h is rep ai r g roup in cl u d es th e rou tin e ch ecks and mai n t en an ce step s t h at are b oth requ ired b y BM W u n d er t h e t erms of th e v eh icl e wa rrant y p rotectio n an d reco mmen d ed b y BM W to en su re l on g and reliab l e v ehicl e op eratio n . No te: Asi de f rom kee pi n[...]

  • Page 35

    mid-200 0 mod els BM W in t rod u ced n ew serv ice int erv al software wh ich calcu l at es serv ice b ase d on th e amo u n t of fu el u sed . W h en SI I d etects total f u el con su mp tion th at eq u al s t h e p rese t l imits (in g al l ons), t h e inst ru men t cl u st er ind icate s t h at serv ice is requ ired. Usi n g a 32 8i as an ex a [...]

  • Page 36

    Se rvice Interval Indica tor (SII), resett i ng T h e SI I sign als t h e n eed f or b asi c rout ine maint en ance: En g ine oi l an d oi l f il ter ch an g e, after t h e eng ine h as b ee n warmed u p . BM W-recomme n d ed ad d itio n al mai n t en an ce as listed in Tabl e a . No te: For referen ce, the BMW oil servi ce req uiremen ts are app r[...]

  • Page 37

    A ft ermarke t r ese t t ools th at can rese t all mod els wi th t h e DL C can b e p u rch ased from on e of t h e f ol l owi n g su p p l ie rs: A ssenm acher Sp ecia l ty To ol s 64 40 Od ell Pl ace , Boul d er, C O 80 30 1 30 3-5 30-2 424 h t tp : / /www . astt oo l .com Baum T oo l s Unl imited, I n c. P.O . Box 586 7, Saraso t a, FL 34 27 7-5[...]

  • Page 38

    Press bu t ton ag ai n and h ol d f or app rox . 5 second s u n t il " Rese t " or "Re" fl ash . Wh il e d isp l ay is f l ash ing , p ress b u t ton b rie f l y t o rese t SII . A ft er d isp l ay h as sh own n ew int erv al , t h e f oll ow ing will ap p ear in d isp l ay for app rox . 2 second s: "En d SI A ". T h e[...]

  • Page 39

    an d In spe ct i on I I req uir eme nts are ap proximatel y eq uival ent to t he maintena nce req uiremen t s that other Euro pea n ma nu facturers spe ci fy. I nspe ct i on I i s norma l l y du e at i ntervals w i t h a maxi mum of 30,00 0 m i l es or 24 mon t hs. In spe cti on I I i s no rmall y due at i nterva l s w i t h a maximum of 60,00 0 mi[...]

  • Page 40

    M a i n tenanc e T a bl e s T h e in terv als f or most t asks l isted in th e maint en ance t abl e b elow are d et ermi n ed b y th e SI I. Ex cept where n oted , th e mai n ten an ce items l isted ap p l y t o all model s and mod el years cov ered b y th is m anu al. The col u mn s on t h e righ t sid e of each tab l e g iv e q u ick-refe rence [...]

  • Page 41

    Tabl e b. I n spec ti on I se rvice M ai ntenance item To o ls re q ui red N ew p arts re qu ired Warm engi n e re q ui red De aler se rv i ce re comm end ed Addi ti on al re pair in fo rm ation Under ca r ma int enance Chan g e en g ine oi l an d fil ter. 020 Check t ransmission an d d ifferent ial(s) f or ex t ern al l eaks. 230 240 Check CV j oi[...]

  • Page 42

    Tabl e b. I n spec ti on I se rvice M ai ntenance item To o ls re qu ired Ne w parts re qu ired Warm engi n e re q ui red De al er ser vice re comm end ed A d di tio n al re pair i nfo rm ation cent eri n g h u b s (all oy wheels onl y). Check th ickn ess of p arki n g b rake l in ing s onl y wh en repl acing rear b rake p ads. Check op era tion of[...]

  • Page 43

    Tabl e b. I n spec ti on I se rvice M ai ntenance item To o ls re qu ired Ne w parts re qu ired Warm engi n e re q ui red De al er ser vice re comm end ed A d di tio n al re pair i nfo rm ation Check en g ine coo l ant system/h eater h ose conn ections f or l ea ks. Check coolan t l ev el and ant ifree ze p rotectio n l ev el. A d d coo l ant as n [...]

  • Page 44

    Tabl e b. I n spec ti on I se rvice M ai ntenance item To o ls re qu ired Ne w parts re qu ired Warm engi n e re q ui red De al er ser vice re comm end ed A d di tio n al re pair i nfo rm ation system. Check aim of wa sh er j ets an d ad j u st if n ecessa ry. Check con d itio n and fu n ction of seat b elt s. 720 V isu all y ex am in e all ai rb a[...]

  • Page 45

    Tabl e b. I n spec ti on I se rvice M ai ntenance item To o ls re qu ired Ne w parts re qu ired Warm engi n e re q ui red De al er ser vice re comm end ed A d di tio n al re pair i nfo rm ation Check b raking p erforma n ce, steeri n g , h eating , air cond itioner operatio n . Check manu al t ran smissi on and cl u t ch operatio n or aut oma t ic [...]

  • Page 46

    Tabl e c. I n spec tio n I I se rv ice M ai ntenance item To ol s re qu ired Ne w parts re q ui red Warm engi ne re qu ired De al er ser vice re comm end ed A d di tio n al re pair i nfo rm ation Spark p lu g ser vice Re p l ace spark p l u g s ev ery 10 0,000 mil es. 020 Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. M ai n[...]

  • Page 47

    020-3 Fl u i d a n d Lu bri ca n t Speci f i ca ti on s T h e ill u st ratio n sh ows en g ine oil v iscosi t y (SA E g rade) v s. operating t emp era t u re rang e for t h e BM W en g in es cov ere d in t h is manu al . Fl u id an d l u b ricant cap acitie s and sp ecifica t io n s f or E46 cars are l isted in Ta b l e d . WA RN I NG! Th e us e of[...]

  • Page 48

    Tabl e d. F l ui d s and l ub ricants Fl ui d Approxi ma te ca pacity Specification ZF A 5S 32 5Z Co mp l ete refill : 9.0 liters (9.5 US q t. ) Oil an d fil t er ch ang e: 4.0 liters (4.2 US q t. ) BM W 83 22 9 40 7 80 7 (Ex x on LT 71 14 1) BM W 83 22 0 02 4 35 9 (T ex aco ET L 80 72 B) GM A 5S 36 0R GM A 5S 39 0R Differ enti al, fron t o r rea r[...]

  • Page 49

    u se d in t he manu al trans miss i on. Use o f su ch an oil co uld sho rte n the ser vice l ife o f th e tra nsmiss i o n . B r a ke fluid Brake f l u id absorb s moistu re ea sily, and moi stu re in th e fl u id affect s b rake p erforma n ce and rel ia b il ity. This is wh y b rake f l u id sh ou l d b e fl u sh ed from t h e system ev ery t wo [...]

  • Page 50

    T h e p owe r steeri n g fl u id is Dex ron II I® A TF, or equ iv al ent . T h e system is p erma n en t l y fil l ed an d d oes n ot h av e a d rai n . Routin el y add in g A TF is n ot req u ired u n l ess t h e system is l ea kin g . T ra nsmi ss ion fluid, a uto m atic T h e aut omatic tran smissi on s in st all ed in th e E46 model s are f il[...]

  • Page 51

    020-4 En gi n e Oi l Se rv i ce With th e int rod u ct io n of syn t h etic oil and ex tend ed oil ch ang e int erv als, a n ew oil f i l t er wi th imp rov ed fil t er p ap er d esi g n wa s in trod u ced . The n ew fil ter p aper resists d et eri oratio n cau sed b y h igh oil temp eratu res ov e r an ex t end ed time. No te: Early styl e oil f i[...]

  • Page 52

    pu bl i cati on . If there i s an y dou bt ab out w ha t proce du res ap pl y t o a spe ci f i c mode l or mode l year, or w hat i ntervals shou l d be f oll ow ed , reme mber that an au t ho ri z ed BMW de al er ha s t he latest i nformati on on fact ory-re commen ded maintena nce. Engine oil, c hec ki ng le v el En g ine oi l l ev el is ch ecked [...]

  • Page 53

    q t. capacity), are described in 01 0 General . No te: I f using a " fast-l ube " servi ce faci l i t y for oil cha ng es, make sure t he t ech ni ci an ha nd-starts and t orq ue s t he eng i ne oi l dra i n plug using h and -tool s. Pow er tools can st ri p t he t hre ads of t he p l ug an d t he oi l pa n. - Run en g ine f or a f ew min[...]

  • Page 54

    CA UTI ON! Pu l l th e l o os e pl ug away fro m the hole quick l y to av oid bein g s calded by h o t oil. I t w il l ru n o u t q uic kly wh en t he p lug is rem ov ed . I f pos sib l e, us e g l ov es to p ro tec t yo ur hand s. - Wh en oi l f l ow h as d iminish ed to an occasio n al d rip, rei n stal l d rain p l u g with a n ew metal sealin g[...]

  • Page 55

    - Re f il l cran kcase wi t h oil. A p p rox imate oil capacity is l isted in T ab l e d . Use d ipst ick t o ch eck corre ct oi l l ev el. - Start en g in e an d ch eck t h at oil p ressure warnin g l ig h t imme d ia tel y g oe s ou t. - A l l ow eng in e t o ru n f or a few minu t es to circul ate n ew oil, th en ch eck for l eaks at d rai n p l[...]

  • Page 56

    020-5 En gi n e Com pa rtm en t M a i n ten a n ce T h e inf orma tion u n d er th is h ea d ing d escri b es rout ine mai n ten ance other th an oi l ch an g e d one in t h e en g in e compartmen t. I t is n ot n ece ssary f or th e car t o b e raise d an d su p p orted off th e g roun d . Informatio n on oil ch ang e is g iv en earlier in t h is [...]

  • Page 57

    mass ai r f l ow sen sor ( ar row ) int o retai n ing cl ip s in ai r f il ter u p p er h ousin g . Coo ling sys tem s e r v i ce Ro u t in e coo l ing syst em mainten ance consists of maint aining t h e coolant l ev el an d insp ecting h ose s. Beca u se th e coolan t 's ant i-corro sion and anti-f ree ze add itiv es g rad u all y l ose th ei[...]

  • Page 58

    ill u stration sh ows ex amp l es of d ama g e to coolan t h oses. A n y of cond itio n s sh ow n i s cause f or repl ace men t. (Co u r tesy of Gates R u b b er Comp any, I n c.) Engine driv e bel t s e rvice Dri ve b elt s and p u l l eys t ransf er p owe r from t h e eng ine cran ksh aft t o v ario u s acce ssorie s. E46 mod els u se t wo p oly-[...]

  • Page 59

    Simi l arl y, t u rn main eng ine d riv e b elt ten sio n er l u g ( B ) cl ockw ise and remov e b el t . WA RN I NG! Ob se rv e car e wh en replacing belts. Per so nal in jur y co u l d re su l t i f a tensio n er springs back i nto position u n co n tro l labl y. CA UTI ON! Mar k d rive belt ro tatio n di rec ti o n i f re mo vi ng and reu sing a[...]

  • Page 60

    OBD II en h an ced emi ssio n stan d ards requ ire th e eng in e cont rol mod u l e (ECM ) to monitor t h e ox yg en con ten t in th e ex h aust b oth b efore and aft er th e catalytic con v erter. This al l ow s f or tig h t er cont rol of th e tail p ip e emi ssions and al so all ows th e ECM to d ia g n ose conv erter p robl ems. I f t h e ECM d[...]

  • Page 61

    Park car on l ev el g rou n d wi t h eng in e off . Le v el is corre ct if it is b etwee n M I N and M AX marks on d ip stick. I f l ev el is b el ow M I N mark, st art eng in e an d ad d fl u id t o rese rv oi r to b rin g l ev el u p . Stop en g in e and rech eck l ev el. Ha n d -tig h t en reserv oir cap. Pow er stee ri ng fl u id Re commen d ed[...]

  • Page 62

    Re mov e p l astic t rim cov ers ( ar row s ). Re mov e cov er h ol d d own b ol t s. Re mov e ig n itio n coil g rou n d in g h arnesses ( ar row s ). Re mov e ig n itio n coils: Pu l l u p on sp ring cl ip s t o d isco n n ect ig n itio n coil h arn ess conn ectors. Re mov e coi l moun tin g b olt s. Re mov e coi l s. - Re mov e sp ark p l u g s.[...]

  • Page 63

    Be su re to reinst all coil g rou n d in g h arness. Spark p lu g rec o mme n d ation s Bosch FG R7 DQP NGK BKR6 EQUP Ti gh teni n g torqu e Sp ark p l u g t o cyl ind er h ead 25 Nm (18 f t -l b ) Ve ntilation m ic rofilter, repla c ing Working at cowl h ousing insid e eng in e compartmen t, twist microfilt er cov er retai n ers ( ar row s ) 90° [...]

  • Page 64

    020-6 Oth er M ech a n i ca l M a i n ten a n ce B a ttery , c he ck ing a nd cl e aning T h e b att ery is l oca ted in th e righ t side of th e l u g g ag e compartmen t. Simpl e mai n t en an ce of t h e b att ery and its terminal con n ections will ensu re max imu m startin g p erformance, especia l l y i n winter wh en col d er temp era t u re[...]

  • Page 65

    Clean m ai n ch assi s g rou n d terminal n ex t t o b att ery. Corro sio n can b e wa sh ed awa y with a b aki n g soda an d wa ter sol u tion th at wi l l n eu t ralize a cid . A p p l y solu t io n care fu l l y, t h oug h , sin ce it wi l l also n eu tral ize aci d in sid e b attery. Re con n ect cabl e cl amp s, p osi t i v e (+) cabl e f irst[...]

  • Page 66

    onl y. No te: The original eq ui pmen t battery i n E46 mod el s i s mai ntena nce free. T he original el ectrolyt e w i l l norma l l y l ast t he en t i re servi ce l i f e of the ba t tery un der mod erate cl i mate cond i t i ons. B a ttery , re pla ci ng T h e ori g in al equ ip men t BM W b at tery is equ ip p ed with a b u il t-in h yd rome [...]

  • Page 67

    d ama g ing t h e b att ery. No te: Al w a ys di sconn ect t he neg ati ve (-) cab l e f i rst, and con nect i t l ast . W hi l e chan gi ng t he battery, cl ean aw ay an y corro si on i n or aro un d the ba t tery tray. De si gn chara ct eri sti cs of the con verti ble bod y cau se vi bra ti ons to oscil l ate i n t he trunk a rea . There f ore, t[...]

  • Page 68

    Di sc b rake p ad wea r can b e ch ecked th r oug h open in g in cal iper: M ea su re d istan ce ( A ) of b rake p ad "ear" to b r ake rotor. See 340 Brake s . Compare to sp eci ficatio n b elow. Unb ol t cal iper f rom st ee r ing arm t o p roperl y insp ect: Brake p ad t h ickn ess ( A ) Brake rotors Co n d itio n of cal iper seal ( B )[...]

  • Page 69

    Check th at b rake h ose s are corre ct l y rout ed t o av o id ch afin g or kinkin g . I n sp ect u n ions an d b rake calip ers for sig n s of f l u id l ea ks. I n sp ect rig id l ines f or corro sio n , d ent s, or oth er d amage. I n sp ect f l ex ibl e h ose s f or cracking . Re p l ace f aul ty h oses or l ines, see 34 0 Brakes . WA RN I NG![...]

  • Page 70

    up one more st op (cli ck). Dri ve the car ap proximatel y 40 0 meters (1,300 ft . ) an d rel ea se the bra ke. T o rech eck t he ad justmen t of t he parking bra ke see 340 Brake s . Clut ch fluid, c he ck i ng T h e h yd rau l ic cl u tch an d t h e b r ake system sh are th e same rese rv oi r and th e same b rake fl u id . C l u t ch f l u id l [...]

  • Page 71

    env ironmen t al cond itio n s. If sh ort- d istance d r iv in g p red omi n ates, th e moi st u re an d cond en sation in th e system will n ot fu l l y d ry out . This will l ea d to ea rl y corro sio n d ama g e and more f requ en t rep l aceme n t . Sch edu l ed maint enan ce of t h e ex h au st system is l i mited t o insp ect io n : Check to [...]

  • Page 72

    Check rear d ifferent ia l oil l ev el at rea r d ifferent ia l fil l er p l u g ( ar row ). - Check l u b rica n t l ev el with car o n a l ev el su rface: Re mov e oi l fil l er p l u g . Le v el is corre ct wh en f l u id j u st rea ch es edg e of f ill er h ole. I f n ecessa ry, t op u p f l u id . I n stal l and t igh ten oil f ill er p l u g [...]

  • Page 73

    th e d riv er's seat. A p rotectiv e co v er mu st b e remov ed to access th e f il ter. Fu el fil ter for M 52 T U eng in e is sh own in ill u str atio n . E46 cars wi th M 54 eng in e are equ ip p ed with a fu el fil ter th at h as a b u ilt in f u el p ressu re regu l ator. - Di scon n ect b att ery n egativ e (-) cabl e. - Dra in f u el fi[...]

  • Page 74

    is rem ov ed . Do n ot sm oke o r w or k near h ea ters or other fi re h aza rds. Ke ep a fire ext in gu isher hand y. CA UTI ON! Clea n thor ou ghly aro u nd th e fi lter co nn ectio n s b efo re rem ov i n g th em. No te: W hen i nstal l i ng fuel fi l ter cover, t ake care t o reinstal l foam rub ber sea l i n front of cover corre ctl y t o prev[...]

  • Page 75

    Sus pens ion, front , i ns pec ting I n sp ectio n of t h e f ront su sp ension an d steeri n g in cl u d es a ch eck of all mov ing p arts f or wea r and ex cessi ve p l ay. I n sp ect b all j oi n t and t ie -rod ru b b er sea l s an d b oo ts for cracks or tears th at coul d al l ow th e en t ry of d irt, water, an d other cont ami n an ts. On A[...]

  • Page 76

    p ressures can b e fou n d on t h e d r i v er's d oo r p il l ar an d in t h e ow n er's manu al. No t e th at t ire pr essures sh ou l d b e h igh er when t h e car is more h ea v ily l oa d ed. WA RN I NG! Do n ot in flate any tire to a pres su re hi g her than th e tire' s ma ximu m in flati o n pres su re li sted on th e sidewal[...]

  • Page 77

    T ra nsmi ss ion s e rv i c e, m a nual M anu al tr ansmissio n serv ice con sists of insp ectin g for l ea ks an d ch ecki n g th e fl u id . Ev iden ce of tran smissi on l eaks is l ike l y to b e seen aro u n d t h e d riv eshaft moun t ing fl an g e an d at t h e b ott om of th e b ell h ou sin g . No te: For more i nforma t i on on i de nti fy[...]

  • Page 78

    whenev er n ew t ire s are instal l ed. No te: See 320 Steeri ng and W hee l Al i gnme nt for a mo re de t ai l ed discussi on of ali gnme nt req uiremen t s an d specif i cati ons. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. M ai nt en an ce h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20M[...]

  • Page 79

    020-7 Body a n d I n teri or M a i n ten a n ce B ody a nd hinges , l ubric ating T h e d oo r l ocks and l ock cyl ind ers can b e l u b ricated with an oil t h at con t ai n s g raph ite. T h e b od y and d oo r h in g es, th e h ood l atch , an d th e d oo r ch eck r ods sh oul d b e l u b ricated with SA E 30 o r SA E 40 eng in e oi l . Lu b ri[...]

  • Page 80

    wa sh p rodu ct . Rinse u sin g p l en t y of cl ea r water. W ip e th e b od y d ry wi t h a soft cl oth towel or ch amo is t o p rev ent wa t er-spott in g . Interior c a re Di rt sp ots can u su al l y b e remo v ed with l u kewa rm soa p y wa t er or a d ry f oa m cl ea n er. Use sp ot r emo v er for g rea se and oil sp ots. Do not p ou r th e [...]

  • Page 81

    Se at be lts Di rt and oth er ab rasi v e p articl es wi l l d ama g e sea t b el t webb in g . If it is n ece ssary t o cl ea n seat b el t s, u se a mild soap sol u t ion. Bl each an d oth er stron g cl eaning ag en ts may we ake n th e b elt webb ing an d sh ou l d b e av oided . WA RN I NG! Do n ot clea n the sea t bel t w ebb in g u sin g d ry[...]

  • Page 82

    Co mmercia l or sel f -serv ice car wa sh es may n ot b e b est f or t h is, as th ey may recycle t h e sal t-con taminated water. Wa x ing For a l on g -l ast ing , p rotectiv e, an d g l ossy f inish , ap p l y a h ard wax after th e car h as b ee n washed and d ried. Use carn aub a or syn th et ic b ase d p rodu ct s. Wax ing is n ot n eeded aft[...]

  • Page 83

    alcohol or ammo n ia so l u t ion, or a n on-ab rasiv e cl eanser t o cl ean th e wi n d sh ie l d . Wip er b l ad e ch atter may b e caused b y d irty or wo rn b l ad es, b y a d irty wi n d sh ie l d , or b y b ent or twisted wi p er arms. Cl ea n th e b l ades and wi n d sh ield as describ ed abov e. A d j u st th e wi p er arm so th at th ere i[...]

  • Page 84

    OBD-2 On -Boa r d Di a g n os ti cs (OBD I I ) OBD II is an acronym f or On - Boa rd Di ag n ostics II , t h e seco n d g en era t ion of on-b oard self -d iagn ostic equ ip men t requ ireme n ts. T h ese st and ards wer e ori g in al l y mand ated for Californ ia v ehicl es. Sin ce 199 6 t h ey h av e b een app l ie d t o al l p assen g er v ehicl[...]

  • Page 85

    rese t using the spe ci al scan t ool. Re movi ng the conn ector f rom t he ECM or disconn ecti ng the ba tt ery w i l l no t era se the fault memory. T h e ex t ra h ard war e n ee d ed t o operate th e O BD I I syst em consists mainl y of th e f ol l ow ing : A d d itional ox yg en sensors d ow n st rea m of t h e catal yt ic conv erters Fu el ta[...]

  • Page 86

    T h e M I L wi l l come on u n d er th e fol l owi n g con d itions. A n eng i n e man agement system faul t is d etected f or t wo consecu tiv e OB D I I d riv e cycl es. A catal yst d ama g ing fau l t . A comp on ent malfu n ct io n (su ch as catalyst d et eri oratio n ) causes emi ssions t o ex ceed 1.5 t ime s OBD II st and ard s. M anu factu [...]

  • Page 87

    Addi tio n al i nf orma t io n, M IL : A f aul t cod e is stored wi th in th e ECM u p on th e first occurr ence of a fau l t in t h e syst em b eing ch ecke d . T wo compl ete consecu tiv e d riv e cycl es wi th t h e fau l t p rese n t ill u minate t h e M IL . T h e ex ception to th e two-faul t requ ire ment is a catalyst d ama g ing f aul t , [...]

  • Page 88

    With th e u se of a u n iv ersa l or 'g en eric' scan t ool con n ected to t h e DLC (Di ag n ostic Link Co n n ector), d iagn ostic trou b l e cod es (DT Cs) can b e ob t ai n ed, along wi th th e cond itio n s associ ated wi t h th e ill u min atio n of th e eng ine serv ice l igh t. Usi n g a more ad v anced or BM W-d edicated scan too[...]

  • Page 89

    i nstall ed. Professiona l di ag nosti c scan t oo l s ava i l ab l e at t he ti me of thi s printi ng i ncl ud e the BMW factory tools ( DI Splus an d MoDiC) and a small numb er of aftermarke t BMW -spe ci f i c tools. The CS2 000 from Baum Too l s Un l i mi ted , t he Re t ri ever from Assenma cher Spe ci alt y T ools, and t he MT 25 00 from Snap[...]

  • Page 90

    requ ired t ests. T h e ECM mu st reco g n ize t h e l oss or imp airm ent of t h e sign al or compon ent an d d etermine if a sign al or sensor is f aul ty b ased on 3 cond itions: Sign al or compon ent sh orted t o g roun d Sign al or compon ent sh orted t o B+ Sign al or compon ent missing (open circu it) T h e OBD II syst em mu st monitor al l [...]

  • Page 91

    ECM cann ot d et ermi n e th e env ironmen t or en g in e operating cond itions d u e t o missing or fau l t y sign al s it will set a fau l t cod e an d , d epen d in g on cond itio n s, il l u min ate th e M I L. Ox yg en sensor mon itoring : W h en d riv e cond itions all ow , respon se rate an d swi t ch in g time of each ox yg en sensor is mon[...]

  • Page 92

    Sp eci fic cyl in d er(s) Sev erity of t h e misfire ev ent Emissi on s rel ev ant or catalyst d ama g ing M isfire d etectio n is an on -g oing monitoring p rocess th at is onl y d isa b l ed u n d er certai n l imite d cond itions. Seco n d ary ai r in j ection monitoring : Seco n d ary ai r in j ection is u sed t o redu ce HC and CO emissi on s [...]

  • Page 93

    set an d id en tify th e fau l t y b ank(s) . I f after comp l eting t h e n ex t col d start a faul t is ag ai n p rese n t, th e M IL wi l l b e ill u minated . Fu el system mon itori n g : Th i s monitors rece iv es h ig h p rio rity. It l ooks at t h e fu el d eliv ery n eeded (l on g / sh ort t erm fu el trim) f or p rop er eng in e op era tio[...]

  • Page 94

    ch eck system in t egrity. O n M S 43 .0 cars, a more so p h isticated DM T L (Di ag n ostic M od u l e - Lea k De t ectio n ) p u mp is u sed . Driv e cy c le T h e OBD II d riv e cycl e is an imp ortant concep t in u n d erstan d ing O BD I I requ ireme n ts. T h e p u rp ose of t h e d riv e cycl e is to ru n all of th e emissio n - related on -[...]

  • Page 95

    OBD-3 BM W Fa u l t Codes (DT Cs ) Below is a co mp reh ensiv e l isting of BM W DT Cs an d th e corre sp ond ing SA E P-cod es. T a ble a . Diagnos tic trouble c odes (D T Cs ) BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explan ation 1 I g n ition coil cyl . 2 I n p u t an al og timing (100 mV ) DM E in itia t es se con d [...]

  • Page 96

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 8 P01 01 M ass air fl ow circuit rang e/p erf. I n p u t an al og (0-5 V) Failed sign al r ang e ch eck against p redefin ed d iag n ostic l imi t s. 10 En g ine coo l ant temp . circu it rang e/p erf. I n p u t an al og (0-5 V) Sign al ran g e is ch ecke d against p [...]

  • Page 97

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 23 P02 06 I n j ector circu it cyl . 6 Ou tp u t d ig ital p u l se widt h (activ e l ow ) DM E f in al stag e will set f l ag wh enev er a sh ort t o g rou n d , a sh ort to b at tery v ol t age or a d isconn ection b etwee n ou tp u t t ransistor an d comp onen t ex[...]

  • Page 98

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 33 P02 05 I n j ector circu it cyl . 5 Ou tp u t d ig ital p u l se widt h (activ e l ow ) DM E f in al stag e will set f l ag wh enev er a sh ort t o g rou n d , a sh ort to b at tery v ol t age or a d isconn ection b etwee n ou tp u t t ransistor an d comp onen t ex[...]

  • Page 99

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 45 M u l t i f u n ct io n al steeri n g wh eel, tog g l e-b it I n p u t b inary stream (0-1 2V ) Ev ery 0.5 sec. a messa g e t h at in cl u d es a t ogg l e b it (tog g l es b etwee n 0->1 and 1->0 ) is t ransmitt ed. Chang e b it is monitored t o ind icate p [...]

  • Page 100

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n sh u n t resistor (l imitatio n v ol t age) t h en seco n d ary ign itio n v olt ag e is d etected and sh u n t r esi stor may b e f aul t y. 57 P03 25 Knock sen sor 1 circuit, (Bank 1) circuit cont inu ity I n p u t an al og ampl itu d e (13 -19 kHz) Pl au sibil ity [...]

  • Page 101

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n tran sistor and comp onen t ex ists. 74 A C compr esso r relay Ou tp u t d ig ital on/ off (activ e l ow ) DM E f in al stag e will set f l ag wh enev er a sh ort t o g rou n d , a sh ort to b at tery v ol t age or a d isconn ection b etwee n ou tp u t t ransistor an [...]

  • Page 102

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n sp ring w ith in motor t h rott l e b ody. 11 0 P15 42 Pe d al sen sor p otent io meter 1 I n p u t an al og (0-5 V) Failed sign al r ang e ch eck against p redefin ed d iag n ostic l imi t s. 11 1 P15 42 Pe d al S ensor Potent io meter 2 I n p u t an al og (0-5 V) Fa[...]

  • Page 103

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 11 7 P15 42 Pe d al sen sor p otent io meter p l au sibil ity I n p u t an al og (0-5 V) I f t h ere is a d ifference g reater t h an sp ecifie d b etwee n t wo redu n d an t sign als f rom p oten tiome t er, fau l t will b e set. 11 8 P01 20 M S 42 M otor th rottl e [...]

  • Page 104

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n d isconn ection b etwee n ou tp u t tran sistor and comp onen t ex ists. 12 4 P15 93 D ISA , rang e/ p erf. Ou tp u t d ig ital on/ off (activ e l ow ) DM E f in al stag e will set f l ag wh enev er a sh ort t o g rou n d , a sh ort to b at tery v ol t age or a d isco[...]

  • Page 105

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 13 1 C A N t ime out (in str 2) I n p u t b inary stream b it d ata (0-1 2V ) CA N me ssage b et we en DM E /EG S n ot recei v ed wi t h in ex p ected t ime . 13 2 C A N t ime out (in str 3) I n p u t b inary stream b it d ata (0-1 2V ) CA N me ssage b et we en DM E /[...]

  • Page 106

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n swi tch is " l ow" for l ong er t h an p redet ermi n ed t ime . 14 2 M S 43 D M T L mod u l e fau l t DM E in tern al v alu es l ogical 14 3 P14 76 EV A P: cl amped tu b e ch eck I n p u t d igital freq u en cy (0-12 V) Freq u en cy of LDP pu mp s ree d sw [...]

  • Page 107

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n on inp u t l in e. 15 3 P01 50 Ox yg en sensor p re-ca t (Bank 2), sh ort t o b att ery v olt . I n p u t an al og (0-5 V) O x yg en sen sor sign al rang e is ch ecked to d etermine if el ectrica l sh orts ex ist on in p u t l in e. V olt age sig n al must b e wi th i[...]

  • Page 108

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 16 0 M S 43 T h rottl e v al v e p osi t ion cont rol l er DM E in tern al v alu es l ogical 16 1 M S 43 T h rottl e v al v e p osi t ion cont rol l er DM E in tern al v alu es l ogical 16 2 M S 43 T h rottl e v al v e p osi t ion cont rol l er DM E in tern al v alu e[...]

  • Page 109

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 18 8 P11 32 Ox yg en sensor h eate r, p re-cat (Bank 1), insu f f ici en t Ou tp u t d ig ital p u l se widt h (activ e l ow ) DM E in t ernal l y calcu l ated h eate r p ow er is ch ecke d against p redefin ed d iag n ostic l imi t s. 18 9 P11 33 Ox yg en sensor h ea[...]

  • Page 110

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n sign al. If mor e t h an t wo ign itio n sig n al s are n ot reco g n ized t h an th ere mig h t b e a p robl em in f ee d b ack l in e. 21 1 P15 10 I d l e con trol v alv e stu ck DM E in tern al v alu es l ogical Fu n ct io n al ch eck ag ai n st a cal cu l ated v a[...]

  • Page 111

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 22 2 P01 25 I n su f ficie n t coolant temp . to p ermit cl ose d l oo p operatio n I n p u t an al og (0-5 V) Co m p ari son of actu al coolant t emperatu re against cal cu l ated DM E v alu e wh ich v arie s with l oad sign al. 22 3 P11 80 Ox yg en sensor p ost-cat [...]

  • Page 112

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n swi tch f aul t wi l l set. 23 2 P01 79 Ox yg en sensor p re-ca t (Bank 2), swi tch time too sl ow I n p u t an al og (h ig h is l ea n ) ( 0-5 V) Ch ecks am oun t of t ime ox yg en sen sor takes to switch f rom rich to l ea n and v ice v ersa. I f it takes too l on g[...]

  • Page 113

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n for cyl ind er 2 is l ong er, f aul t wi l l set. 24 0 P03 03 C yl . 3 misfire d etected DM E in tern al v alu es l ogical Cra n ksh aft sp eed/ acce l era tion is monitored b y crank sensor. T ime f or ea ch cyl ind er combu stion is compared against av g. of oth ers[...]

  • Page 114

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 24 5 P14 23 Se con d ary ai r inj ection (Bank 1), fl ow too l ow I n p u t an al og (0-5 V) Ch ecks to see if ox ygen sensor reacts t o incr ea se in u n metered ai rfl ow g enerated b y seco n d ary air pu mp operatio n . O x yg en sen sor mu st sen se l ean cond it[...]

  • Page 115

    100-1 Gen era l T h is sect io n cov ers system d escri p tions and g en era l in f orma tion on en g ines and eng ine man agement systems. A l so cov ered is b asic eng in e trou b l esh oo tin g . For sp ecific repair p rocedu res, refer to th e ap p rop riate rep ai r g roup : 11 0 En g in e Re m ov al an d I n stal l ation 11 3 Cylin d er Hea d[...]

  • Page 116

    3.0 liter) en g in es were in trod u ced. T h is eng in e incorp orates a l l t h e t echn ical featu res of t h e M 52 T U eng in es with add ition of fu l l y el ectron ic th rottl e contr ol an d en h an ced emi ssio n contr ols. Ta b l e a. En g ine sp eci ficatio n s l ists eng in e sp ecifica t ions f or t h e v eh icles cov ered b y t h is m[...]

  • Page 117

    M o d el ye ar Eng i ne code No. of cy l in d er s Displace me n t cc (cu. i n .) B o re / str o ke C o mpre ss i o n ra ti o To rqu e l b-ft/ rpm Hors ep ow er Hp/rpm i n . ) T orque/pow e r graphs M 52 T U 2.5 l iter M 52 T U 2.8 l iter En g i n e- Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s[...]

  • Page 118

    M 54 2 .5 l iter M 54 3 .0 l iter En g i n e- Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 4 of 19 2/ 25/ 2009 9: 58 PM[...]

  • Page 119

    Cyli nder bloc k a nd cra nkshaft T h e cyl ind er b l ock is ca st al u minu m all oy (A l Si9C u 3) with cast iron cyl in d er l iners. The cyl in d ers are ex p osed on al l sides t o circu l ating coolant . T h e coun terwe i g h t ed cran ksh aft rotates in repl ace abl e sp l it-sh el l mai n b ea r ing s. Oil wa ys d rill ed in t o th e cran[...]

  • Page 120

    Con nec ting rods a nd pist ons T h e forg ed st ee l con n ectin g rods u se repl acea b l e sp l it- sh ell b ea rin g s at th e cranksh af t end an d solid b u sh in g s at t h e p iston p in end . T h e p iston s are of t h e th ree - ring t yp e wi th t wo u p p er compr essi on r ing s an d a l ow er one-p ie ce oi l scraper rin g . Fu l l -f[...]

  • Page 121

    Each ex h aust manifol d asse m b l y incorp orate s a catal ytic con v erter. T h e conv erters are moun ted cl ose t o th e eng in e f or faster h ea t u p . Pre- an d p ost-catal yst ox ygen sensors are a moun t ed in each ex h aust manifol d . Coo ling sys te m T h e coo l in g syst em circul atio n is d esi g n ed so t h at coo l an t fl ows d[...]

  • Page 122

    all ows t h e eng in e t o b e operated at h ig h er cont rol l ed t emperatu res d u rin g l ow an d p art t h rottl e. This opt imize s operating temp eratu res in b oth cyl in d er h ead an d b l ock, red u ces f rictio n an d th ere b y f u el con su mp t ion. T h e coo l in g syst em is d esign ed to: Re d u ce op era t in g t emp era tu r es [...]

  • Page 123

    torq u e b y ch an g in g t h e intake air f l ow conf igu ratio n f or v arying en g ine sp ee d s. T h is h elp s achiev e op timu m torq u e th roug h out t h e en tire RPM ran g e. Durin g eng in e op era tion, a cl ose d reso n ance v alv e g iv es t h e int ake ai r ch arge th e d yn ami c eff ect of l on g int ake ru n n ers at l ow to mid -[...]

  • Page 124

    T h e int ake ma n ifol d in cl u d es int ake tu rb u l en ce p orts. The 5.5 mm (0.21 7 in. ) tu rb u l en ce p orts ch ann el idl e and l ow sp eed air d ire ct l y f rom t h e idl e sp eed cont rol v al v ed t o on e int ake v al v e of ea ch cyl ind er. Ro u t in g int ake a ir t o one in take v alve p er cyl ind er causes t h e air ch arge t [...]

  • Page 125

    conv erter an d f aste r redu ct ion in emi ssion s. Ov eral l imp rov ed f u el economy. See 117 Camshaft Ti m ing Chain s f or V A NOS system t esting an d rep ai r inf orma t ion. Engine m a na gem e nt s y st e m T h e Sie mens eng ine man agement systems u sed in E46 cars comb ine f u el inj ect io n , ign itio n an d oth er f u n ct ions u n [...]

  • Page 126

    Co n n ector 1: Vo l t ag es and g rou n d s Co n n ector 2: Ancill ary sign als (ox yg en sen sors, CA N, etc. ) Co n n ector 3: En g in e sign als Co n n ector 4: Ve h icl e sig n als Co n n ector 5: Ig n itio n sig n al s No te: The fl ash EEPROM ( chip) i s specifi call y `pro grammed ' to the veh i cl e. It ha s the cap abil i t y t o be [...]

  • Page 127

    (ECT ) in cyl ind er h ead su p p l ies coo l an t t emp era tu r e information to th e EC M . ECM o u tpu ts: Fu el inj ect or open in g d u ratio n . I n t ake an d ex h au st v al v e t imi n g v ia th e V A NOS system. T h e radiator coo l ing f an an d th e h eate d coo l ant th ermostat. M otor-d riv en t h rot tl e v alv e: M DK in M S 42.0 [...]

  • Page 128

    Fu el p u rg e v alv e and fu el t ank l ea kag e d ia g n osi s p u mp (LD P or DM -TL ). Fu el meteri n g : The ECM met ers p ressur ize d f u el b y ch ang in g th e open ing t ime (p u l se widt h ) of t h e f u el inj ect ors. The ex act amoun t of f u el inj ect ed is d etermined b y th e amoun t of time th e inj ectors are open . To ensu re [...]

  • Page 129

    Co n t rol of col d air in take v ol u me. For ex ampl e, at ai r temp era t u res b el ow 0°C (32°F), el ectronic t h rottl e cont rol (M DK/EDK) is al so open ed d u rin g idl e. Smoo t h idl e sp ee d s regard l ess of l oa d and in p u t s Lo wer rp m rang e Smoo t h tr ansition from acceleratio n to d eceleratio n I d l e sp eed stab ilizati[...]

  • Page 130

    I f t h e fau l t cau ses incr ea sed ai r f l ow (actu ator failed open ), V A NOS an d kn ock cont rol are d eactiv ated. This redu ces eng in e p erformance n oticea b l y. T h rott l e cont rol: Th e th rottl e v alv e p l ate is electron ica l l y operated f or p reci se th rottl e op eratio n , OBD II compl iant f or fau l t mon itori n g , a[...]

  • Page 131

    I g n ition f u n ction: a d istribu t orl ess ig n itio n system with in d iv id u al ign ition coils f or ea ch cyl ind er is emp l oyed. Th e coi l s are moun t ed ov er t h e sp ark p l u g s and conn ect t o th e p l u g s v ia a sh ort l ea d . T h e Sie mens systems u se mu l t ipl e sp ark ign itio n t o redu ce emi ssions and ex t en d sp [...]

  • Page 132

    Si e m e ns DM E M S 4 3 .0 En g i n e- Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 18 of 1 9 2/ 25/ 2009 9: 58 PM[...]

  • Page 133

    Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. En g i n e- Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 19 of 1 9 2/ 25/ 2009 9: 58 PM[...]

  • Page 134

    100-2 Dri v ea bi l i ty T rou bl es h oot i n g T h e Sie men s syst ems are soph isticated sel f-d iagn osing O BD II systems. T h ese syst ems cont in u ousl y monitor comp onen ts an d r eco rd an d store v alu ab l e diag n ostic inf ormatio n . I f th e `Check En g in e' or `Serv ice En g ine Soo n ' l ig h t [ al so kn own as th e [...]

  • Page 135

    v olt s for a b attery wi t h a 25% ch arg e. Ev en a fu l l y ch arg ed b att ery cann ot d eliv er p owe r u n l ess it is p roperl y conn ected to t h e electr ica l syst em. Check th e b att ery terminal s for corro sion or l oose cabl e conn ect io n s. I f th e b attery d oes n ot mai n t ain th e p roper v ol t age, t h e ch arg ing syst em [...]

  • Page 136

    Good g roun d s are critical to p roper DM E operatio n . If a g roun d con n ectio n h as n o v isibl e f au l ts b u t is stil l su sp ect, mea su re th e v olt age d rop acro ss t h e conn ection. A l arg e v ol t age d rop ind icates h igh resistance, ind ica tin g th at t h e conn ect io n is corroded , d irty or d ama g ed. Clean or repair th[...]

  • Page 137

    eng in e compart ment , b eh ind l ef t h ea d l ig h t assembl y (h eadl ig h t asse mb l y sh ow n remov ed). M ai n f u el p u mp g rou n d ( arr o w ) b eh ind righ t rea r sea t b ack rest. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. En g i n e- Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/[...]

  • Page 138

    110-2 En gi n e Rem ov a l a n d I n s ta l l a ti o n Be su re to cov er all p ai n ted su rf ace s b efore b eginn in g t h e remov al p roce d u re. As an ai d t o in stal l atio n , l abel all comp onen ts, wi res and h oses b efore remov in g th em. Do n ot reu se g aske t s, O -rin g s or seals d u r ing rea ssemb l y. WA RN I NG! Du e to ris[...]

  • Page 139

    Re mov e h ou sing f or int eri or v ent il ation micro f ilt er. Re mov e u p p er cov er an d micro f ilt er. Op en wi ring h arn ess l oo m cov er ( A ) and remo v e wi res. Unf asten screw s ( B ) a n d remo v e l ow er micro f il ter h ou sin g . Re mov e in take manifold cov er: Re mov e p l astic t rim cov ers ( ar row s ). Re mov e cov er h[...]

  • Page 140

    I f ox yg en se nso r harnes s co nn ec to rs ar e separ ated, b e su re to ma rk them so th at th ey can b e re as sem b l ed as befo re. Working at l eft rear of en g in e compartmen t: Pee l ru b b er edg e sea l off top of p anel . T wist p l astic p an el retainers ( ar row s ) 90° and p u l l ou t t o remo v e. Di sen g ag e p an el fr om h [...]

  • Page 141

    Li f t off con n ector l oo m and l ay asi d e. Re mov e compl ete ai r f ilt er h ou sing : De t ach v acu u m l in e at in t ake b oot ( A ). Di scon n ect electr i cal h arn ess conn ector on m ass ai r f l ow se n sor ( B ). Re l ea se mass air fl ow sensor cl ips ( C ). Re mov e f ilt er h ou sing mou n tin g screw s ( D ). De t ach air d u ct[...]

  • Page 142

    8 - Ho se cl amp 28 - 33 mm 9 - Ho se cl amp 77 - 84 mm Wh ere app l icabl e: P u l l t h rott l e cabl e u p wa rd s out of ru b b er retai n er ( A ) and u n h ook b all en d of cab l e ( B ) f rom th r ottl e actu ator. No te: Mod el s eq uippe d w i th M54 en gi nes d o no t use a throttl e cab l e mou nted to throttl e hou si ng . Re mov e n u[...]

  • Page 143

    De t ach el ectrica l h arness con n ector at fu el tan k v ent ing v alv e ( A ). Disco n n ect h ose at q u ick d isconn ect f itt ing ( ar row ). Re mov e d ip stick g u ide t u b e: De t ach wiri n g h arness b racke t s from t u b e ( A ). De t ach f u el l in es f rom tu b e ( B ). Re mov e l owe r g u ide tu b e moun t ing b olt ( C ). Pu l [...]

  • Page 144

    pres su re (app ro x. 3 - 5 b ar or 45 - 75 psi) and ma y be expelled u n d er p re ssu re . Do n o t smo ke or wor k n ear heate rs or o ther fire hazar d s. Kee p a fi re ex ti n g uisher h andy. B efo re di sc o n n ec t in g fu el h o ses , wrap a clo th ar ou n d fue l h os es to abso rb any l eak i ng fue l . Ca tch and d ispos e of es caped [...]

  • Page 145

    tools 13 5 281 / 13 5 282 . CA UTI ON! Fue l ma y be ex pell ed u n d er pres su re . Do n ot sm ok e o r w or k n ea r heate rs o r other fire h aza rds. Kee p a fire ex ti ngu i sher handy. B efo re di sc o n n ec t in g fu el h o ses , wrap a clo th aro und fue l h os es to abso rb any lea king fu el. Pl u g all open fue l li n es . Working u n [...]

  • Page 146

    Li f t u p man ifold j u st en oug h t o d etach p osi t iv e cabl es from st arter motor terminal 50 ( ar row ). - Re mov e in take manifold from cyl ind er h ead wh il e care f u l l y ch ecki n g for el ectrical conn ections or h ose s. CA UTI ON! Stu ff clean rag s in to open i nt ak e por ts to prev ent any p ar t s fro m falli ng in to the en[...]

  • Page 147

    Engine ass e m bly, r em oving and inst al ling No te: The i ntake manifol d must be r emo ved as de scri be d earli er to f aci l i t ate en gi ne asse mbl y remo val . Re mov e cyl in d er h ead top cov er : Re mov e p l astic t rim cov ers ( ar row s ). Re mov e cov er h ol d d own b ol t s and l ift off cov er . Dra in en g in e coo l an t and [...]

  • Page 148

    hum ans and p ets. Pets ar e attra cted to co olant b eca us e of its sweet sm ell and tas te. Co n su l t a ve terinarian imme d i ate l y i f co olant is i nge sted by an animal. No te: Ca t ch and dispose of dra i ne d coo l an t acco rdi ng t o l ocal, st ate, and fed eral l aw s. Re mov e h oses from t h ermosta t h ousin g b y releasi n g l o[...]

  • Page 149

    De t ach coolant h ose at f ront l eft sid e of eng in e b y eng in e mou n t b y rel ea sing l ock ( ar row ). - Unb ol t p owe r st ee ring f l u id rese rv oi r an d p u l l aside with out d etachin g h ose s. Ti e t o f end er wi t h cord or st iff wir e. Working at E -b ox at l eft rear of en g in e compartmen t: De t ach en g in e electrical [...]

  • Page 150

    Re mov e p owe r st ee rin g p u mp: Re mov e st ee rin g p u mp p u l l ey. Re mov e f ront an d rea r p u mp moun t ing b olt s ( ar rows ). Ha n g p u mp fr om b ody u sin g stiff wi re. Re mov e A / C compressor moun t in g b olt s ( ar rows ) an d A /C comp ressor from its moun t in g b racke t with out d isco n n ecting , d istortin g , or d [...]

  • Page 151

    b ottom of seco n d ary air p u mp . Re mov e b racke t f rom stru t towe r. Separate o x yg en sen sor elect rica l h arness con n ectors ( arr o ws ) and moun t ing cl ip ( A ) on rig h t si d e of eng in e. Re mov e ch assis g roun d st rap ( arr ow ) at rig h t en g ine moun t in g p ed estal. I n stal l an en g ine l iftin g d ev ice (BM W 11 [...]

  • Page 152

    Wh en rei n stal l in g , make su re l ocating p in on l eft eng ine mou n t ( arr o w ) seats corre ct l y in sl ot of su b f rame b oss. - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : Re p l ace al l g askets, O-rin g s and sea l s. Chang e en g ine oil and fil ter an d ch eck all oth er f l u id l ev els. See 020 M[...]

  • Page 153

    Ti gh teni n g torqu es Co ol an t d rain p l u g to cyl ind er b l ock 25 Nm (18 f t -l b ) En g in e moun t t o sub f rame M 10 4 5 Nm (33 ft -l b ) Ex h au st man ifold t o cyl in d er h ead M 6 10 Nm (8 f t-l b ) M 7 or M 8 20 Nm (15 f t -l b ) I n t ake manifol d t o cyl ind er h ea d M 7 15 Nm (11 f t -l b ) M 8 22 Nm (16 f t -l b ) Ra d iato[...]

  • Page 154

    113-1 Gen era l T h is g rou p cov ers E46 cylin d er h ead remo v al and in stal l ation as well as cyl ind er h ead/v alv e d ia g n osi s p roce d u res. T h e inf orma tion g iv en in t h is rep ai r g roup assu mes th at t h e en g ine is inst all ed in th e en g ine b ay. In ord er to remo v e th e cyl ind er h ea d f rom th e eng in e b l oc[...]

  • Page 155

    T orq u e wrench w/ fl ex ex t en sio n BM W sp eci al t oo l 00 9 25 0 E-12 To rx socke t BM W sp eci al tool 11 2 25 0 Cra n ksh aft l ocking t oo l B M W sp ecia l tool 11 2 300 Ca msh af t l ocking tool BM W sp ecia l tool 11 3 240 Ca msh af t l ocking tool b racket BM W sp eci al t oo l 11 3 24 4 Li f t er retai n ing su ct ion cu p BM W sp ec[...]

  • Page 156

    Ca msh af t b eari n g cap r emo v al t oo l BM W sp ecia l t ool 11 3 26 0 / 11 3 27 0 T iming ch ain t ensioner t oo l B M W sp eci al t oo l 11 4 22 0 V A NOS adj u st men t p l ate BM W sp ecia l tool 11 6 150 Seco n d ary sp rocket setu p t oo l BM W sp eci al t oo l 11 6 18 0 A ir l in e adap ter B M W sp ecia l t oo l 11 3 45 0 Cy li n d er [...]

  • Page 157

    Seco n d ary ch ai n ten sioner l ock p in BM W sp ecia l t ool 11 3 29 2 Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Cy li n d er Hea d Rem oval and I n stal la tion h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 4 of 4 2/ 25/ 2009 9: 48 PM[...]

  • Page 158

    113-2 Cyl i n der Hea d Rem ov a l WA RN I NG! Du e to risk o f p er sona l i nj u ry , be su re th e eng i n e is co ld befo re beg i nn i n g th e re mo va l proc edur e. Cylin d er h ead remo v al an d in st al l atio n is a compl icated rep ai r p rocedu re. V A NOS cont rol u n it, timing ch ain , and camshaft remov al and in st all ation al l[...]

  • Page 159

    CA UTI ON! Prio r to di sco nn ect in g the batter y, rea d th e battery di sc o n n ec t ion cau tions giv en at the fro n t o f th is manua l on p ag e viii. Disc onnecting the b atter y ma y er ase fau l t co d e(s ) sto red i n co ntro l mo d u le mem or y. Check fo r fau lt co d es us i ng specia l B MW di ag n os tic equ ip me nt. Re mov e mi[...]

  • Page 160

    Re mov e cov er h ol d d own b ol t s from in take cov e r an d l ift off cov er. Working abov e en g in e, d isconn ect t h e fol l owi n g : A Posi t iv e eng in e l ead at B+ terminal B M anifol d v acuu m l ine C Ox yg en sensor con n ectors (l abel conn ectors b efore d isco n n ecting ) D El ectrica l h arness con n ector f or int ake air tem[...]

  • Page 161

    Di scon n ect eng ine v en t h ose f rom cyl ind er h ead cov er b y sq u eezi n g sides of sp rin g cl ip ( arr o w s ). Disconn ect V A NOS solen oi d electrical h arness conn ector ( A ). Di scon n ect fu el in j ector electrical conn ectors f rom inj ectors: Use small screw d r iv er t o p ry on e corner of wi r e l ock cl ip on f u el inj ecto[...]

  • Page 162

    p u l l in g it f orwa rd awa y f rom mass ai r fl ow sen sor. No te: I n t his st ep , mass air f l ow sen sor rema i ns attache d t o rubb er ai r duct. Lo osen cl amp s 2 an d 8 and remov e mass ai r f l ow sen sor and air d u ct . 1 - T h r ottl e asse mb l y 2 - Ho se cl amp 77 - 84 mm 3 - Y-d u ct 4 - A ir d u ct 5 - Ho se cl amp 83 - 90 mm 6[...]

  • Page 163

    Working at t h rottl e hou sin g : T u r n h arness p l u g ( arr o w ) coun t erclockwi se and remov e. Di scon n ect electr i cal h arn ess conn ector at idl e sp ee d cont rol v al v e ( ar row ) d ire ctl y ab ov e th rott l e h ou sin g . Working u n d er fron t corn er of in t ake manifol d , d isco n n ect el ectrical h arness conn ector at [...]

  • Page 164

    Re mov e d ip stick g u ide t u b e: Di scon n ect wi r ing h arn ess b racke ts fr om tu b e ( A ). Di scon n ect fu el l in es fr om retai n ing cl ip s ( B ). Re mov e l owe r d ip stick g u ide t u b e moun t ing b olt ( C ). Pu l l out g u ide tu b e. Re mov e sch ræd er v al v e cap ( ar row ). Usi n g a tire ch u ck, b l ow f u el b ack th [...]

  • Page 165

    pro fess ional au tom o t ive li ft or j ac k sta n ds desig n ed f o r the p ur p o se . A floo r jack i s not adequ ate su p por t. - Re mov e p rotectiv e eng ine sp l ash g u ard f rom b eneath eng ine compartmen t. Working b en ea th car (on l ef t side u n d er d riv er seat), remov e f u el f il ter cov er an d cl amp off f u el h ose( s) ( [...]

  • Page 166

    Separate fu el l ine su p p ort b racke t at rear of in take manifol d . T h r ea d f u el l in e(s) ou t of rear of eng in e compart ment wh il e l iftin g fu el rai l ou t . Re mov e in take manifold moun t ing n u t s ( ar row s ). Li f t u p man ifold enou g h t o d iscon n ect p osi t iv e cabl es from st arter motor terminal ( ar row ). Re mo[...]

  • Page 167

    2 of en g in e b l ock ( arr o w ). Dra in r adiator int o a 3-gal l on p ai l b y remo v ing p l astic d rain p l u g at l owe r l eft end of r adiato r ( ar row ). WA RN I NG! Us e cau tion w h en d raini ng and di spo si ng o f engine co olant. Co olant is p o iso nou s and l ethal to hum ans and p ets . Pe ts are attr acte d to co o lant beca u[...]

  • Page 168

    Re mov e b ol t on t op of rese rv oi r. Li f t t ank an d d isco n n ect electrical conn ections t o p u mp and t o wa sh er fl u id l ev el sensor. Di scon n ect h ose s to wind sh ie l d wa sh er and h eadl igh t wa sh er. Ti l t rese rv oi r to p rev e n t f l u id from l ea kin g out . Re mov e second ary air p u mp : Di scon n ect h ose at on[...]

  • Page 169

    Re mov e ig n itio n coils. Di scon n ect ign ition coil h arn ess conn ectors. Re mov e coi l moun tin g fasten ers. Re mov e coi l s. Re mov e g rou n d st raps. Set coil h arness to l eft side of eng in e compart ment . - Re mov e cyl in d er h ead cov er moun t ing fasten ers and remo v e cyl ind er h ead cov er. No te: The cyl i nd er he ad co[...]

  • Page 170

    Dou ble VA NO S com ponents (M 52 T U, M 5 4 e ngine) 1 - Impu l se wh eel moun tin g n ut 2 - Exhaust ca mshaft impu l se wh eel 3 - Sprin g p late 4 - Th rust spac er (T = 3.5 mm) 5 - Spl in ed shaft 6 - To rx scr ew 7 - Exhaust se con d ar y sprock et 8 - Sec o n dary timin g chain 9 - Spl in ed slee ve 10 - Prima ry sprock et 11 - Th re ad ed l[...]

  • Page 171

    14 - Sprocke t moun tin g n ut 15 - Sprin g p late 16 - Spl in ed shaft 17 - In tak e ca mshaft sprock et 18 - Lo ca tin g stud 19 - Th rust spac er 20 - In tak e ca mshaft impu l se wh eel 21 - Chain tension er ra i l 22 - Cr ankshaft sprock et 23 - Prima ry chain tension er 24 - Prima ry chain 25 - Lo ca tin g stud 26 - Gu i de rail 27 - Lo ca ti[...]

  • Page 172

    Re mov e b an j o b ol t f rom V A NOS u n it oil p ressur e l ine. Use ban j o bol t to att ach BM W sp ecia l tool 11 3 45 0 (compressed ai r f ittin g ) to V A NOS con t rol u n it. Co v er oi l h ole ( arr o w ) in V A NOS u n it wi th sh op t owe l t o capt u re oil which wi l l sp ray when compressed ai r is ap p l ied . - C onn ect comp ress[...]

  • Page 173

    Re mov e sealing p l u g f rom sp eci al t oo l b ore on l ow er l eft side of en g in e b l ock n ear f l ywh ee l . Secur e cranksh af t in TD C p osi t ion with BM W sp ecia l t oo l 11 2 30 0 ( ar row ). Unscrew and remov e t wo cyl in d er h ea d cov er stu d s ( arr o w s ) at rear of cyl ind er h ead. Secure camsh afts in TD C p osi t ion u [...]

  • Page 174

    Oil wil l d r ai n f rom p l u g s ( arr o ws ) wh en remo v ed. Ha ve a cont ai n er and rag s rea d y. Do n ot al l ow oi l t o ru n ont o d riv e b el ts. Pu l l sealin g cap s straigh t out of V AN O S u n it with BM W sp eci al tool 11 6 1 70 , or wi th sh ort n ose p l ier s. No te: Add i ti onal oil may drain f rom VANOS un i t . Re mov e se[...]

  • Page 175

    Do n ot cr ank th e engine w ith VA NOS u n i t re mo ved. T he spli ned shaft on the i n tak e c am shaft mig h t sl ip o ut o f the VA NOS spl in e teeth, ca u sing the in tak e ca m to n o l o nge r be p o si tively co nn ecte d to th e ti ming c hain , allowin g f o r p o ss ib l e pi sto n /valve in terf er ence . No te: The VANOS unit w i l l[...]

  • Page 176

    Re mov e ex h au st camshaft imp u l se wheel mou n tin g n u t s ( ar rows ). Re mov e impu l se wheel ( A ). Re mov e sp rin g p l ate ( A ). Re mov e in take camshaft sp r ocke t moun t in g n u t s ( arr ow s ) and remov e sp ring p l ate (l ab ell ed F RO NT ). Re mov e t orx screws from ex h au st camshaft sp rocke t ( ar rows ). Cy li n d er[...]

  • Page 177

    Li f t off ex h aust an d in t ake sp rocke t s tog eth er with second ary ch ain , th ru st sp acer ( A ) f rom ex h aust camsh aft , and sp l in ed sh aft ( B ) from in take camshaft . CA UTI ON! Spl i ned shafts s hare th e sa me part num b er fo r b oth i ntake and exhau st ca mshafts. Re mo ve and ma rk u sed spli n ed shafts in or der and re [...]

  • Page 178

    Re mov e p rimary ch ain sp r ocke t moun t in g stu d s ( arr ow s ) on ex h aust camshaft . Li f t p rima ry ch ain sp rocket off ex h au st camshaft . Remo v e sp rocke t from ch ai n . Pl ace t imi n g ch ain on end of ex h aust camshaft . Re mov e l ocating st u d s ( arr o ws ) f rom int ake ca msh aft. Lift off int ake camsh aft th ru st sp [...]

  • Page 179

    Do n ot remo v e en d sp l in e retai n ing screw s f rom camshaft s ( ar row s ). Re mov e cyl in d er h ead cov er moun t ing stu d s ( arr ow s ) from cen t er of cyl ind er h ead. - R emo v e fl ywheel l ocking t oo l f rom tran smissi on b el l h ou sing so t h at cranksh af t is n o l on g er secu red. Li f t p rima ry ch ain and h ol d u n d[...]

  • Page 180

    ce n tere d wi th adapter slee ves . T o av oid cam shaft d am ag e, i t mu st b e re mo ve d befo re any ot h er ca p s. Fit BM W sp eci al tools 11 3 260 ( A ) an d 11 3 27 0 ( B ) to cyl ind er h ead an d screw l on g b ol t s ( arr o w s ) in to sp ark p l u g th rea d s. T ensioners will al ign with th e b ear ing cap s on th e int ake camsh a[...]

  • Page 181

    Hy d rau li c li fters shou ld b e sto red in an uprig ht pos iti on. Us ed h ydra u l ic li fter s mu st b e re placed i nto o riginal l ift er b o res . Cyli nder he ad ass e m bly, re m oving - R emo v e ex hau st man ifol d s. See 18 0 Ex h aust S ystem. Re mov e in take camshaft p osition sen sor ( ar row ) from sid e of cyl ind er h ead. Re m[...]

  • Page 182

    Usi n g BM W sp ecia l t ool 11 2 250 or equ iv al ent , l oose n cyl ind er h ead b ol t s in sev eral st ages in seq u en ce sh own. Di scard h ea d b olt s. No te: BMW special t oo l 11 2 25 0 i s a thi n-w al l ed T orx E12 socke t w i t h an exten ded reach . The cyl i nde r hea d bolt s are recesse d i nto t he hea d be l ow the camsh aft t o[...]

  • Page 183

    113-3 Cyl i n der Hea d I n s ta l l a ti o n Clean cyl in d er h ea d and g asket su rf ace s of cyl ind er b l ock an d al l timing ch ain cov ers. Re mov e f ore ig n matt er and l iq u id f rom b olt h oles. CA UTI ON! Do n ot u se a me t al sc ra per o r wi re bru sh to cle an th e alum i num c ylin d er head or p isto ns. I f n ec es sar y, u[...]

  • Page 184

    operatio n s. Pl ease b e adv ise d th at th ese ind iv id u al j obs m u st b e acco mp l ished in th e order in which th ey ap p ear. Cyl ind er h ea d assembl y, inst al l in g Camshaft s an d v alv etrai n , inst al l in g V A NOS con trol u n it, in stal l in g Cyl ind er h ea d cov er, manifol d s, coo l in g syst em, in stal l in g Cylinde r[...]

  • Page 185

    pos i tion b efo re l o w ering the cylind er head in to pos iti on. A l l p isto ns mu st be ou t of TDC pos iti on to p rev ent va l ve/pisto n i nterfe rence when th e ca mshafts are i nstalled. - Li g h t l y l u b ricate n ew cyl in d er h ea d b ol t s. Inst al l b ol t s and wa sh ers fin g er t igh t. In stal l cyl ind er h ead-to-l owe r t[...]

  • Page 186

    Ti gh teni n g torqu es Stag e 2 +90 ° Stag e 3 +90 ° I n stal l int ake camsh aft p ositio n sensor ( ar row ). - I n stal l ex h aust man ifol d s. See 18 0 Ex h aust System. I n stal l l owe r second ary ch ain g u id e. T ig h t en To rx b olt s ( arr ow s ) to sp eci f icatio n s. T h e b ol t on t h e in take camshaft sid e is l on g and ex[...]

  • Page 187

    A min imu m waitin g time is requ ired fo r th e h ydra uli c lif ter s to "bleed down" after in stalli ng th e ca mshafts in to th e cylin der head, but befo re sy n chro n i zing th e cr anks h aft and va l ve tra i n ti ming. W hen th e ca mshafts are re mo ve d, the hydrau li c l ifters can expand. T hi s ex p ansion ca n cau se i ncr[...]

  • Page 188

    Ro t ate camshaf ts so th at in take and ex h au st l obes f or cyl in d er 1 face ea ch other ( ar row s ). CA UTI ON! B e su re th at cr ankshaft is stil l pos i tioned at leas t 30 ° b ac k fro m TDC. - Pl ace b eari n g caps on cams, b u t d o n ot in st all retainin g n u t s. Fit BM W sp eci al tools 11 3 260 ( A ) and 11 3 27 0 ( B ) to cyl[...]

  • Page 189

    - Re p eat p roce d u re f or ex h aust camshaft . No te: Before t he next step, ob serve w aiti ng ti me for l i f t er bl ee d dow n be fore con t i nuing w i th camsha f t i nstall ati on. Cr anks h aft / valve ti ming waiti ng times 68 °F (20 °C) an d h ig h er 4 minu t es 50 - 68 °F (10 - 20 °C) 11 min u t es 32 - 50 °F (0 - 10 °C) 30 mi[...]

  • Page 190

    Li f t t imi n g ch ain and h ol d u n d er tension . Wh il e mai n t ai n ing t en sio n on t iming ch ai n , rotate cran ksh aft f rom 30 ° b efore TD C in d ire ct i on of rotatio n u p t o cyl ind er 1 T D C p ositio n ( 0|T on f ron t p u l l ey l ined u p with p oint er on l owe r timing ch ain cov er) . Secure cranksh aft in TD C p osi t io[...]

  • Page 191

    Fit t h ru st sp acer to in t ake camshaf t and t igh t en d ow n with t h readed l oca t in g stu d s (p l ace lon g er th readed p ortio n of st u d s int o camshaf t). Ti gh teni n g torqu e I m p u l se wh ee l stu d s t o in take camshaft (M 7) 20 Nm (15 f t -l b ) Fit t op sp rocke t t o p rima ry t iming ch ain and in stal l on ex hau st cam[...]

  • Page 192

    Ti gh teni n g torqu es Ex h au st camsh aft l ocating st u d 20 Nm (15 f t -l b ) I n stal l seco n d ary ch ain ten sioner on cyl ind er h ead ( arrows ). Keep t ensioner compressed u sing BMW sp ecia l tool 11 3 29 2 or su itabl e p in. Fit ex h aust camshaft sp l in ed sl eev e. Co n f irm t h at g ap in sl ee v e sp l in es alig n s wi t h cor[...]

  • Page 193

    Pl ace in take and ex h au st sp rockets in BM W sp ecia l t ool 11 6 18 0. Po sitio n sp l ine g ap on in t ake sp rocket ( arr o w ) as shown an d p l ace seco n d ary ch ain on sp rocke t s. Re mov e ch ain and sp rocke t s from t oo l and sl id e sp rocke ts on camsh aft s. Co n f irm t h at g ap in in t ake sp rocket sp l ines l in es up wi th[...]

  • Page 194

    asse mb l y. I n itia l l y t ig h t en t o app rox . 5 Nm (44 in -l b ) and t h en b ack off b y h alf a tu rn . Fit t h ru st sp acer ( A ) on ex h aust camshaft . I n stal l sp ring p l ate ( A ) t o ex h au st camshaft . M ake su re th at F mark is v isi b l e. No te: I f F mark i s no l ong er vi si bl e, i nstall spring plate so that con vex [...]

  • Page 195

    Pu l l out ex hau st camsh aft sp l ined sh aft to stop . - Press down on seco n d ary ch ain tension er and remo v e t ensioner l ock-down tool . Preload p rimar y ch ai n : T ig h t en ad j u st in g screw on BM W sp eci al t oo l 11 4 22 0 t o sp eci f ie d torq u e. Ti gh teni n g torqu e Prima ry ch ain ten sioner p rel oa d 0.7 Nm (6 in -l b [...]

  • Page 196

    Mak e su re all ga ske t mate rial i s re mo ved f ro m fac e o f cy li n d er head. Clea n se ali n g face and kee p fre e of o i l. If any for ei g n ma t er i al is p res ent o n the sea l i ng su rfa ce , th e ca mshaft timin g w il l b e i nco rr ect. Secure camshaf t sp rockets an d impu l se wheels: T ig h t en mou n t ing screws ( A ) on ex[...]

  • Page 197

    ea ch oth er. - Secure cranksh aft in TD C p osi t ion wi t h BM W sp ecia l tool 11 2 300 . Pl ace BM W sp eci al t oo l 11 3 24 0 ov er camshaft s an d mea su re cl ea rances. No te: I f the exh aust si de of the tool (A) i s no t f l ush w i th t he h ea d, camsha f t ti mi ng i s i ncorre ct . R ese t camsha f t ti mi ng as de scri bed i n 117 [...]

  • Page 198

    re mo ved f ro m fac e o f cy li n d er head. Clean sealin g face and ke ep free of oil. If any fo re ign ma terial i s pres ent on th e se ali ng su rfac e, th e ca mshaft timin g w il l b e i nco rr ect. Chec k l o ca tin g d owe l (A ) and dowel sleev e (B ) at to p o f cy l in d er h ea d fo r d am ag e o r in co rre ct i nstallation. - Re p l [...]

  • Page 199

    Set sc rews have l eft hand threa d . Ti g hten co unter cloc kwise . Ti gh teni n g torqu e Hydrau l ic p i st on to sp l ined sh aft M 6 set scr ew 10 Nm (89 i n -l b ) Re p l ace sealin g caps insid e V A NOS u n it wi t h BM W sp eci al t oo l 11 6 17 0, or sh ort f l at n osed p l iers. I n sert an d secure V A NOS sealin g p l u g s ( arr o w[...]

  • Page 200

    Ti gh teni n g torqu e Oil l in e to V A NOS u n it (b anj o b ol t) 32 Nm (24 f t -l b ) - Re mov e BM W sp eci al tool 11 4 22 0 an d r ei n stal l ch ain t ensioner cyl ind er. Ti gh teni n g torqu e Prima ry ch ain ten sioner cyl in d er to cyl ind er h ea d 70 Nm (52 f t -l b ) - Re mov e f l ywheel l ocking t oo l f rom tran smissi on b el l [...]

  • Page 201

    Ti gh teni n g torqu e Cylin d er h ea d cov er to cyl in d er h ead ( M 6) 10 Nm (89 i n -l b ) - I n stal l ex h aust man ifol d s u sing n ew g aske t s an d n u t s. Coa t manifol d st u d s with copp er p ast e p rio r t o in stal l ing n u ts. Ti gh teni n g torqu e Ex h au st man ifold to cyl ind er h ea d (M 7) 20 Nm (15 f t -l b ) - I n st[...]

  • Page 202

    Ca refu l l y ch eck in take manifold g aske t and rep l ace if n ecessa ry. I n sp ect O -rin g seal b et w een m ass ai r fl ow sen sor and air fil ter h ousin g . To f aci l itate reasse mb l y, coa t seal with acid-f ree gr ea se. CA UTI ON! Wh en rea ttac h in g thro ttle ass embly harnes s co nn ec to r, co n n ec tor i s fully tightened w h [...]

  • Page 203

    Re con n ect b att ery. CA UTI ON! To prev ent d am ag in g e ngine elec tro ni c sy ste ms, i nstall all gr o und wi re s prev i ou sly re mo ved, i ncl u d i ng the gr ou n d w ires for the i gniti o n co il s. Ti gh teni n g torqu es Co ol an t d rain p l u g to cyl ind er b l ock 25 Nm (18 f t -l b ) Ra d iato r coolin g fan t o coolant p u mp [...]

  • Page 204

    113-4 Di a g n os ti c T es ti ng Cylinde r c om press ion, che c ki ng A comp ressio n g au g e is n eeded t o make a comp ressi on test. For accu rate test, t h e b attery and st arter mu st b e capab l e of crankin g t h e eng in e at l ea st 30 0 rp m, and t h e en g in e sh oul d b e at n orma l op era t ing temp eratu re. No te: Performing a [...]

  • Page 205

    Fail u re to re mo ve th e DME m ain re l ay o r attem p ti ng to d isable th e igniti o n sys tem by other met hods ma y res u l t in d ama ge to the engine co ntro l mo d u le (ECM). Re mov e h ou sing f or int eri or v ent il ation micro f ilt er. Re mov e u p p er cov er an d micro f ilt er. Op en wi ring h arn ess l oo m cov er ( A ) and remo [...]

  • Page 206

    remo ved. I n stal l compressio n g aug e in f irst cyl ind er' s sp ark p l u g h ol e, tig h t enou g h to f orm a g ood sea l . - With p arking b rake set, tran smissi on in PA RK or NEU TR AL , an d accelera t or p ed al p resse d t o f l oo r, cran k en g in e wi t h starter. Record h igh est v alu e ind icated b y g aug e. No te: The com[...]

  • Page 207

    Lo w comp ressi on ind ica t es a p oo r l y sealed combu st ion ch amber. Re l ativ el y ev en p ressu res th at are b elow sp ecifica t io n n orma l l y ind icate wo rn p iston ring s an d / or cyl ind er wa l l s. Erratic v alu es ten d t o in d icate v alv e l ea kag e. Dra matic d iff erences b etwee n cyl ind ers are often th e sign of a fai[...]

  • Page 208

    - Re p eat compressio n t est, t h is time wi t h ab out a t ea sp oon of oil sq u irted in t o ea ch cyl in d er. (The oi l will t emporari l y h elp seal b etwe en p iston rin g s and cyl in d er wa l l , p racticall y el imi n ating l ea kag e p ast ring s for a sh ort time.) - I f th is test yie l d s h igh er compressio n readin g t h an "[...]

  • Page 209

    116-1 Gen era l T h is r epair g roup cov ers cyl in d er h ead and v al v etrai n serv ice an d rep ai r. Proce d u res d escribed h ere requ ire th at th e cyl ind er h ea d f irst b e remo v ed as d escri b ed in 113 Cyl ind er He ad Re mov al an d In stal l atio n . No te: For t i mi ng cha i n an d VA N O S rep ai r i nforma t i on , see 11 7 [...]

  • Page 210

    M ost of th e rep ai rs to a cyl ind er h ea d requ ire p reci sio n machin e wo rk t o sp eci f ic t ol era n ces. This t yp e of work sh oul d b e p erformed b y an au t h orize d BM W repair f aci l ity or an A SE certifie d machin ist. Cylin d er h ead j ig BM W 00 1 490 V alv e sea t g rind er BM W 00 3 52 0 V alv e g u ide rea mer BM W 00 4 2[...]

  • Page 211

    V alv e stem seal g u id e BM W sp ecia l tool 11 1 960 Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Cy li n d er Hea d an d V al vetrai n h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 3 of 3 2/ 25/ 2009 9: 47 PM[...]

  • Page 212

    116-2 Cyl i n der Hea d T h is sect io n p rov id es t h e sp ecifica t io n s and sp ecia l recond itio n in g in formatio n n ece ssary t o repair t h e cyl in d er h eads cov ered b y t h is manu al . T h e d isa ssembl ed cyl in d er h ea d sh oul d b e insp ect ed for warpag e and cracks. Ch eck th e v alv e g u id es and v alv e sea t s for w[...]

  • Page 213

    g iv en in T ab l e a . Tabl e a. Cyli nd er h ea d h eigh t Ne w M in i mum heig ht (di mension A) 14 0.0 mm (5.512 in) 13 9.7 mm (5.500 in) Va lves, lea k test T o t est t h e v alv es for l eaka g e, t h e cyl ind er h ead mu st b e d isasse m b l ed wi t h camshaft s and camsh aft carrie rs remo v ed. Inst al l t h e v alv e assembl ies and t h[...]

  • Page 214

    I f th e ca ms h aft is b ein g replace d due to cam l o b e wear, it i s re co mme nd ed that th e co rre spondi n g li fters shou ld also b e re pl ac ed to av oid d ama ging the n ew cam shaft. Hydrauli c lifters, c hec ki ng and repla c ing M odern BM W 6 cyl in d er en g in es u se self -adj u stin g h yd raul ic l ifters t o kee p th e v al v[...]

  • Page 215

    Op en wi ring h arn ess l oo m ( A ), remo v e h arness an d l ay aside. Unf asten screw s ( B ) a n d take off l ow er micro f il ter h ou sin g . - Re mov e eng ine cov er. - De t ach p ositiv e a n d g rou n d conn ections f rom int ake man ifold and cyl in d er h ead cov er, as n ece ssary. Re mov e ig n itio n coils. Di scon n ect ign ition co[...]

  • Page 216

    Use a p l astic or wo od en st ick to p ress d ow n on t op of l i f ter. If th ere is an y n otice ab l e cl eara n ce, th e l ifter i s fau l ty and sh ou l d b e rep l aced. No te: W hen che cki ng a hydra ul i c l i ft er, make sure t he corre spon di ng camsha f t l obe i s faci ng up so that there i s no valve spring pre ssure on t he f oll o[...]

  • Page 217

    116-3 Va l v es Va lves, rem ov ing and i ns tal li ng - Re mov e cyl in d er h ead as d escri b ed in 113 Cyl ind er He ad Re mov al an d In stal l atio n . CA UTI ON! Do n ot let th e hydrau l ic li fte rs fall o u t as the cam shaft car rier is re mo ved. Sp ec ial su ction cu p s ar e ava i l able fro m B M W to h o ld the h ydra u l ic li fter[...]

  • Page 218

    th e v al v es u sing a wire b ru sh or wire wheel. Tabl e c. Valve spec ifi ca tio ns Specification M 52TU 2.5/2.8 eng in es (19 99 - 20 00) M 54 2.5/3.0 eng in es (20 00 - 20 01 ) V al v e h ead d ia. I n t ake 33 .0 mm (1.29 9 in .) Ex h au st 30 .5 mm (1.20 1 in .) V al v e stem d ia. Stan d ard I n t ake 6.0 -0. 015 mm (0.23 62 -0. 0006 in .) [...]

  • Page 219

    Tabl e c. Valve spec ifi ca tio ns Specification M 52 TU 2.5/2.8 engi n es (19 99 - 20 00) M 54 2 . 5/3.0 engi n es (200 0 - 20 01) Ex h au st 6.2 -0. 040 mm (0.24 41 -0. 0016 in .) Va lve guides BM W d oes n ot su p p l y v al v e g u id es as repl aceme n t p arts. If a v alv e g u id e is ex cessiv ely worn , it sh ou l d b e rea med to accept o[...]

  • Page 220

    valve guides w hen rep l acing t he gu i des. BM W su p p l ies ov ersize v al v es. See Ta b l e d for ad d itional in formatio n . Tabl e d. Valve gu id e specifica ti on s Specification s M 52 TU / M 54 engi ne(19 99 - 20 01) V al v e g u id e we ar, max i mu m (v al v e til t cl ea ran ce mea su red with n ew v alv e) 0.5 mm (0.02 0 in. ) V al [...]

  • Page 221

    d isa ssemb l ed and t h e v al v es remov ed as describ ed abov e u n d er V al v es, remo v ing an d in st all ing . No te: BMW spe ci al t oo l s are ava i l able to remo ve t he va l ve stem oi l seals. As an alt ern ati ve, stand ard valve seal remo val tools are avail able f rom most au t omotive parts st ores. Lub ricate n ew se al and in st[...]

  • Page 222

    Tabl e e. Valve se at spec i fi ca ti o ns Specification M 52 TU/M 54 engi n es (19 99 -200 1) B : Corre ct ion ang l e, outsid e 15 ° C : Corre ct ion ang l e, i n sid e 60 ° D : V alv e seat wi d th int ake 1.65 ± 0.25 mm (0.0 65 ± 0. 01 0 in ) ex h aust 1.65 ± 0.25 mm (0.0 65 ± 0. 01 0 in ) E : V al v e sea t out side d ia . int ake 32 . 4[...]

  • Page 223

    117-1 Gen era l T h is r epair g roup cov ers timin g ch ain and V aria b l e Ca m sh aft Ti min g (V A NOS) r epair inf orma tion. T h e timing ch ains are l u b rica t ed b y eng in e oi l an d d o n ot req u ire mai n t en an ce. W orn timing ch ain s an d sp rocke ts can l ead t o noisy op era t ion and erratic v alv e t imi n g . A fau l ty te[...]

  • Page 224

    Cra n ksh aft h u b l ocki n g t ools BM W 11 2 15 0 / 11 2 410 Cra n ksh aft l ocking t oo l B M W 11 2 30 0 Sea l ex tractor t ool B M W 11 2 38 0 Ca msh af t l ocking tools BM W 11 3 24 0/11 3 24 4 I n stal l er b u sh BM W 11 3 28 0 Cam sh af t T i m i n g Ch ain h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man[...]

  • Page 225

    Seco n d ary ch ai n ten sioner l ocking p in BM W 11 3 292 A ir l in e fitt in g BM W 11 3 450 Prima ry ch ain t ensioner tool BM W 11 4 22 0 V A NOS setu p b racket BM W 11 6 15 0 Seco n d ary sp rocket t oo l BM W 11 6 180 Cra n ksh aft h u b l ocki n g t ool BM W 11 8 19 0 / 11 8 200 Cam sh af t T i m i n g Ch ain h tt p: // e bah n .ben t l e [...]

  • Page 226

    Pu l l er f or cranksh af t h u b BM W 11 8 21 0 Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Cam sh af t T i m i n g Ch ain h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 4 of 4 2/ 25/ 2009 9: 50 PM[...]

  • Page 227

    117-2 Cra n k s h a f t Fron t Oi l Sea l T h e cranksh aft fron t seal is l ocate d in th e l ow er timi n g cov er on th e fron t of th e en g in e, b eh in d th e v ibration d amper. No te: Ca rs buil t up t o Jan uary 20 00 are f i t ted w i t h a 2-piece vibrati on da mper and hu b asse mbl y. Cars bu i l t f rom Janu ary 200 0 use an i nteg r[...]

  • Page 228

    Simi l arl y, t u rn main eng ine d riv e b elt ten sio n er h ex ( B ) cl ockwi se and remov e b el t . - Secure cranksh aft h u b u sing sp eci al h ol d ing t oo l s: Up to 1/200 0 p rodu ct ion: u se sp eci al t oo l s 11 2 15 0 an d 11 2 41 0. From 01/20 00 p rodu ction: u se sp eci al t oo l s 11 8 19 0 an d 11 8 20 0. CA UTI ON! Do n ot u se[...]

  • Page 229

    hu b f rom cran ksha ft . Pl ace sp ecia l tool 11 2 38 3 on en d of cranksh aft to cov er th r ea d ed h ol e, an d fit sp eci al t oo l 11 2 38 5, al ign ing g roov e in 11 2 385 wi th keywa y on cran ksh aft ( ar row ). Pu t sp ecia l t oo l 11 2 380 ov er tools inst all ed on cranksh aft, and screw in u n t il it make s f irm cont act w ith th [...]

  • Page 230

    Ti gh teni n g torqu e h u b t o cranksh aft ft -l b ) CA UTI ON! Do n ot u se B MW spec i al too l 11 2 30 0 to hold cra n ks haft statio nary to loo se n o r tighten cra n ksha ft h ub ce n ter bolt. Use o n ly th e spec ial to ols spec i fi ed, or equiv alent h ub holdi ng to o l . I n stal l v ib ratio n d amp er moun t ing b ol ts, where app l[...]

  • Page 231

    117-3 Ca m s haf t T i m i ng Ch a i n s , Rem ov i ng Ca msh af t timin g ch ain remov al requ ires th at t h e en g ine oi l p an b e remo v ed. This req u ires rai sin g t h e eng in e an d /or l ow eri n g t h e f ron t su sp en sio n su b fr ame . See 11 9 Lub ricatio n System . Also req u ired is remo v al of t h e V A NOS u n it an d d isa s[...]

  • Page 232

    viii. Re mov e micro fil ter for in terior v ent ilation . Re mov e micro fil ter h ou sing : Op en wi ring h arn ess l oo m ( A ), remo v e h arness an d l ay aside. Unf asten screw s ( B ) a n d take off l ow er micro f il ter h ou sin g . Re mov e compl ete ai r f ilt er h ou sing : Re l ea se mass air fl ow sensor cl ips ( A ). Re mov e f ilt e[...]

  • Page 233

    Re mov e eng ine cov ers: Re mov e p l astic t rim cov ers ( ar row s ). Re mov e cov er h ol d d own b ol t s. Dra in en g in e coo l an t and remov e coo l an t h ose s. Re mov e ex p ansion t ank cap on radiator. Pl ace a 3-g all on p ail b eneath eng in e to capt u re coolant . Re mov e eng ine b l ock d rain p l u g on ex h aust sid e n ear cy[...]

  • Page 234

    - Re mov e radiator coo l in g f an sh roud an d vi scou s cl u tch coo l ing fan (cars with aut oma t ic tran smissi on) or el ectric co ol i n g fan (cars with manu al tran smissi on). S ee 170 Radia tor and Coo l in g System CA UTI ON! On ca rs wi th visco u s clu tch, 32 mm co o li ng fan mo u n ti n g n u t h as l eft hand threa d s. Re l ea s[...]

  • Page 235

    - Dra in en g in e oil and remov e oil p an as d escribed in 11 9 Lub ricatio n System . - On cars p rod u ced u p t o 1/20 00 wi t h 2-piece v ib ration d amp er: Re mov e v ibr atio n d amper moun t ing b olt s and sep ara te v ibration d amp er and p u l l ey f rom cranksh aft h u b . No te: Ca rs buil t up t o Jan uary 20 00 are f i t ted w i t[...]

  • Page 236

    fitt ing ( arr o w s ). - Di scon n ect electr i cal con n ection at int ake camsh aft p ositio n sen sor ( A ). Re mov e ig n itio n coils an d sp ark p l u g s: Pu l l u p on retainin g cl ips t o d isco n n ect ig n itio n coil h arn ess conn ectors. Re mov e g rou n d in g strap s at coil moun t ing stu d s. Re mov e al l ig n ition coils. Re m[...]

  • Page 237

    Working at l eft f ront of cyl ind er h ead, d isco n n ect el ectrical con n ectio n s at ex h au st camsh aft p osi t ion sen sor an d ex h au st camsh aft V A NOS con t rol v al v e ( ar row s ). Re mov e b an j o b ol t f rom V A NOS contr ol u n it oil p ressur e l ine. Use b anj o b olt to att ach BM W sp eci al t oo l 11 3 45 0 (comp resse d[...]

  • Page 238

    co u nterc l oc kwi se to re ach t he top dead center p o siti on. I n stea d , co mplete ano t her two co mpl ete ro tatio ns. Re mov e sealing p l u g f rom b ore on l ow er l eft sid e of en g in e b l ock b el ow starter. S ecure cran ksh aft in TDC p osi t ion wi t h BM W sp eci al t oo l 11 2 30 0 ( arr o w ). Unscrew and remo v e t h rea d e[...]

  • Page 239

    Ha ve a container an d rags rea dy. Pu l l sea l ing cap s straigh t out of V A NOS u n it with BM W sp eci al tool 11 6 17 0, or wi th sh ort n ose p l iers. No te: Add i ti ona l oil may dra i n f rom VANOS un i t . Re mov e set screws (l eft h and t h read) on en d s of int ake and ex h aust camshaft s. CA UTI ON! Set sc rews have l eft hand thr[...]

  • Page 240

    residua l oi l . Pl ace sho p tow el s be nea th ad ju st ment unit w he n remo vi ng . I f the VANOS control un i t i s rep l aced , or i f r ep ai r op erati on s are comp l eted that may cha ng e camsh aft t i m i ng , the camsh aft ti mi ng must be che cked a s de scri bed l ater i n t his cha pt er. Re mov e p rimary camshaft ch ai n tension e[...]

  • Page 241

    Re mov e sp rin g p l ate ( A ). Re mov e in take ca msh aft sp rocke t moun t ing n u t s ( arr o w s ) and remov e sp ring p l ate (l ab ell ed FRO NT ). Re mov e t orx screw s from ex h au st camshaft sp rocke t ( ar rows ). Li f t off ex h au st an d int ake sp r ocke t s toget h er wi t h second ary ch ai n , t h ru st sp ace r ( A ) an d sp l[...]

  • Page 242

    spli ned shafts in or der to re i nstall i n o riginal loca ti o ns. Re mov e ex h aust camshaft sp l in ed sl ee ve ( A ) and sh af t ( B ). Re mov e second ary ch ain ten sioner moun t ing b olt s ( ar rows ). Re mov e tension er whil e kee p in g l ocki n g p in in p l ace . Re mov e p rimary ch ai n sp rocke t moun t ing stu d s ( arr o w s ) o[...]

  • Page 243

    Set t imi n g ch ai n on ex h aust camshaft end . Working in cyl in d er h ea d cav ity, remo v e timing ch ain cov er b olt s ( ar row s ). Re mov e second ary ch ain l owe r g u id e b olt s ( ar rows ). Re mov e ch ai n g u ide. No te: Bolt on i ntake camsha f t si de i s l ong an d exten ds i nto ti mi ng chain cove r. - Re mov e cranksh aft h [...]

  • Page 244

    to ro tate wh en th e ti ming chains are loo se ned or rem ov ed. T h e pi sto n s ca n co n tac t th e va l ves . Usi n g a d rift of l ess t h an 5 mm d ia met er, d riv e two l ocating d owe l s ( A ) in l eft an d righ t sides of l owe r t imi n g ch ai n cov er t ow ard rea r of car. Re mov e cov er mou n t ing b olt s ( ar row s ) an d care f[...]

  • Page 245

    5 - Prima ry chain tension er 6 - To rx scr ew 7 - Exhaust se con d ar y sprock et 8 - Spl in ed shaft 9 - Sec o n dary timin g chain 10 - Spl in ed slee ve 11 - Prima ry sprock et 12 - Th re ad ed stud 13 - Sec o n dary chain t ension er 14 - Sprocke t moun tin g n ut 15 - Sprin g p late 16 - Spl in ed shaft 17 - In tak e ca mshaft sprock et 18 - [...]

  • Page 246

    23 - Th re ad ed stud 24 - Prima ry chain 25 - Th re ad ed stud 26 - Gu i de rail 27 - Th re ad ed stud 28 - Wo o druff ke y Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Cam sh af t T i m i n g Ch ain h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 16 of 1 6 2/ 25/ 2009 9: 51[...]

  • Page 247

    117-4 Ca m s haf t timi n g ch a i n s , I n s ta l l i n g CA UTI ON! Th e p ro ce dur e ou tl in ed b elow as su me s th at th e ca ms h afts a nd t he cr ankshaft ar e lo cke d i n th e TDC in sta ll atio n p o sit ion w ith spec i al loc kin g to ols as shown ea rl ier . I n sp ect t iming ch ain sp rockets. In sp ect g u id e rai l an d t ensi[...]

  • Page 248

    u p p er en d f rom ex h aust camsh aft. - I f n ecessa ry, rep l ace cra n ksh aft sea l as d escrib ed earl ie r. - T o in st all l owe r t imi n g case cov er: Clean cov er an d cyl ind er b l ock sea l in g su rf aces. Use n ew g aske ts and coolan t p ip e O-rin g . Dri ve timing cov er d ow els in u n til th ey j u st p rotru d e sl ig h tl y[...]

  • Page 249

    Ti gh teni n g torqu es Lo we r timin g cov er to cyl ind er b l ock (M 6) 10 Nm (89 i n -l b ) - I n stal l oi l p an wi t h n ew g asket. See 119 Lu b ricatio n System . Ti gh teni n g torqu e Oil p an t o eng ine b l ock (M 6) 8.8 g rade 10 Nm (89 i n -l b ) 10 .9 g rad e 12 Nm (9 f t-l b ) I n stal l cranksh aft h u b or v ib ration d amper t o[...]

  • Page 250

    I n sert BM W sp eci al t oo l 11 4 22 0 i n cyl ind er h ead an d screw in adj u stmen t screw b y h an d j u st u n t il it con tact s tension ing rail. No te: BMW spe ci al t oo l 11 4 22 0 i s a dummy primary chain t en si on er an d si mulates the functi on of the tensione r. - M ake su re arrow on t op p r ima ry sp rocke t is stil l l in ed [...]

  • Page 251

    Fit ex h aust camshaft sp l in ed sl eev e, alig n in g g ap in sl eev e spl ines with corre sp on d in g g ap on camsh aft sp l ines ( ar row s ). Sl ide sp l ined sh aft on to ex h au st camshaft , al ign in g l arg er tooth with corre sp on d in g g ap of sp l in ed sl eev e. Sl ide sp l ined sh aft in f u rt h er u n til 3 small sl ots in sp l [...]

  • Page 252

    I n stal l int ake camsh aft sp r ing p l ate so th at FRONT mar k is v isi b l e. I n stal l moun t ing n u t s ( arr o w s ) fin g er t igh t. Working at ex h aust sid e, in sert sp rocke t moun t in g T orx screw s in t o th r ea d ed h oles ( ar row s ). I n itia l l y t ig h t en screw s t o app rox . 5 Nm (44 in-l b ). Back off h al f a tu rn[...]

  • Page 253

    I n stal l sp ring p l ate ( A ) t o ex h au st camshaft . M ake su re th at F marki n g is v isi b l e. No te: I f F marki ng i s no l on ger vi si bl e, i nstall spring plate so that con vex si de po i nts forw ard (tow ard fr on t of car). I n stal l ex h aust camsh aft imp u l se wheel, al ig n ing mark ( B ) w ith top edg e of cyl in d er h ea[...]

  • Page 254

    Ti gh teni n g torqu e Prima ry ch ain ten sioner p rel oa d 0.7 Nm (6 in -l b ) Preload ex hau st camsh aft sp rin g p l ate b y p ressi n g on impu l se wh ee l wh ile tig h t enin g moun tin g n u t s ( arr o w s ) fin g er tig h t. I n stal l BM W sp eci al tool 11 6 150 (V A NOS setu p b racke t) t o fron t of cyl ind er h ead t iming case . -[...]

  • Page 255

    ex h au st an d int ake sp rocke t asse mb l ies to app r ox . 5 Nm (44 in-l b ). T orq u e d own moun t ing screws ( A ) and n u t s ( B ) t o final sp ecifica t io n s. Ti gh teni n g torqu es Sp rocket assem b l y to camsh aft in itia l torq u e 5 Nm (44 in -l b ) Sp rocket assem b l y t o cam sh aft M 7 T orx screw ( A ) 20 Nm (15 f t -l b ) M [...]

  • Page 256

    thi s r ep ai r gro up. Du e t o f l exibl e sprocke t de si gn , VANOS un i t tol era nce s, and p l ay i n the VANOS spl i ne s, w he n the camsh aft t i m i ng i s set corre ctl y, the int ake si de of special t oo l 11 3 24 0 may be up to 1 mm (0.04 i n) ab ove the surface of the cyl i nde r he ad (ga p B ). Thi s i s no rm al. Ot he r w i se, [...]

  • Page 257

    T orq u e cran ksh aft h u b cent er b olt , u sing sp ecia l t ools 11 2 150 / 11 2 41 0 (t o 1/20 00 ) or 11 8 1 90 /11 8 20 0 (f rom 1/200 0). CA UTI ON! Do n ot u se B MW spec i al too l 11 2 30 0 (fl ywheel loc kin g to ol) to hold cr ankshaft sta tio n ar y to loo sen or tighten cra n kshaft h ub ce n ter bolt. Us e only th e specia l too ls [...]

  • Page 258

    117-5 Va n os T h e mai n comp onen t s of th e d ou b l e V A NOS system are: I n take and ex h au st camshaft s with h elical sp l ine insert s Ca msh af t sp rockets with adj u stab l e g ears V A NOS actu ators (two p osi tion p iston h ou sing with int ernal /ex t ernal h elical sp l ine cu p ) T h r ee -way solen oi d swi t ch in g v alv es C[...]

  • Page 259

    p osi t ions. T h e Do u b l e V A NOS syst em al l ow s f u l l v ari abil ity of camsh aft t imi n g u p t o t h e l imi ts of th e syst em. W h en th e ECM d etects t h at th e camshaft s are in optimu m p ositio n , t h e sol enoi d s are modu l ated at ap p rox ima tel y 100 - 22 0 Hz to maint ai n oi l p ressu re on b oth sides of th e actu a[...]

  • Page 260

    Tabl e a. VANO S fault codes BM W code P-code Faul t desc rip tio n 19 P1 529 VA NOS solen oid v alv e activ ation, ex h au st 21 P1 525 VA NOS solen oid v alv e activ ation, int ake 10 3 P15 19 V A NOS fau l t y refere n ce v alu e int ake 10 4 P15 20 V A NOS fau l t y refere n ce v alu e ex h au st 10 5 P15 22 V A NOS stu ck (Bank 1) in take 10 6[...]

  • Page 261

    VA NO S control unit 1 - Bolt M 6 2 - Exhaust ca mshaft po siti on sensor 3 - Sea l in g rin g 4 - Ca mshaft end se ali ng pl u g tig h t en t o 50 Nm (37 f t -l b ) 5 - Ca mshaft se al ca p 6 - VAN OS hydraulic pi ston se t scr ew CA UTI ON: l eft h an d th rea d tig h t en t o 10 Nm (89 in- l b ) 7 - Nut M 7 tig h t en t o 14 Nm (10 f t -l b ) 8 [...]

  • Page 262

    9 - Stud M 7 10 - Nut M 6 tig h t en t o 10 Nm (89 in- l b ) 11 - Gask et 12 - Cy l i nd er head 13 - Sea l in g rin g 14 - In tak e ca mshaft se n sor 15 - Bolt M 6 16 - VAN OS control un it 17 - Copp er sea l i ng ring 18 - VAN OS oi l feed li n e 19 - Ba n jo b ol t tig h t en t o 32 Nm (24 f t -l b ) VA NO S control unit, re m ov i ng No te: I [...]

  • Page 263

    n egativ e (-) b attery cab l e. CA UTI ON! Prio r to d isco nn ecting the batter y, rea d th e b atte ry di sc o n n ect ion cau tions giv en at the fro n t of th is ma n ua l o n pag e viii . Disc onn ec ti n g th e batter y ma y er as e fau l t co d e(s ) sto red i n co ntro l mo d u le mem ory . Check fo r fau lt co d es us i n g special B MW d[...]

  • Page 264

    With comp resse d air l in e conn ect ed, tu rn en g in e at l ea st twice in d ire ct ion of rotatio n u n til cyl in d er 1 int ake and ex h au st camsh aft l obes ( arr o w s ) f ace ea ch oth er. Re mov e sealing p l u g f rom b ore on l owe r l eft sid e of en g in e b l ock (f l ywh ee l en d ). Secure cran ksh aft in TD C p ositio n with BM [...]

  • Page 265

    Re mov e sealing caps f rom in sid e V A NOS u n it wi t h BM W sp eci al t oo l 11 6 17 0, or with sh ort f l at n ose p l ie rs. No te: Add i ti onal oil may drain f rom VANOS un i t . Re mov e set scr ew s (l eft h an d t h read) on end s of int ake an d ex h aust camshaft h yd rau l ic p iston s. CA UTI ON! Set sc rews have l eft-hand th re ads[...]

  • Page 266

    Do n ot cr ank or tur n o ve r engine w i th VA NOS unit re mo ved. Pi sto n / va l ve in terf er ence i s pos sib le. VA NO S control unit, inst a ll ing Clean cont act edg es of cyl in d er h ead face and V A NOS u n it an d ap p l y a t h in coa t of sealin g compou n d (3-Bond ® 12 09 or equ i v al ent ) to su r faces. CA UTI ON! Mak e s ur e [...]

  • Page 267

    Re in stal l en g in e su p p ort eye . Ti gh tenin g torqu e V A NOS u n it t o cyl ind er h ead M 6 n u t 10 Nm (89 i n -l b ) M 7 n u t 14 Nm (10 f t -l b ) I n sert an d tig h t en d own V A N O S h yd rau l ic p iston set screw s on int ake and ex h aust camshaft s. CA UTI ON! Set sc rews have l eft hand threa d. Ti g h ten co unter cloc kwise[...]

  • Page 268

    - Fit V A NOS oi l l ine b anj o b ol t with n ew seals. Attach oil l in e to V A NOS u n it. Ti gh tenin g torqu e Oil l ine t o V A NOS u n it ( b anj o b olt ) 3 2 Nm (24 f t -l b ) - A tt ach el ectrica l h arn ess con n ectors to camsh aft p ositio n sen sors an d V A NOS solen oid v alv es. - R emo v e BM W sp ecia l l ocki n g tools from rea[...]

  • Page 269

    of remov al . Ti gh tenin g torqu es R adiator fan (v isco u s cl u t ch ) to coo l an t p u mp 40 Nm (30 f t -l b ) Sp ark p l u g t o cyl ind er h ea d 25 Nm (18 f t -l b ) Cam sh aft t im ing, adjust i ng Use t h is p rocedu re t o ch eck an d , if n ecessa ry, ad j u st camshaft t iming . Th is p roce d u re assu mes th at t h e cyl in d er h e[...]

  • Page 270

    Preload p rimar y ch ai n t en sio n er rai l : T ig h t en ad j u st in g scr ew on BM W sp eci al t oo l 11 4 22 0. Ti gh tenin g torqu e Pri mary ch ain tension er p reload 0.7 N m (6 in-l b ) Unscrew oi l p r essure p ip e f rom V A NOS u n it. Remo v e b an j o b olt f rom oi l p ressur e l ine an d in stal l B M W sp ecia l tool 11 3 450 . CA[...]

  • Page 271

    - U n screw a n d remo v e cyl in d er h ead cov er stu d s at rea r of cyl in d er h ead. Pl ace BM W sp eci al t oo l 11 3 24 0 ov er camshaft s end s and mea su re cl ea rance of t oo l t o cyl ind er h ead su rf ace . No te: I f t he exh aust si de of the tool ( A ) i s no t fl ush w i th the h ead , r eti me the camsh afts as de scri be d be l[...]

  • Page 272

    Lo osen ex h aust camsh aft sp rocke t moun t in g b ol ts ( A ) tu rn . Lo osen ex h aust camsh aft imp u l se wheel mou n tin g n u t s ( B ) 2 tu r n s. Sl ide ou t in take camsh aft sp l in ed sh aft u n t il app rox . 1 mm (0.04 in) of sp l ines ( ar row s ) can b e see n . Pu l l ou t ex hau st camsh aft sp l ined sh aft to st op. - M a ke su[...]

  • Page 273

    Preload p rimar y ch ai n t en sio n in g rail: T ig h t en ad j u st in g scr ew on BM W sp eci al t oo l 11 4 22 0. Ti gh tenin g torqu e Pri mary ch ain tension er p reload 0.7 N m (6 in-l b ) Preload ex hau st camsh aft sp rin g p l at e b y p ressi n g on impu l se wh ee l . Ti g h ten moun t in g n u t s ( arr ow s ) b y h and . Do not tig h [...]

  • Page 274

    app rox . 5 Nm (44 in-l b ). Pretigh t en mou n t ing n u t s ( B ) on ex h au st an d int ake sp rocke t asse m b l ies to app rox . 5 Nm (44 in-l b ). T orq u e d own To r x screws ( A ) and n u t s ( B ) t o fin al sp eci f icatio n s. Ti gh tenin g torqu es Sp rocke t asse mb l y to camsh aft in itia l torq u e 5 Nm (44 in-l b ) Sp rocke t asse[...]

  • Page 275

    no t fl ush w i th the h ead , camsha f t ti m i ng i s i ncorre ct . Re pea t camsh af t ti m i ng proce dure . Du e t o f l exibl e sprocke t de si gn , VANOS unit t ol era nce s and play i n the VANOS spl i ne s, w he n the camsh aft t i mi ng i s set corre ctl y, the i ntake side of special tool 11 3 240 (B) may be up to 1 mm (0.04 i n) ab ove [...]

  • Page 276

    n ew seals. Attach oil l in e to V A NOS u n it. Ti gh tenin g torqu e Oil l ine t o V A NOS u n it ( b anj o b olt ) 3 2 Nm (24 f t -l b ) - R ema i n d er of en g ine asse mb l y is rev erse of d isa ssemb l y. Ti gh tenin g torqu es R adiator coo l ing fan (v isco u s cl u t ch ) to coo l an t p u mp 40 Nm (30 f t -l b ) C yl in d er h ead cov e[...]

  • Page 277

    119-1 Gen era l T h is r epair g roup cov ers l u b rica t ion system t roub l eshooting as well as oi l p an remov al an d oi l p u mp repl aceme n t. Spec ia l tools T h e eng i n e n eeds to b e p rop erly su p p orted wh il e th e fron t su sp en sion su b f rame is remov ed t o access th e l u b ricatio n syst em. If BM W sp ecia l tools 00 0 [...]

  • Page 278

    Engine lubric ation Oil p r essure is g en era ted b y a g ea r -typ e pu mp b ol ted to t h e b ott om of th e en g in e b l ock. T h e oil p u mp is ch ain d riv e n off t h e fron t of th e cranksh aft . Oil p assag es in th e cyl in d er b l ock an d cyl ind er h ead con n ect t h e oi l p u mp to compon ent s su ch as camshaft s, cranksh aft a[...]

  • Page 279

    O i l pre s su re , c hec k ing I n some eng in es access to t h e oi l p ressure warnin g switch p ort may b e ex t remely rest ricted. - Unscrew oi l f il ter cap in ord er t o all ow eng ine oi l t o dr ai n b ack d ow n i n t o oi l p an. Di scon n ect h arn ess conn ector f rom oi l p ressure switch ( ar row ) and remov e swi t ch . CA UTI ON![...]

  • Page 280

    oil sho ul d be t he corre ct gra de . O i l pres sure I d l e (min imum) 0.5 b ar (7 p si) Re g u l ated p ressur e (elev ated eng in e sp eed) 4.0 b ar (59 p si ) - Re mov e p ressu re g aug e and rei n st al l p ressure swi t ch . Ti gh teni n g torqu e Oil p ressu re swi t ch to oil fil t er h ou sing 2 7 Nm (20 f t-l b ) I f testin g sh ows l [...]

  • Page 281

    Warn ing l ig h t on in stru men t p an el mu st l ig h t u p . - Re mov e conn ector from oil p ressure switch . Warn ing l ig h t on in stru men t p an el mu st g o ou t. CA UTI ON! Ru nn i ng the engine w i th the o i l pres su re swi tch d i sc onnecte d may se t a fau l t co de (DTC). No te: I f the l i ght doe s no t go out, the w i ri ng to [...]

  • Page 282

    Re p l ace a f au l ty switch . CA UTI ON! Ke ep i n min d that l ow oil p res su re ma y b e prev entin g the swi tch fro m tu rni n g th e li g h t ou t. If the l ight re mains on w h il e the eng i ne is ru nn i ng, check th e o il p re ssu re as desc rib ed ea rli er. Do n o t d rive th e ca r until t he p ro b l em i s co rr ecte d. Th e eng i[...]

  • Page 283

    119-2 Oi l Pa n T h e oi l p an remo v al p rocedu re requ ires th at t h e eng in e b e su p p orted f rom abov e and t h e f ront su sp ension su b f rame b e u n b ol ted an d l owe red from t h e ch assis. O i l pa n, re m ov i ng and ins ta lli ng (rear w he el drive m odel s) - Ra ise car and p l ace secu rely on j ack stan d s. WA RN I NG! M[...]

  • Page 284

    Pl ace drain pan un de r l i ne s t o catch ATF drips. Re mov e oi l d ipst ick g u ide t u b e: De t ach mou n t ing b ol t ( A ) f rom l eft eng in e moun tin g b racket. De t ach f u el l in es and wi ring h arness b racke t s ( B ). Di scon n ect oi l sep arato r h ose ( C ) from b ase of g u ide t u b e and remo v e tu b e from oil p an. No te[...]

  • Page 285

    Re mov e p owe r st ee rin g p u mp p u l l ey. Re mov e t wo mou n tin g b ol ts f rom th e fron t ( ar rows ) No te: Do no t deta ch po w e r st ee ri ng fl ui d l i nes from pump . Re mov e t h ird p owe r st ee rin g mou n tin g b olt ( ar row ) and remov e p u mp from its moun t ing b racke t. Use st i f f wir e to su sp en d p u mp from ch as[...]

  • Page 286

    Right si de i s sho w n i n pho t o. Le f t i s si mi l ar. Lo osen l owe r eng in e mo u n t f asten ers ( ar row s ). No te: Right si de i s sho w n i n pho t o. Le f t i s si mi l ar. I f app l ica b l e, remo v e fron t rid e l ev el sensor mou n tin g b ol t ( arr o w ) an d l ay sensor aside. Re mov e l eft an d rig h t fr ont cont rol arm b [...]

  • Page 287

    Re mov e l eft con t rol arm b al l j oi n t moun t ing n u t ( arr o w ) at f ront su sp en sio n su b fr ame . Dri ve b all j oi n t ou t fr om su b frame u sing soft h amme r. Pu sh con t rol arm aside. Re p eat for l eft sid e. Su p p ort su sp en sio n su b f rame f rom b elow u sin g ap p rop ria t e j acki n g equ ip men t. Remov e su b f ra[...]

  • Page 288

    materi al f rom matin g su rfaces and u se a n ew g aske t . A p p l y a smal l amo u n t of n on-h ard en ing sealer (3-Bond 12 09® or eq u iv alen t ) t o oi l p an g aske t d ire ct l y b elow j oi n t s ( ar row s ) f or end cov er and f ront timing case cov er. App l y a b ead 3 mm wide b y 2 mm h igh . T ig h t en oi l p an b ol t s t o cyl [...]

  • Page 289

    Use n ew oi l d ipst ick tu b e sealing O-rin g . Fil l eng in e with oil as d escribed in 02 0 M aint enan ce . A ft er ad d ing en g in e oi l , st art an d ru n eng ine. Rai se eng in e sp eed to 2,50 0 rp m u n til oi l p r essure wa rn in g l amp g oe s ou t (ab out 5 seco n d s). No te: BMW do es no t r eco mm en d a f ron t en d ali gnme nt [...]

  • Page 290

    O i l pa n, re m ov i ng and ins ta lli ng (all w hee l drive m odel s) - Ra ise car and p l ace secu rely on j ack stan d s. WA RN I NG! Mak e su re the car i s sta b l e and w ell su pp or ted at all ti me s. Use a pro fess ional au tom o t ive li ft or j ac k sta n ds desig n ed f o r the p ur p o se . A floo r jack i s not adequ ate su p por t.[...]

  • Page 291

    De t ach mou n t ing b ol t ( A ) f rom l eft eng in e moun tin g b racket. De t ach f u el l in es and wi ring h arness b racke t s ( B ). Di scon n ect oi l sep arato r h ose ( C ) from b ase of g u ide t u b e and remo v e tu b e from oil p an. No te: The gu i de t ub e i s sealed in the block using an O-r i ng . Ch eck that t he O -ri ng come s[...]

  • Page 292

    Re mov e t h ird p owe r st ee rin g mou n tin g b olt ( ar row ) and remov e p u mp from its moun t ing b racke t. Use st i f f wir e to su sp en d p u mp from ch assis. De t ach el ectrica l h arness con n ector at oi l l ev el sen sor. - Re mov e l owe r en g ine mou n t fasten ers. I f app l ica b l e, remo v e fron t rid e l ev el sensor mou n[...]

  • Page 293

    Re mov e cont rol arm rear b racket an d b all j oin t moun t in g b ol ts ( arr o ws ) f rom su b f rame . - Re mov e cont rol arms an d fron t d riv e ax l es as d escribed in 310 Fron t Su sp ensio n . - Re mov e f ront d ifferent ia l and rig h t ax l e inn er b ea rin g p ed estal as d escri b ed in 311 Fron t A x l e Fin al Driv e . Su p p or[...]

  • Page 294

    Lo wer oi l p an to r emo v e. CA UTI ON! I f th e o il p an doe s not s epara te ea sil y fro m th e eng in e cy l i nd er bl o ck , a few taps w it h a ru b ber ma l l et sho uld b re ak it free . Do not pry the oil p an l o o se. - Wh en rei n stal l in g oi l p an: T h oroug h l y cl ean all ol d g asket materi al f rom matin g su rfaces and u [...]

  • Page 295

    Ti gh teni n g torqu e M 8 T orx 2 1 Nm (15 ft -l b ) Re in stal l f ront d ifferent ia l and rig h t ax l e inn er b earing p edest al. See 3 11 Fron t A x l e Fin al Driv e . Fil l d iff ere n tial to l owe r ed g e of f ill p l u g . Ti gh teni n g torqu es Fil l or d rain p l u g t o fron t d iff erential 65 Nm (48 f t -l b ) Fron t d iff erent[...]

  • Page 296

    tab ( arr o w ) is seated corre ct l y in su b f rame sl ot. Ti gh teni n g torqu es En g in e moun t t o sub f rame M 10 se l f- l ocking n u t 45 Nm (33 f t -l b ) Fron t of su b f rame t o f rame rail (M 12 b ol t, al wa ys repl ace) 8.8 g rade 77 Nm (57 f t-l b ) 10 .9 g rad e 11 0 Nm (81 f t-l b ) 12 .9 g rad e 10 5 Nm (77 f t-l b ) Re ar of s[...]

  • Page 297

    Be sure t o ali gn the front end aft er thi s pro cedu re. Ti gh teni n g torqu es Stab ilizer b ar t o frame rai l (M8 n u t ) 22 Nm (16 f t -l b ) Steeri n g col u mn u n iv ersa l j oi n t cl ampin g screw (M 8 b ol t, u se n ew b ol t)- 22 Nm (16 f t -l b ) A l l w he el drive oil pan, front diff e re ntial a nd fron t s ubfram e ass e m bly 1 [...]

  • Page 298

    12 . 9 g rad e t igh t en to 105 Nm (77 f t -l b ) 6 - Bolt M 12 (always re pl ace ) tig h t en t o 11 0 Nm (81 f t-l b ) 7 - Bolt M 10 (always re pl ace ) tig h t en t o 59 Nm (44 ft -l b ) 8 - Bolt M 10 (always re pl ace ) tig h t en t o 59 Nm (44 ft -l b ) 9 - Bolt M 12 tig h t en t o 77 Nm (57 ft -l b ) 10 - Fron t con trol ar m w it h ball jo [...]

  • Page 299

    119-3 Com po n en t Repl a ce m en t O i l pre s su re w ar ning s w i tch T h e p ressure w arnin g switch is l ocated u n d er t h e int ake manifol d , in t h e re ar of th e oil f ilt er h ousin g . No te: Sw i tch remova l may req ui re i ntake man i f ol d remo val. Ti gh teni n g torqu e Oil p ressu re swi t ch to oil fil t er h ou sing 2 7 [...]

  • Page 300

    Oi l pump remova l req ui res l ow e ri ng the front susp ension subframe t o remo ve the oil pa n. - Dra in oil as d escribed in 020 M ai n ten ance . - Re mov e oi l p an as d escribed ea rl ier. Re mov e oi l p u mp sp rocket mou n t ing n u t (l eft -h an d th rea d ) ( ar row ). Lift sp rocke t off t ogeth er wi t h d riv e ch ai n . Re mov e [...]

  • Page 301

    11 - Oil p ick-u p p ipe 12 - Bol t M 6 -t igh t en t o 10 Nm (89 in-l b ) - On en g ines with int egrat ed oi l p u mp an d oil scraper: Remo v e oi l p u mp wi th scrap er. - On en g ines with separate oi l p u mp an d scrap er: First remo v e moun tin g b olt s and wi t h d r aw oil p u mp in take p ipe. Re mov e oi l p u mp mou n tin g b ol t s[...]

  • Page 302

    Ti gh teni n g torqu es p an (M 12) Oil p an t o eng ine b l ock M 6, 8.8 g rade 10 Nm (89 in-l b ) M 6, 10 . 9 g rad e 12 Nm (106 i n -l b ) M 8, 8.8 g rade 2 2 Nm (16 ft -l b ) Oil p u mp t o eng in e b l ock (M 8) 22 Nm (16 f t -l b ) Oil p u mp sp rocket t o oi l p u mp sh aft M 10x 1 l eft -h an d th rea d 2 5 Nm (18 f t-l b ) T ransmissio n b[...]

  • Page 303

    120-1 Gen era l T h is r epair g roup cov ers compon en t repl aceme n t inf ormatio n f or th e ign ition system. Wh en d ia g n osing en g ine man agement p robl ems, in cl u d ing on -b oar d d ia g n ostics (O BD I I) f aul t code analysis, al so refer t o th ese repair g roup s: 10 0 En g in e– G en eral 13 0 Fu el Inj ection El ectrica l W [...]

  • Page 304

    Prima ry v ol t age t est h arness BM W 12 7 02 0 Seco n d ary v ol tag e test h arn ess BM W 12 7 03 0 I g n itio n coi l t est adap ters BM W 12 7 04 0 Engine m a na gem e nt BM W E46 eng in es u se an ad v anced eng in e manag ement syst em kn own as Di g ital M otor El ectron ics (DM E). DM E incorp ora t es on- b oa rd d iagn ostics, fu el inj[...]

  • Page 305

    A d d itional i n f orma tion abou t DT Cs an d eng in e manag ement syst em el ectronic system d iagn osi s is p rov id ed in O BD On Boa rd Diagn ostics at t h e rea r of th is manu al . Tabl e a. En g in e mana g em ent sy ste ms Y ea r: Eng i ne DM E syst em 19 99 - 20 00: M 52 T U B25 M 52 T U B28 Sie mens M S 42 . 0 20 01 : M 54 B25 M 54 B30 [...]

  • Page 306

    Do n ot to uc h or d i sc o nn ec t any ca b l es fro m th e co i ls w h il e th e eng i ne is ru n n in g o r b ein g cr anked b y th e sta rter . Th e ignit ion sys tem pro duc es hi g h vo l tag es th at ca n b e fata l. A vo id co ntact wi th expo sed ter min als. Us e extr eme cau tion wh en w or kin g on a ca r w it h the igniti o n swi tched[...]

  • Page 307

    d ime n sional map similar t o t h e one sh ow n i s d igital l y st ore d in t h e EC M . T h e initial ign itio n p oin t is d etermi n ed b y t h e cran ksh aft sp eed sen sor d u rin g crankin g . O n ce th e en g ine is ru n n in g , timing is cont in u al l y ad j u sted b ased on operating cond itio n s. B a sic troublesho oting princi ples [...]

  • Page 308

    fu n d amental l y wo rking - d eliv ering v olt age to t h e sp ark p l u g s. A h ard-st arting or p oo r- ru n n in g eng ine, h ow ev er, may ind ica t e a p rob l em with h ow well t h e sp ark is d eliv ere d . Fau l ty or wo rn ig n ition comp on ent s, su ch as old sp ark p l u g s, or an ind iv id u al coil p robl em may b e th e cause. WA[...]

  • Page 309

    7 - T ermination osci l l ations No te: See Ig ni ti on co i l asse m bly, t esti ng an d replaci ng a s described l ater. Tabl e b. Ig n iti o n trac e d iag no stics Par am eter Ig n iti on voltage lo w I gn iti o n volt age hi g h Sp ark p l u g electrod e g ap too small t oo b ig Sp ark p l u g electrod e cond ition - worn/ b u rn t Sp ark p l [...]

  • Page 310

    On ce en g in e misfire has b ee n d etect ed and t h e fau l t codes d ownl oad ed f rom th e ECM , it is n ece ssary to fol l ow a d ia g n ostic p ath t o corre ct th e p robl em. T h e ign ition su b set of t h e d iagn ostic p ath is sh ow n in Ta b l e d . Ign ition system p rob l ems Tab le c. M i sfire fault cod es P cod e BM W faul t cod e[...]

  • Page 311

    Compon ent Cond it io n Test Re p air Seco n d ary circu it Wet coi l Co rr oded coil conn ection s Seco n d ary circu it Check f or wa t er l eak. Check resistance v alu es (see T ab l e e ). I g n ition coil Prima r y or second ary circuit on or sh orted Ho u sin g cracked, d ama g ed Prima ry an d seco n d ary circuits (see Ta b l e e ) Re p l a[...]

  • Page 312

    Co n nec t and d isco nn ect th e DME sy stem w iri ng and test equipment leads o nly wh en th e i g ni ti o n is OF F. B e fo re ope ra ti n g th e sta rte r wi thou t sta rting the engine (for ex ample w h en mak i n g a co mpre ss i on tes t) alw ays d isable the i gniti o n . CA UTI ON! Prio r to d isco nn ecting the b atte ry, re ad the batter[...]

  • Page 313

    o n l y as specified by B MW , as desc rib ed in thi s ma nua l, or as desc rib ed by th e in stru me nt ma nu fac tu re r. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. I g n i tion Sy s tem h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 11 of 1 1 2/ 25/ 2009 9: 54 PM[...]

  • Page 314

    120-2 I gn i ti on Sys tem Serv i ce Ignition firing order Each ig n itio n coi l is mou n t ed abov e t h e corre sp ond ing sp ark p l u g . Cylin d er 1 is at t h e f ron t of t h e en g ine. Ig ni ti on firin g o rder M 52 TU /M 54 eng in e 1 - 5 - 3 - 6 - 2 - 4 Disabling ignition s y st e m T h e ig n itio n syst em op era t es in a l eth al v[...]

  • Page 315

    (ECM) o r the i gniti o n co i ls may res ult. No te: Spa r k pl ug replaceme nt i s cove red i n 02 0 Mai nten ance . Ch ecki n g f or sp ark is d i f ficu l t on eng in es with d istr ibu t orl ess ign itio n syst ems. T ry remov in g t h e sp ark p l u g s and in sp ecting f or d ifferences b etwe en t h em. A p oor-firi n g p l u g may b e we t[...]

  • Page 316

    Un fasten screws ( B ) and remov e l ow er microfilter h ousin g . - R emo v e p l astic en g in e cov er from t op of v alv e cov er b y p ryin g off b ol t cov ers and remov in g cov er moun tin g b ol ts. Di sconn ect h arn ess conn ector from coil. Co n n ect mu l t imete r b etwe en terminal 15 (+) in con n ector an d g roun d . - T u rn ig n [...]

  • Page 317

    Co il p rimary resi st an ce at coil t erm in als Sp ark p l u g con n ector resistance Co m p are re su l t s t o sp ecifica t ion in Ta b l e e . Tabl e e. I g ni ti on co il res istance Compon ent Term i n als Res i sta nce Co il p rimar y 1 (-) an d 15 (+) app rox . 0.8 Co il seco n d ary N . A . Sp ark p l u g conn ector Bosch 1 k 20 % Beru 1.[...]

  • Page 318

    Co m p are sco p e p att ern wi th d iagrams in B asi c t roub l eshooting p rin cipl es . No te: W hen replaci ng i gnit i on coil s, en sure t ha t t he re pl ace ments are from t he same man ufacture r w i t h the same pa rt/ code nu mbe rs. I f i ndivi dua l coi l s w i t h the corre ct spe ci fi cati ons a re no t ava i l able, al l coi l s sh[...]

  • Page 319

    - R ai se car and su p p ort in a safe mann er. WA RNI NG! Mak e su re the ca r is stable and w ell su pp or ted at all t ime s. Use a prof es si o n al au to mo ti ve li ft or jack sta nd s designe d for the pur p os e. A floo r jack is not adequa te su p p o rt. - R emo v e u n d er-eng ine sp l ash g u ard s. Working j u st u n d erneath starter[...]

  • Page 320

    ECM fau l t memo r y. Cam sh aft pos ition s ensors T h e camshaf t p osi tion sensors are u sed b y th e eng in e man agement syst em f or V A NOS cont rol, sequ ent ia l f u el inj ect io n and kn ock cont rol. Intake ca m sh aft pos ition sens or, r e plac i ng - M ake certain ig n itio n h as been t u rn ed off . - R emo v e h ou sing f or t h [...]

  • Page 321

    Di sconn ect col d air d u ct tu b e ( E ). - D isco n n ect h arn ess conn ector f rom V A NOS sol en oi d and u n scr ew sol enoid from V A NOS con tr ol u n it. Be p rep are d with sh op rag s t o catch oil rel ea sed from VA NOS u n it. Re m ov e camsh aft sen sor ( ar row ) f rom l eft f ront of cyl ind er h ea d , n ex t t o top of oi l fil t[...]

  • Page 322

    sens or, r e plac i ng - M ake certain ig n itio n h as been t u rn ed off . Working at fron t of eng ine on ex hau st ( righ t ) side, d etach ex h au st camshaf t p ositio n sen sor electrical h arn ess conn ect or ( ar row ). - R emo v e camshaft sensor f rom righ t f ront of cyl in d er h ead. - I n stal l atio n is rev erse of rem ov al . Use [...]

  • Page 323

    Re m ov e kn ock sensor mou n tin g b ol ts ( A ) on sid e of cyl ind er b l ock. Re m ov e sen sors. CA UTI ON! No te th e in stalled an g l e of the kno ck se nso r on t he b loc k befo re re mo vin g i t. Re i n stall th e sens or in the sam e pos i ti o n. B e su re to u se a to rque w re n ch wh en ti ghtenin g th e se nso r mo untin g b o lt.[...]

  • Page 324

    130-1 Gen era l T h is r epair g roup cov ers serv ice an d repair for t h e Sie m ens en g ine manag eme n t syst ems u sed on t h e E46 model s cov ered b y t h is man u al. A d d itional eng in e manag ement inf orma t ion may al so be fou n d in t h e fol l owi n g rep air gr oup s: 10 0 En g in e– G en eral 12 0 I g n ition System 16 0 Fu el[...]

  • Page 325

    (malf u n ct ion in d icator l amp) in t h e inst ru men t cl u st er is il l u min ated, b egin trou b l esh oo tin g b y h oo king u p a BM W-comp atibl e scan tool . T h e rich d ia g n ostic cap abil itie s of t h ese syst ems h av e t h e p otent ial t o sav e h ours of d ia g n ostic time, incorrect comp onen t repl aceme n t an d p ossib l e[...]

  • Page 326

    Fu el l ine p l u g s BM W 13 5 281 / 13 5 28 2 A ft ermarke t DTC scan tool Bau m CS2 000 (Sou rce: Bau m Too l s Unl imited) Fu el l ine cl amp BM W 13 3 01 0 Fu el rai l t o p ressu re g au g e fitt in g B M W 13 5 22 0 No te: Professiona l di ag nosti c scan t oo l s ava i l ab l e at t he ti me of thi s printi ng i ncl ud e the BMW factory too[...]

  • Page 327

    of q ua l i t y O BD scan t ools. I n add i ti on to the BMW pro f essi on al l i ne of scan too l s, there are ma ny i ne xpe nsi ve `ge neric' OBD II scan t oo l soft w are pro grams an d han dh el d units ava i l ab l e. A l thou gh t he se t oo l s ha ve l i mi t ed capa bi l i t i es as comp ared t o the de di cated too l s, they are pow [...]

  • Page 328

    motor dr iv en th rottl e v alve , d ou b l e V A NOS system, radiator coo l ing f an, electricall y h eated th ermo stat, as well as oth er out p u t s. T h e ill u stration on t h e f oll owi n g p ag e sh ow s t h e M S 42 . 0 EC M inp u ts and outp u t s. The M S 43 .0 syst em is simi l ar in operatio n , with t h e main d iff ere n ce b ei n g[...]

  • Page 329

    Wa rnings a nd ca utions For p ersonal safety, as we l l as th e p rotectio n of sen sitiv e electron ic compon ent s, ad h ere to t h e wa rn ing s and caut ions on th e fol l owi n g p ages. WA RN I NG! Gaso li n e is h ighly f lamm abl e and its vapo rs ar e ex p l o sive. Do n o t sm o ke o r w or k on a car n ea r heate rs o r other fire h aza[...]

  • Page 330

    ru nn i ng. Do n ot to uc h or d i sc o nn ec t any ca b l es fro m th e co i ls wh il e th e eng i n e is ru n n in g o r b ein g cr ank ed b y th e sta rter . Co n nec t and d isco nn ect th e DME sy stem w iri ng and test equipment leads o nly wh en th e i g ni ti o n is switched of f. Re n ew fu el sy ste m hos es , cl am p s and O- rings any t[...]

  • Page 331

    quick test s. Disc onn ec ti n g th e batter y m ay er as e fau l t co d e(s ) sto red i n me mo ry . Ch ec k f o r fault co des prior to di sc o n n ec tin g th e b atte ry ca b l es . Wait at leas t 40 se co nd s afte r tu rnin g off the i gniti o n befo re re mo ving the engine co n tro l mo dule (ECM) co n necto r. If the co nn ecto r is rem ov[...]

  • Page 332

    130-2 El ectri ca l Ch ecks a n d Com po n en t T es ti n g T rou b l esh ooting and f au l t d iagn osi s on OBD II cars is b est p erfo rmed u sin g an electron ic scan tool. Ho we v er, it may b e n ece ssary to p erform b asic tests of th e en g in e manag ement main compon ent s, f u el syst em or wi ring . CA UTI ON! Th e tes ts in t hi s se [...]

  • Page 333

    l eft rear of en g ine comp artmen t. Check for v olt ag e at t ermi n al 6 of mai n relay socket ( 30 - red wi re). I f b attery v olt age is p rese n t contin u e testin g . I f b attery v olt age is n ot p rese n t, ch eck l arge red wi r e in rel ay socke t . See El ectrica l W iring Di ag rams. - Re in stal l rel ay and t u rn ig n itio n on. [...]

  • Page 334

    I f b attery v olt age is n ot p rese n t and al l earlier tests are OK, rel ay is faul t y an d sh ou l d b e rep l ace d . Fuel pum p rel a y, test ing T h e ECM en ergizes th e fu el p u mp relay b y p rov idin g t h e coi l side of th e relay with g r oun d . Dur ing start ing , th e fu el p u mp ru n s as l ong as th e ign ition swi t ch is in[...]

  • Page 335

    The gro und at termi nal 4 i s sw i t ched by the ECM. T he ECM harn ess must be con nected t o che ck t he sw i t che d grou nd con necti on . - I f n o fau l t s are f oun d u p to t h is p oi n t , tu r n ig n ition key off. Usi n g a fu sed (14 g au g e) j u mp er wi re, conn ect rel ay conn ector t erminal 6 to terminal 2 . Th e fu el p u mp s[...]

  • Page 336

    T h e fu el system retains f u el p ressu re in th e syst em wh en th e eng in e is t u rn ed off. To p rev en t f u el f rom sp raying on a h ot en g in e, syst em f u el p ressu re sh oul d b e reliev ed b efore d isco n n ecting fu el l in es. O n e meth od is to tig h tl y wrap a sh op t owe l aroun d a fu el l in e fittin g an d l oo sen or d [...]

  • Page 337

    Re mov e f u el rail cov e r b y p r yi n g off n u t cov ers ( arr o w s ) and remov in g n u t s. Unscrew sch ræder v al v e cap ( ar row ) from f u el rail. Un screw fu el tan k cap t o release p ressu re to v en t t an k. - Usi n g a b rie f b u rst of comp resse d ai r (max imum of 3 b ar or 43 .5 p si) b l ow fu el b ack th r oug h retu rn l[...]

  • Page 338

    130-3 Com po n en t Repl a ce m en t A ft er d iagn osin g an d repl aci n g a fau l t y eng in e manag ement comp onen t , b e su re to u se a BM W-comp atib l e scan tool t o ch eck and cl ear th e f au l t memo ry in t h e ECM . Di ag n ostic trou b l e codes are g iv en in O BD On Boa rd Di ag n ostics at th e b ack of t h is b oo k. Fuel r ai [...]

  • Page 339

    Working abov e en g in e, d isconn ect electrical h arn ess conn ectors: V A NOS cont rol u n it h arn ess conn ector ( A ) Co n n ectors f or o x yg en sen sors ( B ) Co n n ector f or int ake air temp era t u re sensor ( C ) CA UTI ON! Mar k ox yg en senso r harnes s co nn ecto rs in o rder to av oid re ver si ng them dur i ng i nstallation. I n [...]

  • Page 340

    WA RN I NG! Do n ot sm ok e o r w o rk n ea r heate rs o r other fire h aza rds. Ke ep a fire ext in gu isher hand y. B efo re d isco nn ecting fu el hos es, w ra p a clot h aro u n d f u el hos es to abso rb any l ea kin g fu el. Ca tch and disp o se o f es caped fue l. Pl u g a ll open fuel li n es . A l w ay s unscr ew the fue l tank ca p to rel[...]

  • Page 341

    remo v al tool 16 1 050 or eq u iv alen t. Sea l off fu el l in e(s) wi t h BM W sp eci al tools 13 5 281 / 13 5 282 . CA UTI ON! Fue l ma y be ex pell ed u n d er pres su re . Do n ot sm ok e o r w or k n ea r heate rs o r other fire h aza rds. Kee p a fire ex ti ngu i sher handy. B efo re di sc o n n ec t in g fu el h o ses , wrap a clo th aro un[...]

  • Page 342

    b olt s. Re p l ace an y wire ties re mov ed d u rin g r emo v al p rocedu re. CA UTI ON! Re p lace a ny fl exibl e fu el li n es whi ch were pi n ched shu t d u ri ng tes ti ng. Fuel pre ss ure regula tor, repla c ing E46 fu el p res sure re g ul ator lo ca tio n DM E M S 42 . 0 u n d er l ef t side of car, in 3/2-wa y v alv e DM E M S 43 . 0 u n [...]

  • Page 343

    - Re mov e l ocking sp rin g cl ip retai n ing f u el p ressure reg u l ator. - Wrap a shop rag aroun d regu l ator, t h en remov e r egu l ator from 3/2 way v alv e by p u l l in g straigh t d own. - I n stal l ation is r ev er se of remov a l . Re p l ace sealin g O-rin g s. M ass a ir flow (M A F) s e nso r, rem oving and inst a lli ng CA UTI ON[...]

  • Page 344

    No ad ju st ment t o air f l ow sen sor i s po ssi ble. Engine coola nt t em pe ra ture (ECT) sens or, re pla ci ng T h e eng i n e coo l an t temp eratu re (ECT ) sensor is l ocated towa r d t h e rear of t h e cyl ind er h ead b el ow int ake ru n n er n o. 6. Int ake man ifold remov a l is requ ired to access th e ECT sen sor. CA UTI ON! B e su [...]

  • Page 345

    Ti gh teni n g torqu e ECT sen sor t o cyl ind er h ead 13 Nm (10 f t -l b ) Intake ai r tem pe rature (IA T ) s e ns or, repla c ing T h e int ake air temp eratur e (I A T ) sensor is l oca t ed at t h e top cent er of th e in t ake manifol d . The in take ai r t emperatu re sensor f u n ct io n s t o adap t or fin e tu n e th e f u el m ix t u re[...]

  • Page 346

    - De p ress l ocking cl ip on si d e of temp era t u re sensor and p u l l straigh t ou t of in take manifol d . - I n stal l ation is r ev er se of remov a l . Use a n ew sea l ing O -ring at b ase of sen sor and l u b rica t e wi t h asse mb l y l u b ricant for ease of inst all at io n . T hrott l e a s s e m bly , re m ov i ng and inst al ling [...]

  • Page 347

    Di scon n ect v acu u m l ine at int ake b oo t ( A ). Di scon n ect electr i cal h arn ess conn ector on m ass ai r f l ow se n sor ( B ). Re l ea se mass air fl ow sensor cl ips ( C ). Re mov e f ilt er h ou sing mou n tin g screw s ( D ). Di scon n ect ai r d u ct con n ectio n s ( E ) an d l ift compl ete ai r fil ter h ousin g out of en g in e[...]

  • Page 348

    u p wa rd s out of ru b b er retai n er ( A ) and u n h ook b all en d of cab l e ( B ) f rom th r ottl e actu ator. Re mov e n u t s an d b ol t ( arr ows ) retai n ing wir in g h arn ess con d u it to th r ottl e b ody. Working at t h rottl e hou sin g : Turn h arness p l u g ( ar row ) cou n tercl ockwi se and remov e. Working at sid e of int ak[...]

  • Page 349

    Di scon n ect electr i cal h arn ess conn ectors ( arr o w s ) at oil p ressu re send er an d oi l t emperatu re sen d er at b ase of oi l f il ter h ou sin g . Re mov e d ip stick g u ide t u b e: Di scon n ect wi r ing h arn ess b racke ts fr om tu b e ( A ). Uncl ip f u el l ines from t u b e ( B ). Re mov e l owe r g u ide tu b e moun t ing b o[...]

  • Page 350

    Re att ach t h rottl e asse mb l y h arness con n ector with care. A rrow on f u l l y t ig h ten ed con n ector mu st l in e u p with correspon d in g arro w on t h rot tl e assembl y h ousin g . On DM E M S 42.0: Re attach th r ottl e cab l e an d ad j u st as d escri b ed l ater. Use BM W scan t ool to rese t ECM adap tation v al u es. T hrott l[...]

  • Page 351

    Th rottl e ca ble clea rance M ax . p l ay at th rottl e p l ate l ev er 3 mm (0.125 in. ) - Fu l l th r ottl e ad j u st ment (man u al tran smissi on): With ign ition key on p ress p ed al fu l l y t o st op . Check t h rott l e an g l e u sing scan t ool. A d j u st p edal stop if n ecessa ry. Th rottl e angl e spec ifi ca ti on s M an u al tran[...]

  • Page 352

    Th rottl e angl e spec ifi ca ti on s Kickdown st op cont acted 76 ° - 80 ° Kickdown p ressu re p oint ran g e 84 ° - 88° Fu l l -l oad d ownsh ift 10 0% Idle speed c ontrol v a lve, repla c ing T h e idl e sp ee d con trol v al v e is moun t ed u n d er t h e int ake manifold adj acent t o t h e d ip stick t u b e b racke t . T h e v alve can [...]

  • Page 353

    Re mov e f ilt er h ou sing mou n tin g screw s ( D ). Di scon n ect ai r d u ct con n ectio n s ( E ) an d l ift compl ete ai r fil ter h ousin g out of en g in e compartmen t, p u l l in g it forwa rd aw ay f rom mass air f l ow sensor. No te: I n t his st ep , mass air f l ow sen sor rema i ns attache d t o i ntake du ct . Lo osen cl amp s 2 an [...]

  • Page 354

    Working at sid e of int ake manifold , d isco n n ect el ectrical h arness conn ectors: I d l e cont rol v alv e ( A ) I n take manifol d r eso n ance v al v e ( B ) - Di scon n ect b yp ass h ose from id l e contr ol v al v e. - Re mov e id l e cont rol v al v e: Re mov e id l e cont rol v al v e b racke t moun t ing fasten ers. Sl ide con t rol v[...]

  • Page 355

    No te: Re pl ace men t ECMs must be cod ed w i th ap pl i cati on i nforma t i on (i . e. en gi ne cod e, t ran smi ssi on t ype, etc. ) pri or to i nstall at i on . Co nsu l t an autho r i z ed BMW de al er be f ore rep l acing t he ECM. Al t ern ati vely, code d EC Ms may be ava i l ab l e at an ad dit i ona l cost. - Di scon n ect n eg ativ e (-[...]

  • Page 356

    - I n stal l ation is r ev er se of remov a l . Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Fu el In j e ction h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 19 of 1 9 2/ 25/ 2009 9: 55 PM[...]

  • Page 357

    130-4 ECM Pi n A ss i gn m en ts ECM p in assig n ment s are g iv en in Ta b l e b . ECM p in assi g n men t -DM E M S 42.0 and M S 43.0 . This inf ormatio n may b e h el p fu l when d ia g n osi n g fau l t s to or f rom th e ECM . If al l in p u t s an d wi rin g are O K b u t op era t ional p robl ems stil l ex ist, th e ECM itself m ay b e f au[...]

  • Page 358

    in th e conn ector. A s an alt ern ativ e, t h e h arness con n ector h ou sing can b e separate d so th at el ectrica l ch ecks can b e made f rom t h e b ack of th e conn ector. T a ble b. ECM pin a ss ignm e nt-D M E M S 42 . 0 a nd M S 4 3 .0 Conn ect or X600 01 9-pin bl ack Pin Sig n al Compo n ent/fu ncti on Notes 1 O u tp u t Ter min al 15 U[...]

  • Page 359

    Conn ect or X600 02 24 -p i n b lack Pin Sig n al Compon ent/f un ction Notes 9 n ot u sed 10 n ot u sed 11 n ot u sed 12 I n p u t Sig n al , 3/2-wa y v al v e, ru n n i n g l osses (M S 42 .0) 3/2 wa y v al v e, ru n n ing l osses (M S 42 . 0) 13 I n p u t Hea t er, p reca tal yst ox yg en sen sor 2 He at ed ox yg en sen sor 2 in fron t of catal [...]

  • Page 360

    Conn ect or X600 03 52 -p i n b lack Pin Sig n al Compon ent/f un ction Notes sensor 2 Inp u t Sign al , ex h au st camshaft sensor 1 Ca m sh aft p ositio n sensor II 3 Inp u t Sign al , su ction j et p u mp v alv e (2.8 L, 3.0 L) Su ction j et p u mp v alv e 4 O u tp u t Th rottl e v alv e su p p l y (M S 42 . 0) T h rottl e v alv e (M S 42 . 0) 5[...]

  • Page 361

    Conn ect or X600 03 52 -p i n b lack Pin Sig n al Compon ent/f un ction Notes 19 I n p u t Sig n al , t h rottl e p otent iome t er 1 T h rottl e v alv e 20 Grou n d Gr oun d , th rott l e p osi tion sensor T h rottl e v alv e 21 Grou n d Gr oun d , cran ksh aft p ositio n sen sor Cra n ksh aft p ositio n sensor 22 Ou t p u t Sign al , in take ai r[...]

  • Page 362

    Conn ect or X600 03 52 -p i n b lack Pin Sig n al Compon ent/f un ction Notes 38 I n p u t Sig n al , cyl in d er 6 f u el inj ect or Cylin d er 6 f u el in j ector 39 I n p u t Sig n al , oil l ev el sen sor Oil l ev el sen sor 40 I n p u t Sig n al , V A NOS in l et v alv e V A NOS inl et v alv e 41 I n p u t Sig n al , V A NOS out l et v alv e V[...]

  • Page 363

    Conn ect or X600 04 40 -p i n b lack Pin Sig n al Compon ent/f un ction Notes 2 Inp u t F ee d b ack sign al, eng in e st art I n st rum ent cl u st er cont rol modu l e 3 Inp u t Sign al , seco n d ary air inj ect io n p u mp Seco n d ary air inj ection p u mp relay 4 Inp u t Sign al , electric f an A u x il iary fan motor 5 n ot u sed 6 n ot u se[...]

  • Page 364

    Conn ect or X600 04 40 -p i n b lack Pin Sig n al Compon ent/f un ction Notes 20 Ou t p u t Di ag n ostic mod u l e t ank l eak (DM TL ) d etection (M S 43 . 0) Le ak d etectio n (DM TL ) (M S 43 .0) 21 I n p u t Sig n al , oil l ev el sen sor I n st ru men t cl u ster con trol modu l e 22 I n p u t Sig n al , p rocesse d wheel sp eed, rig h t r ea[...]

  • Page 365

    Conn ect or X600 04 40 -p i n b lack Pin Sig n al Compon ent/f un ction Notes 37 I n p u t /ou t p u t CA N b u s sig n al, l ow Co n n ector, CA N b u s 38 Grou n d Gr oun d , coolant out l et temp eratur e sensor T emperatu re sensor 39 Ou t p u t Sign al , coolan t ou tl et temp eratur e T emperatu re sensor 40 n ot u sed Conn ect or X600 05 9-p[...]

  • Page 366

    170-1 Gen era l T h is sect io n cov ers comp onen t repair inf orma t ion for th e en g ine coo l ing system. T h e E46 coo l ing system u ses a centr ifu g al -typ e b elt -d riv en coolan t p u mp , an electric p r ima ry coolin g f an , and an el ectrica l l y h eate d th ermostat. T h e coo l ing syst em is u n iq u e in t h at th e coolin g f[...]

  • Page 367

    Ex p ansion t ank cap t est ad ap ter BM W 17 0 00 7 Coo ling syst e m (DM E M S 42 .0 ) Radia to r a n d Cool ing Sy s tem h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 2 of 6 2/ 25/ 2009 9: 56 PM[...]

  • Page 368

    Coo la nt pum p A centr ifu g al -typ e coo l an t p u mp is moun t ed t o t h e f ront of th e eng ine. T h e b el t-d riv en p u mp circul ates coo l an t th roug h t h e syst em when ev er th e en g in e is ru n n in g . T he rm os tat A n electricall y h eated t h ermo stat regu l ates th e eng i n e coo l an t temp eratur e and is cont rol l e[...]

  • Page 369

    app l ica tion. On cars with au tomatic tr ansmissio n s, th e ma in f an is el ectric and mou n t ed on th e b u mp er sid e of t h e rad iato r. The f an is cont roll ed b y t h e DM E con trol m odu l e v ia t h e ou t p u t f inal st ag e. A d d itional l y a b el t-d riv en f an v ia a v isco u s fl u id coup l ing (cl u tch ) is att ached to [...]

  • Page 370

    v alu es in th e fan p ow er out p u t st ag e t o conf irm t h at t h e f an is op era t in g corre ct l y. No te: I f t he ECM stored a cooli ng f an fault , che ck that t he f an is no t seiz ed an d that i s spins freely. W hen A/ C i s sw i t ched ON, t he electri c f an i s not i mmediatel y turne d on. Aft er t he eng i ne i s sw i tched O F[...]

  • Page 371

    and d ispos i n g of eng i n e co o lant. Co ola nt i s poiso nou s and l ethal to h u ma n s and p ets. Pets ar e attr acte d to co o lant beca us e o f i ts swee t sme l l and taste . Co n su l t a ve t er i narian imme d i ate l y i f co o lant is in ge sted b y an ani ma l . CA UTI ON! A v o i d ad di ng co l d w ate r to th e co o lant wh i le[...]

  • Page 372

    170-2 T rou bl es h oot i n g Begin t h e d iagn osis of coo l ing syst em p robl ems wi t h a th oro u g h v isu al insp ection. If n o v isual f aul t s are f oun d , it is recomme n d t h at th e DM E syst em b e ch ecke d for st ore d d ia g n ostic f aul t codes (DT Cs) u sing BM W scan tools DI S (Dia g n ostic Inf orma t ion System) or M oD [...]

  • Page 373

    p u l l ey and ch eck f or p l ay in al l d ire ct ions. Sp in p u l l ey an d ch eck th at sh aft ru n s smoo th l y with out p l ay. No te: The coo l ant pro vi des l ubricati on for t he pu mp shaft, so an occasion al dro p of coo l ant l ea ki ng f rom t he pum p i s acce ptable. I f coo l an t dri ps stead i l y from t he vent hole, the pu mp [...]

  • Page 374

    A coolin g syst em p ressure t est is u sed to ch eck f or in tern al l eaks. Some of t h e commo n sou rces of in tern al l eaks are a faul t y cyl ind er h ead g asket, a cracke d cyl ind er h ead, or a cracked cyl in d er b l ock. T o d o a coo l ing syst em p ressur e test, a sp eci al p ressu re tester is n ee d ed . WA RN I NG! A t nor ma l o[...]

  • Page 375

    Tabl e a. Co ol i ng sys t em test pres sure s Compon ent Tes t p res sure p si) Ra d iato r cap 2 b ar (29 p si) CA UTI ON! Exc eedin g the spec ifi ed t es t pres su re co uld d am ag e the radiato r o r other sys tem co mpo nents. Combust i on cham ber l ea k test - I f you su sp ect th at comb u st io n ch amber p ressure is l eaki n g in t o t[...]

  • Page 376

    ind icate trou b l e, t h e el ectrica l l y h ea t ed th ermostat may b e fau l t y. Check for th ermo stat d iagn ostic f aul t codes (DT Cs) u sing BM W scan tools DI S or M oDi C or equ iv al en t. DTC s p ertai n ing t o cooling syst em malf u n ct io n s are l isted in Ta b l e b . See also OBD O n Boar d Di ag n ostics at th e b ack of th is[...]

  • Page 377

    170-3 Cool i n g Sys tem Serv i ce Coo la nt , draini ng and filli ng WA RN I NG! A l l o w the co o l i ng sy ste m to co ol befo re o p eni ng o r draini n g th e co o li ng sy stem . - Ra ise fron t of car and su p p ort safely. CA UTI ON! Mak e su re the car i s sta b l e and w ell su pp or ted at all ti me s. Use a pro fess ional au tom o t iv[...]

  • Page 378

    Co o l ant i s poiso nou s. It i s es pec i ally lethal t o p ets . Clea n up spi ll s imme d i ate l y and rin se the are a wi th water . Pl ace emp ty 3-g all on p ai l u n d ern ea t h ex h au st sid e of eng in e b l ock. Lo osen and remov e eng in e b l ock coo l an t d rain p l u g ( arr o w ). No te: The block drain plug i s l oca t ed on th[...]

  • Page 379

    Tap w ater may cause corrosion of rad i at or, eng i ne and coolan t ho ses. Co ol an t can o ft en b e reu sed pro vi ded it i s cl ean an d l ess than tw o yea r s ol d. Do no t reu se coo l ant w hen replaci ng dama ged en gi ne p arts. Con t aminated coo l ant may da mage t he eng i ne or coo l i ng syst em. Tabl e c. Co ol i ng sys t em capa c[...]

  • Page 380

    - Sl ow l y add coolant u n t il it sp il l s from b l eed screw. W h en coolan t sp ill ing f rom b l eed screw s is f ree of air b u b b l es, t ig h ten screw . Run en g ine u n t il it reaches op era tin g temp era t u re. A ft er en g ine h as coo l ed, r echeck coo l an t l ev e l . T op u p so th at coolan t l ev el ind icator is at M A X . [...]

  • Page 381

    Working at t op of f an sh rou d , remov e screw an d ex p an sio n riv e t ( ar rows ) h old ing fan sh rou d to rad ia tor. Uncl ip or d isco n n ect electrical conn ector(s) from rig h t sid e of sh r oud . No te: Shro ud i s de t ache d f rom rad i ator at t hi s po i nt but can on l y be remo ved l ater w hen f an and cl utch assemb l y i s re[...]

  • Page 382

    Ti gh teni n g torqu es wi th BM W t ool 11 5 04 0 30 Nm (22 f t -l b ) Fan t o v iscous cl u t ch 10 Nm (89 i n -l b ) Ele c tric c ooling fan, re pla ci ng (m odels w ith m a nual trans m i s s ion) On model s wi th man u al t ransm issi on , th e p rima ry coo l in g fan is el ectricall y operate d and is mou n t ed on t h e en g ine side of th [...]

  • Page 383

    trans m i s s ion) T h e electric coolin g fan on cars wi t h automatic tr ansmissio n is mou n t ed b ehin d th e fron t b u mp er, in fron t of th e A /C con d en ser. - Re mov e ai r in take d u ct as d escri b ed ab ov e. - Re mov e f ront b u mp er. See 51 0 Ex terio r Tri m, Bu mp ers . - Di scon n ect fan electrical conn ector ( arr o w ) on[...]

  • Page 384

    T h e electricall y-h ea ted t h ermostat is an int egral p art of t h e t h ermo st at h ou sing . T h e operatio n of th e th ermostat is monitored b y t h e DM E cont rol mod u l e. I f a fau l t y t h ermostat is su sp ect ed, t h e DM E cont rol mod u l e sh oul d b e int erro g ated f or stored f aul t codes u sing an ap p rop ria t e scan to[...]

  • Page 385

    Use n ew sea l ing g asket. Fil l system with cool ant as d escri b ed u n d er Co olan t, d rai n ing an d f i l l in g Ti gh teni n g torqu es En g in e b l ock d rain p l u g t o b l ock 25 Nm (18 f t-l b ) Ra d iato r d rai n p l u g t o rad ia t or 2 - 3 Nm (18 - 27 i n -l b ) Coo la nt pum p, re plac i ng T h e eng i n e coo l an t p u mp is [...]

  • Page 386

    Re mov e eng ine d riv e b el t : Lev er tension er h ex ( l ar ge arr o w ) in cl ockw ise d irectio n (f acing eng in e) an d sl ip b el t off coo l an t p u mp p u l l ey. No te: Mark directi on of dri ve belt rotati on i f reu si ng be l t. - Re mov e coolant p u mp p u l l ey b ol t s and remov e p u l l ey f rom p u mp . - Re mov e p u mp mou[...]

  • Page 387

    Ti gh teni n g torqu es Ra d iato r d rai n p l u g t o rad ia t or 2-3 Nm (18-2 7 i n -l b ) Radia to r, r em oving and ins ta lli ng - Ra ise fron t of car and su p p ort safely. CA UTI ON! Mak e su re the car i s sta b l e and w ell su pp or ted at all ti me s. Use a pro fess ional au tom o t ive li ft or j ac k sta n ds desig n ed f o r the p u[...]

  • Page 388

    Working on rid e side of radiator, release h ose retai n ing cl ip s ( A ) and d isco n n ect l ow er coo l ant h ose fittin g from rad ia tor ( B ). - Working u n d erneath radia t or, d isco n n ect h arness conn ector from coolan t l ev el sen sor. Wh ere app l icabl e, d isconn ect automatic tr ansmissio n f l u id (A TF) coo l er l ines f rom [...]

  • Page 389

    No te: Al t ern ati vely, detach AT F coo l er f rom rad i at or by pu l l i ng up on q ui ck rel ease cl i ps an d pu l l i ng coo l er from radiator tank. Re mov e p l astic b ol t s at t op of radiator ( ar row s ). Pu l l rad ia tor u p an d ou t of car. - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : Do n ot coa t[...]

  • Page 390

    sta n ds desig n ed f o r the p ur p o se . A floo r jack i s not adequ ate su p por t. - Re mov e sp l ash sh ield from u n d er eng in e. - Dra in r adiator and en g ine b l ock as d escri b ed earlier . WA RN I NG! A l l o w co o li n g sys tem to co o l b efo re o p enin g o r draini ng sy ste m. - Re mov e compl ete ai r in take fil ter h ousi[...]

  • Page 391

    Re mov e coolant l ev el sensor ( 9 ) b y twisting cou n tercl ockwi se an d p u l l ing out of b ott om of t an k. 1 - T h ermostat (AT F h eat ex ch ang er) 2 - Ex p ansion t ank cap 3 - La b el 4 - Ra d iator 5 - M oun tin g b racket 6 - Sea l ing O -ring 7 - Self -tap p in g screw 8 - Co n n ector (A TF h eat ex ch an g er) 9 - Co ol ant l ev e[...]

  • Page 392

    Ti gh teni n g torqu es Ra d iato r d rai n p l u g t o rad ia t or 2 - 3 Nm (18 - 27 i n -l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Radia to r a n d Cool ing Sy s tem h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /1... 16 of 1 6 2/ 25/ 2009 9: 57 PM[...]

  • Page 393

    200-1 Gen era l T h is sect io n cov ers th e repairs related to th e cl u t ch , m anu al and au tomatic tran smissi ons, sh ift l in kages, d riv e sh aft s, and t ransf er case (all wheel d riv e v ehicl es onl y). F or repairs related t o d riv e ax l es and f ron t and rear fin al d riv e d iff ere n tials, see 311 Fron t A x l e Fin al Driv e[...]

  • Page 394

    T h e manu al tran smissi ons u se a sin g l e cl u tch d isc wi th d u al-mass f l ywh ee l . For f u rt h er inf ormatio n , see 21 0 Clu t ch . M anu al tr ansmissio n s h av e a metal ID p l ate mou n ted on t h e side of th e tran smissi on. D o n ot rely on n u mb ers cast on t h e t ransmissio n case for ident ificatio n . Tab le a. M an ual[...]

  • Page 395

    man ufa ctured f rom 08 /98 to 03/00 are eq uippe d w i th t he A5S 360 R automa t i c transmissi on. V eh i cl es pro du ced after 03 / 00 u se t he A5S 32 5Z t ran smi ssi on. GM man u f actu red t ransmissio n s h av e th e I D t ag l oca t ed on t h e l ef t h an d sid e of t h e t ransmissio n h ou sin g , b ehin d t h e tran smissi on sel ect[...]

  • Page 396

    210-1 Gen era l T h is r epair g roup cov ers repl ace m ent of th e cl u t ch mech anical and h yd raul ic compon ent s. Rea d t h e p rocedu r e th r oug h b efore b egin n in g a j ob. No te: See 200 T ran smi ssi on –Gen era l f or transmissi on ap pli cati on i nformati on . Spec ia l tools T h e 3 Seri es BM W empl oys a trad itio n al st y[...]

  • Page 397

    Clu t ch l in ing g aug e BM W 21 2 080 Clu t ch cent ering mand rel BM W 21 2 14 2 SA C cl u t ch l ock tool BM W 21 2 150 Clu t ch d iaph rag m ten sioning t oo BM W 21 2 16 0 SA C ten sioning t oo l BM W 21 2 17 0 Clu tch h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /2... 2 of 3 2/ 25/ 2009 10: 15 PM[...]

  • Page 398

    SA C l oca tin g rin g BM W 21 2 180 Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Clu tch h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /2... 3 of 3 2/ 25/ 2009 10: 15 PM[...]

  • Page 399

    210-2 Cl u tch Hydra u l i cs T h e cl u t ch is h yd rau l ica l l y actu ated b y th e master an d sl av e cyl ind ers. Cl u t ch d isc we ar is aut oma ticall y t ake n u p th r oug h t h e sel f adj u stin g p ressu re p l ate sp rin g s, making p erio d ic adj u stmen t s u n n ece ssary. A soft or sp on g y f eel to th e cl u t ch p edal , l [...]

  • Page 400

    A tt ach p ressure b rake b l eeder t o fl u id rese rv oi r an d p u mp b l eeder a f ew time s to p ressu rize hyd raul ic f l u id system. CA UTI ON! Do n ot ex cee d 2 bar (29 p si) pres su re at th e fluid res er vo i r wh en b l ee d i ng o r flus h i ng the hydrau li c sy ste m. B rak e fluid is p oiso nou s, h i g hl y co rr osiv e and dan [...]

  • Page 401

    - Sl ow l y operate clu t ch p edal ab out 10 times. F il l rese r v oi r with cl ean fl u id as n ecessa ry. - Unb ol t sl av e cyl in d er from tran smissi on. Fit BM W sp ecial t oo l 21 5 03 0. Press sl av e cyl ind er p u sh rod compl etel y in t o sl av e cyl ind er. - Ho l d sl av e cyl in d er so th at b l eeder v alv e is at t h e h ig h e[...]

  • Page 402

    [...]

  • Page 403

    Di sen g ag e p an el fr om h ose s an d wi rin g h arn esse s an d remov e from eng in e compart ment . Separate br ake b ooster v acuu m h ose at on e wa y v al v e ( A ). P l u g h ose en d s. - Di scon n ect cl u t ch p ed al from cl u tch master cyl ind er p u sh rod b y remo v ing secu ring p in . Re mov e master cyl in d er mou n tin g b olt[...]

  • Page 404

    Bl ee d cl u t ch h yd rau l ics as d escri b ed earlier . Conn ect n egativ e cabl e to b attery l ast. Ti gh teni n g torqu es Clu t ch master cyl ind er t o p edal cl u st er 22 Nm (16 f t -l b ) Fl u id l in e t o master cyl in d er or sl av e cyl ind er 20 + 5 Nm (15 + 4 f t -l b ) Clut ch slave c y li nder, re pla c ing - Pinch off b rake fl [...]

  • Page 405

    equ iv alen t ). During inst all at io n b e su re p u sh rod tip en g ag es rece ss in cl u tch release l ev er. Fil l fl u id reserv oir wi t h cl ean f l u id. Bl ee d cl u t ch h yd rau l ics as d escri b ed earlier . Ti gh teni n g torqu es Clu t ch sl av e cyl ind er t o tran smissi on 22 Nm (16 f t-l b ) Fl u id l in e t o sl av e cyl ind er[...]

  • Page 406

    210-3 Cl u tch M echani ca l T h e tran smissio n mu st b e remo v ed from t h e eng ine t o access th e cl u t ch mechan ica l comp on ent s. It is reco mmen d ed th at t h e cl u t ch d isc, p ressure p l ate and rel ea se b ea r ing b e repl aced d u rin g a cl u t ch ov erhau l . Be su re to ch eck th e b ottom of th e b ell h ousin g f or oi l[...]

  • Page 407

    - Re mov e t ransmissio n f rom eng ine. See 230 M an u al Tra n smissi on . - Re mov e release b ea r i n g fr om tran smissi on in p u t sh aft . Re mov e cl u t ch rel ea se l ev e r b y p u l l in g aw ay f rom sp rin g cl ip in d ire ction of ar row . Lo ck fl ywh ee l in p osi tion u sin g BM W sp eci al t oo l 11 2 17 0 or eq u iv alen t . I[...]

  • Page 408

    - T u r n t ool h an d l e in u n t i l cl u t ch d ia p h rag m sp r ing is f u l l y tension ed. - Re mov e six b ol t s f rom p erime t er of p ressure p l ate. Remo ve sel f adj u stin g cl u t ch u n it an d cl u t ch d isk. Clutch as se mbly and hydra u li cs Clut ch, insp ec ting - I n sp ect cl u tch d i sc for wea r, cr acks, l oo se riv e[...]

  • Page 409

    ex cessiv e ru n ou t (wa r p ing ). Re p l ace if n ecessa ry. No te: Mea sure t he dep t h of cl utch l i ni ng at l i ni ng rivets. I f sha l l ow est ri vet de pth i s l ess t ha n 1 mm (0.04 i n.), rep l ace cl utch disk. - I n sp ect f l ywh ee l f or scori n g , h ot sp ots, cracks or l oose or worn g u id e p in s. Re p l ace fl ywh ee l if[...]

  • Page 410

    Ne w sel f ad j u st in g cl u t ch ( SA C) p ressur e p l ates come wi t h a l ocki n g p l ate in stal l ed t h at maintains sp rin g ten sion on th e self ad j u st ing sp rin g s. T h is l ocking ring must n ot b e remo v ed u n t il t h e p ressu re p l ate is secu rel y inst al l ed on t h e f l ywheel with t h e cl u tch d isk in p l ace . C[...]

  • Page 411

    release l ev er. - I n st al l t ran smissi on. See 23 0 M an u al Tra n smissi on . Ti gh tenin g torqu es T ran smissio n t o eng in e (To rx b ol t s) M 8 22 Nm (16 f t -l b ) M 10 43 Nm (32 f t -l b ) M 12 72 Nm (53 f t -l b ) Clut ch, inst a ll ing us e d pre ss ure plate No te: Before i nstal l i ng a use d Self Adj usti ng Cl utch (SAC) pre [...]

  • Page 412

    Ce n t er cl u t ch d isk wi t h BM W sp eci al t oo l 21 2 14 2. A comp ara b l e cl u tch al ign ment tool may b e u sed . Remo v e th readed h and l e of cl u t ch al ig n men t tool WA RN I NG! B e su re clu tch d i sc i s fac in g the co rre ct w ay . Th e d isc sho u l d b e ma rk ed eng in e side or transm issio n side. - M o u n t sel f ad [...]

  • Page 413

    Ti gh tenin g torqu es T ran smissio n t o eng in e (To rx b ol t s) M 8 22 Nm (16 f t -l b ) M 10 43 Nm (32 f t -l b ) M 12 72 Nm (53 f t -l b ) T ra nsmi ss ion pilot bea ring, re plac ing - R emo v e cl u t ch as d escribed ear l ier. Re mov e t ransmissio n p ilot b eari n g f rom end of cranksh aft u sin g BM W sp ecia l tool 11 2 340 or equ i[...]

  • Page 414

    230-1 Gen era l T h is r epair g roup cov ers ex tern al tran smissi on serv ice , in cl u d ing remov al and in stal l ation of t h e t ransmissio n u n it. Int ernal t ran smissi on rep ai r is n ot cov ered. S p eci al p ress t oo l s an d p roce d u res are re q u ired to d isa ssemb l e an d serv i ce t h e int ern al g ea r train. Spec ia l t[...]

  • Page 415

    Selector seal d rift BM W 23 0 22 Ou t p u t sea l d rift BM W 23 2 30 0 M anu al tr ansmissio n s u sed are b ased on en g in e ap p l icatio n . Co n su l t 200 T ran smissio n –Gen eral for t ransmissio n app l ica tion in f ormatio n . Ta b l e a. M anu al tr ansmissio n g ear ratio s l ists g ea r ratio sp eci ficatio n s. No te: Do no t rel[...]

  • Page 416

    230-2 T ra n s m i s s i o n Fl u i d Serv i ce M anu al tr ansmissio n s in stal l ed in th e 3 Seri es are n orma l l y f ill ed wi th a "Lifetime " man u al t ransm i ssio n fl u id (BM W M TF LT -1) and d o n ot req u ire p eri od ic f l u id ch an g es. Tra n smissio n s fil l ed with M T F LT -1 l ifetime oi l are ident ified with a[...]

  • Page 417

    I n stal l and t orq u e d rain p l u g . Re mov e f ill p l u g ( B ) f rom side of tran smissi on. Sl ow l y fil l tran smissio n with f l u id u n t il f l u id ov erfl ows fil l h ole. I n stal l and t orq u e fl u id f ill p l u g .n oth ing Fl ui d capac i ty Getrag tran smissi on 1.0 l iter (1.1 US q ts) ZF t ran smissi on 1.2 liters (1.3 US[...]

  • Page 418

    230-3 T ra n s m i s s i o n Serv i ce B a c k -u p li ght sw itch, repl ac ing Ra ise and safely su p p ort ve h icle t o acce ss b ack-u p l igh t swi t ch . Unscr ew swi t ch fr om tran smissi on . No te: The ba ck-up l i ght sw i tch ( ar row ) on Get rag t ran sm i ssi ons is i n the l eft si de of t he t ran smi ssi on. The ba ck-up l i ght s[...]

  • Page 419

    Re mov e d riv eshaft . See 260 Dri ve sh aft . Re mov e t ransmissio n mou n t b olt s ( A ). Re mov e t ransmissio n crossme mb er b ol ts ( B ) and t il t d ow n rea r of t ran smissi on . On al l wheel d riv e cars: Re mov e f ront an d rea r d r iv esh afts. See 260 Dri v esh aft Re mov e t ransf er case crossme mb er b ol ts ( ar rows ) an d [...]

  • Page 420

    Co at n ew selector sh aft sea l with tran smissi on f l u id. Dri ve n ew sea l in fl u sh wi t h h ou sing . Use BM W sp eci al sea l in st all ation t oo l 23 1 14 0 or equ iv alen t an d a soft-f aced ( p l astic) h amme r. - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g ; I n stal l d riv eshaft u sin g n ew l ock n[...]

  • Page 421

    Ti gh teni n g torqu es M 10 (1 0.9 g rade) 60 Nm (44 f t -l b ) M 12 (1 0.9 g rade) 10 0 Nm (74 f t-l b ) T ransmissio n / tran sfer case crossme m b er to ch assis (M 8) 21 Nm (15 f t-l b ) T ransf er case t o tran smissi on (M 10) 41 Nm (30 ft -l b ) O utp ut s ha ft seal , re pla c ing (t r ansm iss ion inst a l le d) - Ra ise and safely su p p[...]

  • Page 422

    CA UTI ON! Ti l tin g th e eng in e to lower the tra n smis sio n ca n l ea d to d am ag e to va riou s co mponents due to l ack of clea rance . - Bend b ack an d remo v e tran smissi on out p u t coll ar n u t l ockpl at e. Re mov e col l ar n u t with 30 mm th in -wall ed d ee p socke t . Co u n t erh old outp u t f l ang e t o p rev ent it f rom[...]

  • Page 423

    On Get rag S5D 25 0G tr an smi ssi ons BMW reco mmen ds hea t i ng the ou t put fl ang e to abo ut 176 F (80C ) t o aid i n i nstall at i on . T his can be do ne by placi ng t he f l ang e i n ho t w ater. - Co at b eari n g su rface of col l ar n u t wi t h sea l er an d in stal l n u t . T ig h t en coll ar n u t in t wo stag es. Inst all n ew l [...]

  • Page 424

    (t r ansm iss ion re m ov ed) Re p l ace m ent of t h e inp u t sh af t sea l requ ires th e remo v al of t h e tran smissi on f rom th e v eh icl e as d escri b edl ater in t h is repair g rou p . - Re mov e cl u t ch rel ea se b ea r i n g and release lev er f rom insid e b ell h ousin g . Re mov e b ol ts ( ar rows ) f or cl u t ch release -b ea[...]

  • Page 425

    Ti gh teni n g torqu e Gu ide sl eev e to t ransm i ssio n M 6x 12 b ol t 10 Nm (89 i n -l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. M anu a l Tran sm i s si on h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /2... 8 of 8 2/ 25/ 2009 10: 17 PM[...]

  • Page 426

    230-4 T ra n s m i s s i o n Rem ov a l a n d I n s ta l l a tio n Re mov al an d in st all atio n of th e tran smissi on is b est accompl ished on a l ift u sin g a t ransmissi on j ack. The eng in e mu st b e su p p orted f rom ab ov e u sing ap p ropr ia te su p p ort eq u ip ment . T h is al l ow s t h e eng in e t o p iv ot on its moun t s t o[...]

  • Page 427

    Re mov e h ou sing f or int eri or v ent il ation micro f ilt er. Re mov e u p p er cov er an d micro f ilt er. Op en wi ring h arn ess l oo m cov er ( A ) and remo v e wi res. Unf asten screw s ( B ) a n d remo v e l ow er micro f il ter h ou sin g . Re mov e h eate r b u l kh ea d cov er. Re mov e eng ine comp artment sid e trim p an el . T u rn [...]

  • Page 428

    w hee l dri ve 3 Series sed ans an d w ago ns bui l t up t o 11 /00 an d cou pes bu i l t up to 10/99 . Pan styl e f ron t en d rei nforcem en t s are used on rear w hee l dri ve sed ans an d w ag on s buil t af ter 12 / 00, cou pes bu i l t af ter 11/99 and all con verti bles. Al l w heel dri ve mod el s req ui re no reinforceme nt due to t he con[...]

  • Page 429

    of tr ansmissio n . See 250 Gearshift Linkag e . - Unb ol t cl u tch sl av e cyl ind er from side of tran smissio n . Do n ot d isco n n ect f l u id h ose. Su sp en d sl av e cylin d er from ch assis u sing stiff wire . CA UTI ON! Do n ot o p era te clu tch pedal wi th slav e cylin der re mo ve d fro m tra n smis sio n. - Lo osen kn u rl ed screw [...]

  • Page 430

    Wh en inst all ing a n ew tran smissi on, b e su re to tran sfer p arts f rom old tran smissi on if app l ica b l e. T h oroug h l y cl ean inp u t sh aft an d cl u tch d isc sp l in es. Ligh tl y l u b ricate tran smissi on inp u t sh af t b efore in st all in g . Be su re b ell h ou sing d owe l s ( ar row s ) are correctl y l oca ted . Ce n t er[...]

  • Page 431

    Ti gh teni n g torqu es (tu b u l ar st yl e) 42 Nm (31 f t -l b ) (p an st yl e) 59 Nm (44 ft -l b ) + 90° Rub b er mou n t to tran smissi on or b racke t n u t (M 8) 21 Nm (15 f t -l b ) Sl av e cyl ind er to tran smissi on 22 Nm (16 f t-l b ) T ransmissio n crossmember t o ch assis M 8 21 Nm (15 f t -l b ) T ransmissio n t o eng in e (To rx -h [...]

  • Page 432

    240-1 Gen era l T h is sect io n cov ers mai n t enan ce and repl aceme n t of th e E46 aut omatic tran smissi on. I n tern al rep ai rs t o th e automatic tr ansmissio n are n ot cov ered. S p eci al t oo l s an d p roce d u res are requ ire d to d isasse mb l e and serv ice int ernal aut oma tic t ransm issi on compon ent s. A u t oma t ic t rans[...]

  • Page 433

    absolu t ely n ecessa ry, th ey are especia l l y h elp f u l wh en d ealin g wi th th e remov al and rep l aceme n t of th e torq u e conve rter. En g ine su p p ort b racke t BM W 00 0 200 / 20 8 Oil p an su p p ort b racket BM W 11 8 022 T orq u e con v erter socket BM W 24 1 10 0 Sp l in e b ore al ig n ment t ool BM W 24 2 30 0 T orq u e con v[...]

  • Page 434

    d ea l er ab out a f actory recond itio n ed u n it or a tran smissio n rebu il d . 32 3i/Ci an d 32 8i/Ci mod els manu f actu red f rom 08 /98 to 03/00 are equ ip p ed with th e A 5S 36 0R aut omatic tran smissi on. V ehicl es p rod u ced after 03 / 00 a re equ ip p ed wi t h t h e A 5S 325 Z tran smissi on. Tab le a. Automatic tra n sm i ss i o n[...]

  • Page 435

    240-2 T ra n s m i s s i o n Serv i ce T h e aut oma tic t ransm issi on s inst all ed in th e 3 Seri es are fil l ed with eith er De x ron II I A TF, or T ex aco 80 72B a sp eci al l ife-time oi l . CA UTI ON! Mixin g d if fer ent types o f tra n smis sio n fluids w i ll l ead to tra n smis sio n failur e. No te: The transmissi on l ubr i can t i [...]

  • Page 436

    Mak e su re the car i s sta b l e and w ell su pp or ted at all ti me s. Use a pro fess ional au tom o t ive li ft or j ac k sta n ds desig n ed f o r the p ur p o se . A floo r jack i s not adequ ate su p por t. - Warm u p d riv etrain b y ru n n ing eng in e u n t il A TF r ea ch es sp eci fied temp era t u re. A p p l y b rake an d , whil e idl [...]

  • Page 437

    wi ll spil l fro m th e fil l er ho l e wh en th e fil l p lug i s rem ov ed. - Re in stal l f ill p l u g u sin g n ew sea l in g rin g . Ti gh teni n g torqu es A TF d rain p l u g t o A TF su m p A 5S 36 0R / A 5S 39 0R (M 14) 20 Nm (15 f t -l b ) A 5S 32 5Z 35 Nm (26 f t -l b ) A TF f ill p l u g to A T F su mp A 5S 36 0R / A 5S 39 0R (M 14) 20[...]

  • Page 438

    Pu l l A TF f l u id st rainer f rom tran smissi on p u mp h ou sin g . If st rai n er sea l in g rin g rema in s in p u mp h ou sin g remo v e u sing a seal p u l l er. - I n stal l ation is r ev er se of remov a l . A l wa ys r epl ace sea l f or d rain p l u g and al l g asket(s) and O -ring s. Clean su mp and su mp mag n et(s) u sing a l in t- [...]

  • Page 439

    Automatic tra nsmis sion flu i d ca pac i ty wi th ou t t orqu e conv erte r 6.2 liters (6.5 q t) A 5S 32 5Z (3.0 l iter) wi th t orqu e conv erte r 8.7 liter (9.2 q t) wi th ou t t orqu e conv erte r 6.1 liter (6.4 q t) Ti gh teni n g torqu es A TF d rain p l u g t o A TF su m p A 5S 36 0R / A 5S 39 0R (M 14) 18 Nm (14 f t -l b ) A 5S 32 5Z 35 Nm [...]

  • Page 440

    240-3 T ra n s m i s s i o n Rem ov a l a n d I n s ta l l a tio n Re mov al an d in st all atio n of th e tran smissi on is b est accompl ished on a l ift u sin g a t ransmissi on j ack. Use caution an d safe wo rksh op p ractices when worki n g b eneath car and l ow eri n g tran smissi on. CA UTI ON! B e su re th e v ehicl e is p ro perly su pp o[...]

  • Page 441

    re ad th e batter y d isco n nectio n ca utio n s give n at the fro nt o f th is ma n u al on p ag e vii i . Re mov e eng ine coolin g int ake h oo d fasten ers ( ar row s ) at fron t of eng in e compartmen t. - Re mov e eng ine d riv en coolin g fan , u n f asten coo l ing f an cowl and p u l l sl igh t l y u p ward s. See 170 Ra d iator and Coo l[...]

  • Page 442

    Mak e su re the car i s sta b l e and well su p p o rte d at all ti me s. Use a pro fess i onal au tom otive lift or jack sta nd s d es i gned for the pur p os e. A fl o or jack is no t adequ ate su pp or t. Re mo va l of transm i ss ion w il l ca us e eng i n e to ti p u n less eng i ne su p por t i s u sed. - Re mov e eng ine sp l ash g u ard f r[...]

  • Page 443

    remo v e cabl e f rom b racket. (A 5S 32 5Z tran smissio n sh own. ) Di scon n ect electr i cal h arn ess conn ector(s) f rom t ransmissio n b y tu r n ing b ayonet l ock rin g (s) ( ar row s ) coun t erclockwi se. On A 5S 325 Z d isco n n ect two conn ectors on t h e l eft side of t h e tran smissi on. On A 5S 360 R / A 5S 39 0R d isco n n ect t h[...]

  • Page 444

    Re mov e b el l h ou sing -to-eng in e moun t ing b olt s ( ar rows ). - I n stal l BM W sp eci al tools 24 4 131 and 24 4 135 t o secure t orq u e conv erter in p l ace d u rin g tran smissi on remo v al. CA UTI ON! Do n ot allo w th e to rque c onv er ter to fall o ff th e tra nsmiss ion i n pu t shaft. - Re mov e t ransmissio n b y p u l l ing b[...]

  • Page 445

    I n stal l n ew O-rin g s on tran smissi on coo l er l in es, wh ere app l ica b l e. I n sp ect en g in e d riv e p l ate f or cracks or elon g ated h ol es. Re p l ace if n ecessa ry. Check to b e su re t orqu e conv erter is sea t ed correctl y in tran smissio n d u rin g f in al inst al l ation. Wh en moun tin g tran smissio n to eng in e, t h [...]

  • Page 446

    Ti gh teni n g torqu es Fron t su sp ension rei n forceme n t t o ch assis (M 10 ) 4 2 Nm (30 f t -l b ) T orqu e con v erter t o d riv e p l ate (M 10) 45 Nm (33 f t -l b ) T ransmissio n su p p ort crossme m b er to ch assis 23 Nm (17 f t -l b ) T ransmissio n t o eng in e (To rx -h ead wi th washer) M 8 21 Nm (15 f t -l b ) M 10 4 2 Nm (31 ft -l[...]

  • Page 447

    250-1 Gen era l T h is r epair g roup cov ers tr ansmissio n g ea r sh ift an d l in kage serv ice f or b oth manu al an d au tomatic tran smissio n equ ip p ed ve h icl es. Spec ia l tools BM W su g g ests t h e u se of on e sp eci al tool in t h e remov al of th e g ear sh ift l ev er f or man u al t ransmissio n eq u ip p ed v ehicl es. Pin wre [...]

  • Page 448

    250-2 M a n u a l T ra n s m i s s i on Gea rs h i f t M anual T ra nsmi ss ion Gea r s hi ft Linka ge s 1 - Rubb er b o ot 2 - Shi ft l ev er bear i n g 3 - Shi ft arm bear i n g 4 - Shi ft arm 5 - Shi ft l ev er 6 - Selec to r rod 7 - Space r rin g 8 - Circ l i p 9 - Dowel pi n 10 - Lo ck rin g 11 - Washer 12 - Gear se lector rod j oi nt 13 - Be [...]

  • Page 449

    Use t h e ab ov e il l u st ration as a g u id e when remov ing and in st all in g t h e l inkag e. - R emo v e sh ift kn ob b y p u l l ing kn ob straigh t off th e manu al g earshift . No te: Re moval of t he shif t knob w i l l req ui re ab out 90 l bs. of f orce . Do n ot t w i st knob or l oca ti ng key can be da m ag ed. - Pry u p on rear of [...]

  • Page 450

    va riou s co mponents due to lack of clea rance . Working ab ov e transmissio n , d isconn ect sh ift rod f rom g earshift l ev er b y p u l l in g off sh ift rod r etai n in g cl ip in d irectio n of arro w ( 1 ). Dise n g age sh ift rod f rom g ear sh ift l ev er ( 2 ). Note wa sh ers on ei t h er sid e of sh ift rod en d . Re l ea se g ea r sh i[...]

  • Page 451

    I nstal l rub be r gromme t corre ct l y so t ha t i t sea l s out w ater. - C onn ect sh ift rod to sh ift l ev er. I n st all tran smissio n crossmember. Li f t tran smissi on and t ig h ten crossme mb er b ol ts. Before conn ecting t h e sh ift rod to th e l ev er, b e su re th e g ea rsh ift l ev er is facing t h e correct wa y as il l u st rat[...]

  • Page 452

    250-3 A u tom a ti c T ra n s m i s s i on Gea rs h i f t I n E46 models, t h e el ectronic immo b ilizer (EWS) p rev ent s starter operatio n u n l ess t h e g ea r p osi t ion is Park or Ne u t ral . Gea r s hift m e c hanism , adjust i ng (aut om a tic trans m i s s ion) - Posi t ion g ea rsh ift l ev er in Park. - Ra ise v ehicl e t o g ai n ac[...]

  • Page 453

    A utom a tic s hi ft lock , che c ki ng fu nction (auto m a tic trans m i s s ion) T h e aut oma tic sh iftl ock u ses an el ectric solenoid t o l ock t h e sel ector l ev er in Park or Ne u t ral . Depressing t h e foot b rake with t h e ig n ition on energ izes th e solenoid , all ow in g t h e l ev er t o be mov ed int o a d riv e g ea r. T h e [...]

  • Page 454

    l ev er can n ot b e mov ed out of Park or Ne u tral . I f any fau l t s are f oun d ch eck th e electrical operatio n of th e sh iftl ock solenoid an d ch eck f or wi rin g fau l t s to or from t h e t ransmissio n con t rol modu l e (T CM ). See 61 0 El ectrical Co mp on en t Loca t io n s and El ectrical Wiring Dia g rams. No te: The solen oid i[...]

  • Page 455

    Shift int er loc k, c hec k ing fu nction (auto m a tic trans m iss ion) T h e sh ift in terl ock u ses a cab l e b etwee n th e ign ition switch an d t h e shift l ev er t o l ock t h e sh ift l ev er in th e p ark p osi tion when t h e key is in t h e off p osi tion or remo v ed. T h is f eatu re also p rev en t s t h e key from b eing remov ed f[...]

  • Page 456

    260-1 Gen era l T h is r epair g roup cov ers th e repair and repl aceme n t of d riv eshaft s an d d riv e sh aft comp on ent s. Driv e ax l es are cov ered in 311 F ront Ax l e Fin al Driv e and 331 Re ar A x l e Fin al Driv e . Spec ia l tools BM W su g g ests t h e u se of a sp ecia l tool in t h e release of th e cl ampin g sl ee ve which acts[...]

  • Page 457

    d riv e sh aft ru n s f rom t h e t ransf er case to th e fr ont d ifferent ia l . The f ront d riv e sh aft b olt s t o t h e t ransf er case and d iff ere n tial d irectl y, u sin g n o fl ex ibl e ru b b er d isk. Rea r w he el dri v e dri ves ha ft as s em bly A l l w he el drive drives ha ft ass e m blie s 1 - Fron t d rives h aft as sem b l y[...]

  • Page 458

    tig h t en t o 10 0 Nm (74 f t-l b ) 6 - Re ar drives h aft as sem b l y 7 - Dr i ves h aft ce n ter bear i ng moun t T roublesho oting T h e source of d riv elin e v ib ratio n s an d n oi se can b e d iff icu l t t o p in p oi n t . En g in e, tran smissi on, fron t an d rear ax l e, or wheel v ib ratio n s can b e tr ansmitt ed th r oug h t h e [...]

  • Page 459

    tab s on t h e d riv eshaft t u b es. I n add ition to in sp ecting f or f aul t y d riv eshaft p arts, th e in st all ed ang l es of th e d riv esh aft sh oul d al so b e con sidered. Fu rth er in sp ection requ ire s remov al of th e d riv esh aft s. Ch eck th e f ron t cen tering g u id e on th e tran smissio n ou tp u t f l an g e for d amage o[...]

  • Page 460

    Ta b l e a. D riv eshaft t rou b l eshooting l ists symp toms of d riv eshaft p rob l ems and t h ei r p r obab l e causes. M ost of th e repair inf ormatio n is cont ained with in t h is repair g roup . No te: W i t h t he dri vesh aft i nstal l ed , t he actual amo un t t hat the un i versal jo i nts pi vot i s l i mi t ed. F or the most accura t[...]

  • Page 461

    Sym p to m Probabl e caus e Corr ective action Univ ersal j oi n ts worn or sei zed. Check u n iv e rsal j oint p l ay and mov ement. Re p l ace driv esh aft if n ece ssary. Sl idin g coup l in g sei zed . Re mov e d riv eshaft and ch eck mov ement of sl idin g coup l in g . Cl ean cou p l in g sp l in es an d repl ace p arts as n ece ssary. Dri ve[...]

  • Page 462

    Sym p to m Probabl e caus e Corr ective action M ou n tin g fl ang e b ol ts l oo se or h ol es wo r n . Re mov e d riv eshaft and ch eck t ran smissi on out p u t fl ang e an d fin al d riv e inp u t f l an g e. Re p l ace if n ecessa ry. Dri ve sh aft u n b al an ced. Check d riv eshaf t for l oo se or missing b al an ce we ig h t s. Hav e d r iv[...]

  • Page 463

    260-2 Rea r Dri v es h a f t Serv i ce Re p air kits for t h e u n iv ersa l j oint s are n ot av ailabl e for BM W d riv eshaft s. Worn or d ama g ed u n iv ersa l j oi n t s u su al l y requ ire repl aceme n t of th e d riv e sh aft . 1 - He x b ol t, M 12 2 - Ce n t ering sl eev e 3 - Fl ex ibl e d isk 4 - Fron t section of d riv esh aft 5 - Cla[...]

  • Page 464

    fin al d riv e h av e b ee n remo v ed and inst all ed . If al l oth er p arts of th e d riv e sh aft h av e b een in sp ected an d foun d to b e oka y, b u t t h ere is stil l n oise or v ibration, d riv e sh aft al ig n ment sh oul d b e ch ecke d . T h ere are two imp ortant d riv eshaft alig n ment ch ecks. Th e first is to make su re th at t h[...]

  • Page 465

    Rear drives haft, rem oving WA RN I NG! B e su re th e wh ee l s are of f th e g ro u n d b efo re re mo ving the drives h aft. S et the p ar king brak e befo re re mo ving th e drive shaft. On ce th e d riv esha f t h as bee n re mo ved, th e ve hi cle ca n ro l l re ga rdles s o f wh ether th e tra n smis sio n i s in ge ar or not. Th e d riv es [...]

  • Page 466

    Usi n g BM W sp ecia l t oo l 26 1 040 , l oo sen th rea d ed cl amp ing sl eev e on d riv e sh aft a f ew tu rn s. - Re mov e cent er su p p ort b ea r ing moun t ing b olt s. - Re mov e d riv eshaft b u t d o n ot separate t wo h alv es. Pu l l d ow n on center of d riv esh aft t o f aci l itate remo v al. No te: I f drivesha f t halves w ere se [...]

  • Page 467

    height of the center bear in g o r tra n smis sio n su p por t us i n g shi ms is 3 mm (0.12 i n .). - T ig h t en t h readed sl ee v e on d riv e sh aft t o p rop er torq u e. - I n stal l h ea t sh ield s. - I n stal l ex h aust syst em. See 18 0 Ex h aust System . Conn ect wi ring h arness t o ox yg en sensors. - Ro ad t est v ehicl e t o ch eck[...]

  • Page 468

    Ti gh teni n g torqu es (repl ace b ol t s) Fl ex -disc t o d riv esh aft or tr ansmissio n fl an g E M 10 (8 . 8 gr ade) 4 8 Nm (35 f t -l b ) M 10 (1 0.9 g rade) 60 Nm (44 f t -l b ) M 12 (1 0.9 g rade) 10 0 Nm (74 f t-l b ) T ransmissio n crossme m b er to b ody (M 8) 21 Nm (15 f t -l b ) No te: Bolt grad e i s m arke d on the bo l t he ad . W h[...]

  • Page 469

    un supp orte d, t he rea r un i versal jo i nt may be da mag ed . - Unb ol t f l ex -d isc f rom d riv eshaft . No te: Re moval an d i nstal l ati on of t he bolt s may be made ea si er by placi ng a l arge ho se cl amp aro un d the fl ex-disc, and ti ghten i ng t he cl amp sl i gh t l y t o comp ress t he co up l i ng. I n stal l n ew fl ex -d isc[...]

  • Page 470

    Ti gh teni n g torqu es M 10 (1 0.9 g rade) 60 Nm (44 f t -l b ) M 12 (1 0.9 g rade) 10 0 Nm (74 f t-l b ) T ransmissio n crossme m b er to b ody (M 8) 21 Nm (15 f t -l b ) Center bea ring a ss e m bly , repla c ing T o rep l ace th e center b ear ing asse mb l y, t h e d riv eshaft m u st b e remo v ed from t h e car. T h e cen ter b ea r ing asse[...]

  • Page 471

    inn er h u b of b ea r i n g . Pu l l in g on outer ring of moun t may t ea r ru b b er, and en t ire b eari n g asse mb l y wil l n ee d t o b e rep l ace d . - Before in stal l atio n , make su re d u st g u ard is on d r iv esh aft, and th en p ress cent er moun t on to d riv e sh aft f l u sh with d u st g u ard. - Pl ace cl amp in g sl ee v e,[...]

  • Page 472

    sh oul d f it sn u g l y on t h e tran smissi on outp u t sh aft. No te: Some dri vesh aft s ha ve a dust cap i nstall ed on t he e nd of the drivesha ft , ove r t he center i ng gu i de. T he du st cap may be come be nt or dist orted w hen t he drivesha f t i s remo ved o r i nstall ed. Da mage t o the du st cap sho ul d no t affect the cen tering[...]

  • Page 473

    - I n stal l d riv eshaft as d escri b ed ea rl ier. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Drive sh a ft s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /2... 11 of 1 1 2/ 25/ 2009 10: 20 PM[...]

  • Page 474

    260-3 Fron t Dri v es h a f t Serv i ce Re p air kits for t h e u n iv ersa l j oint s are n ot av ailabl e for BM W d riv eshaft s. Worn or d ama g ed u n iv ersa l j oi n t s u su al l y requ ire repl aceme n t of th e d riv e sh aft . Front driv eshaft , r em oving a nd ins ta lli ng CA UTI ON! Do n ot mo ve vec h icle u sin g engine power once [...]

  • Page 475

    - I n stal l ation is r ev er se of remov a l . Ti gh teni n g torqu es Dri ve sh aft t o d riv e fl an g e (M 10 ) 70 Nm (52 f t-l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Drive sh a ft s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /2... 2 of 2 2/ 25/ 2009 10: 21 PM[...]

  • Page 476

    [...]

  • Page 477

    270-2 T ra n s f e r Ca se T ra nsf e r c a s e, re m ov i ng and ins ta lli ng - Ra ise v ehicl e an d saf ely su p p ort to access tran sfer case. WA RN I NG! Wh en raising the car us i ng a floo r jack or a hyd ra u l ic li ft, ca refu l ly p o sition th e jack pad to prev ent d am ag in g the car body. A su i table li n er (woo d , ru b ber, et[...]

  • Page 478

    Re mov e t ransmissio n crossmember ( ar row s ). - De t ach t ran sfer case v ent tu b e. - Kee p in g t h e d riv eshaft in p l ace, remo v e n u t s retainin g rea r d riv e sh aft t o tran sf er case at fl ex ibl e d isc. CA UTI ON! Do n ot allo w th e drives h aft to hang down. Th is may d am age u n i ve rs al joints at d rive shaft end s. - [...]

  • Page 479

    b efore in st all in g . On manu al t ransmissio n cars: Re p l ace sealin g O-rin g b etwee n tran smissi on and t ransf er case. No te: W hen refi l l i ng tran sf er ca se, reche ck oi l l eve l aga i n aft er d ri vi ng car ap proximatel y 20 0 meters (600 f t). Ti gh teni n g torqu es T ransmissio n crossme m b er to b ody (M 8) 21 Nm (15 f t [...]

  • Page 480

    300-1 Gen era l T h is sect io n cov ers g en era l i n f orma tion for f ront and rear susp ension , steeri n g system, and t h e el ectronic b r aki n g an d stabil ity con trol systems. Front and re a r s y spens ion syst e m s ( rea r w hee l drive) Front su s pe ns i on I n rea r wheel d riv e cars, t h e con tr ol arm on ea ch side con n ects[...]

  • Page 481

    Each f ront st ru t assembl y in cl u d es a tu b u l ar st ru t h ou sin g wi t h an in t egrated sh ock absorb er and a l arge coil sp rin g . T h e u p p er stru t moun t in cl u d es a coil sp ring seat an d str u t b eari n g . A ru b b er b u mp st op l imits su sp en sion t rav el . The steeri n g arm cl amps t h e l owe r en d of t h e stru[...]

  • Page 482

    are d esign ed wi t h ant i-d iv e g eo metry. T h is d esign redu ces th e n orma l ten d en cy f or t h e f ront of th e v ehicl e t o d iv e u n d er h ard b raki n g . Co n t rol arm p ositio n is fix ed , with n o adj u stmen t p rov isio n s on th e contr ol arms for al tering f ront wheel al ign men t . A stabil izer b ar mou n ted to b oth [...]

  • Page 483

    from t h e rear wheel d riv e v ersi on and h av e also b ee n rel oca t ed t o p rov ide fron t ax l e cl ear an ce. T h e fr ont st abil izer b ar h as b een increase d in d ia m eter to accommo d ate th e add itional wei g h t . See Ta b l e a . T h e str u ts are sh orter th an th e rea r wheel d riv e v ersio n . Rei n f orce m ent p l ates h [...]

  • Page 484

    ea se p arki n g an d city d riv ing . A t h igh sp eeds, assi st is red u ced t o en su re stab il ity. T h e steeri n g l in kage con n ects th e rack-a n d -p in ion u n it th rou g h t ie rod s t o th e stee rin g arms. The t ie rod en d s all ow th e whee l s to p iv ot and react t o su sp en sio n t rav el. On al l wheel d riv e model s, t h [...]

  • Page 485

    th e sam e l ayout as t h e rear wheel d riv e v ersi on. T h e rea r su sp ension trav el of th e E46 al l wheel d riv e is app r ox . 17 mm (0.67 in .) l ess t h an t h e rea r wh ee l d riv e v ersi on . T h e rea son f or th e red u ced t rav el in th e rea r is to p rev ent ex cessi v e b od y rol l as a resul t of t h e h ig h er b ody p rofi[...]

  • Page 486

    l igh t on t h e d ash b oard. T ir es and w he el s T ire size is critical t o th e pr oper op era tion of t h e an ti-l ock b rake system an d traction cont rol syst em. Sev eral d iff ere n t styl es of wh ee l s in 15 , 16 , and 17 inch d ia m eters are av ai l abl e from an aut h ori zed BM W d ealer. On al l wheel d riv e cars, st an d ard wh[...]

  • Page 487

    300-2 El ectron i c Bra ke a n d Sta bi li ty Con trol Sys tem s A l l E46 v eh icl es are eq u ip p ed with an A n t ilock Braking Syst em (A BS). Earl y p rodu ct ion model s featu red A BS with A u t oma t ic Stab il ity Co n t rol (ABS /A SC). La t er mod els came eq u ip p ed with A BS and Dyn ami c St abil ity Co n trol (A BS/DSC). DSC b u il[...]

  • Page 488

    DSC 19 99 - 200 0 Dynami c Stab ility Co n tr ol T ev es M K 20 DSC 1 - DSC con trol modu l e and h yd raul ic u n it, rig h t rear of en g in e compartmen t 2 - Brake fl u id reserv o ir, master cyl ind er and DSC b rake p ressu re sensors, l eft rear of en g ine compartmen t 3 - DSC p rech arge p u mp , l eft rear o f eng in e compart ment , u n [...]

  • Page 489

    4 - Fron t wh ee l sp eed sen sor, at ea ch fron t steering arm 5 - Steeri n g an g l e sensor, at b ase of u p p er st ee ring col u mn 6 - La t eral acceleratio n sensor, b ehin d d riv er’ s kickp anel 7 - Ro t atio n al acceleratio n (yaw) sensor, u n d er d riv er’s sea t, u n d ern ea th ru g No te: There i s no prech arge pump i n t his [...]

  • Page 490

    T h e electron ica l l y cont roll ed A BS mai n t ains v ehicl e st abil ity and con trol d u rin g emergen cy b raki n g b y p rev en t ing wh ee l l ock-up . A BS p rov id es opt i mu m d ece l eratio n an d stabil ity d u rin g ad v erse con d itions. It automatica l l y ad j u st s b rake syst em h yd raul ic p ressur e at each wh ee l t o p r[...]

  • Page 491

    may also be r eferre d t o as ASC+T (Automa t i c Stabil i ty Con t rol+ Tracti on ). T h e A SC system imp rov es traction b y electron ica l l y app l ying t h e rear b rake s when t h e rear d riv e wheels are sp inn ing at a faster rate t h an t h e f ront wheels. The comb in ed A BS/AS C contr ol mod u l e, operating t h roug h th e A BS h yd [...]

  • Page 492

    requ ires sp ecia l test eq u ip ment and kn ow l ed g e and sh ou l d b e p erforme d onl y b y an au th ori zed BM W d ealer. T ab l e c. AS C in d ica t or l amp fu n ction l ists t h e con d itions ind ica t ed b y t h e A SC ind icator l ig h t in t h e in st ru ment cl u ster. AB S/ASC tra ctio n control sy stem 1 - Wh ee l speed se n sor 2 -[...]

  • Page 493

    In di cator lamp Con d iti on A ction / Us e Li g h t off A SC monitoring mode A u tomatic A SC operatio n Press A SC b u t ton , l ig h t come s on A SC off (d isabl ed) Ro cking t h e car to g et ou t of sn ow or oth er loose sur face Dri vi n g with sn ow ch ai n s Press A SC b u t ton , l ig h t g oes out A SC monitoring mode A u tomatic A SC o[...]

  • Page 494

    2 - Stee r ing an g l e sen sor 3 - R otatio n al rate (yaw) sen sor 4 - Bra ke p ressu re sensor 5 - A BS wheel sp eed sensors 6 - Eng in e con t rol modu l e Ou tp u t s 7 - A BS/DSC h yd raul ic system 8 - I g n itio n (sp ark) 9 - Fu el in j ection 10 - T h rottl e v alv e T h e DSC syst em can b e t ogg l ed on an d off b y a swi t ch mou n te[...]

  • Page 495

    Sy s tem functions Each of t h e el ectronic b r aki n g and stab il ity con trol systems in cl u d e su b -syst ems which u se th e h yd rau l ic u n it/ cont rol mod u l e an d sensors t o carry out ad d itional syst em f u n ct io n s. The fou n d ation of th e st abil ity cont rol systems is A n til ock Braki n g Syst em (A BS) wi t h th e fol [...]

  • Page 496

    wheel b rake circuit d u rin g corn ering if activ ation t h reshol d v al u es are ex ceeded . Electr o n ic b rak e p ropo rtio ni ng (EBV) El ectronic b rake p rop ortioning ad j u sts b raking force to t h e rear wheels b ase d u p on t h e v eh icle' s l oa d ing , fr ont t o rear, to max imi ze th e v ehicl e's b raki n g p owe r. U[...]

  • Page 497

    Pressure rel ea se Wh en int erv ent io n is n ece ssary: T h e ch an g eov er v al v e in t h e h yd rau l ic u n it en ergizes and cl oses inl et v al v es f or th e two fron t wheel s and t h e rear wheel wi t h tr actio n . T h e rea r b rake circuit in take v al v e is energ ize d and open ed to rear wh eel wi th ou t t ractio n . Re t u rn / [...]

  • Page 498

    Dr ag to rqu e r edu ction (M SR) Durin g d eceleratio n an d en g in e b raking cond itions en g ine d rag torq u e can cau se th e re ar wheel s of a v ehicl e t o l ock on l ow t ractio n su rfaces, esp ecia l l y in h ig h sp eed, l ow g ea r d riv in g . T h is can l ead to l oss of t raction in t h e rea r. W h en d riv e wheel sp ee d is sl [...]

  • Page 499

    Wh en DBC f u n ct io n is activ a ted , b r aki n g p ressur e wi l l increase at al l wh ee l s u p t o th e A BS reg u l ation p oint . DBC wi l l cont inu e u n t il t h e d riv er release s t h e b rake p edal , b rake p ressure d rops, or th e v ehicl e sl ows to u n d er 3 mp h . M ax i mum brak e con tr ol (M BC ) M ax im u m b rake cont ro[...]

  • Page 500

    th reshol d V ehicl e road sp ee d d rops b el ow 3 mp h Teve s M K 20 ASC d i agra m Su spe n si on , St eer i n g a n d Brakes — Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /3... 14 of 2 4 2/ 25/ 2009 10: 24 PM[...]

  • Page 501

    Teve s M K 20 DSC Diagram Su spe n si on , St eer i n g a n d Brakes — Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /3... 15 of 2 4 2/ 25/ 2009 10: 24 PM[...]

  • Page 502

    Ve hic le ne tw ork T h e h yd rau l ic u n it/ con trol modu l e commun ica t es with some sensors an d many oth er con trol modu l es ov er t h e CA N-b u s. T h e CA N-bu s is a system of wi ring t h at fu n ctions l ike a com p u t er n etwor k, al l owi n g d i f ferent comp onen t s to commu n icate ov er t h e same d ata l ine, at t h e same[...]

  • Page 503

    from A SC/DSC switch on d ash . A BS con t rol modu l e sig n al s t u rn inst ru men t cl u ster warnin g l amp s on d u rin g A SC/DSC regu l at io n . Hydraul ic unit/control m odule T h e h yd rau l ic u n it is mou n t ed in conj u n ction with t h e con t rol modu l e. Wh il e t h e h yd rau l ic u n it and cont rol modu l e fu n ct io n as o[...]

  • Page 504

    20 01 Bosch DSC I II 5.7: Hall effect 20 01 T ev es M K 60 DSC : M ag n etore sistiv e 1 - Fastenin g element 2 - Groun d cont act 3 - Se n sor wir ing 4 - Se n sor h ou sing 5 - M e t al p u l se whee l 6 - Se n sor element su p p ort 7 - Ev alu ation modu l e 8 - Se n sor element 9 - M a g n et 10 - Pick-up su rf ace CA UTI ON! Th e ma g n eto re[...]

  • Page 505

    DSC later al a c c el era tion s enso r T h e l atera l acce l era t ion sensor p r ov ides th e DS C con trol mod u l e wi t h an inp u t sign al b ased on th e d egr ee of l atera l acce l eratio n (g forces) th at t h e v eh icle ex p eriences. Base d on a 5 v olt refere n ce v olt ag e, t h e sen sor wi l l retu rn an ou tp u t v olt ag e th at[...]

  • Page 506

    Bosc h DSC I I I 5.7 di agram Su spe n si on , St eer i n g a n d Brakes — Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /3... 20 of 2 4 2/ 25/ 2009 10: 24 PM[...]

  • Page 507

    DSC rot ational ra te (ya w ) sens or T h e rotatio n al rate sensor p rov i d es a anal og v ol t age sig n al t o th e DSC con trol modu l e to in d icate th e ro t atio n al sp ee d (yaw ) of t h e v eh i cl e on its v ertical ax is. T h e cont rol mod u l e su p p l ies a 5 v olt refere n ce v olt ag e to t h e sen sor. The sensor retu r n s a [...]

  • Page 508

    ang l e sensor rep l aceme n t or repairs to th e stee rin g col u mn . T h is reca l ibr atio n is p erforme d u sing eith er th e DI S or M oD iC BM W scan tools. DSC press ure sens or T h e DSC p ressu re sen sor(s) p rov ides th e A BS/DSC cont rol mod u l e an an al og v olt ag e sign al in p rop ortio n to b rake p ressur e in th e master cyl[...]

  • Page 509

    Br ake l ig h t swi tch T h e b rake l igh t switch in p u t si g n al is u sed b y t h e cont rol mod u l e t o d etermine which stab ility con trol rout ine is n ecessa ry. The con tr ol modu l e wi l l int erru p t A u t omatic Stabil ity Co n t rol (A SC) fu n ct io n s if t h e b rake p edal is d epressed d u ring A SC op era tion. O n v ehicl[...]

  • Page 510

    cont rol mod u l e. Wh en fl u id l ev e l is t oo l ow , t h e circu it is b r oke n an d t h e A SC/DSC fu n ct ions are tu rn ed off . No rm al b raking and A B S remai n s u n aff ected. Warnin g l am p s Braki n g and st abil ity cont rol war n in g l igh ts 1 - A SC/DSC war n in g l igh t. l l l u m inates solid l y when ASC / DSC syst em h a[...]

  • Page 511

    300-3 T rou bl es h oot i n g Stab l e h an d l in g and rid e comfort b oth d epen d on th e int eg rity of th e su sp en sio n an d st ee rin g compon en ts. A n y symp t om o f in stab ility or imp reci se roa d f ee l may b e caused b y w orn or d ama g ed su sp en sion comp on ent s. Wh en trou b l esh ooting su sp en sio n an d steeri n g p r[...]

  • Page 512

    Sym p to m Probabl e cause R epairs v ibrat i on or sh immy Worn su sp en sio n b u sh in g s (cont rol arm or t rai l ing arm) Re p l ace wo rn b u sh ing s. 310 , 33 0 Worn fron t su sp ension b al l j oi n t s (con t rol arm, steeri n g arm or steeri n g tie-ro d en d ) Re p l ace wo rn b al l j oi n t s. 310 Un b alan ced or b en t wh ee l s/ t[...]

  • Page 513

    Sym p to m Probabl e cause R epairs Su sp en sio n n oi se, esp eci all y ov er b u mp s (d ru mmin g , rattl ing ) Worn fron t u p p er str u t moun ts Re p l ace up p er st ru t moun t s. 310 Worn su sp en sio n b u sh in g s (cont rol arm or t rai l ing arm) Re p l ace wo rn b u sh ing s. 310 , 33 0 Worn stab il ize r b ar ru b b er moun ts Re p[...]

  • Page 514

    trou b l esh oo tin g of major A BS compon ent s r equ ires sp ecia l t est equ ip men t an d kn ow l edg e and sh ou l d b e p erformed b y an aut h orize d BM W d ealer. A BS is sel f- tested b y t h e con trol modu l e ea ch t ime th e car is st arted. On ce th e test is comp l ete, t h e A BS d ash b oard wa rn ing l ig h t t u rn s off. If t h[...]

  • Page 515

    missi n g , cl og g ed or corro d ed teeth , or oth er d ama g e t h at cou l d al ter t h e cl ea r ance b etwe en th e sen sor t ip and tooth ed wh ee l . Ride he ight Ri d e h eigh t measurement ( A ) at eith er ax l e is taken f rom cent er of wh eel arch to b ottom of wh ee l rim. I f t h e ride h eigh t is out sid e th e sp eci f icatio n l i[...]

  • Page 516

    Wh eel size S t andard sus pen sion Spo rt suspension Roug h road suspension All wh eel d rive suspension 16 in ch 58 9 mm (23 .19 in . ) 57 4 mm (22 . 59 in.) 60 6 mm (23 .86 in. ) 60 6 mm (23 .85 in . ) 17 in ch 60 4 mm (23 .77 in . ) 58 9 mm (23 . 19 in.) 62 1 mm (24 .44 in. ) 62 1 mm (24 .44 in . ) 18 in ch 61 7 mm (24 .29 in . ) 60 2 mm (23 . [...]

  • Page 517

    310-1 Gen era l T h is r epair g roup cov ers th e repair and repl aceme n t of compon ent s th at make u p th e f ront su sp en sion of E46 cars. See 300 Su sp ensio n , St ee rin g an d Brake s-G eneral f or a d escription of th e fron t su sp ensio n and comp onen t s, as we l l as sp eci ficatio n f or sett ing rid e h ei g h t . Spec ia l tool[...]

  • Page 518

    Upp er st ru t n u t remov al socke t BM W 31 2 21 0 Fron t coi l sp ring comp resso r B M W 31 3 12 0 Ball j oint p u l l er (all wh ee l d r iv e BM W 32 2 04 0 Ball j oint p u l l er BM W 32 3 090 Ou t er CV j oi n t remo v al t oo l BM W 33 2 11 1/116 / 11 7 Fron t Su spe n si on h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E4[...]

  • Page 519

    Sl ide h ammer wi t h ad apt er BM W 33 4 20 1/202 / 20 3 33 2 116 I n n er b eari n g race p u l l er set BM W 33 4 40 0 Front s uspens i on cons truction Some fr ont su sp en sio n comp on ents are const ru ct ed of we igh t sav ing materi al s. F or ex amp l e, t h e cont rol arms (in rea r wh ee l d riv e mo d el s) are forg ed al u minu m. Thi[...]

  • Page 520

    se l f-l o cking fast ener s any time they ar e l oo se n ed o r re mo ved. Do n ot in sta ll b olts and n uts co ate d wi th underc oating wax, as th e co rr ec t ti g hteni n g tor q u e ca n n o t b e as sur ed. A l ways clea n th e th rea ds wi th so lvent befo re in sta ll ation, or in sta ll new parts . Do n ot atte mpt to weld or str aighten[...]

  • Page 521

    as sem b l y (6 cy li nd er models) 1 - Upper str u t moun t 2 - Coil spring 3 - Strut ass embly 4 - Control arm 5 - Control arm bu shi ng and moun t 6 - Ti e rod 7 - Stee rin g rac k 8 - Fron t stabi li zer bar 9 - Fron t suspension subfram e 10 - Stee rin g arm 11 - Stabil izer bar li n k Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s[...]

  • Page 522

    310-2 Sh ock A bs orbers a n d Spri n gs No te: Setti ng the ri de h eight i s cove red i n 300 Suspe nsi on , Steering an d Brakes- Gene ral . T h e fron t su sp ension sh ock ab sorbers in E46 cars are M cPh erson st ru t s. The stru t is a major comp onen t of th e su sp en sio n an d su p p orts th e sp rin g . M ost st ru t asse mb l y compon [...]

  • Page 523

    No te: Right si de sho w n i s i n i l l ustrati on. Left si de bracke t al so holds brake pad w e ar sen sor w i re. - Unb ol t b rake calip er asse mb l y, kee p in g b rake h ose con n ected . Su sp en d b r ake calip er f rom ch assi s u si n g stiff wi re. See 340 Brake s . Re mov e A BS wh eel sp eed sensor moun t ing b olt ( ar row ). Sl ide[...]

  • Page 524

    of stabi l i z er b ar l i nk ball joint w h i l e remo vi ng moun t i ng nu t . Re mov e t ie rod ou ter en d n u t . Use BM W sp ecia l t ool 32 3 09 0 or equ iv alen t t o p ress t ie rod en d off steeri n g arm. - Re mov e l owe r b al l j oint n u t. Use BM W sp ecia l t ool 32 3 09 0 or equ iv alen t t o separate st ee rin g arm from cont rol[...]

  • Page 525

    stru t towe r sl ots ( ar rows ). CA UTI ON! Do n ot re mo ve ce nter str ut re taini n g nut. - Lo wer stru t asse mb l y from car. Wh en inst all ing st ru t assembl y in to car: M ake su re l ocatin g p in ( ar row ) of stru t b ear ing is p ositio n ed corre ct l y in st ru t t owe r. I f factory al ig n ment l oca t in g p in is missi n g , ma[...]

  • Page 526

    Ha v e car p rofessi onal l y al ig n ed when j ob is compl ete. Ti gh teni n g torqu es Brake cal iper t o steeri n g arm 11 0 Nm (81 f t-l b ) Ro ad wheel t o h u b 100 ± 10 Nm (74 ± 7 f t -l b ) Stab ilizer b ar l in k to st ru t 59 Nm (44 f t -l b ) Steeri n g t ie rod to steeri n g arm 6 5 Nm (48 f t-l b ) Steeri n g arm t o cont rol arm 65 [...]

  • Page 527

    3 - Rive t (all w heel drive or rou gh road p ac kage on ly) 4 - Strut b ea ring re i n force ment (all wh eel d rive or rou gh road pack age o n ly) 5 - Self lo cking flang ed n u t M 8 tig h t en t o: 24 Nm (18 ft -l b ) (18 mm f l an g e) 34 Nm (25 ft -l b ) (21 mm f l an g e) 6 - Space r p l ate (all wh ee l d riv e or roug h road pack age o n [...]

  • Page 528

    pad 16 - Strut Strut as sem bly , disas sem bling and a ss em bl ing Re p l aci n g th e str u t, u p p er st ru t m oun t or sp ring req u ires th at t h e stru t asse mb l y first b e remov ed from t h e car an d d isa ssemb l ed . F or a g u id e t o p arts u sed d u rin g compon en t repl ace men t, see t h e acco m p anyin g d iagram. - R emo [...]

  • Page 529

    related compon ent s. - R epl ace stru t, u p p er st ru t mou n t or sp ring , as n eeded. No te: Springs an d/or st ruts should alw ays be rep l ace d i n pa i rs. Be su re th at rep l aceme n t st ru ts are marke d with th e same code as th e on es b ei n g remo v ed . No te: Aft erma rket st ruts are not marke d. V ehicl es with " rou g h [...]

  • Page 530

    A ssembl y i s rev erse of d isa ssemb l y, n oting t h e f ol l ow ing : Li n e u p sl ot in sp rin g p ad with corre sp on d in g sl ot in l ow er sp ring sea t . Use a n ew u p p er st ru t self l ockin g n u t . Ti g h ten n u t f u l l y b efore releasi n g sp ring comp resso r . Be su re u p p er sp rin g p ad is corre ct l y in stal l ed to [...]

  • Page 531

    10 - Stru t h ou sing 11 - Lo catin g p in 12 - Protectiv e cap 13 - Upp er sp ring p ad 14 - Wash er 15 - Upp er sp ring seat 16 - Sp ring 17 - Lo wer sp rin g seat Ti gh tenin g torqu e U p p er st ru t moun t to str u t sh aft M 14 self -l ocki n g n u t 64 Nm (47 f t-l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. F[...]

  • Page 532

    310-3 Fron t En d Rei n f orcem en t I n rear wheel d riv e model s, a f ront end rei n f orceme n t is b ol ted to t h e rear o f th e su b fr ame and attach ed to t h e frame rai l s. CA UTI ON! Do n ot drive v ehicle w i thou t th e fro n t end re in fo rc em ent i n p lac e. Da mag e to the fro nt su spension may res ult. T h e tu b u l ar f ro[...]

  • Page 533

    larg er (66 mm ) fro n t contr o l ar m bus h in gs . Th e d iffere n ce in th e ear l y pro d uc ti on and l ate r pl ates ca n o n l y be d isce rned b y re mov i ng the p l ate . I n ord er to saf ely u se an early p rodu ct ion p l ate in a car wi t h l arger b u sh in g s, in sert app rop riate size d wa sh ers b etwe en fr ame rails and rei n[...]

  • Page 534

    310-4 Fron t Su bf ra m e T h e fron t su b frame p rov ides rig id moun t ing p oi n t s f or th e en g in e, su sp en sio n , and stee rin g comp onen t s. T h e su b f rame is n ot n ormall y su b j ect to wea r and sh ou l d on l y b e repl aced if stru ctu ral l y d amaged . Re ar wh ee l d riv e and al l wheel d riv e model s d iff er sig n i[...]

  • Page 535

    sta n ds beneath a stru ctu ra l chass i s point. Do n ot pl ac e jac k sta n d s u n d er su spension p ar ts. - Re mov e sp l ash sh ield u n d er eng in e compart ment . - Re mov e f ront en d rei n f orce m ent. See F ront E n d Re inf orce ment ea rl ier in t h is g rou p . On cars eq u ipp ed with x en on h ea d l ig h ts: Re mov e f ront rid[...]

  • Page 536

    Re p eat for l eft sid e. Re mov e st ee rin g rack moun tin g b ol ts ( ar row s ) at f ron t of su b f rame . Su sp en d rack out of t h e way wi t h st iff w ire. Re mov e righ t l owe r en g ine moun t fasten er ( ar row ). - Re p eat on l eft sid e Su p p ort su sp en sio n su b f rame f rom b elow u sin g ap p rop ria t e j acki n g equ ip me[...]

  • Page 537

    and matin g su r faces are cl ean to ensu re p roper t igh ten in g an d alig n ment . Use n ew self -l ocking n u t s or b olt s, wh ere ap p l icabl e. Lo wer eng in e ont o en g in e moun t s, all owi n g it t o sett l e fu l l y b efore tig h t enin g eng ine mou n t b ol t s. Wh en th e j ob is comp l eted, h av e fron t en d p r ofessi on al [...]

  • Page 538

    Ti gh teni n g torqu es M 12- 10 . 9 b ol t s 11 0 Nm (81 f t-l b ) M 12- 12 . 9 b ol t s 10 5 Nm (77 f t-l b ) Front s ubfram e , rem ov ing a nd ins ta lli ng (all w hee l drive m odel s) Usi n g en g in e su p p ort eq u ipm ent , raise eng in e u n t il wei g h t of eng ine is su p p orted . - Ra ise car and remov e f ron t wheels. WA RN I NG! [...]

  • Page 539

    Working at r ea r rig h t corn er of fron t su b f rame , u n h ook h ea tsh ie l d from su b f rame ( arr o w ). Re mov e l eft en g in e moun t fasten er ( ar row ). - Re p eat for rig h t sid e. - Working at r igh t f ront of su b f rame , d etach p owe r steering l in es. Re mov e st abil ize r b ar anch or f asteners ( ar row s ) f rom fron t [...]

  • Page 540

    - Re p eat for rig h t sid e. Working at l eft sid e of su b frame, remo v e inn er con t rol arm b al l j oi n t moun t ing b racke t b ol ts ( arr o ws ) f rom su b f rame . Ha n g cont rol arm u sin g stiff wi re. WA RN I NG! Do n ot allo w th e co n tro l arm to h ang fro m the ou ter (st eer in g ar m) b all joint. Th is can d am ag e th e bal[...]

  • Page 541

    I n stal l ation is r ev er se of remov a l , n oting th e f ol l ow ing : M ake su re al l b ol ts, b olt h ol es, and matin g su r faces are cl ean to ensu re p roper t igh ten in g an d alig n ment . Use n ew self -l ocking n u t s or b olt s, wh ere ap p l icabl e. Lo wer eng in e ont o en g in e moun t s, maki n g su re l oca tin g p in on l e[...]

  • Page 542

    Ti gh teni n g torqu es Steeri n g r ack to su b f rame (M 10 b ol t) 42 Nm (31 f t-l b ) Su b f rame ad apt er to b od y M 10 b olt (always repl ace ) 59 Nm (44 f t -l b ) Su b f rame f ront to b ody M 12- 8.8 b olt 77 Nm (57 f t -l b ) M 12- 10 . 9 b ol t 11 0 Nm (81 f t-l b ) M 12- 12 . 9 b ol t 10 5 Nm (77 f t-l b ) Su b f rame rear to adap ter[...]

  • Page 543

    8 - Bolt M 10 (always re pl ace ) tig h t en t o 59 Nm (44 ft -l b ) 9 - Control arm rea r brac ket 10 - Bolt M 12 (always re pl ace ) tig h t en t o 11 0 Nm (81 f t-l b ) 11 - Ja ck po i nt 12 - Sub fra me moun tin g b ol t M 12 (se e torqu e table) 13 - Control arm in ner ball jo i nt 14 - Bolt M 12 tig h t en t o 77 Nm (57 ft -l b ) 15 - Self lo[...]

  • Page 544

    A Ou ter b al l j oint att ach ed t o steeri n g arm B I n n er b al l j oint att ached t o f ront su b f rame C Bu sh in g and b racket att ached to th e frame rai l (rear wheel d riv e model s) or fron t su b f rame (all wheel d riv e model s) No te: Re ar w hee l dri ve f ron t con t rol arm i s sho w n i n t he i l l ustrati on. On al l model s[...]

  • Page 545

    6 - Bra cket mou n t ing b ol t 7 - I n n er b all j oint (all wh ee l d riv e onl y) 8 - Ba l l j oint mou n t ing b ol t Con trol arm , re m oving a nd inst a ll ing (rea r w he e l drive m ode ls) - R ai se car an d remov e wh ee l . WA RN I NG! Mak e s ur e th at the car i s firmly su pp or ted on j ac k stands d es igned for the p u rpo se. Pl[...]

  • Page 546

    Re mov e cont rol arm in n er b all j oint moun t in g n u t ( arr ow ) at su b frame. Dri ve b al l j oi n t sh aft out of su b frame u sin g soft faced h ammer . Su p p ort cont rol arm wh il e remo v ing cont rol arm b racket b ol t s ( ar row s ) f rom frame rai l . - R emo v e cont rol arm. I n sp ect r ea r b racket ru b b er b u sh ing for w[...]

  • Page 547

    I f one co ntro l ar m re ar ru bb er bus h i ng is d am ag ed, b us h i ngs on both sid es mu st be replace d . No te: Co ntr ol arm rea r bush i ng replace men t i s cove r ed l ater i n thi s grou p. - I n st al l atio n is rev erse of remov al , n oting t h e f ol l ow ing : M ake sure al l th rea d b ore s, b ol ts, n u t s an d mating su rfac[...]

  • Page 548

    Ti gh tenin g torqu es Ou t er b al l j oint t o steer in g arm M 12 self -l ocki n g n u t (always repl ace) 6 5 Nm (48 f t-l b ) R oad wh eel to h u b 10 0 ± 10 Nm (74 ± 7 f t -l b ) Con trol arm , re m oving a nd inst a ll ing (all w hee l drive m ode ls) - R ai se car an d remov e wh ee l . WA RN I NG! Mak e s ur e th at the car i s firmly su[...]

  • Page 549

    Re mov e in n er b all j oint mou n t ing b racket b ol ts ( ar rows ) f rom su b f rame. Su p p ort cont rol arm. W orki n g at rear of su b f rame , remo v e cont rol arm rear b racke t moun tin g b ol ts ( arr o ws ). - R emo v e cont rol arm. I n sp ect r ea r b racket ru b b er b u sh ing for wea r. Check b al l j oint s f or d amage, l oo sen[...]

  • Page 550

    I nner ball joint an d con t rol arm rear bu shi ng rep l ace ment i s covere d l at er i n thi s gro up. - I n st al l atio n is rev erse of remov al , n oting t h e f ol l ow ing : M ake sure al l th rea d b ore s, b ol ts, n u t s an d mating su rfaces are cl ean. Use n ew self -l ocking n u ts or b olt s, where app l ica b l e. Ha v e v eh i cl[...]

  • Page 551

    WA RN I NG! Mak e s ur e th at the car i s firmly su pp or ted on j ac k stands d es igned for the p u rpo se. Place the jack sta n ds beneath a stru ctu ral chas sis point . Do not pl ac e jack stands under su spension p ar ts. - R emo v e sp l ash sh ie l d u n d er e n g in e compartmen t . Re mov e in n er b all j oint f asteners f rom cont rol[...]

  • Page 552

    Ti gh tenin g torqu es I n n er b all j oint to contr ol arm M 14 self -l ocki n g n u t (always repl ace) 8 0 Nm (59 f t-l b ) Con trol arm bus hings, rea r w hee l drive CA UTI ON! Ne ver reu se a ru bb er b u sh in g that has been p u l l ed o ff th e co n tro l ar m. T he ru bb er co ated i n n er slee ve is d estr oy ed w hen it i s pulled o f[...]

  • Page 553

    I n sp ect b u sh in g b racket. Rep l ace b racke t if th ere is a cent er p u n ch mark at b oss A . WA RN I NG! I f a b u shin g brac ket wi th th e ce nter punch mar k is reu se d wi th a n ew bus h i ng, th e b u shin g m ay fall ou t. Use p ress t ools to remov e ol d b u sh in g and p ress in n ew . Be su re t o l in e u p marks on n ew b u [...]

  • Page 554

    protrusio n (rea r w heel d rive m od els) D i me n sio n 6 0 mm bu shin g 66 mm bu shi ng A = To t al b u sh in g l eng t h (n omi n al) 50 . 5 mm (1.9 9 in. ) 53 .5 mm (2.11 in .) B = Bracke t w id th (n omi n al) 34 .0 mm (1.36 in .) C = F ix ed mea su reme n t 8.5 mm (0.3 3 in. ) 12 .0 mm (0.47 in .) D = Protru sio n 8.0 mm (0.3 1 in) 7.5 mm (0[...]

  • Page 555

    Ti gh tenin g torqu e b racke t to f rame ra il M 10 b ol t (al ways repl ace) Con trol arm bus hings, all w he el drive CA UTI ON! Ne ver reu se a ru bb er b u sh in g that has been p u l l ed o ff th e co n tro l ar m. T he ru bb er co ated i n n er slee ve is d estr oy ed w hen it i s pulled o ff d ry . Chec k wit h an aut h o rized B MW parts d[...]

  • Page 556

    CA UTI ON! Ne ver reu se a ru bb er b u sh in g that h as been p u l led o ff th e co n tro l arm . Th e ru bb er co ate d in n er sleev e i s destr o yed w h en i t i s p u ll ed o ff dry. Wh en inst all in g b u sh in g on cont rol arm: Co at con trol arm p in an d ru b b er moun t wi t h app rop ria t e l u b rica n t t o facilitate in stal l at[...]

  • Page 557

    WA RN I NG! A fter in stallation, the car mu st b e left undi stu rbed fo r a mini mu m of 30 min u tes . Leav e car on th e g ro und b ut av oid ma jor mo ve me n t. A fter appro x. 30 minute s, th e lubrica n t u sed t o sli de on the bus h i ng wi l l h av e eva p or ate d and the co ntro l ar m w il l be co rre ctl y se ated i n th e ru b b er [...]

  • Page 558

    310-5 Sta bi li zer Ba r Stabil ize r ba r, r em oving a nd ins ta lli ng On E46 model s t h e st abil ize r b ar l in ks attach t o t h e stru t assem b l ies. - Ra ise car and su p p ort safel y. WA RN I NG! Mak e su re that the car i s firmly su pp or ted on jack stands d es igned fo r th e p u rpose . Pl ac e the j ac k sta n ds beneath a stru [...]

  • Page 559

    I f n ecessa ry, l oo sen and remov e stabil izer b ar l in k mou n t in g n u t ( arr ow ) from st ru t . De tach l ink f rom stru t h ousin g . No te: Use a thi n w ren ch to cou nterh ol d shaft of stabi l i z er b ar l i nk ball joint w h i l e remo vi ng moun t i ng nu t . - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi[...]

  • Page 560

    310-6 Fron t W heel Bea ri n g s T h e fron t wh ee l b ea r ing s are p erma n ent l y sealed an d r equ ire n o mai n t en an ce. On rear w h eel d riv e model s, th e b ea r ing is in teg ral with t h e wh eel h u b and A BS p u l se wheel an d p ressed on th e st ee rin g arm st u b ax l e. 1 - Steeri n g arm an d stu b ax l e 2 - Dust g u ard [...]

  • Page 561

    su pp or ted on jack stands d es igned fo r th e p u rpose . Pl ac e the j ac k sta n ds beneath a stru ctu ra l chass i s point. Do n ot pl ac e jac k sta n d s u n d er su spension p ar ts. Pry off d u st cap f rom cen ter of wheel h u b . B end b ack st ake d p art ( arr o w ) of wheel h u b (ax l e) col l ar n u t . - Re mou n t wh eel and l u [...]

  • Page 562

    - I f out ermost b eari n g in n er race stays on st ee ring arm st u b ax l e, u se BM W sp eci al tool set 33 4 40 0 or two-jaw pu l l er to remov e race. CA UTI ON! Do n ot re us e a wh ee l bear in g as sem b l y o n ce it has been rem o ved. Th e re mo va l p ro ce ss d es t ro ys th e bear i n g . T o remov e inn ermost in n er race: Unb ol t[...]

  • Page 563

    M oun t wheel and l u g b ol ts. Lo wer car to g rou n d t o g ain l ev erage. Ti gh teni n g torqu es Brake cal iper t o steeri n g arm 1 10 Nm (81 ft -l b Brake rotor t o wheel h u b 16 Nm (12 f t-l b ) Ro ad wheel t o h u b 100 ± 10 Nm (74 ± 7 f t -l b ) - With an assistant ap p l ying b rakes, tig h t en coll ar n u t . Ti gh teni n g torqu e[...]

  • Page 564

    acco mp l ished b y remov ing t h e st ee rin g arm and wh ee l h u b from t h e car an d separating th e compon ent s on t h e b ench . - Ra ise car and remov e f ron t wheel. WA RN I NG! Mak e su re that the car i s firmly su pp or ted on jack stands d es igned fo r th e p u rpose . Pl ac e the j ac k sta n ds beneath a stru ctu ra l chass i s po[...]

  • Page 565

    Re mov e t ie rod ou ter en d n u t . Use BM W sp ecia l t ool 32 3 09 0 or equ iv alen t t o p ress t ie rod en d off steeri n g arm. - De t ach con tr ol arm from f ront ax l e su b f rame as d escribed ea rl ier. - Re mov e out er b al l j oi n t n u t . Use BM W sp ecia l t ool 32 3 09 0 or equ iv alen t t o separate st ee rin g arm and st ru t[...]

  • Page 566

    Re mov e circl ip ( 3 ) from st eeri n g arm . 1 - Steeri n g arm 2 - Wh eel b eari n g 3 - Ci rcl ip (al wa ys rep l ace ) 4 - Dust g u ard 5 - Wh eel h u b - Dri ve wheel b ea ring ou t of steeri n g arm u sing a p ress w ith app rop riate ad apt ers. CA UTI ON! Do n ot re us e a wh ee l bear in g as sem b l y o n ce it has been rem o ved. Th e r[...]

  • Page 567

    - Re p l ace circl ip , making su re rin g is corre ct l y sea t ed . - Pl ace d u st g u ard ov er st eer ing arm h u b . - Dri ve wheel h u b in to b ea rin g u sing a sh op p ress. CA UTI ON! Pre ss o n l y o n th e in ner ra ce . T h e bear i n g is dama ged if i t is n o t pres sed on us in g the in n er rac e. - I n stal l ation of st ee ring[...]

  • Page 568

    Ti gh teni n g torqu es Steeri n g arm p inch b ol t at stru t h ousin g 81 Nm (60 f t -l b ) Ro ad wheel t o h u b 100 ± 10 Nm (74 ± 7 f t -l b ) T ie rod t o steeri n g arm 65 Nm (48 f t -l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Fron t Su spe n si on h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W[...]

  • Page 569

    311-1 Gen era l T h is r epair g roup cov ers th e serv ice and rep l ace ment of compon en t s t h at make u p t h e fr ont d riv e ax l e f or v ehicl es eq u ipp ed wi th al l wheel d riv e. T h is d riv e system is in teg rated in to t h e fron t su sp ensio n of t h ese model s. For a g en eral d escription of t h e fron t su sp en sio n an d [...]

  • Page 570

    T ran smissio n f l ang e h old er BM W 23 0 02 0 I n n er CV j oi n t p u l l er BM W 31 1 17 0 I mp act d r ift BM W 31 5 13 0 Ou t er CV j oi n t remo v al t oo l BM W 33 2 11 1/116 / 11 7 Sy s tem descri pt ion T h e fron t ax l e f inal d r iv e u n it is int egrated in t o th e eng in e oil p an on al l wheel d riv e equ ip p ed mod el s. The[...]

  • Page 571

    b ea r ing p ed estal b ol t t o each sid e of a modified oi l p an. Powe r is t ran smitted to th e fr ont d ifferent ia l f rom t h e tr ansf er case v ia a d riv e sh aft , an d ou t t o f ront d riv e h u b s th roug h t wo dr iv e ax l es. All w heel d rive fron t di ffer ential and fron t subfram e 1 - Fron t sub fra me 2 - Righ t axle bear i[...]

  • Page 572

    8 - Bolt M 10 (always re pl ace ) tig h t en t o 59 Nm (44 ft -l b ) 9 - Bolt M 12 tig h t en t o 77 Nm (57 ft -l b ) 10 - Fron t con trol ar m w it h ball jo i nt and rea r moun tin g brac ket 11 - Fron t di ffer ential 12 - Fron t di ffer ential drain pl ug tig h t en t o 65 Nm (48 ft -l b ) 13 - Bolt M 10 tig h t en t o 45 Nm (33 ft -l b ) 14 - [...]

  • Page 573

    Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Fron t Ax l e Fin a l Dri ve h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /3... 5 of 5 2/ 25/ 2009 10: 27 PM[...]

  • Page 574

    311-2 Dri v e A xl es T h e fron t d riv e ax l es for al l wheel d riv e equ ip p ed mod el s u se two diff erent typ es of con stan t-ve l ocity (CV ) j oi n t. T h e out er CV j oi n ts are a t radition al d esi g n th at al l ows p ow er to b e d eliv ered f rom t h e ax l e t o th e j oi n t contin u ousl y t h rou g h rotatio n . T h e inn er[...]

  • Page 575

    sta n ds desig n ed f o r the p ur p o se . A floo r jack i s not adequ ate su p por t. - Re mov e f ront wh ee l . - Re mov e sp l ash sh ield from b elow eng in e compart ment . - I f wo rkin g on rig h t sid e, remo v e righ t side h ea t sh ie l d from f ront ax l e su p p ort. Re mov e A BS sen sor ( arr o w ) f rom steeri n g arm. - Uncl ip b[...]

  • Page 576

    Su p p ort cont rol arm. W orki n g at rear of su b f rame , remo v e cont rol arm rear b racke t moun t in g b ol ts ( arr o ws ). - T il t st eer ing arm t o one sid e, out of th e wa y. - Usi n g BM W sp ecia l t oo l 31 1 170 or equ iv alen t p r y b ar, p r y in b oar d CV j oint ou t of fr ont d ifferent ia l or b ea r ing p ed estal . No te:[...]

  • Page 577

    Be su re to restake n ew col l ar n u t at ou tb oard en d of d r i v e ax l e after tig h t enin g to correct t orq u e sp eci f icatio n s. Ca u l k ax l e th r ea d s. T op u p d ifferent ial f l u id. See Fron t d iff erential oil, ch ecki n g and fil l in g Ti gh teni n g torqu es Brake cal iper t o steeri n g arm 11 0 Nm (81 f t-l b ) Co n tr[...]

  • Page 578

    WA RN I NG! Mak e su re ca r is stable and well su pp or ted at all ti me s. Use a pro fess ional au tom o t ive li ft or j ac k sta n ds desig n ed f o r the p ur p o se . A floo r jack i s not adequ ate su p por t. - Re mov e sp l ash sh ield from b elow eng in e compart ment . Re mov e in n er b all j oi n t mou n tin g b racke t b ol ts ( arr o[...]

  • Page 579

    1 - Ri g h t ax l e b eari n g p edestal 2 - Fron t d iff erential 3 - I n p u t sh af t sea l 4 - Small d u stcov er 5 - La rg e d u st cov er 6 - Di f f ere n tial p l u g 7 - Pl u g sealing rin g 8 - Dri ve ax l e radial seal wi t h l ock ring , l eft 9 - O-rin g 10 - En g in e oil p an 11 - Driv e ax l e radial seal wi t h l ock ring , righ t N[...]

  • Page 580

    I n sert in b oard end of d riv e ax l e p artia l l y int o d iff ere n tial h ou sing or b ea r ing p ed estal . With d r aw p rotectiv e sl ee v e f rom sea l in g l ip , cu t p rotectiv e sl ee v e and remov e sl eev e. Co n t in u e inst al l in g d riv e ax l e u n t il sp ring cl ip sn aps au d ibl y int o p l ace . No te: Al w a ys r ep l a[...]

  • Page 581

    O uter CV j oint boot , re plac ing No te: W hen rep l acing CV bo ots, use comp l et e bo ot repa i r ki t s. A ki t w i l l i nclude a new boo t, cl amp i ng ban ds, spe ci al l ubrican t , an d a ne w outer CV jo i nt axl e ci rcl i p. A ki t i s avail abl e from an auth oriz ed BMW de aler parts de partmen t. - Re mov e d riv e ax l e f rom v e[...]

  • Page 582

    - A p p l y Lo ct ite® 270 or an equ iv alen t h ea v y-d u t y l ocki n g compou n d to d riv e ax l e sp l ines. WA RN I NG! Do n ot let lock i n g co mpou nd co n tac t ball s in joint. A p pl y only a th i n co at to co ver spl in es. - Pack outer CV j oi n t wi th f resh g rea se. Ta p CV j oi n t on to sp l ined end of d riv e ax l e u n til[...]

  • Page 583

    Re p l ace con tr ol arm b racket b ol ts. Be su re to restake n ew col l ar n u t at ou tb oard en d of d r i v e ax l e after tig h t enin g to correct t orq u e sp eci f icatio n s. Ca u l k ax l e th r ea d s. T op u p d ifferent ial f l u id. See Fron t d iff erential oil, ch ecki n g and fil l in g Ti gh teni n g torqu es Ball j oin t b racke[...]

  • Page 584

    - Re mov e circl ip retaining t ripl e roll er b earing to d r iv e ax l e and remo v e trip l e roll er b eari n g . - Sl ide b oot off d riv e ax l e. Sep arate inn er CV j oi n t b oot ad apt er f rom b oo t . - Clean al l ol d l u b ricant off ax l e sp l ines and t ripl e roll er b ea r ing sp l ines. - I n stal l n ew inn er CV j oi n t b oot[...]

  • Page 585

    b oo t kit. - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : M ake su re in b oard en d of d riv e ax l e aud ib l y sn ap s in t o p l ace. Re p l ace con tr ol arm b racket b ol ts. Be su re to restake n ew col l ar n u t at ou tb oard en d of d r i v e ax l e after tig h t enin g to correct t orq u e sp eci f icatio [...]

  • Page 586

    3 - Circ l i p 4 - Trip l e r ol l er bear i n g 5 - In ner CV jo in t bo ot adapter 6 - Clam p 7 - In ner CV jo in t bo ot 8 - Dr i ve ax l e shaft 9 - Clam p Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Fron t Ax l e Fin a l Dri ve h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s [...]

  • Page 587

    311-3 Fron t Di f f eren ti a l Proce d u res f or repl aceme n t of O -rin g sea l b etwe en th e en g in e oi l p an and th e f ron t d ifferent ial or righ t sid e b ea r ing p ed estal are cov ered in F ront ax l e d ifferent ial, remov in g and inst all in g and Ri g h t ax l e b earing p edestal , remov in g and in stal l in g . Front diff e [...]

  • Page 588

    Fi nal d rive d rain and fil l Oil sp ecifica t io n s BM W SA F -X O syn th et ic oi l Fron t ax l e d iff ere n tial oi l capacity 0.7 l iters (0.74 US q ts. ) Ti gh teni n g torqu e Fron t ax l e d iff ere n tial d rain / fil l p l u g 65 Nm (48 f t -l b ) Front ax l e diff ere ntial , rem oving and inst a lli ng - Di scon n ect b att ery n egat[...]

  • Page 589

    Re l ea se n u t at top on righ t eng in e moun t ( ar row ). Re mov e n u t ( ar row ) at b ottom on l eft eng in e moun t. - Ra ise eng ine ap p rox ima t ely 10 mm (0.4 in .). - Re mov e f ront wh ee l s. Un b ol t b rake cal ipers an d su sp en d from b ody u sin g stiff wire . See 340 Brake s . - Re mov e f ront d riv esh aft . See 260 Driv es[...]

  • Page 590

    Su p p ort l eft con t rol arm. W orking at rea r of su b f rame , remov e cont rol arm rea r b racket mou n t ing b olt s ( arr ow s ). - Re p eat for rig h t sid e. Re mov e l eft t ie r od ou t er end n u t ( ar row ). Use BM W sp ecia l t ool 32 3 09 0 or eq u iv alen t t o p ress tie rod en d off st eeri n g are . - Re p eat for rig h t sid e.[...]

  • Page 591

    No te: Be pre pare d to catch oi l dri ps f rom dif feren t i al or ri ght si de be ari ng pe destal. Working on l ef t side of car: Re l ea se p inch b ol t ( arr ow ) at t op of steering arm. Pu l l steering arm d own f rom st ru t asse mb l y. Re mov e st ee rin g arm, d r iv e ax l e, and cont rol arm assembl y as on e u n it. Re p eat for rig [...]

  • Page 592

    ha rnesse s an d othe r und er bod y comp one nts are clear du ri ng remo val . De t ach v en t t u b e f rom p ort ( A ) on f ront ax l e d iff ere n tial. Remo v e moun tin g b olt s ( B ) and remov e f ront ax l e d ifferent ia l . - I n stal l n ew se alin g rin g , coating insid e edg e wi t h asse mb l y l u b ricant . Pu sh assembl y rin g u[...]

  • Page 593

    Ti gh teni n g torqu es Brake cal iper t o steeri n g arm 11 0 Nm (81 f t-l b ) Co n trol arm b racke t t o fron t su sp en sio n su b f rame (rep l ace b ol ts) 59 Nm (44 f t -l b ) En g in e moun t t o su b f rame M 10 self l ocki n g n u t 45 Nm (33 ft -l b ) Fron t ax l e d iff ere n tial to oi l p an 45 Nm (33 f t -l b ) Fron t ax l e d iff er[...]

  • Page 594

    Ti gh teni n g torqu es M 12- 10 . 9 b ol t 11 0 Nm (81 f t-l b ) M 12- 12 . 9 b ol t 10 5 Nm (77 f t-l b ) Su b f rame rear to adap ter M 12 b ol t (always repl ace ) 11 0 Nm (81 f t-l b ) Right ax l e bea ring pede s tal, rem oving and inst a lli ng - Li f t v eh icle and su p p ort safely. WA RN I NG! Mak e su re ca r is stable and well su pp or[...]

  • Page 595

    Su p p ort cont rol arm. W orki n g at rear of su b f rame , remo v e cont rol arm rear b racke t moun t in g b ol ts ( arr o ws ). - Usi n g BM W sp ecia l t oo l 31 1 170 or equ iv alen t p r y b ar, p r y in n er CV j oi n t ou t of b ea r ing p ed estal . - Re l ea se p inch b ol t at top of steeri n g arm. Pu l l steer in g arm d ow n from st [...]

  • Page 596

    on oil pa n, t he asse mbly ri ng i s forced ove r seali ng ri ng an d rema i ns i n pl ace . - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : A l wa ys r epl ace d riv e ax l e radial sea l b efor e inst al l ing d riv e ax l e. T op u p d ifferent ial f l u id. See F ront d ifferent ial oil, ch ecking and fil l in g T[...]

  • Page 597

    WA RN I NG! Mak e su re ca r is stable and well su pp or ted at all ti me s. Use a pro fess ional au tom o t ive li ft or j ac k sta n ds desig n ed f o r pur p os e. A fl o o r jack i s not adequ ate su p por t . - Re mov e f ront d riv esh aft . See 260 Driv esh aft - Pry out in p u t f l an g e retaining n u t l ock p l ate. Usi n g a centerp u [...]

  • Page 598

    BM W sp ecia l t ool 31 5 13 0 or equ iv alen t d rift. - Re p l ace d u st sh ield s. - Clean in p u t f l ang e and in stal l in to d ifferent ia l h ousin g . T ig h t en d own n u t u n t il p u n ch marks alig n . I n stal l n ew inp u t fl an g e reta in i n g n u t l ocki n g p l ate. CA UTI ON! Do n ot to rque i np ut flange re tain i ng nu[...]

  • Page 599

    320-1 Gen era l T h is r epair g roup cov ers steeri n g wheel and col u mn remo va l an d st eeri n g system serv ice , incl u d in g wheel alig n ment inf ormatio n . No te: I gnit i on l ock cyl i nde r replacem en t i s covere d i n t his secti on. For i nformati on o n steering column mou nted sw i tches i ncl ud i ng t he i gn i ti on sw i t [...]

  • Page 600

    T ie rod en d r emo v al t ool BM W 32 3 09 0 Fron t camber adj u stin g tool BM W 32 3 14 0 Stee ring syst e m T h e v ari abl e-assi st p owe r steering system con sists of an en g ine-d riv en h yd raul ic p u mp , a rack-a n d -p i n ion steeri n g r ack asse mb l y with an int eg ral h yd raul ic cont rol v al v e, and con n ectin g l inkag e [...]

  • Page 601

    l ine f rom t h e steeri n g rack t o th e rese rv oi r l oops int o t h e ai r stream in fron t of th e v ehicl e and is u sed as a steeri n g f l u id coo l er. T h e steeri n g r ack and l in kag e re q u ire n o mai n ten ance oth er th an alig n men t and p erio d ic insp ection for wo rn compon ent s. The ru b b er rack b oo t s and t ie -r o[...]

  • Page 602

    Do n ot re us e se l f-lock i ng nuts . Th ey are d es i gned to be us ed o n l y o n ce and ma y fail if reu se d. A l w ay s replace th em w it h new loc kin g nuts . Do n ot in sta ll b olts and n uts co ate d wi th underc oating wax, as co rre ct ti g hteni n g tor q ue ca n n o t b e as sur ed. A l ways clea n th e th rea ds wi th so lvent bef[...]

  • Page 603

    320-2 Steeri n g W h eel Stee ring w he el , rem ov ing a nd ins ta lli ng - Ce n t er st ee r ing wh ee l . M ake su re fron t wheel s are p oi n ted straigh t ahead. - Di scon n ect n eg ativ e (-) cab l e from b attery. CA UTI ON! Prio r to di sco nn ect in g the b atte ry, re ad th e batter y d isco n nectio n ca utio n s give n at the fro nt o[...]

  • Page 604

    The stee ri ng column a nd stee r i ng w he el are matchmar ked ( arr ow ) at t he factory. Co nfi rm t hese marks be f ore remo vi ng w he el from col umn. - Re mov e st ee rin g wheel. - Wh en rei n stal l in g steeri n g wheel: A l ign st ee rin g wh eel and col u mn match marks. A l ign st ee rin g wh eel to al ign ment p ins l ocated on steeri[...]

  • Page 605

    320-3 Steeri n g Col u m n Stee ring c olum n ass e m bly 1 - He x b o lt (M 14 x 1.5) tig h t en t o 63 Nm (46 ft -l b ) 2 - Ca b le du ct 3 - Stee rin g col umn adju stm ent l ev er 4 - Upper ste ering colu mn 5 - Lo wer ste erin g colu mn w i th un iver sa l j o in t 6 - To rx b o lt (M 8 x 33 ) tig h t en t o 22 Nm (16 ft -l b ) 7 - Fl ex ib l [...]

  • Page 606

    tig h t en t o 22 Nm (16 ft -l b ) 12 - Stee rin g col umn moun tin g brac ket 13 - Colu mn return spring 14 - Nut (M 8) tig h t en t o 4.8 Nm (3.5 ft -l b ) recheck as n ecessa ry Ignition lock c yl inder , rem oving and inst al li ng T o remo v e th e rin g ant en n a p rior to remo v ing ig n ition l ock cyl in d er, it is n ecessa ry t o remov [...]

  • Page 607

    Re in stal l atio n is rev erse of remo v al . Low e r st ee r ing colum n, re m oving and inst a ll ing No te: Once the l ow er st ee r i ng col umn has be en remo ved there w i l l be no end stop for t he steering w hee l . In ord er to preve nt da m ag e t o con tact ri ng i n steering column, f ol l ow pro cedu ral st ep s as l i st ed. 1. Unlo[...]

  • Page 608

    Working n ear firew all , remo ve p in ch b olt at u n iv e rsal j oint an d remo v e l owe r steeri n g colu mn . No te: Up per steering column i s keyed t o l ow er steering column un i versa l joint. It can on l y be i nstal l ed i n one posit i on. I n st all ation is rev er se of r emo v al , n oting th e fol l ow ing : Re p l ace fl ex ibl e [...]

  • Page 609

    Pu sh in sid es of u p p er t rim cov er ( ar row s ) t o release f rom l owe r t rim. Pu l l b ack and u p on u p p er t rim. Pry g ent l y t o d et ach fl ex ib l e cov er from u p p er t rim. Li ft off trim. Re mov e l eft f ootwe l l ( p edal cl u st er) trim p anel . Re mov e screws ( A ). Re mov e f asteners ( B ). Di sconn ect elect rica l h[...]

  • Page 610

    Unp l u g conn ector at f oo twell in terio r l igh t ( A ), if eq u ip p ed . Sl ide l ock at O BD II con n ector ( B ) in d irectio n of ar row . Unp l u g conn ector at cel l u l ar p h on e sp eake r ( C ) if eq u ip p ed . - R emo v e l owe r st ee rin g colu m n as d escribed ear l ier. T o remo v e stee rin g col u mn l ow er t rim, d riv e [...]

  • Page 611

    Re mov e sh ift in t erlock cabl e ( A ) if n ecessa ry. - D isco n n ect el ectrical h arness conn ector at EW S 3.3 rin g an t en n a ( B ). - Worki n g at steer in g col u mn , d etach wi ring h arn ess fr om cabl e d u ct. Dri l l out st eeri n g colu mn mou n t ing sh ear b ol t ( A ), and remov e mou n tin g b ol t ( B ). Re mov e l owe r st [...]

  • Page 612

    u n t il b ol t h ead sh ears off. M ake sure l ock of in terl ock cab l e sn aps in to p l ace . Wh en inst all in g col u mn t op tr im p anel , rep l ace ex p ansion n u t f or trim retainin g screw . Wh en inst all in g l ow er trim p an el , p u sh ex p ansion riv et p in int o riv et u n t il p in h ea d is fl u sh wi t h riv et h ead. Ti gh [...]

  • Page 613

    320-4 Pow er Steeri ng Sys tem T h e p ow er steeri n g f l u id reser v oir is l oca t ed on th e l ow er l eft f ront of t h e eng in e. CA UTI ON! Maintain clean co n d it ions wh en wor kin g wit h ope n p o wer ste ering fluid l in es . Plug off power stee rin g li nes and co n nectio ns to ke ep ou t co ntamination. Pow er stee ri ng fl u id [...]

  • Page 614

    6 - Ba n jo b ol t M 16 tig h t en t o 40 Nm (30 ft -l b ) 7 - Pow er stee rin g ra ck 8 - Pre ssurized flu id li ne 9 - Fl ui d return l i ne 10 - Fl ui d coo l er 11 - Ra ck bo o t kit 12 - Ti e rod n ut tig h t en t o 65 Nm (48 ft -l b ) 13 - O u ter t ie rod end 14 - Clam p ring 15 - O u ter t ie rod end lo ck nut tig h t en t o 45 Nm (33 ft -l[...]

  • Page 615

    fl u id reserv oir wi t h cl ean f l u id. Fil l l ev el t o M AX mark on d ip stick. - Start en g in e. Sl ow l y t u rn st ee ring wheel from l ock to l ock a minimu m of t wo time s. - T u rn en g in e off and ch eck fl u id l ev el, ad d in g more if n ecessa ry. P ow e r s tee r ing pum p, rem oving and inst al li ng - Empt y p ow er steeri n [...]

  • Page 616

    - R emo v e fron t st abil izer bar anch ors and swing st abil ize r b ar d ow n ou t of th e wa y. S ee 310 Front Su sp en sio n . Re mov e p u m p m oun t in g b olt s ( arrows ) and remov e p u mp . Rea r wh ee l d riv e model sh ow n . - I n st al l atio n is rev erse of remov al , n oting t h e f ol l ow ing : M ake sure al l th rea d b ore s,[...]

  • Page 617

    Stee ring ra c k , r em oving a nd inst a ll ing - Empt y p ow er steeri n g fl u id reserv oir u sin g cl ea n syrin g e. Do n ot reu se fl u id. - R ai se f ron t of car, an d remo ve wheels. Remo v e sp l ash sh ie l d f rom u n d er en g in e. M ake re ference measurement ( A ) of l eft out er t ie rod en d to t ie rod . Reco rd mea su reme n t[...]

  • Page 618

    Working u n d erneath car, remov e fl u id l ine b anj o b olt s ( ar rows ) f rom st ee rin g rack. CA UTI ON! Plug o ff power st eer in g li n es and co nn ectio n s to kee p ou t co ntamin atio n . No te: I t may be nece ssary t o remo ve othe r comp on ents t o gain acce ss t o steering rack. Re mov e l owe r st ee ring col u mn fl ex ib l e j [...]

  • Page 619

    M ake sure al l th rea d b ore s, b ol ts, n u t s, sp l ines an d mat ing su rf aces are cl ean. Use an ti-sei ze p aste on inn er tie rod th rea d s. Use n ew self -l ocking n u ts wherev er app l ica b l e. Use keyed compon ent s to rea ssembl e st ee r ing col u mn f l ex ibl e j oi n t t o steeri n g rack sh aft. M ake su re wheel s are straig[...]

  • Page 620

    Ti gh tenin g torqu es M 14 b an j o b ol t 35 Nm (26 ft -l b ) M 16 b an j o b ol t 40 Nm (30 ft -l b ) O uter tie rod e nd, re pla ci ng - R ai se f ron t of car. Remo v e roa d wheel. WA RN I NG! Mak e s ur e th e ca r is fi rm ly su p p o rte d o n jack stands d es igned for th e pur p os e. Pl ac e th e j ac k stands beneath a stru ctu ral cha[...]

  • Page 621

    No t e correct pl ace m en t of i nne r tape r on l ocking ri ng Lo osen ou ter t ie ro d end l ock n u t ( ar row ). - U n screw tie rod en d fr om tie rod sh aft. - I n st al l atio n is rev erse of remov al . M ake sure al l th rea d ed p arts are cl ea n . Use ant ise ize p aste on inn er tie rod t h rea d s. Use n ew self -l ocking n u ts, wh [...]

  • Page 622

    pur p os e. Pl ac e th e j ac k stands beneath a stru ctu ral chas sis point . Do not pl ac e jack stands under su spension p ar ts. - R emo v e out er tie rod en d self -l ocking n u t , an d separate out er tie rod end b all j oint as d escri b ed abov e. M ake a reference measurement of ou ter tie rod end t o tie rod. Record mea su reme n t . No[...]

  • Page 623

    Wh en rea ssembl in g , g rea se tie rod tap er so th at rack b oot su p p ort b u f fer or smal l end of rack b oot ( i nset ) sl id es on tie rod when t ie rod is t ig h t en ed, p rev en t ing rack b oo t f rom twisting . - I n st al l atio n is rev erse of remov al , n oting t h e f ol l ow ing : M ake sure al l th rea d ed p arts are cl ea n .[...]

  • Page 624

    320-5 W h eel A l i g n m en t Proper h an d l in g , stab ility, tire we ar an d d riv ing ea se d epen d u p on th e correct alig n ment of al l f our wheels. Th e fron t ax l e is alig n ed in relation to t h e rear ax l e, t h en t h e f ront wheels are al ign ed in relation t o one anot h er. T h is is kn ow n as a fou r-wheel or th r u st- ax[...]

  • Page 625

    WA RN I NG! Wh il e p er for ming alignme nt pro cedu res , ma ke su re th e c ar i s sta b l e and well su p por ted at all times . Use a p ro fess i ona l au tom otive li ft or j ac k sta n d s desig ned fo r the pur p os e. A fl o or jack is no t adequ ate su pp or t. Norm al l oaded p ositi o n Each f ront seat 68 Kg (15 0 l b ) Re ar sea t (ce[...]

  • Page 626

    Par ame ter Standard suspension All w heel dri ve suspension Spo rt suspension R o ug h road suspension Ca mb er (d ifference b etwe en l eft/ rig h t max . 15') max imu m all owabl e d ev iatio n b etwee n sides -1° 30 ' ± 15' -1° 15 ' ± 15' -2° 04' ± 15 ' -4 6' ± 15 ' Geome t rica l ax i s d ev [...]

  • Page 627

    No te: Steering rack can be ce ntere d by ali gni ng cen t ering mar k on steeri ng sha f t w i t h l ug on steeri ng rack. To keep st ee ri ng w he el cente red , ad just both ti e rod s eq ual amo unts. Make sure the r ub ber bo ot on the rack move s f ree l y on the ti e rod an d do es not beco me tw i st ed . Ti gh tenin g torqu e T ie rod l oc[...]

  • Page 628

    - I n st al l B M W sp ecia l t ool 32 3 03 0 ov er alig n ment l u g ( A ) an d adj ace n t b ol t. Use t oo l t o ad j u st p osi t ion of b racke t. Re mov e t oo l an d t igh t en t rai l in g arm b racke t moun tin g b ol ts. Ti gh tenin g torqu e R ear t railin g arm b racke t to b ody 77 Nm (57 ft -l b ) Co pyrigh t © 2006 Robert Ben tley, [...]

  • Page 629

    330-1 Gen era l T h is r epair g roup cov ers remo v al an d repl aceme n t of E46 rea r su sp ension compon ent s. A g eneral d escription of th e rea r su sp en sio n , ride h ei g h t sp ecifica tions and a tr oub l esh ooting g u ide can b e foun d in 300 Susp ension, Steeri n g and Brake s-G eneral . A d d itional compon ent rep l aceme n t in[...]

  • Page 630

    Dri ve ax l e p ress BM W set 33 2 11 5/116 / 11 9 Fl an g e p u l l er BM W set 33 2 11 6/ 4 20 1/4 202 / 4 20 3 I n n er b eari n g race p u l l er BM W set 33 4 40 0 Wh eel b eari n g ex t ractor B90 (Sou rce: Baum Too l s Un l imi t ed) Rear su s pe ns i on description BM W u ses an in d ep end ent rea r su sp en sio n con sisting of an u p p e[...]

  • Page 631

    su sp en sio n . T h e rea r su b frame (fin al d riv e carri er) su p p orts t h e rea r d iff erential an d p rov id es mou n tin g p oint s for t h e u p p er and l owe r con trol arms. The u p p er contr ol arm on each side p r ov id e th e l ow er sp ring p erch for t h e coil sp rin g . T h e u p p er an d l ow er con trol arm on ea ch sid e [...]

  • Page 632

    330-2 Rea r Sh ock A bs orbers a n d Spri n gs Re p l ace sh ock absorb ers and sp ring s in p ai rs on l y. Rear sh ock a bs orbe r, re m ov i ng and inst al ling - Ra ise car and remov e rear wheels. WA RN I NG! Mak e su re that the car i s firmly su pp or ted on jack stands d es igned fo r th e p u rpose . Pl ac e the j ac k sta n ds beneath a s[...]

  • Page 633

    compartmen t t o acce ss u p p er sh ock absorb er moun t. - On Sp ort Wag on mod els: Working in cargo comp artmen t, remov e side tr im n ex t to r ea r seat b ackre sts. - Su p p ort sh ock absorb er f rom b elow whil e remov in g u p p er moun t ing n u t s. Lo wer sh ock absorb er out of wh ee l h ousin g . T ran sf er sh ock t op m oun t in g[...]

  • Page 634

    M ake su re rectan g u l ar th r u st wa sh er on l ow er moun tin g b ol t is b etwe en b ol t h ead and sh ock absorb er ru b b er. T ig h t en l owe r sh ock ab sorber b olt to its f in al t orqu e once car is on g roun d . Ti gh teni n g torqu es Ro ad wheel t o h u b 100 ± 10 Nm (74 ± 7 f t -l b ) Sh ock absorb er t o trailin g arm (car in n[...]

  • Page 635

    su b f rame . Re mov e rea r b rake l in e b racket moun t ing b olt ( ar row ). Detach b racket from t rai l in g arm. CA UTI ON! A vo id dama ging the b rak e h o se by str etchin g wh en th e trailin g a rm is lower ed. Su p p ort tr ai l ing arm f rom b elow u sin g an ad j u stab l e j ackst and . Re mov e sh ock absorb er l owe r mou n tin g [...]

  • Page 636

    - T o in st all sp rin g : Co at top sp rin g p ad with anti-f rictio n p aste (e.g . , tire moun t ing p aste). Sl ow l y l ift su sp ension b ack int o p osi t ion, makin g su r e coi l sp ring is corre ct l y sea t ed in u p p er and l ow er sp ring seats. Wh en su sp en sio n h as b een l ifted su ff icie n tl y, rea tt ach sh ock absorb er to [...]

  • Page 637

    Ti gh teni n g torqu es p ositio n ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Rear s u sp en s io n h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /3... 6 of 6 2/ 25/ 2009 10: 30 PM[...]

  • Page 638

    330-3 Rea r Su sp en s i on A rm s , Su bf ra m e a n d Bu s h i n g s T h e trailin g arms, con t rol arms and th eir moun tin g b u sh in g s cont rol t h e p osi t ion of t h e rear wheels. A damaged su sp en sio n arm or worn b u sh ing s will ch ang e th e rear wheel alig n ment an d may adv ersely affect h an d l in g and stabil ity. WA RN I [...]

  • Page 639

    4 - Upper control ar m o u ter b ol t se l f-l ocking M 12 nu t tig h t en t o 11 0 Nm (81 f t-l b ) 5 - Trailin g ar m 6 - Lo wer control ar m ecc entric bo lt ecc entric flat M 12 was her se l f lo cking M 12 nu t tig h t en t o 11 0 Nm (81 f t-l b ) 7 - Trailin g ar m front b ol t se l f-l ocking M 12 nu t tig h t en t o 11 0 Nm (81 f t-l b ) 8 [...]

  • Page 640

    13 - Lo wer control ar m i n ner M 12 bo lt l ock pl ate tig h t en t o 11 0 Nm (81 f t l b ) T ra il ing a rm , re m oving and inst a ll ing - R ai se r ea r en d of car and rem ov e wheel. WA RN I NG! Mak e s ur e th at the car i s firmly su pp or ted on j ac k stands d es igned for the p u rpo se. Place the jack sta n ds beneath a stru ctu ral c[...]

  • Page 641

    CA UTI ON! A v o i d d ama ging the b ra ke hos e b y str etchin g wh en th e traili ng ar m i s lower ed. - R emo v e fu el tan k p rotectiv e p an el, if eq u ip p ed. Re mov e A BS p u l se sensor f rom tr ai l ing arm. - U n cl ip p u l se sen sor and p ad sensor (if ap p l icabl e) h arn esse s fr om cont rol arm an d l ay asi d e. Su p p ort [...]

  • Page 642

    - U n b ol t u p p er and l ow er con trol arms from t railing arm. Note d irectio n of b olt insertion in b oth arms. T o remo v e trailin g arm: M ake re ference marks t o l ocate trailin g arm b racke t t o b ody in ord er to maint ai n alig n ment sp eci f icatio n s. Re mov e t rai l ing arm f ron t b racke t moun t in g b ol ts ( ar rows ). W[...]

  • Page 643

    I n st all n ew rea r wh ee l b ea rin g s. I n sert con t rol arm moun tin g b ol ts in d irectio n p rev io u sl y marked. A l ways u se n ew se l f- l ocking n u t s. T r ansf er b rake syst em comp onen ts to n ew arm as d escribed in 340 Brake s . Ha v e car p rofessi onal l y alig n ed when j ob is compl ete. No te: BMW -supp l i ed replaceme[...]

  • Page 644

    Ti gh tenin g torqu es n orma l l oa d ed p osi t ion) T railin g arm b racket to b od y (M1 2 b ol t ) 77 Nm (57 ft -l b ) T railin g arm to u p p er or l owe r contr ol arm (M 12 b olt ) 110 Nm (81 f t -l b ) Upp er c ont rol a rm , rem oving and inst al li ng - R emo v e d riv e ax l e as d escri b ed in 331 Rea r A x l e Fin al Driv e . WA RN I[...]

  • Page 645

    - I f n ece ssary, remov e rid e l ev el sensor f rom u p p er con t rol arm. - U n b ol t u p p er cont rol arm f rom b oth trailin g arm and rear su b f rame . No t e d irectio n of b ol t insert io n . No te: For cl eara nce reaso ns, i t m ay be ne cessary to unb ol t t he di f feren ti al f rom the sub f rame and push i t t ow ard the rea r of[...]

  • Page 646

    Ti gh tenin g torqu es R oad wh eel to h u b 10 0 ± 10 Nm (74 ± 7 f t -l b ) Sh ock absorb er to trailing arm car in n orma l l oa d ed p osi t ion 10 0 Nm (74 f t -l b ) U p p er con tr ol arm to rear su b frame M 12 b ol t 77 Nm (57 ft -l b ) U p p er con tr ol arm to tr ai l ing arm M 12 b olt 1 10 Nm (81 ft -l b ) Low e r c ontrol arm , re m [...]

  • Page 647

    - U se a soft h ammer to t ap cont rol arm out of its moun tin g p oints. - I n st al l atio n is rev erse of remov al . Wel d ed seam of con trol arm faces u p ward. T o inst all mou n t ing h ardware at su b f rame , insert l ock p l ate int o open ing in su b f rame f rom b el ow . Li n e u p ecce n tr ic b olt h ea d wi t h marks made p rev iou[...]

  • Page 648

    De t ach rear d riv eshaft f rom rea r d iff ere n tial. S ee 260 Driv esh aft . De t ach rear d riv e ax l es from rear d iff ere n tial. Remov e rea r d ifferent ial. See 331 Rea r A x l e Fin al Driv e . De t ach rear cont rol arms as d escribed ear l ier Re mov e rea r su b f rame mou n tin g fasten ers ( ar rows ) wh il e su p p ortin g su b f[...]

  • Page 649

    Ti gh tenin g torqu es M 10 comp ressi on n u t 64 Nm (47 f t -l b ) M 10 To rx b ol t 85 Nm (63 ft -l b ) Lo wer cont rol arm t o su b fr ame (M 12) 110 Nm (81 f t -l b ) Su b frame to b ody (M 12 ) 77 Nm (57 f t -l b ) U p p er con tr ol arm to su b frame (M 12 ) 77 Nm (57 f t -l b ) Re ar subframe as sem b l y 1 - Re ar subfram e (fin al drive c[...]

  • Page 650

    tig h t en t o 77 Nm (57 ft -l b ) 8 - M 8 bo lt 8.8 g rade t ig h ten to 21 Nm (15 ft -l b ) 10 . 9 g rad e t igh t en to 30 Nm (22 ft -l b ) 9 - M 14 bo l t tig h t en t o 17 4 Nm (12 8 ft- l b ) 10 - Bushin g 11 - M 14 se l f-l o ck i n g coll ar n u t 12 - Bushin g 13 - Stop w as her 14 - M 12 re d u ce d shaft bo l t tig h t en t o 77 Nm (57 f[...]

  • Page 651

    Su p p ort car secu rely b efore startin g wo rk u n d erneath r ea r su sp en sion. WA RN I NG! Mak e s ur e th at the car i s firmly su pp or ted on j ac k stands d es igned for the p u rpo se. Place the jack sta n ds beneath a stru ctu ral chas sis point . Do not pl ac e jack stands under su spension p ar ts. Traili ng arm f ront bu shi ng - Be [...]

  • Page 652

    Ti gh tenin g torqu es b racke t T railin g arm b racke t to b ody 77 Nm (57 ft -l b ) Upper or l o wer control arm o u ter bu shi ng (i n t ra i l in g arm ) - U p p er con trol arm b u sh in g : Re mov e t rai l ing arm f rom car as d escribed ear l ier. Note d ire ct ion of b ol t insertion. - L owe r con t rol arm b u sh ing : De tach l ow er c[...]

  • Page 653

    Ti gh tenin g torqu es M 24 2 50 Nm (18 4 f t-l b ) M 27 3 00 Nm (22 1 f t-l b ) D riv e ax l e to f inal d riv e fl an g e M 10 x 20 mm To rx b olt 83 Nm (61 f t -l b ) M 10 x 46 mm b ol t (b l ack) 10 0 Nm (74 ft -l b ) M 10 x 46 mm b ol t (silv er) (al wa ys repl ace) 80 Nm (59 f t -l b ) Lo wer cont rol arm to tr ai l ing arm M 12 ecce n t ric [...]

  • Page 654

    Be su re th at l on g er coll ar of b u sh in g ( A ) is on same side as b ev el in con trol arm. Ou ter b u sh in g h ou sin g mu st b e fl u sh wi th con trol arm b ore wh en fu l l y p ressed in . Ha v e car p rofessi onal l y alig n ed when j ob is compl ete. Ti gh tenin g torqu e D riv e ax l e coll ar n u t t o d riv e fl an g e M 24 2 50 Nm [...]

  • Page 655

    Re ar subframe bu shi ng - R emo v e su b f rame a s d escribed ea r l ie r. - I n case of d amage to su b f rame moun t in g stu d t h reads, rep l ace stu d . - I n case of d amage to su b f rame moun t in g stu d t h reads in b od y, repair u sing Helicoi l t h read insert M 12 x 1.5 x 18. - Pre ss ol d b u sh in g out and in st all n ew b u sh [...]

  • Page 656

    Ti gh tenin g torqu e M 10 x 20 mm To rx b olt 83 Nm (61 f t -l b ) M 10 x 46 mm b ol t (b l ack) 10 0 Nm (74 ft -l b ) M 10 x 46 mm b ol t (silv er) (al wa ys repl ace) 80 Nm (59 f t -l b ) R oad wh eel to h u b 10 0 ± 10 Nm (74 ± 7 f t -l b ) Sh ock absorb er to trailing arm (car in n orma l l oa d ed p osi t ion) 10 0 Nm (74 f t-l b ) Su b fra[...]

  • Page 657

    330-4 Rea r Sta bi l i zer Ba r T h e rea r st abil ize r b ar is moun t ed t o th e rear su b f rame a n d attach ed v ia stabil izer b ar l in ks t o t h e rea r u p p er contr ol arms. 1 - Stab ilizer b ar 2 - Self -l ocking n u t M 8 3 - Rub b er moun t in g 4 - Clampin g su p p ort 5 - Bolt M 8 6 - Bolt M 7 - Stab ilizer l in k su p p ort b ra[...]

  • Page 658

    330-5 Rea r W h e el Bea r i n gs T h e rea r wh ee l b ea r i n g is a u n itized asse mb l y an d is n ot rep ai rab l e separate l y. Sp eci al p ress tool s, to b e u sed with t h e trailing arm attach ed t o th e car , are requ ired t o repl ace a wheel b eari n g . Re ad t h e p roce d u re t h roug h b efore b egin n in g th e j ob. Rear w h[...]

  • Page 659

    Re mov e d riv e fl an g e f rom b eari n g asse mb l y u sing imp act st yl e p u l l er (BM W sp ecia l too l s 33 2 11 6, 33 4 20 1/202 / 20 3 or equ iv al en t). CA UTI ON! Th e wh eel b ea rin g is d es t ro ye d wh en t he d rive fl ange is rem o ved. Do not atte mpt to re us e bear i ng. No te: Use BMW spe ci al t oo l set 33 4 40 0 or eq ui[...]

  • Page 660

    M ake su re al l matin g su r faces are cl ea n - I n stal l n ew bearing asse mb l y u sing p ress too l s (BM W sp eci al tools 33 3 261 / 26 4/ 26 5 or equ iv alen t . - I n stal l n ew cir cl ip. CA UTI ON! A p pl y for ce o nl y to o ute r ra ce wh en i n sta ll in g bear i ng. Mak e su re that the b ea ring is pres sed i n far eno ug h to co [...]

  • Page 661

    - Re in stal l d riv e ax l e. Ti gh teni n g torqu es Brake rotor t o d riv e fl an g e (M 8) 1 6 Nm (12 f t-l b ) Brake cal iper t o trailin g arm (M 12) 67 Nm (50 f t -l b ) Dri ve ax l e coll ar n u t to d riv e f l ang e M 24 25 0 Nm (184 f t-l b ) M 27 30 0 Nm (221 f t-l b ) Dri ve ax l e to f in al d riv e f l ang e M 10x 20 mm To rx b ol t [...]

  • Page 662

    331-1 Gen era l T h is r epair g roup cov er remo v al an d repair information for t h e rea r d riv e ax l e sh afts, CV j oint s an d CV j oi n t b oots. A l so cov ere d is rear d ifferent ial (fin al d riv e ) remo v al p rocedu res an d seal repl aceme n t inf ormatio n . I n tern al repairs of t h e diff erent ial asse mb l y are n ot cov er [...]

  • Page 663

    Ou t p u t f l ang e sea l d rift BM W 33 3 40 0 I n p u t f l an g e seal d rift BM W 33 3 430 Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Rear Ax l e Fi n al Dri ve h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /3... 2 of 2 2/ 25/ 2009 10: 32 PM[...]

  • Page 664

    331-2 Dri v e A xl es T h e d riv e ax l es u se const an t-v el ocity (CV ) j oint s on b oth end s. Tw o d iff ere n t styl es of CV j oin ts h av e b ee n su p p l ie d wi t h E46 v eh icles. Refer to t h e acco mp anyin g ill u str atio n : Ball cage CV j oint . Tra d itio n al d esi g n CV j oint wi th t h ick metal h ousin g (app r ox . 40 mm[...]

  • Page 665

    - Ra ise rea r of car. Remo v e rea r wheel. WA RN I NG! Mak e su re that the car i s firmly su pp or ted on jack stands d es igned fo r th e p u rpose . Pl ac e the j ac k sta n ds beneath a stru ctu ra l chass i s point. Do n ot pl ac e jac k sta n d s u n d er su spension p ar ts. - De t ach rear stabil izer b ar anch or b olt s from rear su b f[...]

  • Page 666

    I n stal l roa d whee l and l ower car t o g roun d . With an assistant ap p l ying b rakes, tig h t en d riv e ax l e coll ar n u t t o its fin al t orqu e. Stake a n d cau l k coll ar n u t. Ti gh teni n g torqu es Dri ve ax l e coll ar n u t to d riv e f l ang e M 24 25 0 Nm (184 f t-l b ) M 27 30 0 Nm (221 f t-l b ) Dri ve ax l e to d ifferent [...]

  • Page 667

    CV joint boot s No te: W hen rep l aci ng a CV joint bo ot, use a comp l ete CV jo i nt boo t rep ai r ki t . The ki t w i l l i ncl ude a ne w boo t , cl amping ban ds, special l ubri can t , an d a new i nne r CV jo i nt ci r cl i p. The ki t i s avail able f rom an autho ri ze d BMW dea l er parts dep artment. The ou t er CV joint cann ot be rem[...]

  • Page 668

    inn er h u b t o ax l e sh aft. Su p p ort in n er h u b at ar rows when p ressing ax l e sh aft out of j oi n t . - C l ea n all ol d l u b ricant of f sh aft sp l in es and in n er j oint 's sp l ines. CA UTI ON! I f th e CV j o i n t mu st be d isas se mbl ed fo r clea n i ng and in spectio n , b e su re to ma tchma rk in ner and ou ter rac[...]

  • Page 669

    side of h u b is f aci n g sh aft . WA RN I NG! Do n ot let th e loc ki ng co mpou nd co ntact the b alls in the j o in t. A p pl y o n l y a th in co at to co ver th e spli n es . - Wh il e su p p ortin g ax l e sh aft , p ress inn er h u b of CV j oi n t on t o shaf t. I n st all n ew circlip . No te: Do not l et t he ba l l hub pivot more than 2[...]

  • Page 670

    [...]

  • Page 671

    331-3 Rea r Di f f eren ti a l A l l rea r d ifferent ia l work req u ire s some meth od of rai sin g th e car and su p p ortin g it secu rely wh ile t h e work is p erforme d . Jack st and s and a fl oor j ack can easily b e u sed , b u t u se ex treme caution wh en worki n g b eneath th e car. See 010 G eneral . No te: Re moval of rear subfra m e[...]

  • Page 672

    The dif feren t i al fl uid l evel i s corre ct w hen t he f l ui d be gins to spil l f rom the fi l l pl ug. - I n stal l and t igh ten f il l p l u g . Differ ential oi l Di ff ere n tial oil capacity Re ar whee l d riv e 0.9 l iter (0.95 US q t. ) A l l wh ee l d riv e 1.0 l iter (1.06 US q t. ) Oil sp ecifica t io n BM W SA F -X O syn th et ic [...]

  • Page 673

    Re mov e h eat sh ield b etwe en rei n f orceme n t b race and ex h aust p ipe. Re mov e b ol ts ( A ) mou n tin g b race to u n d erca rria g e. Re mov e n u t s ( B ) moun t in g b race and f ront of rea r su b f rame t o u n d ercarri ag e. Lo wer and remov e reinf orce ment . No te: I f ne cessary, t i l t rear half of exha ust system dow n. Su[...]

  • Page 674

    d ifferent ia l moun tin g b olt s: I n stal l b ol ts f ing er t ig h t . T ig h t en f ront b olt s ( B ). T ig h t en rear b olt ( A ). Ti gh teni n g torqu es Di ff ere n tial d rain or fil l p l u g 70 Nm (52 f t -l b ) Di ff ere n tial t o rea r su b frame Fron t mou n t (M 12 b ol ts) 95 Nm (70 f t -l b ) Re ar moun t ( M 14 b ol t) 17 4 Nm [...]

  • Page 675

    Differ ential oi l Di ff ere n tial oil capacity Re ar whee l d riv e 0.9 l iter (0.95 US q t) A l l wh ee l d riv e 1.0 l iter (1.06 US q t. ) Oil sp ecifica t io n BM W SA F -X O syn th et ic oi l Diff e re ntial m oun ting bus hings - I f rea r d iff ere n t ia l mou n t in g b u sh in g are wo rn , d ama g ed or oi l soa ked : Re mov e d iff er[...]

  • Page 676

    331-4 Rea r Di f f eren ti a l Oi l Sea l s Lo w oil l ev el caused b y fau l t y oil seals may b e th e cause of n oisy diff erential operatio n . T h e d riv e fl ang e (sid e) and inp u t sh aft (f ront ) oi l seals can b e repl aced wh ile t h e d iff erential is inst all ed . No te: Do no t mi st ake l ea ki ng CV joints for fl ang e sea l l e[...]

  • Page 677

    Su spend the d eta ched d rive axle fro m the car b ody w i th a stiff wi re hoo k to p re ve nt dama g e to the o ute r CV joint. Pry out p u t f l ang e from d iff erent ial. F or l ev er age, u se a woo d en d owe l as sh ow n . No te: Be pre pare d to catch drippi ng oil i n a pa n. I nspe ct fl an ge at t he po i nt w he re the oil sea l r i d[...]

  • Page 678

    Ti gh teni n g torqu e Dri ve ax l e to d ifferent ial f l an g e M 10x 20 mm To rx b ol t 83 Nm (61 f t -l b ) M 10x 46 mm b ol t (b l ack) 10 0 Nm (74 ft -l b ) M 10x 46 mm b ol t (silv er) ( always repl ace) 80 Nm (59 f t -l b ) Input drive flange oil s ea l , repla c ing - Ra ise car and su p p ort safel y. Re mov e rea r su sp ension reinforce[...]

  • Page 679

    side. M ake match in g marks on d iff erential inp u t sh aft , coll ar n u t and d riv esh aft fl an g e. - Pry l ock p l ate fr om n u t. Co u n t erhol d in p u t fl ang e wi t h BM W sp ecia l t ool 23 0 02 0 or equ iv alen t an d remo v e col l ar n u t . - I f n ecessa ry, u se p u l l er to remov e inp u t fl ang e. No te: Be pre pare d to c[...]

  • Page 680

    Differ ential oi l Di ff ere n tial oil capacity Re ar whee l d riv e 0.9 l iter (0.95 US q t) A l l wh ee l d riv e 1.0 l iter (1.06 US q t. ) Oil sp ecifica t io n BM W SA F -X O syn th et ic oi l - Re maind er of assembl y is rev erse of d isasse mbl y. Ti gh teni n g torqu es Dri ve sh aft t o d iff erential f l an g e M 10 co mp ressio n n u t[...]

  • Page 681

    340-1 Gen era l T h is r epair g roup cov ers b rake se rv ice: Brake p ad s, cal ipers, and d isks M aster cyl ind er, b rake b ooster, and p arking b rake A BS/A S C and A BS/ DSC compon ent rep l aceme n t A BS/A S C and A BS/ DSC syst em d escri p tions are co v ered in 300 Su sp en sio n , Steering an d Brakes- General . Spec ia l tools BM W r[...]

  • Page 682

    Brake p ad l inin g g au g e BM W 34 1 26 0 V acuu m t ester BM W 34 3 10 0 Factory d iagn ost ic tool DI Sp l u s or M oD iC E4 6 brak e sys tem BM W E46 mo d el s are equ i p p ed wi t h v acuu m p owe r -assi st ed f ou r-wheel d isc b rake s with an int eg ral Antil ock Brake System (A BS). S ing l e-piston calip ers act on v ented fr ont an d [...]

  • Page 683

    conj u n ction with en g in e manag eme n t contr ols to cont rol wh ee l sp in an d mai n t ain v ehicl e st abil ity whil e b raking . A d d ed midway th rou g h t h e 199 9 mod el yea r was Dynami c St ab ility Contr ol (DSC ). T h is system u ses A SC techn ol ogy, b u t imp l ements wh ee l sp ee d mod u l ation t h roug h out al l stages of d[...]

  • Page 684

    Y ea r (m o del) Sys tem (ma n u fac t urer ) Id enti fiers DSC 2 00 1 (rea r wheel d r i v e) Dynamic Stab ility Co n t rol (T ev es M K 60 DSC ) Co n t rol modu l e/h yd rau l ic u n it moun t ed u n d er master cyl ind er. No p rech arge p u mp DSC 2 00 1 (all wh ee l d r iv e) Dynamic Stab ility Co n t rol (Bosch DSC II I 5.7) Co n t rol modu l[...]

  • Page 685

    cyl ind er is l eaki n g in t ernal l y, or f l u id is l ea kin g ex tern all y. Ch eck all b rake f l u id l ines and coup l in g s f or l eaks, ki n ks, ch afing an d corro sion . I f n o l eaks can b e fou n d , th e maste r cyl ind er is fau l t y an d sh oul d b e repl ace d . Check b rake b oo st er: Re mov e v acu u m h ose ( A ) f rom b ra[...]

  • Page 686

    Oil -cont aminated or g l aze d p ads wi l l cause st op p ing d istan ces t o increase . I n sp ect t h e rotors for g l azi n g , d isco l oratio n and scori n g . St ee r ing wheel v ib ratio n wh il e b raki n g at sp ee d is often cau sed b y warped rotors, b u t can also b e cau sed b y worn su sp en sio n compon ent s. Wh en trou b l esh oot[...]

  • Page 687

    water , as b ra ke fluid w i ll remo ve pain t. A lways u se new brak e fluid fro m a fre sh, unopened co n tain er . B r ak e fluid wi l l abso rb mo i stu re fro m th e air. T hi s ca n l ea d to co rro sio n p ro bl em s in th e b ra ki ng sy stem, and wi l l also lower the brak e fl uid's boil in g point. Dispo se o f b rak e fl u id pro p[...]

  • Page 688

    Sym p to m Probabl e caus e Re p airs Lo w p edal aft er system b l ee d ing M aster cyl in d er f aul t y Re p l ace ma ster cyl ind er. Pedal sp ong y or b rake s work onl y when p edal is p u mp ed A ir in b rake f l u id Bl ee d syst em u sin g f actory or comp atibl e d ia g n ostic tool M aster cyl in d er or electron ic cont rol system f au [...]

  • Page 689

    Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Brak e s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /3... 9 of 9 2/ 25/ 2009 10: 33 PM[...]

  • Page 690

    340-2 Bl eedi n g bra kes Brake b l ee d in g is u su all y d on e for on e of two rea sons: Eith er t o repl ace old b rake f l u id as p art of rou tin e mai n t en an ce or to ex p el t rapp ed ai r in th e syst em t h at r esul t ed f rom open ing th e b rake h yd r aul ic syst em d u ring repairs. A l wa ys u se n ew b rake f l u id from an u [...]

  • Page 691

    conn ect BM W Dia g n osi s and I n formatio n Syst em (DI S) to 20 p in Da t a Li n k Co n n ector (DLC ) u n d er h oo d (199 9 model s), or 16 pin DL C/O BD II con n ector u n d er d ash (20 00- 20 01 model s). Call u p serv ice fu n ction Bl eedin g A BS/A S C or serv ice fu n ction Bl ee d ing A BS /DSC, d ep en d ing on which syst em th e v e[...]

  • Page 692

    - Proce ed wi t h rema inin g wheels in order as l isted earlier. Ti gh teni n g torqu es Bl ee d er screws (wr ench size): 7 mm screw 3 .5 - 5 Nm (2.5 - 3.7 f t -l b ) 11 mm screw 12 - 16 Nm (9 - 12 ft -l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Brak e s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/[...]

  • Page 693

    340-3 Bra ke Pa ds , Ca l i pers , a n d Rotors Brake p ad s can b e repl aced with out d isco n n ecting th e b rake f l u id h ose f rom th e cal ip er or h av i n g to b l ee d th e b rake s. T h e rotors can b e rep l aced wi t h ou t d isasse m b l in g wheel h u b an d b ea r ing . A l ways machin e or repl ace rotors in p air s. Re p l ace p[...]

  • Page 694

    T orq u e t o 30 Nm (22 f t-l b ) 2 - Br ake calip er Brake l in e: t orq u e t o 18 Nm (13 ft -l b ) See Calip er remo v al 3 - Br ake p ad w ear se n sor See Brake p ad we ar sensor 4 - Br ake p ad anti-rattle clip See Brake p ad ant i-ra t t l e cl ip 5 - Br ake p ads Re p l aceme n t wa rn ing at 3.0 mm (0.11 in. ) See Brake p ads 6 - Fron t b [...]

  • Page 695

    and f ree f rom g rea se See F ront b rake rotor 8 - Re ar brak e rot or re tain i ng scre w T orq u e t o 16 Nm (12 f t-l b ) 9 - Re ar brak e rot or M ake sure con tact su rf ace s are cl ea n and f ree f rom g rea se. Parki n g b rake d r u m d ia . 16 0 mm ( 6.3 in. ) See Rea r b rake rotor For b rake rotor sp eci f icatio n s see Ta b l e c an[...]

  • Page 696

    M ake sure con tact su rf ace s are cl ea n and f ree f rom g rea se See Brake p ad carri er 13 - Br ake p ad ca rrier reta i n in g bo lts Fron t : torq u e t o 11 0 Nm (81 f t -l b ) Re ar: t orqu e to 65 Nm (48 f t -l b ) Oil b olt s l igh tl y. M ake sure con tact su rf ace s are cl ea n and f ree f rom g rea se. Cali per r em oval Re mov e p l[...]

  • Page 697

    calip er p iston will h av e t o b e p resse d b ack int o cal iper b ef ore calip er can b e remov ed . CA UTI ON! Pre ssing ca l i per pi sto n in ma y c au se brak e fl uid res er vo i r to o ver fl o w . To prev ent th i s, u se a clean syr i n g e to first re mo ve so me fluid fro m res erv oir. Op en calip er b l ee d er screw onl y when ap p[...]

  • Page 698

    B r a ke pa d w e ar sens or Ca ref u l l y p ry p ad wea r sensor from b rake p ad. I n sert b rake p ad wear sen sor int o cu t out in n ew p ad where app l ica b l e. I f b rake l inin g in d ica tor l ig h t ill u minated p rio r t o b rake p ad repl acement, repl ace we ar sensor. Ro u t e p ad we ar sensor wiri n g th roug h cal ip er o p en [...]

  • Page 699

    B r a ke pa d li ning t hic kne ss T o mea su re b rake p ad l in ing t h ickness: - I n sert BM W sp ecial tool 34 1 260 at ei t h er f ront righ t wh ee l or l eft rea r wheel - M o v e wh ee l u n til n otch for b rake we ar ind icator can b e seen t h roug h wheel open in g . - I n sert tip of t ool int o n otch so th at th e b ody of t ool res[...]

  • Page 700

    Tabl e c. Bra ke roto r re con d iti o nin g spe cificatio ns Fron t Re ar V ent ed rotor w ear l imit (min. th ickn ess) 20 . 4 mm (0.8 0 in. ) 17 .4 mm (0.68 in .) M ax . machin e l imi t p er friction ring si d e 0.8 mm (0.0 3 in. ) 0.8 mm (0.03 in .) WA RN I NG! Co n firm ro to r wear l imit spec ifi ca tions g i ven i n T abl e c wi th specifi[...]

  • Page 701

    b efore in st all in g . Wh en inst all in g n ew rea r b rake rotors, t h e p arking b r ake sh ou l d b e adj u sted . See P arki n g b rake . Ti gh tenin g torqu e Brake rotor t o h u b moun t ing screw 16 Nm (12 f t-l b ) B r a ke pa d c arri e r re m ov a l Re mov e b rake p ad carrie r moun t i n g b ol ts ( ar rows ) an d remo v e p ad carri[...]

  • Page 702

    340-4 M a s ter cyl i n der T h e b rake master cyl in d er is mou n t ed to th e fr ont of t h e v acu u m b ooste r on th e d riv er si d e b u l kh ea d . CA UTI ON! A l l U.S. ma rke t E46 ve h icles are equ i pp ed w ith A n til o ck B rak i ng Sys tem (A B S) and either A u tom atic Stabil ity Co ntro l (A SC ) o r Dynam i c Stabil ity Co ntr[...]

  • Page 703

    Re mov e sid e trim p an el f rom l eft rear of eng in e compart ment : Re mov e ru b b er strip f rom t op of trim p an el at b rake b oo st er. De t ach v acu u m l in e ( A ) from b rake b ooster Y-conn ect or, u n h ook from t rim p an el and p u sh to side. Unh ook p l astic v acu u m l in e and p osi t iv e starter cab l e ( B ) f rom t rim p[...]

  • Page 704

    p recharg e p u mp su p p l y h ose. Pl u g h ose and reser v oir t o p rev ent fl u id l eaka g e or cont ami n atio n . - Re mov e b rake fl u id rese rv oi r. - Working at m aster cyl in d er: Di scon n ect b rake fl u id l in es and electrical h arn ess conn ectors f rom master cyl ind er as n ee d ed. On v eh icl es equ ip p ed with Tev es DSC[...]

  • Page 705

    pus h ro d and b o os t er p u shrod. Us e car e n ot to ov er-to rqu e ma ster cylin der mo u nti n g n u ts. Th is co u l d d ama ge brak e boo ste r and prev ent p ro p er va cu u m b u i ld -u p. - Co n n ect b r ake f l u id l ines t o master cyl ind er. Ti gh teni n g torqu e Brake f l u id l ines t o master cyl in d er 1 8 Nm (13 f t-l b ) N[...]

  • Page 706

    340-5 Bra ke boos te r T h e b rake b ooster is moun ted t o t h e b u l kh ea d on d riv er ' s sid e of en g in e compartmen t, d ire ctl y b eh in d b rake master cyl ind er. A is v acuu m h ose from in take man ifold . B is one-wa y v al v e. In take manifol d v acuu m acts on a l arg e d iaph rag m in b rake b ooster to red u ce b rake p [...]

  • Page 707

    co nn ectio n s b efo re di sc o n n ec t in g. - Di scon n ect n eg ativ e (-) cab l e from b attery. CA UTI ON! Prio r to di sco nn ect in g the b atte ry, re ad th e batter y d isco n nectio n ca utio n s give n at fro n t of thi s ma nua l o n pag e viii . - Usi n g a cl ea n syrin g e, emp ty b rake f l u id rese rvo ir. WA RN I NG! B rak e fl[...]

  • Page 708

    Di scon n ect electr i cal h arn ess conn ectors at l eft f oo twell t rim p an el and remov e p an el : Unp l u g conn ector at f oo twell int eri or l igh t ( A ), if eq u ip p ed . Sl ide l ock at O BD II conn ector ( B ) in d irectio n of ar row . Unp l u g conn ector at sp eake r ( C ). Re mov e cl ip ( A ) an d sl id e b rake b oo st er p u s[...]

  • Page 709

    moun t ing n u t s. Re p l ace sealin g O-rin g b etwee n master cyl ind er and b rake b oo st er. Bl ee d b rake syst em as d escri b ed ea rl ier. CA UTI ON! Do n ot o ver -to rque th e ma ste r cy l in d er mo untin g bolts. T hi s co uld dama ge th e brak e boo ste r and prev ent p ro per va cuu m build -u p . Ti gh teni n g torqu es Brake mast[...]

  • Page 710

    340-6 Pa rki ng bra ke T h e p arki n g b rake is a b rake d r u m system in teg rated in to t h e rear b rake rotors. T h e p arki n g b rake can b e adj u st ed wi t h th e wheels in stal l ed , alt h oug h t h e rea r wheels will h av e to b e rai sed off th e g roun d . A d j u st in g th e p arki n g b rake b eco mes n ece ssary u n d er t h e[...]

  • Page 711

    Do n ot pl ac e jack sta nd s under su spensio n parts. - Re mov e one l u g b ol t from each rea r wheel. T u rn roa d wh eel u n t il l u g b ol t h ol e l ines u p wi th p arking b rake adj u st er (app rox imatel y 65° to rear of wh ee l centerl in e). Use f l at-b l ad ed screwdriv er to t u rn adj u ster. O n l ef t wheel, tu r n ad j u ster[...]

  • Page 712

    b rake warnin g l igh t stays l it. If p arki n g b rake l ig h t g oes o u t , contact switch m u st b e ad j u st ed. - I n stal l p arki n g b rake l ev er b oot. I n stal l roa d whee l l u g b olt s. Ti gh teni n g torqu e Ro ad wheel t o h u b 10 0 ± 10 Nm (74 ± 7 f t -l b ) P a rk ing bra ke sho es, re m ov i ng and inst al ling - Ra ise r[...]

  • Page 713

    th in coa t of g rease t o sl id ing p arts and p in s. - I n stal l ation is r ev er se of remov a l . Be su re to ad j u st p arki n g b rake cabl es as d escribed ea rl ie r . P a rk ing bra ke c a ble, r epla c ing T h e p arki n g b rake is act u ated b y two separate Bowden cabl es b etwe en th e p arki n g b rake h and l e and t h e p arking[...]

  • Page 714

    - Re mov e compl ete ex hau st syst em as describ ed in 180 Ex h au st System . - Re mov e cent er t u n n el h eat sh ield . Pu l l p arking b rake cabl e ou t of b od y g u id e tu b e ( ar row s ) and d etach fr om rout ing b racke t s, n ot i n g corre ct rout in g for reinstal l atio n . Re mov e one l u g b ol t from rear wheel . T u r n wh e[...]

  • Page 715

    Pu l l cabl e out of b ack of b acking p l ate. - T o reinst all : Pu sh n ew ca b l e h ou sin g in to h ole in b ack of b acking p l ate. Pu sh f ree (p arki n g b rake h and l e) end of cab l e in to h ou si n g u n til end of cab l e sn ap s au d ibl y in t o h old er insid e b rake dr u m. Re rou t e n ew cab l e u n d er car, att ach ing to b[...]

  • Page 716

    340-7 A BS Com p on en t Repl a ce m en t CA UTI ON! I f th e tires on th e ca r are of di ffer ent mak es, th e A SC sy stem ma y ov er-re ac t. O n ly fi t ti re s o f the sam e mak e and tre ad patter n . I n ad ve rse co n d iti ons, su ch as try i ng to r oc k th e ca r o ut o f d ee p sno w o r an o th er so ft su rf ace , or wh en snow cha i[...]

  • Page 717

    WA RN I NG! Mak e su re the car i s firmly su p por ted o n jack sta n ds d es i gned for th e pur p os e. Place th e jack stands beneath a stru ctu ra l chass i s point. Do n ot pl ac e jack sta nd s under su spensio n parts. Fron t sen sor: Un screw mou n t ing b olt at steering arm ( arr o w ). Re ar sen sor: Re mov e sensor from its b ore ( arr[...]

  • Page 718

    of M ol ykote® Long t erm 2 or an equ iv alen t g rea se to imp u l se sensor and h ousin g . - I n stal l ation is r ev er se of remov a l . Ti gh teni n g torqu e A BS wh eel sp eed sensor t o steering arm / t rai l ing arm 8 Nm (6 f t -l b ) A B S im pulse w he e l A BS imp u l se whee l repl aceme n t may b e n ee d ed in case of d ama g e or [...]

  • Page 719

    n ot rep l acea b l e separately. See 331 Re ar A x l e Final Driv e f or CV j oi n t an d d riv e a x l e rep l aceme n t p roce d u res. DSC later al a c ce le ra tion s e ns or, repla c ing Re ar wh ee l d riv e cars: The l atera l accleratio n sen sor is l ocate d on th e l eft side d riv er's footwe l l , u n d er t h e p anel trim on r e[...]

  • Page 720

    rotatio n al rate sensor is l oca t ed on t h e l eft sid e of t h e car, u n d er t h e d riv er's sea t . A l l wh ee l d r iv e cars: The rotational rate sensor is comb ined int o one u n it with th e l atera l acceleratio n sen sor. I t is moun t ed u n d er t h e d riv er's seat, in fron t of th e l ef t sea t rail. - Re mov e d riv [...]

  • Page 721

    Ti gh teni n g torqu es Sensor b r acke t t o b ody 8 Nm (6 ft -l b ) DSC s tee ring a ngle sens or V ehicl es equ ipp ed with DSC h av e a steeri n g an g l e sen sor ( arr o w ) mou n t ed to th e steering colu mn rig h t abov e th e p edal cl u ster. Repl ace men t of t h is compon ent req u ires sp ecia l tool s t o p roperl y alig n t h e stee[...]

  • Page 722

    rem oving and inst a lli ng CA UTI ON! E46 ca rs requ i re spe cial B MW se rvice equ i pment to pro p erly bl ee d the b ra ke s. Rem ov al of the h ydra ulic u n i t i s not rec om mended unless thi s equ i pment is ava i lab le. For safe ty re aso n s, th e brak e sy stem on car s wi th A B S mu st b e b led u sing th e pro cedu res d es cr ib e[...]

  • Page 723

    C - Ri g h t f ront D - Re ar f rom master cyl in d er E - Ri g h t rear F - Le f t rear Re mov e b rake fl u id in p u t an d outp u t l in es. Sea l op en b rake fl u id l in es and b ore s with su itabl e p l u g s t o p rev en t con t ami n atio n . - Ca refu l l y remo v e b rake lin es f rom any r etai n ers or g romme t s t h at may b e in t[...]

  • Page 724

    M ake su re b rake l i n es are securel y seated in g rommets b efore in st all in g b rake l ines in h yd raul ic u n it b ores. Bl ee d b rake s as d escribed earlier. Ti gh teni n g torqu es Brake l in es to h yd rau l ic u n it 18 Nm (13 f t-l b ) Brake master cyl ind er t o b rake b ooste r 2 6 Nm (19 ft -l b ) Hydrau l ic u n it t o b ody 8 N[...]

  • Page 725

    - Usi n g a cl ea n syrin g e, emp ty b rake f l u id rese rvo ir. WA RN I NG! B rak e fluid is h ighly co rr o sive and dange ro us to th e envir onme nt . Dispo se o f i t p ro p er ly. Re mov e in terio r v en til atio n microfilter h ousin g . Re mov e u p p er cov er an d micro f ilt er. Op en wi ring h arn ess l oo m ( A ) and remo v e wi res[...]

  • Page 726

    outp u t l in es f rom p u mp . Re mov e el ectrica l h arness conn ector. Li f t p u mp to rel ea se from l ow er moun t ing p ad. Sl ide p u mp ou t of retainin g r ing . - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : Be su re to rep l ace ru b b er p u mp moun t s if d ama g ed or wo rn . Wh en inst all ing v acuu [...]

  • Page 727

    400-1 Gen era l T h is sect io n cov ers system d escri p tions and g en era l in f orma tion f or th e rep ai r g roup s f oun d in 4 Body and 5 Bod y Eq u ipm ent . E4 6 Se da n Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Body - Gen e ral h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man[...]

  • Page 728

    400-2 Body A s s em bl y T h e b od y st yl es of E46 cars cov ere d b y th is m anu al are t h e 4-door Sedan , 4-door Sport W ag on, 2-d oor Co u p e and 2-d oo r Co n v ertib l e. Body d ime n sions v ary sl igh tl y among model s. Dime n si ons are g iv e n in inch es. E4 6 Se da n E4 6 Sport W a gon Body - Gen e ral h tt p: // e bah n .ben t l[...]

  • Page 729

    E4 6 c onv e rtible E4 6 Coupe Body - Gen e ral h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /4... 2 of 8 2/ 25/ 2009 10: 37 PM[...]

  • Page 730

    B ody sh el l T h e BM W 3 Serie s ch assis is a u n ib ody d esi g n const ru ct ed of h igh st ren g th steel. A t t achin g p arts, su ch as th e fron t fen d ers, rea r q u arter p anel s, d oo rs, tru n k l id and h oo d are also con stru cted of st ee l . Co mp u ter ai d ed d esign (CA D) tech n iq u es h av e b ee n u sed in refin ing E46 b[...]

  • Page 731

    T h e E46 b ody sh el l was d esi g n ed so th at t h e v ib rations of t orsi on al t wisting and b en d in g are sep ara t ed in t o d iscre te compon ent s an d in th e in aud ib l e rang e. T h e cu rren t Sedan d esi g n ensu res th at th e b ody twists at 29 hert z an d b en d s at 26 h ertz. Ex terior and a e rodynam i cs With its t radition[...]

  • Page 732

    app rox imately 0.31 f or th e Sedan an d 0.32 f or th e Co u p e model s. Fen d ers. The ex t erio r p an els are corro sion- resi st an t zinc coate d (g alva n ized) steel . T h e fron t f en d ers are b ol ted on . F or f ront f end er repl aceme n t inf orma t ion, see 41 0 F end ers, En g ine Ho od . Bu mp ers. T h e f ront an d rear b u mp e[...]

  • Page 733

    refinement . I n t eri or materi al s and col ors, th e soft top an d t h e l ig h t -all oy wheels h av e b ee n care fu l l y m atch ed. A l t h ou g h t h e aut omatic Co n v ert i b l e roof is stan d ard , a h ard -top in b od y col or with h eate d rea r wi n d ow is av ailab l e as an opt ion f or t h e cold sea son . T h e Co n v ertib l e [...]

  • Page 734

    b ackre st wh en th e v ehicl e is in d ang er of t u rn i n g ov er. A Co n v ertibl e b ody n ormall y f l ex es and v ibrat es, tr ansf erri n g oscill ations to t h e p asseng er comp artment . In t h e E46 Co n ve rt ibl e, BM W u t il ize s a u n iq u e b attery tray in t h e t ru n k as a v ib ratio n d ampen in g syst em t o coun teract t h[...]

  • Page 735

    Spo rt Wago n capac i ti es C argo capacity: R ear seat b ackrest u p 43 5 l iters (15 . 4 cu . f t. ) R ear seat b ackrest fol d ed d own 13 45 l iters (47 .5 cu . ft .) Lo ad capacity: I n carg o compartmen t 5 40 Kg (11 91 l b . ) On roof 75 Kg (165 l b . ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Body - Gen e ral h[...]

  • Page 736

    400-3 Sa f ety a n d Secu r i ty Fea tu res A l arg e n u mb er of n ew or imp rov ed safety an d security featu res are incorp ora t ed in E46 cars. Sa fety c a ge T h e b od y safety cage is a con tin u ation of an estab l ish ed BM W con cept f or p asse n g er p rotection. Tub u l ar imp act stru ctu res b u il t int o th e b od y p rov id e p [...]

  • Page 737

    El ectrica l comp on ent s in th e l ocks are fu l l y en capsu l ated an d cann ot b e p icke d ea sil y. The n ew d oo r h and l es, l atch es and l ock asse m b l ies o f fer improv ed rel ia b ility an d secu rity ag ainst th eft . Do or p osi t ion an d l ock con d ition are d etected b y h all sensors. Roo f padding I n ad d ition to t h e si[...]

  • Page 738

    A i rba gs A s man y as 8 ai rb ags are in st all ed in E46 cars, d ep end in g on mod el. T h e fron t air b ag s op erate wi t h ou t sodium azide p rop el l ant , widel y considered an irritant when an ai rb ag is d epl oye d . Starting wi th 200 0 mod els, " smart" fron t p asseng er an d d riv er ai rb ags we re in st all ed . These [...]

  • Page 739

    A l w ay s d i sc onn ec t the batter y and co ver the n eg ative (-) batter y term in al w i th an in su l ato r befo re sta rtin g di ag nost ic, tro ublesho otin g or se rvice w o rk on ca rs fi tted wi th SRS, and b efo re doing any weld in g o n the car . B a ttery safety term i nal (B S T ) A p yrotechn ic ( ex p l osi v e ch arge) d ev ice a[...]

  • Page 740

    system. A n t i-th eft al arm (DWA ). This is a d ea l er-i n st all ed op t io n for wh ich t h e E46 v eh icles are factory-wi r ed. W h en arme d , t h e system mon itors d oor l ock contact s an d tru n k an d en g ine h oo d l ocks and sou n d s a sire n if it d etects tamp eri n g . T il t sen sor. Lo cated in th e righ t side of th e t ru n [...]

  • Page 741

    400-4 I n teri or Fea tu res E46 int erio rs h av e a u n iq u e ch aracter, wi t h a combin ation of sp orty f ea t u res and in n ov at iv e d esi g n . A l l b ody v ersi ons wer e made in a wide ch oi ce of int eri or an d ex terio r colors. New col ors wi t h match in g l ea th er or l ea t h ere t t e u p h ol stery we re in t rodu ced for ea[...]

  • Page 742

    adj u stab l e f ront sea t s, an d electricall y adj u stab l e an d h ea t ed rear-v iew mirro rs. In side t h e car t h ere a re rea d ing l igh t s at f ou r seating p ositio n s. T h e sea t s h av e a p assi v e int ernal v ent ilation syst em: Cyl in d rical cav ities wi t h in t h e cu sh io n s an d b ackrests g enerate a p u mp in g eff e[...]

  • Page 743

    For secur ity reaso n s, t h e rel ea se l ev er t o f old t h e rea r sea t b ackre st forwa rd is in st all ed in th e tru n k. I n Sp ort W agon mod el s: Re ar sea t b acks are sp l it 60/40 wi t h t h e center arm rest on th e l ef t sea t b ack. The cen ter arm rest incorp ora t es a n on ad j u stab l e h ea d rest. W h en f old ed d own, t [...]

  • Page 744

    d ispl ays. Serv ice I n terv al Displ ay cal cu l ates v ehicl e serv ice n eeds, b ased on cu rrent d riv ing p att erns, and in d icate s to th e d riv er when th e car requ ires serv ice. I n teg rated on -b oar d n av igatio n system, b ase d on Gl obal Po sitio n ing Syst em (GPS) tech n ol ogy, is opt ionall y av ailab l e on E46 cars. W h e[...]

  • Page 745

    Wash ers . Ce n t ral l ocki n g wi t h p owe r t ru n k release . S ee 515 Centr al Lo ckin g and A n ti-th ef t . Keyless ent ry (F ZV ) Pow er wind ow cont rol . See 51 2 Do or W ind ows . Ca r/ key memory I n terio r l ig h t ing A l arm system (DWA ) El ectronic con su mer sl eep mode. See 600 El ectrical Syst em– General . Ot h er fu n ct i[...]

  • Page 746

    No te: Al l 19 99 mod els an d cars pro duce d t hrou gh Jun e 200 0 are eq uippe d w i th t he DLC socke t i n the rea r ri ght corne r of t he en gi ne comp artment. I n cars prod uce d aft er Jun e 20 00, the DL C socket i n t he e ngine comp artment has be en discontinued . Al l scan t oo l code s can now be acce ssed throu gh the OBD II i nter[...]

  • Page 747

    Sport Wa gon interior fea tures Chil d seats. There are t h ree chil d seat h old d own an ch ors b eh ind t h e rear sea t b ack rest. Pl astic t rim cov ers are u sed t o h ide t h e an ch ors. Ca rg o are a. T h ere is a sp ring -l oaded b l ind and a carg o safety n et inst al l ed b ehin d t h e rea r seat. Storage. There are ex tra st ora g e[...]

  • Page 748

    410-1 Gen era l T h is r epair g roup cov ers repl ace m ent of th e fr ont f en d ers an d remov a l an d inst all at io n of t h e eng in e h ood. No te: The bo dy i s painted at the factory aft er asse mbl y. Rea l i gn m en t of bod y pan el s may exp ose un pa i nted metal. Paint all exp osed metal once t he w ork i s comp l et e. Spec ia l to[...]

  • Page 749

    410-2 Fron t Fen ders Front fender, rem ov ing a nd ins ta lli ng - Ra ise h ood. Rai se an d saf ely su p p ort f ront of v eh icl e. WA RN I NG! Wh en raising the car us i ng a floo r jack or a hyd ra u l ic li ft, ca refu l ly p o sition th e jack pad to prev ent d am ag in g the car body. A su i table li n er (woo d , ru b ber, etc . ) sho uld [...]

  • Page 750

    and remov e retainin g screw ( arr o w ) . Re mov e l owe r fen d er att ach ing b ol t s ( ar row s ) at rear of wheel h ousin g . With d oor open remov e u p p er f end er to d oo r p ost attach in g b ol t (arrow ). Re mov e screw ( a rr o w ) at f ront of fend er. Fen der s, En g i n e Hood h tt p: // e bah n .ben t l e y pu bli s h e rs .com /[...]

  • Page 751

    Re mov e b ol ts ( ar rows ) al on g t op ed g e of fen d er. - Ca refu l l y remo v e fen d er f rom b ody. - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : Before in stal l ing n ew f end er, cl ean old sealant and p rot ectiv e coating from mou n tin g su rf ace s. Posi t ion n ew f end er and l oose l y inst all al [...]

  • Page 752

    410-3 En gi n e Hood Hoo d, ra ising t o s er v i c e pos ition CA UTI ON! Do n ot switch o n the w i nd shiel d wi p er s w ith the engine h oo d ra i sed. A s a p re cau tion, re mo ve the w ip er mo to r fu se. See 610 Electr i ca l Co mponent L oc ations . Th e h o od i s h ea vy. B efo re re mo vi ng the h oo d su p por ts, b e su re to have a[...]

  • Page 753

    electrical h arn ess conn ector ( B ) from h eated n ozzl es. - De t ach g as-ch arg ed h ood su p p orts f rom h oo d . CA UTI ON! Th e h o od i s h ea vy. B efo re re mo ving the h o o d su p por ts o r h oo d re taini n g bolts, b e su re to have a n as sista n t help su pp o rt the h oo d. Lo osen u p p er h oo d h ing e b olt s ( A ). Re mov e[...]

  • Page 754

    Clea ra n ce specification Ho od edg es to adj oi n ing b od y p anel (g ap ) 5.5 mm (0.216 in. ) I f h ei g h t ad j u st men t at rea r of h oo d cann ot b e comp l eted u sin g u p p er h ing e, l oosen l ow er h ing e b olt s ( ar row s ) and reposi t i on as n ecessa r y. Pl astic coa t in g on t op of h in g e st op screw mu st n ot b e d ama[...]

  • Page 755

    minimal cl ear ance. Turn stop d isk to mov e h oo d f ron t stop fu r th er ou t. - He ig h t at f ront of h ood is set u sing sp ring p in s and ru b b er st op b u f fers. Hoo d rel ea se c a ble a nd s pring pins , a djus ting Before adj u st ing h oo d p in s, b e sur e th e h oo d is al ign ed ev enl y t o fen d ers and f ront p an el . - M a[...]

  • Page 756

    Lo ct ite®270 or equ i v al ent , an d rei n st al l . - Unscrew ru b b er st op b u ff ers abov e h ea d l ig h t assembl ies u n t il th ey su p p ort h oo d when cl osed wi t h ou t mov eme n t. - T est h ood for corr ect cl osure an d open ing . If h ood d oe s n ot sp rin g open , l en g t h en sp rin g p in s. T o l en g t h en sp ring p in [...]

  • Page 757

    8 - Stop b u ffer 9 - Sprin g p in 10 - Lo wer ho o d lo ck 11 - Sauce r h ea d sc rew 12 - Ecc entric w heel 13 - He x n u t w ith pl ate 14 - Hood catc h 15 - Bowd en ca b l e, ce n ter Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Fen der s, En g i n e Hood h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E[...]

  • Page 758

    B MW > 3 28 > 2000 > 2 .5L L6 (M52) Logout We lcome teth o m a@gma il. com h tt p: / / eba h n .be n tley p u bl i sh e r s.com /header.j s p 1 of 1 2/ 25/ 2009 10: 40 PM[...]

  • Page 759

    Tech In fo Search Enter V ehicl e I ndentification Nu m be r ( V IN ): C hoose vehicl e: DTC Xpr ess TM C hoose D iagnosti c T rouble C ode (D TC): Veh i cle 411-1 Gen era l T h is repair g rou p cov ers f ront an d rea r d oor repair in formatio n . I t in cl u d es remo v al an d in stal l atio n of in terior f ront d oor t rim p anel s, rea r d [...]

  • Page 760

    411-2 Doors WA RN I NG! E46 ca rs are fi tted w it h side-impact airbag s in the fro n t d o or s. W h en se rvicing doo rs on car s w i th fro n t side-impact a irbag s, alw ay s di sc o n n ec t th e n eg ative (-) batter y ter min al. See 7 21 A irbag Syste m (SRS) fo r cau tions and p ro ce d u res re l atin g to the airbag sys tem. Front or re[...]

  • Page 761

    With d oor fu l l y open , remov e p in b ol ts ( ar row ) f rom t op an d b ottom d oor h ing es. Re mov e d oor ch eck moun t in g b ol t ( ar row ). - Re mov e d oor b y l iftin g u p off l ow er h ing e h alv es. CA UTI ON! B e car efu l not to dama ge doo r or o th er pain ted b o d y su rfa ces . Mak e su re n o l oa d i s pl ace d o n wi rin[...]

  • Page 762

    A d j u st d oor st riker so th at t rai l in g edg e of f ront d oo r is sl ig h t l y h igh er (1 mm / 0.04 in. ) th an l ea d in g ed g e of rea r d oor. See 515 Central Lo ckin g and A n t i-th eft . Re p air any p ai n t d ama g e and p ai n t any ex p osed metal. CA UTI ON! I n 2-doo r mo dels, re mo ving and in sta ll i ng the d oo r ma y up[...]

  • Page 763

    airbag s in the fro n t d o or s and as an o p ti o n o n 4-do or models . W hen se rvicing doo rs on car s w i th fro n t side-impact a irbag s, alw ay s di sc o n n ec t th e n eg ative (-) batter y ter min al. See 7 21 A irbag Syste m (SRS) fo r cau tions and p ro ce d u res re l atin g to the airbag sys tem. - Close door wind ow compl etely. - [...]

  • Page 764

    - I n stal l ation is r ev er se of remov a l . Lub ricate d oo r ch eck b efore inst all in g . Use n ew moun tin g b olt s wh en rei n st al l in g t h e sid e-impact ai rb ag to th e d oor (where app l icab l e). Ti gh teni n g torqu e Do or ch eck to d oor 2 4 Nm (16 ft -l b ) Doo r hinge adj us tm e nt I f th e inst all ed d oor is u n ev en o[...]

  • Page 765

    Ti gh teni n g torqu es Do or h ing e to d oor 20 Nm (15 f t -l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Doors h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /4... 6 of 6 2/ 25/ 2009 10: 40 PM[...]

  • Page 766

    411-3 Door Pa n e l s WA RN I NG! E46 ca rs are fi tted w it h side-impact airbag s in the fro n t d o or s and as an o p ti o n o n 4-do or models . W hen se rvicing doo rs on car s w i th fro n t side-impact a irbag s, alw ay s di sc o n n ec t th e n eg ative (-) batter y ter min al. See 7 21 A irbag Syste m (SRS) fo r cau tions and p ro ce d u [...]

  • Page 767

    - For rear trim p an el : Pry ou t wi n d ow switch at t op of armrest. Pry off con cea l in g p l u g s ( arr o ws ) from u n d er armrest. Re mov e d oor p anel retai n ing screws ( ar row s ). Uncl ip d oo r p anel f rom d oor p erim eter u sing a t rim p an el tool . Pu l l p an el retai n ing cl ip s off one at a time. Doors h tt p: // e bah n[...]

  • Page 768

    Pry off in sid e d oo r rel ea se Bow d en cabl e at en d of cl ip ( arr o w ). Pu l l off p an el : De tach cabl e f rom int eri or d oo r rel ea se l ev er. - Di scon n ect rad i o sp ea ker h arn ess conn ector. - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : Re p l ace an y d ama g ed p l astic p arts or cl ips. Re[...]

  • Page 769

    Rear side trim pane l, re m oving and inst al ling (Co upe m odel ) - Re mov e rea r seat cu sh io n . Re mov e rea r b ackre st side sectio n . See 52 0 Seats . Usi n g a trim t oo l , g en tl y p ry u p d oor th r eshold trim. St arting at A -p ill ar, p ress radiu s of t rim d ownwar d s whil e sl idin g t rim forwa rd off trim cl ip s. Re mov e[...]

  • Page 770

    Re mov e t rim p l u g s on sid e p an el armre st . Re mov e in sert p an el retainin g screw s. Gent l y p ry sid e p an el insert fr om u p p er an d l ow er side p anel s. Di scon n ect electr i cal h arn ess conn ectors as n ecessa ry. - Re mov e u p p er side t rim p an el: Re mov e t rim retai n in g riv et f rom u p p er corn er at d oo r. [...]

  • Page 771

    - I n stal l ation is r ev er se of remov a l . M ake su re t o rep l ace an y b roke n trim cl i p s. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Doors h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /4... 6 of 6 2/ 25/ 2009 10: 41 PM[...]

  • Page 772

    412-1 Gen era l T h is r epair g roup cov ers tr u n k l id an d tailg ate remov a l an d inst al l ation. A l so incl u d ed h ere are rep l ace ment p roce d u res for th e g as-charg ed su p p ort st rut s t h at h old t h e t ru n k l id or tailg ate in t h e op en p osi t ion. No te: The bo dy i s painted at the factory aft er asse mbl y. Rea [...]

  • Page 773

    412-2 T ru n k Li d T runk li d, re m ov ing a nd ins ta lli ng Ra ise tru n k l id. Op en tool kit an d remov e screws attach ing t oo l kit t o tru n k l id ( wh ite ar row s ). Uncl ip r etai n ing st rap at tru n k l id and remov e t oo l kit. Re mov e in su l ating l iner ex p an sio n riv ets ( b lack arr o w s ), b y p ryin g u p p er p orti[...]

  • Page 774

    T runk li d, a li gning Ra ise tru n k l id. Working at l ow er corners of tru n k l id, u n screw out ru b b er b u f fers ( arr o w s ) on l eft and righ t sid es. I n sp ect p ads ( arr o ws ) on each sid e of l atch asse mb l y for d amage or wea r an d repl ace if n ece ssary. Re mov e p rotectiv e caps at t ru n k l owe r trim p an el an d l [...]

  • Page 775

    screw an d p rotectiv e cap. I f stop screw h as remov ab l e p rotectiv e ca p ( ar row ) r emo v e p rotectiv e ca p from st op screw. A d j u st stop screw so t h at h ead is set t o ( A ) 10 mm (0.40 in .) abov e b ore h ei g h t . T o ad j u st tru n k l id g ap at rea r f en d er: Lo osen b olt s retai n in g t ru n k h in g e to tr u n k l i[...]

  • Page 776

    T o ad j u st tru n k l id at l ock: Re mov e p rotectiv e caps f rom trim p anel and l oose n screws retai n ing l atch asse mb l y u n t il it can j u st b e mov ed . I n sp ect p ads ( arr o ws ) on each side of l atch asse mb l y for d ama g e or we ar an d repl ace if n ece ssary. I n sert key in tru n k l ock, an d h old key in u n l ock p os[...]

  • Page 777

    top of stop screw , and g ent l y cl ose t ru n k l id . A d j u st h eigh t of st op screw u n til p aper st rip can b e remo v ed with sl igh t resi stan ce. O n ce stop screw h ei g h t h as b ee n ad j u sted , l owe r adj u sted h ei g h t of stop screw 2.5 mm (0.1 in .) t o acco m modate for stop screw p rotectiv e cap. Fit p rotectiv e cap o[...]

  • Page 778

    - Re mov e st ru t f rom tru n k l id. - I n stal l ation is r ev er se of remov a l . Re p l ace retainin g cl ips d amaged d u rin g r emo v al . Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Tru n k L i d, Tai lgat e h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /4... 6 of 6 2/[...]

  • Page 779

    412-3 T a i l ga te (Sport w a g on m od el s ) T a il gate, re m ov ing and ins ta lli ng - Ra ise compl ete tailg ate. Rem ov e int eri or t rim an d d isco n n ect wi ring h arnesses. - Di scon n ect l eft an d righ t su p p ort stru ts as d etai l ed b el ow. - Wh il e su p p orting t ailg ate, remo v e h ing e b olt s for t ailg ate on l ef t [...]

  • Page 780

    case of an el ectrica l f ai l u re. T h e release is l ocated in t h e rea r carg o are a, alon g th e l owe r edg e of t h e rear apron b ehin d a small access co v er. - Working in side car, at b ase of tailg ate: Re mov e release cov er. Pu sh l ev e r towa rd d r iv er' s sid e ( ar row ). T a il gate sup port st rut, rem oving and inst a[...]

  • Page 781

    Ra ise rea r wind ow. Remo v e inn er trim from g l ass p anel b y r eleasi n g cl ips on trim f rom retai n ers ( ar row s ). F or cl ari ty, trim is remov ed in p h oto. No te: Use t w o pl asti c prying w edg e tools to release ea ch pin retai ning tri m. Re l ea se sp oi l er moun tin g b olt s ( ar row s ). Di scon n ect wi ring t o b rake l i[...]

  • Page 782

    Su p p ort wi n d ow in open p ositio n . Working at t op of t ai l g ate, l oo sen screw s ( ar rows ) on ea ch wind ow h ing e. Note p osi tions of an y sp ace r s for reinstal l atio n . CA UTI ON! Re ar wi nd ow i s h ea vy. Use a sec ond pers on to su p por t w in d o w prior to re l eas i ng fro m h in ge s. - Re mov e screws a n d l ift off [...]

  • Page 783

    Cleara n ce of t h e rea r w in d ow is adj u sted b y ad d in g or remo v ing sh ims b etwe en h in g e b racket an d rea r wind ow (max imu m of t h ree sh ims). A d j u st sp oiler g ap t o b od y l ast. He ig h t of sp oiler is set b y alig n ment of t h e rear h atch . G ap of sp oiler t o b od y is set b y adj u stin g sp oiler att achmen t b[...]

  • Page 784

    Tail g ate and rea r wi nd o w p ositi o n gap adju stme n t Re ar wi n d ow / tailg ate ( F ) 4 ± 1 mm (0.16 ± 0.04 in. ) Re ar wi n d ow / tailg ate ( G ) 5.4 ± 1 mm (0.21 ± 0.04 in. ) T o ad j u st fit of t ailg ate to b od y: Close tailg ate an d open r ea r wi n d ow . T ailg at e h in g e b ol ts ( A , b ehin d trim) sh ou l d b e cent er[...]

  • Page 785

    Ti gh teni n g torqu es Lo ck n u t f or stop b u f fer (M 8) 15 Nm (11 ft -l b ) Lo osen screw s ( arr ow s ) and rep osi tion rea r l atch t o fu rth er a d j u st g ap b etwe en tailg ate and b od y at sid es, and t o assure smooth op era tion. - T o ad j u st striker p ositio n : Close tailg ate sl owly, all ow ing striker to cen ter itsel f on[...]

  • Page 786

    Re t igh t en l ock n u t when wind ow l atch operates smoo t h l y. T o ad j u st rea r wind ow l ock p ositio n , initiall y l oose n l ock m oun t in g b olt s ( ar row s ). Close wi n d ow sl ow l y, all ow ing l ock to cen ter itself on striker. T ig h t en mou n t ing b ol ts, t h en ch eck rea r wind ow to b ody g aps as shown ab ov e. Co py[...]

  • Page 787

    510-1 Gen era l T h is r epair g roup in cl u d es repair inf orma t ion for th e ou tsid e rea r v ie w mirro r, f ron t an d rea r b u mp ers, an d th e ea sil y remov abl e ex t eri or t rim p arts. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Ex t er i or Tr i m , Bu m pers h tt p: // e bah n .ben t l e y pu bli s h e [...]

  • Page 788

    510-2 Ou ts i de Rea r Vi ew M i rrors M any of t h e mir ror compon ent s are separate l y av ailab l e f rom an au th orized BM W d ealer, incl u d in g th e g l ass an d outsid e p l astic h ousin g . O uts ide m i rror gla ss , r epla c ing CA UTI ON! Mirro r sho uld b e at o r abo ve ro om tem p era tur e b efo re re mo val. Oth er w i se , sm[...]

  • Page 789

    abov e. Re mov e h ou sing retainin g screw s ( ar row s ) and l ift off rear h ou si n g . T il t mirror h ou sing forwar d and compress p l astic retai n ers ( ar rows ) and l ift off fron t h ou sin g . No te: The front mi rror hou si ng i s retai ne d b y eit he r t hre e or four cl i ps, de pe nding on mod el . - I n stal l ation is r ev er se[...]

  • Page 790

    Gent l y p ry off d oo r in n er t rim p anel from retainin g cl ips ( arr o ws ). Di scon n ect electr i cal h arn ess conn ectors f or wi n d ow ant i-trapp ing p rotectio n and sp eake r ( arr o ws ), if equ ip p ed . Re mov e in n er d oo r p anel t rim. On sedan mod els, trim st rip ex ten d s aro u n d wi n d ow to d oor l atch are a. Su p p [...]

  • Page 791

    Check mirror fu n ction b efore inst all in g cov eri n g p arts. Ti gh teni n g torqu e Ou tsid e mirro r t o d oor (M 6) 6 Nm (4.5 ft -l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Ex t er i or Tr i m , Bu m pers h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 4 of 4 2[...]

  • Page 792

    510-3 Bu m pers Front bum pe r ass e m bly 1 - Impact absorbe r 2 - Space r 3 - Ca p 4 - Sup po rt b ra ck et 5 - Bumper brac ke t bo lt tig h t en t o 41 Nm (30 ft -l b ) 6 - Protec ti ve rubb er strip 7 - Li ce nse pl ate brac ket 8 - To w ey e cove r 9 - Bumper cover 10 - Ca rrier b umper 11 - Gril l 12 - ASA b ol t tig h t en t o 41 Nm (30 ft -[...]

  • Page 793

    Front bum pe r, r em oving a nd inst a ll ing - R ai se an d p rop erly su p p ort v ehicl e. WA RN I NG! Mak e s ur e th at the car i s firmly su pp or ted on j ac k stands d es igned for the p u rpo se. Place the jack sta n ds beneath a stru ctu ral chas sis point . Do not pl ac e jack stands under su spension p ar ts. - Worki n g u n d ern eath [...]

  • Page 794

    out side t emperatu re sen sor at rear of l eft side of b u mp er and temp eratur e swi t ch at rear of rig h t side of b u mp er. - Sl ide b u mp er straigh t off sid e b racke ts. - I n st al l atio n is rev erse of remov al , n oting t h e f ol l ow ing : Sl ide sid e b rackets on b u mp er an d b ody careful l y t ogeth er. M ake sure g ap b et[...]

  • Page 795

    Rea r bum pe r ass e m bly 1 - Ca p 2 - Ca ske t 3 - Impact absorbe r 4 - Ca rrier b umper 5 - Sup po rt b ra ck et 6 - Br ack et 7 - Protec ti ve rubb er strip 8 - Bumper cover 9 - Lo wer part cove r 10 - To w ey e cove r 11 - ASA b ol t tig h t en t o 41 Nm (30 ft -l b ) 12 - Bumper brac ke t bo lt tig h t en t o 41 Nm (30 ft -l b ) Rea r bum pe [...]

  • Page 796

    WA RN I NG! Mak e s ur e th at the car i s firmly su pp or ted on j ac k stands d es igned for the p u rpo se. Place the jack sta n ds beneath a stru ctu ral chas sis point . Do not pl ac e jack stands under su spension p ar ts. Re mov e b u m p er su p p ort b ol ts u sing sp eci al BM W tool 00 2 15 0. Re mov e n u t from b u mp er cov er retai n[...]

  • Page 797

    I nstal l t he bump er bracke t bo l t w i t h threa d l ocki ng comp oun d such as Lo ct i t e®27 0 or eq ui valent. Ti gh tenin g torqu e Bu mp er b racket to i mp act absorb er (M 10 b ol t) 41 Nm (30 f t -l b ) Rea r bum pe r im pac t abso rber, re plac ing - R emo v e b u mp er as d escribed abov e. - R emo v e l u g g age comp artment f l oo[...]

  • Page 798

    Bu m p er h eigh t , ad j u st ing . Ti gh tenin g torqu es Bu mp er b racket to i mp act absorb er (M 10 b ol t) 41 Nm (30 f t -l b ) I mp act ab sorber t o ch assi s (M 8 nu t ) 2 2 Nm (16 f t-l b ) B um pe r he ight, adj us ting T h e adj u stmen t p roce d u re app l ie s to ei t h er f ront or rea r b u mp ers. A 14 mm all en socke t is n ee d[...]

  • Page 799

    b ol t at imp act ab sorb er. Usi n g a 12 - i n ch ex ten sio n an d a 14 mm A l l en socket, t u rn ad j u stin g col l ar cl ockw ise or cou n t erclockwi se as n ee d ed to ch an g e h eig h t of adj u stin g coll ar. - R ei n stal l mou n tin g b ol ts and ch eck b u mp er h eig h t. Re fit fron t b u mp er. Ti gh tenin g torqu es Fron t b u m[...]

  • Page 800

    510-4 Exteri or T ri m Ex terio r t rim is retai n ed t o th e b ody b y p l astic cl ip s and f asteners t h at m ay b e d ama g ed d u r ing remo v al. Be su re t o h av e n ece ssary fasten ers on h an d when reinst al l ing ex terio r t rim p iece s. B M W e m ble m , re m ov i ng and ins ta lli ng T h e p roce d u re g iv en b el ow ap p l ies[...]

  • Page 801

    I n stal l ation is r ev er se of remov a l . Re p l ace an y cl ips or cl ip cov e ring b oo t s d amaged d u r ing remov al . Radia to r gril l, re m ov ing and ins ta lli ng - Op en h ood. Gent l y p ry ou t t ab on l eft or righ t sid e of g ril l trim ring ( A ), as we l l as tab s on b ottom. - Feed g ril l out t h rou g h open in g . Be care[...]

  • Page 802

    Headl ight hous i ng t rim panel , rem oving and inst a lli ng - Op en h ood. - Re mov e sp ray n ozzl e of v ehicl es equ ip p ed with h eadl ig h t cl ean i n g systems. See 61 1 W ipers an d Wash ers . Uncl ip in n er tab at rad ia t or su p p ort . - Press pan e d ow n wa rd , out of retai n ing b rackets. Feed ou t retai n ing h ook at f end e[...]

  • Page 803

    512-1 Gen era l T h is r epair g roup cov ers d oor g l ass, wi n d ow reg u l ator an d p owe r wi n d ow motor repair inf orma tion. CA UTI ON! A l l E46 mo dels are equipp ed w it h side-impact a irbag s in th e fro n t doo rs . So me mo d els ar e also equ i pp ed w ith airbag s in th e rea r doo rs . B e su re to re ad the airbag warnin g s an[...]

  • Page 804

    P ow e r w indow s Pow er wind ow f ea t u res in E4 6 mod els incl u d e: Co n t rol of t h e fr ont and rea r d oor wi n d ow motors is carrie d ou t d ire ct l y b y th e Gen era l M odu l e (GM V ). On e-tou ch operatio n in b oth d ire ct ions on al l f ou r wind ow s, where app l ica b l e. Ca b l e t yp e wi n d ow re g u l ator u sed for al[...]

  • Page 805

    cu stomize d with th e Car M emory fu n ction. See 515 Ce n t ral Lo ckin g and A n ti-th ef t . A ft er th e ign itio n is switch ed off , electric wind ows can b e op era ted u n t il a d oor is opened or u n t il 16 minu t es h as el apsed . T h e GM V b ases wi n d ow motor end p ositio n on cu rrent d raw (l oa d ). There is a max imu m wi n d[...]

  • Page 806

    W indow s w itche s T h e p u sh -p u l l t yp e wind ow swi t ch p rov ides th e GM V with a coded g r oun d sign al. Hold in g a switch at th e first d etent p rov ides a sin g l e g r oun d sig n al on one w ire re q u estin g th e GM V to open t h e wind ow. Wh en release d , th e g roun d sign al is remo v ed an d t h e wi n d ow moto r st op [...]

  • Page 807

    I n 4-door m odels, t h e rea r wind ow ch ild l ocko u t switch ( ar row ) is incorp orate d in th e d riv er' s wind ow switch b l ock to t h e l eft of th e sh ift er. W h en activ ated, it p rov ides a con stan t g rou n d sign al t o t h e GM V , p rev ent ing t h e wind ows from b ei n g operated fr om th e r ea r d oor swi tch es. T h e[...]

  • Page 808

    d oor l ock. I f t h e GM rece iv es a requ est t o operate conv en ience cl osing or op enin g for more th an 11 0 seco n d s, th e fu n ct io n i s d eactiv ated an d a fau l t cod e is st ore d . W indow anti-t rap prot ec tion I n 4-door m odels, a ru b b er p ressure g u ard l oca t ed at t h e top edg e of ea ch d oor f rame consists of t wo [...]

  • Page 809

    a wi n d ow mo t or is a ct i v ated . I t cou n t s ea ch cycl e and stores th e n u mb er in memo ry. A ft er t h e st op fu n ct io n l imit is rea ch ed and t h e wind ow motor is d eactiv ated, th e GM V sl owly rev e rses th e stored coun t of activ atio n u n t il t h e stored n u mb er equ al s 0, t h u s all ow ing th e wi n d ow motor t o[...]

  • Page 810

    to th e wi n dow reg u l ato r sho uld always b e di sc o n n ect ed to prev ent p in chi ng fin ge rs in th e mo vin g wi n d o w me chanism. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Door W i n d ow s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 8 of 8 2/ 25/ 2009 10:[...]

  • Page 811

    512-2 W i n dow Serv i ce, 4-door M odel s Sedan an d Sp ort W ag on d oors are simi l ar. Use th e fol l owi n g p roce d u res for wind ow serv ice on th ese m odels. WA RN I NG! E46 ca rs are fi tted w it h side-impact a irbag s in th e fro n t doo rs . So me ar e equipped w ith airbag s in the rea r d o or s as well . Wh en ser vicing the d o o[...]

  • Page 812

    Win d ow sh oul d con tact b l ock, th en imme d ia t el y rev erse d ire ct ion and l owe r b y app rox . 25 mm (1 in. ). No te: Anti -tr ap str i p i s i ntegr ated i nto t he molding st ri p of t he do or w i ndo w frame. Front w indow anti-trap s trip, rem oving - Re mov e f ront d oo r p an el an d v apor b arrie r as d escrib ed in 411 Doo rs[...]

  • Page 813

    1 - Win d ow frame mold in g 2 - Clip 3 - Do or corn er sp eake r cov er 4 - Foam insu l atio n 5 - M oun tin g cl ip - A ft er inst al l ation, rech eck ant i-trap p rotectio n . Rear w i ndo w a nti-t r ap st r ip, rem oving - Re mov e rea r d oo r p an el and v apor b arri er as d escri b ed in 411 Do ors . De t ach wind ow fr ame mold ing st ri[...]

  • Page 814

    against t h e wind ow sea l u n iformly. No te: I f the w i ndow doe s not con t act the w i ndow seal un i forml y, w i nd no i se or w ater i nf i l t rati on may re sult . - Re mov e f ront d oo r p an el as d escri b ed in 411 Do ors . - Di scon n ect n eg ativ e (-) cab l e from b attery. Then remov e airbag u n it and v ap or b arrie r f rom [...]

  • Page 815

    - Re mov e f ront d oo r p an el as d escri b ed in 411 Do ors . - Di scon n ect n eg ativ e (-) cab l e from b attery. Then remov e airbag u n it and v ap or b arrie r f rom d oo r . See 72 1 A irb ag Syst em (SRS) . WA RN I NG! Prio r to di sco nn ect in g the b atte ry, re ad th e batter y d isco n nectio n ca utio n s give n at the fro nt o f t[...]

  • Page 816

    w i ndow retai ne rs every ti me t he glass i s remo ved from t he doo r. T u r n wind ow g l ass care f u l l y insid e d oo r cav ity and l ift ou t of d oo r . - I n stal l ation is r ev er se of remov a l . Re p l ace p l astic wi n d ow retai n ers once g l ass is insid e d oor. Use n ew moun tin g b olt s wh en rei n st al l in g sid e-impact[...]

  • Page 817

    (4.5 in. ) f rom b ott om. Re mov e wi n d ow retai n ing screw ( in se t ) at wi n d ow regu l ator rai l . WA RN I NG! On ce th e wi n dow i s p o si tioned co rr ectly, di sc o n n ec t h ar ness co nn ecto r fro m power w i nd o w mo tor to p re ve n t accidental o p er atio n o f the w in d o w. De t ach p l astic wi n d ow re tainer f rom g l[...]

  • Page 818

    Ti gh teni n g torqu e Side-impact airbag to d oor 8.5 Nm (75 i n -l b ) Win d ow to regu l ator g u id e 8 Nm (71 in-l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Door W i n d ow s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 8 of 8 2/ 25/ 2009 10: 45 PM[...]

  • Page 819

    512-3 W i n dow Serv i ce, 2-door M odel s 2-door models are equ ip p ed with th e "cl ose wi t h d oor sh u t " featu re. I n t h is mode, th e wi n d ow g l ass mov es d ow n sl igh t l y wh en t h e d oor lat ch is activ ated , t h en j ams u p tig h t l y against th e wea th er-str i p when th e d oo r is f u l l y cl ose d . WA RN I [...]

  • Page 820

    T h e fol l owi n g ad j u stmen ts can b e made t o th e wi n d ow: Lo n g itu d in al adj u st men t Pretension (or wi n d ow rake ) Para l l elism (or wi n d ow t ilt ) V ertica l ad j u st men t (or retraction d ept h ) Gl ass p rotru sio n ( when open ) Di st ance b etwe en side wind ow and d oor wi n d ow Eme rgency op er ation A d j u st in [...]

  • Page 821

    Close door as f ar as p ossi b l e with out forcing . Co u p e mod els: To p ed g e of g l ass mu st rest on d oor sea l ( A ). Co n ve rt ibl e model s: G ap b etwee n d oo r an d B-p ill ar ( B ) mu st b e 25 mm (1 in . ). No te: W i ndo w must seal w i th w ater drain at mi rror t ri an gl e i n A-pi l l ar. - Use d oor h and l e t o open rotary[...]

  • Page 822

    Posi t ion wind ow ap p rox . 15 5 mm (6.1 in. ) abov e d ea d b ottom. Working care f u l l y with a p l astic p rying tool, d etach out sid e trim st rip f rom d oo r . Re ach t h rou g h d oor b ores ( A ) u sing T orx d riv er E7 on ex t en sio n with ratch et wre n ch (BM W sp ecia l t oo l 41 6 120 or equ iv alen t ). Loo sen b u t d o n ot r[...]

  • Page 823

    of wind ow out er sea l in g l ip. I f n ecessa ry, rep l ace side wind ow trim. Wi n do w l o ng itu d in al ad ju stme nt Di mension A 1 - 2 mm (0.0 4 - 0. 08 in. ) Do or wi n d ow rear edg e t o sid e wi n d ow sea l (Co u p e) 6 ± 0.75 mm (0.24 ± 0.03 in. ) Co n ve rt ibl e model s: W h en al l th e wa y u p , measure d oor wi n d ow gap to s[...]

  • Page 824

    - Re mov e out er d oor trim st rip as d escri b ed earlier . La t ch d oo r t o f irst catch of d oor l ock ( A ). Ch eck th at t op of wind ow re st s on ru b b er d oor sea l ( B ). Re ach t h rou g h rear b ore in d oo r with BM W sp ecia l t ool 41 6 12 0 or equ iv alen t r atchet wrench . Lo osen wind ow adj u st men t To rx screw ( A ) 18 0?[...]

  • Page 825

    Adj usti ng the de pth that t he w i ndo w retracts i nto t he doo r seal i nsu res that w i nd no i se and w a ter l ea kage past w i ndow i s kep t t o a mi ni mum. Para l l elism. To p ed g e of d oo r wind ow mu st b e p ara l l el t o cont our of wa t er d rai n in roo f. No te: W i ndo w pa r all el i sm i s also r efer red t o as w i nd ow t[...]

  • Page 826

    Pry out ru b b er p l u g s at b ase of d oo r . Starting at rear of d oor, reach th r oug h b ore in d oor to t u rn To rx screw ( A ). No te: Torx screw si z e i s T 20 . Re p eat at f ront b ore. Ra ise wi n d ow an d ch eck f or p ara l l el ism and correct d ep t h of retractio n . Re p eat as necessar y. Re in sert ru b b er p l u g s. Front [...]

  • Page 827

    ar row . Li f t off wind ow in n er l ip sea l . I f n ecessa ry, rep l ace any d efectiv e retai n ing cl ip ( ar row ). Posi t ion d oo r wind ow app rox ima t el y 80 mm (3.15 in. ) b elow roo f l in e. I f n ece ssary, t emporari l y r eco n n ect b attery cab l e. WA RN I NG! On ce th e wi n dow i s l o w ere d , di sc o n n ec t h ar ness co [...]

  • Page 828

    W i ndo w rea r moun t i ng ha rdw are w i l l stay w i t h glass. - T il t rear edg e of wind ow g l ass u p and out of d oor. - I f g l ass is b eing rep l aced, t ran sfer wi n d ow rear moun tin g h ard w are (moun t in g sh im, t h readed sl ee v e and cl amp ing retainer) f rom l owe r rea r corn er of g l ass to n ew wi n d ow . - I n stal l[...]

  • Page 829

    Re f er t o acco mp anyin g ill u st ratio n when remov in g Coup e rear v ent wi n d ow or v ent l atch m echan ism. 1 - V ent wind ow d riv e 2 - I n n er cap 3 - Re t ainer 4 - Wash er 5 - Wash er 6 - Sh im 7 - Gl ass su p p ort Wh en inst all ing , make sure U-shap ed open in g in g l ass su p p ort p oints t o rear of car. T o access rea r v e[...]

  • Page 830

    m odel s) Re f er t o acco mp anyin g ill u st ratio n when remov in g Conv ertib l e rear wi n d ow or wind ow motor. 1 - Win d ow moto r 2 - Win d ow regu l ator assembl y 3 - Win d ow g l ass 4 - I n sert 5 - I n n er sea l 6 - Ou t er sea l CA UTI ON! Co nver t ib le re ar wi nd ow rem ov al, in sta ll atio n and adj us tment i s co mplex. If t[...]

  • Page 831

    wi n d ow . Di st ance t o f ront d oo r wind ow (l ong itu d in al ad j u st ment ) ( A ) mu st b e set b y l oose n ing To r x b olt th r oug h b ore in out er sh el l of car, after remov in g ex t erio r sid e trim strip . T o set retractio n d ep th (su b mersi on) in to t op ru b b er sea l ( B ), rear int eri or sid e t rim p anel mu st b e r[...]

  • Page 832

    512-4 W i n dow Regu l a tor Serv i ce WA RN I NG! E46 ca rs are fi tted w it h side-impact a irbag s in th e fro n t doo rs . So me ar e equipped w ith airbag s in the rea r d o or s as well . Wh en ser vicing the d o or wi n do w s o n ca rs wi th side-impact a irbag s, alw ay s di sc o n n ec t th e n eg ative (-) batter y cable. See 7 21 A i rb[...]

  • Page 833

    h arness con n ector ( A ). Re mov e motor mou n tin g b ol ts ( B ). T wist motor sl ig h t l y ( ar rows ) t o cl ea r wind ow regu l ator moun t in g tabs. - Wh en rei n stal l in g : M ake su re wind ow h as n ot trav ell ed fu l l y d ownwa rd . M anip u l ate sp ring -l oa d ed wind ow contr ol cab l e ( C ) t o eng ag e motor teeth t o regu [...]

  • Page 834

    W indow regula tor and m otor, re m oving and inst a ll ing (4-do or m ode ls) Sedan an d Sp ort W agon d oors are simi l ar. Th ere are t wo w in d ow rails in ea ch f ron t wi n d ow regu l ator, on l y one in th e re ar. O t h erwi se t h e f ront and rear regu l ators are similar. No te: BMW reco mmen ds r emo vi ng the w i nd ow reg ulator an [...]

  • Page 835

    - R emo v e v apor b arri er. - D etach wind ow from wind ow regu l ator as d escri b ed earlier. Do n ot remov e wi n d ow f rom d oo r. Pu sh wi n d ow u p an d u se wedg e t o h ol d in p ositio n . De t ach wind ow regu l ator f rom d oo r : Di sconn ect elect rica l h arn ess conn ector ( A ) to p owe r wind ow motor. Re mov e reg u l ator mou[...]

  • Page 836

    Doo r w indow r egula tor and m otor, re m ov ing and i ns tal li ng, (2-do or m odels) - R emo v e d oo r p an el as d escri b ed in 411 Doo rs . - D isco n n ect n egativ e (-) cab l e f rom b attery. Then remov e airbag u n it and v ap or b arrie r f rom d oor . See 721 A irb ag System (SRS) . - R emo v e d oo r g l ass as d escribed ea r l ie r[...]

  • Page 837

    remo v al. - I n st al l atio n is rev erse of remov al , n oting t h e f ol l ow ing : I n sp ect r u b b er in su l ators. Repl ace if b ritt l e. A f ter in serting wind ow regu l ator int o d oor cav ity, in stal l an d t ig h ten d ow n moun t in g n u t s on rea r wind ow rai l . I n st all fron t wind ow rail moun t in g n u t s b u t d o n [...]

  • Page 838

    513-1 Gen era l T h is r epair g roup cov ers int erio r t rim remo v al and in stal l ation p rocedu res. Re f er t o th e foll ow ing rep ai r g roup s f or add itional in f ormatio n : 25 0 G ea rsh i f t Li n kag e 41 1 Do ors (int eri or d oo r p anel s) 61 2 Swi tch es 62 0 I n stru ment s 64 0 He at ing an d A ir Co n d itio n ing ( I HKA co[...]

  • Page 839

    I n terio r tr im and f inish p an els are cl ipp ed or screw ed in to p l ace . M any of th e t rim retainin g cl ips are d esi g n ed t o b e u sed on l y once. Wh en remov in g trim t h at is h eld i n p l ace wi t h cl ip s, it is a good id ea to h av e sp are s on h and b efore b eginn in g t h e j ob . No te: The BMW E46 i s eq ui pp ed w i t[...]

  • Page 840

    CA UTI ON! Wh en w o rk in g o n el ec trical switches o r l ights, always di sc o n n ec t th e n eg ative (-) ca bl e fro m the b atte ry and i n su l ate th e ca b l e end to p re ve nt ac cidental re co nn ec t ion. Prio r to di sco nn ect in g the batter y, rea d th e battery di sc o n n ec t ion cau tions giv en at the fro n t o f th is manua[...]

  • Page 841

    513-2 Cen ter Con s ol e T h e consol e b etwe en th e two fr ont sea t s st arts b ehin d t h e sh ift er h ou sing . I t h ouses t h e p arking b rake h an d l e, option al tel ep h on e and od d ment s storage tr ay. The rear p ortio n of t h e console h ou ses th e ash tr ay and cov ers th e emergen cy b rake cab l e end s. T h e opt io n al f [...]

  • Page 842

    [...]

  • Page 843

    513-3 Da s h boa rd T h e E46 d ash b oa rd asse mb l y in cl u d es th e in st ru ment cl u st er, p assen g er side ai rb ag , g l ov e compartmen t, fu se and relay p an el , radio, IH KA con t rol p anel or on-b oard mon itor (if eq u ip p ed wi t h GPS), f ron t ash tray, sh ifter asse m b l y, and wi n d ow cont rol switch es. Da sh b oa rd r[...]

  • Page 844

    11 - Gl o ve compar tment hi ng e 12 - Stee rin g col umn cove r 13 - Left g lo ve compar tment (op ti on al) 14 - Ce n ter knee protector 15 - Stee rin g col umn knee prot ec to r 16 - Left fo o twell (pedal cluster ) trim panel 17 - Fo ot well l i gh t cove r 18 - Fo ot well l i gh t sock et 19 - Left knee protector Glove c om pa rtm e nt and ri [...]

  • Page 845

    righ t side st rap . Pu l l ou t p in f rom b ott om of l eft sid e d ampen in g r od. Re mov e g l ov e comp artment h in g e moun t in g b racke t screws ( a rr o w s ). Li f t g l ov e compartmen t ov er moun t in g rod to remo v e. Re mov e g l ov e comp artment h ousin g : Re mov e in sert mou n t ing screws ( ar row s ). I f n ecessa ry, rel [...]

  • Page 846

    Stee ring c olum n trim , r em oving and inst al li ng - R emo v e steeri n g wh eel as d escribed ear l ier. Fu l l y l owe r and ex ten d ( arr o ws ) adj u stab l e st ee r ing col u mn . - R emo v e retai n ing screw from t op of steeri n g colu mn u p p er t rim cov er. Pu sh in sid es of u p p er t rim cov er ( ar row ) to r elea se f rom l o[...]

  • Page 847

    to rel ea se. Pu l l d ow n on t rim. - I n st al l atio n is rev erse of remov al . Re p l ace a n y b roken or missing fasten ers. Left f ootw e ll (peda l c lust e r ) t rim panel , re m oving and inst a ll ing - M o v e st ee rin g colu mn t o ma x imu m ex t en d ed p ositio n . Working at trim p anel , remov e screws ( ar row s ) and ex p an [...]

  • Page 848

    Dash boa rd/s hift e r c ons ole ass e m bly , re m ov ing a nd inst a ll ing - D isco n n ect n egativ e (-) cab l e f rom b attery and cov er terminal with insu l ating materia l . CA UTI ON! Prio r to d isco nn ecting the b atte ry, re ad the batter y di sc onnection ca utions give n at the fro nt o f th i s ma nua l on p ag e vii i . Usi n g a [...]

  • Page 849

    Re mov e sh ift er kn ob b y p u l l in g straig h t u p . No te: App l y app rox. 90 l b. of force to pu l l off kno b f rom shi ft rod . - L ift u p an d r emo v e sh ifter b eze l b y p rying g ent l y. - U n cl ip b ottom of sh ift er b oo t f rom cent er consol e t rim b y p u sh in g forwa rd. Pu l l b oot u p aro u n d sh ift er. - R emo v e[...]

  • Page 850

    in stru me n ts to r em o ve trim o r fin i sher str i p - R emo v e screw s b enea t h f inish in g strip . Ca ref u l l y p u l l awa y A -p ill ar trim. - R emo v e h ea d l ig h t switch . See 612 Switch es . - R emo v e inst ru men t cl u st er. See 620 Instr u ment s . - R emo v e I HKA cont rol p anel an d modu l e. See 64 0 Hea tin g an d A[...]

  • Page 851

    d ashb oa rd . - Sim ilarl y, remov e l eft sid e d ashb oa rd mou n t ing screw or ex p an sion riv et. Re mov e d ash b oard moun t in g n u t ( ar row ) at sh ifter con sole. Re mov e mou n tin g n u t s and screw ( ar row s ) at d ashb oa rd face. - T o remov e d ash b oard: Pu l l u p p arking b rake fu l l y. Pu sh sea ts fu l l y b ack. Li f[...]

  • Page 852

    tig h t enin g fast eners. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. I n t er i or Tri m h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 10 of 1 0 2/ 25/ 2009 10: 46 PM[...]

  • Page 853

    515-1 Gen era l T h is sect io n cov ers rep ai r inf ormatio n for d oor, t ru n k an d carg o comp artment l ocks and cen tral l ocki n g . A l so cov ere d are El ectron ic I m mobil iza t i on Syst em (EWS) and an ti-t h eft al arm (DWA ). Kee p in mind t h at E4 6 cars are equ ip p ed with soph isticated and self -d iagn ostic el ectrical syst[...]

  • Page 854

    Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Cen t ra l L ock i n g an d An ti- Th eft h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 2 of 2 2/ 25/ 2009 10: 47 PM[...]

  • Page 855

    515-2 Cen tra l Locki n g No te: There i s a do or l ock key cyl i nde r on the driver's do or on l y Ce n t ral l ocki n g in E46 v eh icl es cont rol s th e d oo r l ocks, tr u n k or cargo compartmen t l ock an d fu el fil l er f l ap l ock. The Cent ral Bod y El ect ronics (ZKE V ) cont rol mod u l e, kn ow n as th e General M od u l e (GM[...]

  • Page 856

    from b eing op ened from t h e in side regardl ess of l ock-bu t t on p ositio n . T h e Gen era l M odu l e (GM V ) an d El ectronic Immo b il i zation ( EWS 3.3) int erface v ia th e K-b u s to mon itor d oub l e l ock st atu s and t o initiate d oub l e l ock ov erri d e. This f ea tu re all ows th e d oor s t o b e op ened f rom t h e insid e i[...]

  • Page 857

    Central lock ing sw i tch T h e cent ral l ocking switch is h oused in a combin ed h ou sin g with th e h aza rd fl ash er switch . T h e cent ral switch l ocks all v eh icl e l ocks ex cep t f or t h e f u el f il l er fl ap . T h e swi tch p rov ides a mo ment ary g roun d inp u t sign al t o th e G M V . T h is inp u t sing l e l ocks each d oor[...]

  • Page 858

    Si ngle lock a nd doub le l ock fu nction Each d oor l ock actu ator in corporates two motors: Sing l e l ock motor con trol s th e mechan ica l l ock mechan ism wh en t h e cent ral l ock switch is p resse d to sin g l e l ock t h e v eh icle. T h e l ock mech anism is fu l l y l ocke d at t h is p oint b u t can st il l b e open ed f rom th e int[...]

  • Page 859

    footwe l l are a. T h e b u tt on p rov id es th e GM V with a g r oun d sig n al wh en p resse d . T h e v ehicl e mu st b e u n l ocke d or sin g l e l ocke d from t h e cent ral l ock swi tch f or th e re mote u n l ock to work. The remote tru n k rel ea se is l ocked ou t wh en t h e tru n k is l ocked in th e v al et settin g or when t h e G M[...]

  • Page 860

    Rem ote entry (FZV) T h e E46 remote (keyless) ent ry system (u su al l y cal l ed FZ V ) u ses a t iny rad io tran smitt er in th e v ehicl e key to l ock an d u n l ock t h e d oors an d t h e t ru n k b y remo t e con trol . 1 Press once: u n l ock d riv er's d oor D WA disarme d i n t eri or l igh t s on Press twice : total u n l ocking H [...]

  • Page 861

    p anic mod e (alarm if equ ip p ed) T h ere are a n u mb er of oth er f ea t u res incorp orate d in FZ V : Lo ckin g / u n l ocki n g of f u el f il l er l id Selectiv e u n l ocki n g of d riv er's d oor (as wi t h key in l ock) A rming /d isarming of DW A al arm system (if equ ipp ed) Re mot e un l ocking of th e tru n k on l y Co mf ort op[...]

  • Page 862

    Key incorp ora tes an LED th at sign als operator of sig n al tran smitt ing , key initializatio n st atu s and key sel f-t est ind icatio n Keys d el i v ered with f our d ifferent colored l ab els. This is h el p fu l to d iff ere n tiate FZ V keys d u rin g initializatio n , p rev ent in g p ossib ility of misassi g n in g key ID wh ich woul d c[...]

  • Page 863

    l ock/u n l ock th e v ehicl e. Th is is a requ ireme n t of th e Key M emo ry f ea tu r e, cov ered b el ow. Car M e m ory /Key M e m ory A n u mb er of featu res and f u n ctions can b e cu st omi zed to t h e d riv er(s) p reference. T h e iden tity of t h e v ehicl e u ser is p rov ided b y a sig n al f rom t h e keyless en tr y syst em (FZ V )[...]

  • Page 864

    He atin g / A / C p refere n ces (I HKA ) Sea t an d mirror p references (trig g ered b y Key M emo ry) I n st rum ent cl u st er d ispl ay u n its (f or ex amp l e: km v s. mil es) Ke y M emory Wh en ev er one of th e FZ V keys is u sed to l ock or u n l ock t h e car, th e u ser is iden tified b y th e GM V . A max imu m of fou r keys can b e p r[...]

  • Page 865

    rece i ved at the GM V. T he refore Ca r Memo ry/ Key Memory featur es w i l l not be acti vated . Rem ote ke y i nitial iza tion I n itia l iza t ion of FZ V keys is requ ire d t o establ ish l ock/u n l ock sign al syn ch ron iza tion wi th t h e G M V . The initializatio n p r oce d u re p rov ides t h e GM V wi t h a key iden t ifica tion n u m[...]

  • Page 866

    the key memo ry f un ct i ons acti vated b y the keys w i l l no t be assi gne d correctl y. Al w ays i nit i al i z e t he ke ys i n the same ord er. Con vertible c entral l ock ing I n C onv ertibl e mo d el s, th e g l ov e compartmen t l ock is in teg rated in t o cent ral l ocking f u n ct io n s. A n ad d itional l ock actu ator is p ositio n[...]

  • Page 867

    I n t eri or t ailg ate release bu tt on at d riv er's kickp an el Unl ock micro switch abov e rea r l ice n se p l ate A n y of t h ese inp u t req u ests t o t h e GM V activ ate t h e t ailg ate l atch motor. T h e GM V wi l l also switch on t h e int eri or l igh ts wi th a t ai l g ate u n l ock requ est. T h e rea r wind ow is open ed wi[...]

  • Page 868

    Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Cen t ra l L ock i n g an d An ti- Th eft h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 14 of 1 4 2/ 25/ 2009 10: 53 PM[...]

  • Page 869

    515-3 Door Ha n dl es a n d Locks A n y time a d oo r l ock is remo v ed and rei n st al l ed , b e su re to ch eck an d r ese t : Unl ocking of rotary l atch Ou t sid e d oor h an d l e ov e rtrav el T h ese adj u st ment s an d measureme n t s mu st b e mad e b y cl osi n g th e d oo r l ock rotary l atch wi th a screwdriv e r, t h en attemp tin [...]

  • Page 870

    re l eas e Bow den ca b l e 3 - Lo ck b ut ton an d rod 4 - 9/20 00 and later models: Bowd en ca b l e brac ket 5 - 9/20 00 and later models: Doo r hand l e in ner me chani sm 5a - M o d els to 9/20 00: Doo r hand l e in ner me chani sm 6 - In ner hand l e moun tin g b ol t 7 - Ke y cylin d er moun tin g b ol t (To rx ) 8 - Gask et 9 - Door l ock w[...]

  • Page 871

    cy l in d er and cove r 14a - Re ar or rig ht do or: O u ter hand l e r ea r anchor 15 - Door strike r cove r 16 - To rx b o lt M 8 tig h t en t o 24 Nm (18 ft -l b ) 17 - Door l ock str i ker 18 - Lo ck p late Rotar y latch u nl o ck i n g, re setting With d oor open , cl ose rotary l atch . - L ock car wi t h key or l ock b u tt on. - U n l ock c[...]

  • Page 872

    adj u stmen t screw, t h en retig h t en. Ca rr y out ch eck ag ai n . No te: The ri ght si de l atch ad ju st i ng screw i s threa ded l eft-han ded . Ti gh tenin g torqu e D oor l ock adj u st ment screw 3 + 2 Nm (27 + 18 in -l b ) O u tsid e h andl e over tr ave l , re se t tin g - With d oo r open , cl ose rota ry l atch wi th a screw d riv er.[...]

  • Page 873

    Doo r l ock , re m oving and inst a ll ing T h e fr ont an d r ea r d oor l ocks for all E46 model s are simi l ar. Early p rodu ct io n cars, u p t o 9/200 0, u se a l ock actu ator wi th an ex tern al l ev er wh ich coup l es wi t h th e out side d oor h an d l e mech anism. Ca rs p rod u ced f rom 9/200 0 u se a Bow d en cabl e to att ach t h e [...]

  • Page 874

    Ra ise wi n d ow to top . CA UTI ON! Guide th e w in dow u p ma n ua l l y in o rder to avo i d bi n di n g . Re mov e wi n d ow regu l ator rea r rail: Re mov e t op and b ottom rail moun t in g fasten ers ( ar rows ). Sl ide r ai l d own, all ow in g it to h ang to t h e sid e out of t h e wa y. WA RN I NG! E46 car s are fi tted w i th sid e-impa[...]

  • Page 875

    - I n st al l atio n is rev erse of remov al , n oting t h e f ol l ow ing : I n sert l ock b u tt on u p th roug h in n er d oor p l ate, t aking care t o av oi d b end ing l in kag e. On mod els p rod u ced t o 9/20 00 : T il t l ock assem b l y out wa rd whil e l ift in g it in t o p osi t ion insid e t h e d oor . This is d one t o make su re l[...]

  • Page 876

    Ti gh tenin g torqu es Win d ow to g u id e 8 Nm (71 i n -l b ) Driv e r 's do or l ock c yl inder, re m oving and inst a ll ing On l y t h e d riv er's d oor is equ ip p ed wi t h a l ock cyl in d er. T h e p rocedu re f or remo v ing t h e d oor h and l e rear an ch or on th e oth er th ree d oors is simi l ar to t h at for remo v ing t[...]

  • Page 877

    On Sed an or Sp ort Wag on : Re p l ace cyl ind er mou n t in g b ol t acce ss h ol e t rim cov er if n ecessa ry. Doo r ha ndle, re m ov i ng and inst a ll ing (t o production date 9/ 2 00 0 ) - On d riv er's d oo r : Re mov e d oo r l ock cyl ind er as d escri b ed earlier. - Oth er d oo rs: Remo v e d oo r h an d l e rea r an ch or. Proce d[...]

  • Page 878

    Doo r ha ndle, re m ov i ng and inst a ll ing (f r om produ ction date 9/ 2 00 0 ) - On d riv er's d oo r : Re mov e d oo r l ock cyl ind er as d escri b ed earlier. - On oth er d oors: Re mov e door h and l e rea r an ch or. Proce d u re is simi l ar to r emo v in g d riv er's d oo r l ock cyl in d er d escribed earlier. Pu l l ou tsid e[...]

  • Page 879

    ex ceed measurement A . I f mea su reme n t ex cee d s sp eci f icatio n , p u l l l ev er out wa rd with fin g ers u n til m ea su r eme n t is corre ct . In sta ll ation di sta nce: i nn er do or hand le l ev er to d o o r M ea su r eme n t A l ess t h an 8 mm (0.32 in. ) I n sert h and l e and sn ap int o p l ace. No te: Take care t ha t the do [...]

  • Page 880

    - Worki n g insid e d oor open ing , sl id e inn er h and l e towa rd f ron t an d remo v e. - I n st al l atio n is rev erse of remov al . No te: I nspect moun t i ng bolt and re pl ace i f ne cessary. Doo r ha ndle inner m ec hanism , re m oving and inst a ll ing (f r om produ ction date 9/ 20 0 0 ) - R emo v e out sid e d oo r h an d l e as d es[...]

  • Page 881

    Take care t o no t da m ag e i nner doo r gu i de du ri ng remo val and i nstal l ati on . - L oosen h and l e mou n tin g b ol t. - Worki n g insid e d oor open ing , sl id e inn er h and l e towa rd f ron t an d remo v e. - I n st al l atio n is rev erse of remov al . No te: I nspect ha ndl e mou nti ng bolt and rep l ace i f ne cessa ry. Bow de [...]

  • Page 882

    Set p osi t ion of st rike r : Wh en cl ose d , rear edg e of f ront d oor mu st b e ev en wi th f ront edg e of rear d oo r (Sed an or Sp ort Wag on) or with rear q u arter p an el (Co u p e or Co n v ertib l e). M ax imum d ev iation all owe d mea su red at A . Wh en cl ose d , sh ou l d er of f ront d oo r mu st b e f l u sh t o sh ou l d er of [...]

  • Page 883

    Ti gh tenin g torqu e b ody p il l ar T runk lock i ng m ec ha nis m T r u n k l ock asse mb l y 1 - Trun k rel ea se micro switch 2 - Conn ecting rod 3 - Lock wi t h microsw itch 4 - Tor x screw M 6 5 - St rike r p l ate 6 - Trim screw 7 - Lock cov er 8 - Tor x b olt M 6 9 - Lock cyl in d er g aske t 10 - Self -t h rea d ing screw 11 - Lo ck cyl i[...]

  • Page 884

    l ice n se p l ate l igh t strip T h e tr u n k l ock cyl in d er d oes n ot actu at e cent ral l ocking con trol . - T o remov e t h e t ru n k l ock micro swi t ch : Re mov e l icence p l ate l ig h t str ip. Separate electrical h arn ess conn ector f rom st rip. Separate micro switch f rom st rip. T o acce ss tr u n k l ock cyl in d er or l ock:[...]

  • Page 885

    Re mov e l ock cyl in d er co v er moun t in g screw s ( arr o w s ). Sl id e cov er to rig h t t o remo v e. No te: On Con verti bl e mode l s: Re move thi rd brake l i ght t o acce ss t runk lock mech an i sm. Use new sel f -tapp i ng screw s t o reinstal l trunk l ock cyl i nd er. Pry ou t rear tru n k ed g e t rim caps ( ar row s ) t o acce ss [...]

  • Page 886

    No te: Do not l ubricate l ock or l ock stri ker w i t h gre ase . T a il gate l ock , e m erge ncy re le ase T h e Sp ort Wag on t ai l g ate can b e u n l ocked u sin g th e cen t ral l ocking swi tch , th e l eft d oor key or th e F Z V remo t e en try syst em. The t ai l g ate can b e open ed b y p u sh in g t h e t ai l g ate release b u t ton[...]

  • Page 887

    6 - Rea r wind ow l ock st rike r 7 - Tai l g ate lock 8 - Tor x b olt M 8 9 - Tai l g ate lock striker 10 - Lo ck p l ate 11 - T ailg ate release micro swi tch 12 - T ailg ate g rip 13 - T ailg ate g rip g asket 14 - T ailg ate T o remo v e tailg ate l ock m icro switch : Re mov e l icense p l ate l ig h t str ip. Separate electrical h arn ess con[...]

  • Page 888

    T o remo v e tailg ate l ock st riker: Op en tailg ate and p ry ou t l ock striker trim f rom b ott om of t ai l g ate. Re mov e one striker moun t in g screw ( ar row s ). T h rea d in M 8 st u d to keep str ike r l ock p l ate f rom f all in g in side d oo r. Re mov e second screw an d st rike r. Re in stal l st rike r b olt s fin g er tig h t. A[...]

  • Page 889

    T o remo v e rea r wind ow l ock: Op en tailg ate. Remo v e tailg ate t rim p anel . De t ach wind ow l ock el ectrica l h arness conn ector ( A ). Re mov e l ock mou n t in g screws ( ar row s ). Sl ide l ock out f rom u n d er rear wi n d ow w ip er motor . Re in stal l l ock moun t in g b ol t s fin g er tig h t . A d j u st l ock p osi t ion b [...]

  • Page 890

    Tail gate and re ar w in d ow po siti on gap adju stm ent R ear sp oi l er / sid e p anel ( A ) 3.75 ± 1.3 mm (0.15 ± 0.05 in. ) R ear wind ow / sid e p anel ( B ) 3.5 ± 1.4 mm (0.14 ± 0.06 in. ) T ailg at e / side p anel ( C ) 3.6 mm ± 0.75 mm (0.14 ± 0.03 in. ) T ailg at e / side p anel (heig h t) fl u sh to 2 mm (0.08 in .) l owe r T ailg [...]

  • Page 891

    515-4 El ectron i c I m m ob i l i za ti on (EW S) E46 cars are eq u ip p ed with a passiv e th eft -p rev ent io n system. T h e El ectron ic I mmob il iza tion S ystem (EW S 3.3) make s it impossibl e to st art t h e en g ine u sing an y m ea n s oth er t h an t h e sp ecia l keys fu rn ish ed with t h e v ehicl e. No te: EW S i s someti mes al s[...]

  • Page 892

    ten keys. On l y an au th orize d BM W d ea l er can p rov id e re p l aceme n t keys. No te: I t i s possi ble t o da mage t he electronic ci rcui try i n t he key, ren dering i t unu sable. I n that case, a ne w key sho ul d be p urch ase d an d i ni t i al i z ed b y an au t ho ri z ed BMW de al er. Starti ng w i t h 20 00 mod el s, t he ba t te[...]

  • Page 893

    Di scon n ect electr i cal h arn ess conn ectors at l eft f oo twell t rim p an el and remov e p an el : Unp l u g conn ector at f oo twell int eri or l igh t ( A ), if eq u ip p ed . Sl ide l ock at O BD II conn ector ( B ) in d irectio n of ar row . Unp l u g conn ector at sp eake r if equ ip p ed ( C ). Re mov e EW S con trol modu l e h arn ess [...]

  • Page 894

    - Gent l y work ring an ten n a off key cyl ind er. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Cen t ra l L ock i n g an d An ti- Th eft h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 4 of 4 2/ 25/ 2009 11: 00 PM[...]

  • Page 895

    515-5 A n ti -T h e f t A l a rm (DW A ) T h e DWA an t i-th eft syst em is a d ealer inst all ed acce ssory opt ion. A l l E 46 v ehicl es are f actory p rep are d to p rov ide th e DWA f u n ct ion. This means t h at t h e v ehicl e is p rewi red and t h e G eneral M odu l e (G M V ) is p r eprog ramme d f or th e syst em. Ho w ev er, on ce th e [...]

  • Page 896

    A nt i-t heft and al ar m syst e m (DWA ) (Se dan m odel s ) DWA a la rm arm i ng/dis a rm i ng T h e DWA al arm is armed ev e ry time th e v ehicl e is l ocked f rom th e ou tsid e with th e d oo r l ock cyl in d er or FZ V key. T h e LED in t h e rear v ie w mirro r f l ash es as an ackn ow l edg men t, alon g with fl ash in g ex t eri or l ig h [...]

  • Page 897

    an activ atio n compon en t . I f aft er 3 seco n d s an y inp u t sig n al n ot in CLOSED statu s is ex cl u d ed ( th is is ackn owled g ed b y th e DWA L ED) p rev entin g f alse al arm activ ation. I f t h e DWA is arme d a second t ime wi th in 10 seco n d s, t h e t il t sensor and int erio r p rotection sen sor are a l so ex cl u d ed as al [...]

  • Page 898

    Doo r c ont a cts T h e d oor l ock Ha l l effect sensors p r ov i d e statu s of d oo r O PEN/CL OSED: Wh en th e d oo r l atch is CL O SED, cu rren t fl ow t h rou g h t h e sensor is <5 mA . Wh en th e d oo r is O PEN, cu rrent fl ow t h roug h th e sen sor is >12 mA . With t h e DWA armed, t h e GM V will activ ate t h e siren if it rece [...]

  • Page 899

    th e key, t h is switch p rov id es a g roun d sign al to t h e G M V p rev entin g t h e DWA fr om activ atin g if armed. Hoo d contact sw itch Lo cated on th e righ t side eng in e compartmen t , th e h oo d con t act switch ( ar row ) p rov ides a g roun d sign al t o t h e GM V sign ifying an op en h oo d . The p l u n g er of th is switch can [...]

  • Page 900

    Tabl e a. DWA L ED sta tus D WA status DWA LED cond i tio n A rmed wi th on e or mor e mon i t ore d i n p u t s n ot in C LOSED p osi t io n (tru n k n ot cl osed, etc.) Ra p id f l ash f or 10 seco n d s, t h en cont inu al sl ow f l ash A l arm activ ated Rapid fl ash for 5 minu t es, th en cont inu al sl ow f l ash R ear med in l ess th an 10 s[...]

  • Page 901

    and is cu rren t l y mon itoring th e v ehicl e an g l e. b . If t h e t ilt sensor d etects a ch ang e in t h e v eh i cl e ang l e when DW A is armed, th e NG sign al is switched to in f orm th e G M V to activ ate th e sire n . Wh en th e til t sen sor rece iv e s t h e ST DW A sig n al f rom t h e GM V , t h e ang l e of t h e v eh icl e is mem[...]

  • Page 902

    p artia l l y op en wind ow) an d adap ts f or th is. I f t h e echoes are con sistent l y similar, n o mov ement is d etected. I f th e echoes are alt ere d or incon sistent , t h e UI S ch an g es to a con st ant cycl e and t h e echo is compared ag ai n . I f t h e incon sisten cy is stil l p rese n t t h e UI S sen d s t h e activ ate sire n si[...]

  • Page 903

    T h e modu l e operates in p u l se mode. T h e radar u n it t ransm its a sig n al , th en p auses f or t h e refl ected sig n al s t o b e rece iv ed b y th e mod u l e. T h e d etectio n rang e o f t h e radar is adj u sted b y r apid switch in g wh en t h e system is armed. T h is al l ows t h e sensor to ad j u st its ran g e t o ei t h er t h[...]

  • Page 904

    th e alarm syst em: KL 30 (p owe r ) KL 31 (g rou n d ) ST DW A sig n al ( arm/d isa rm sig n al from G M V ) NG sig n al (activ ate sire n out p u t sign al to t h e G M V ) T h e arm/d isa rm ou t p u t sig n al from t h e GM V (STD W A ) is p rov ided to th e til t sensor, UI S sensor an d th e sire n simul tan eo u sl y. The arm/d isa rm sig n [...]

  • Page 905

    T h e EW S sig n als th e GM V t o u n l ock th e d oor s an d to d ea ct iv ate th e DWA . Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Cen t ra l L ock i n g an d An ti- Th eft h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 11 of 1 1 2/ 25/ 2009 11: 00 PM[...]

  • Page 906

    520-1 Gen era l T h is r epair g roup cov ers remo v al an d inst all at io n of t h e f ront an d rea r seats. Se at de s i gn and uphols tery T h e fron t sea t s in stal l ed in E46 cars come in eith er manu al or p owe red v ersi ons. They off er firm su p p ort and comfort. Th ei r in tern al con st ru ct i on is eng in ee red to wo rk tog eth[...]

  • Page 907

    Cush ion h eigh t He ad r estrai n ts. Se at m e m ory sys tem I n cars with seat memory, th e d riv er's fron t sea t in corporates two cont rol modu l es: O n e in t h e seat ad j u st ing swi t ch ( ar row ) and th e second u n d er th e seat cu sh io n . The t wo mod u l es p roce ss t h e f oll owi n g : Sea t ad j u stmen ts Co mf ort en[...]

  • Page 908

    of th e sea t memory system are monitored for f aul ts. A ccess t h e fau l t codes u sin g BM W scan t ool DI S or M oD iC . I n Coup e an d Co n v ertib l e model s, t h e ea sy en try f ea t u re f aci l itates acce ss t o th e rear sea t s. Wh en a fron t b ackrest is fol d ed ov er, t h e en tire sea t mov es forwa rd 90 mm (3.54 in. ) to faci[...]

  • Page 909

    P a ss e nger sea t m e m ory m odule Seats h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 4 of 5 2/ 25/ 2009 11: 03 PM[...]

  • Page 910

    Rea r seat c onf i guration Sp l it rea r f ol d ing seats are o p t io n al in th e Sedan an d stan d ard in th e Sp ort Wag on an d Coup e. They are sp l it 1/3 righ t to 2/3 l ef t with a f old in g cen ter armre st in th e l eft p ortio n . The armrest, when f ol d ed d ow n , is equ ipp ed with a storage comp artment an d cu p h old ers. Co py[...]

  • Page 911

    520-2 Fron t Sea ts Sea t remov al and in st all ation is similar for al l v ersi ons. Sea t d isasse mb l y d iffers in d etai l among t h e man y model s of seats. Sea t rep air and compon en t repl aceme n t is p ossibl e once t h e sea t h as b ee n remo v ed fr om th e v ehicl e. Front s e a t, re m ov ing and ins ta lli ng WA RN I NG! Th e fr[...]

  • Page 912

    Do n ot ex p os e p yr ote chni c co mpo nents to tem p er atu res abo ve 75 °C (167 ° F ). Pyr ote chni c co mpo nen ts c an o n l y be teste d elec t rica l ly w h en in sta ll ed, us i n g B MW se rv ice tes ter DI S, MoD i C o r equ ivalent sc an too l. Do n ot fire a pyr ot ec h n ic ga s g enera to r p rio r to di spo sa l . I t mu st be fi[...]

  • Page 913

    Re mov e p l astic cap s ov er f ront sea t moun t ing n u t s, th en remo v e moun t i n g n u t s ( arr o w s ). - Di scon n ect n eg ativ e (-) cab l e from b attery. CA UTI ON! Prio r to di sco nn ect in g the b atte ry, re ad th e batter y d isco n nectio n ca utio n s give n at the fro nt o f th is ma n u al on p ag e vii i . T il t seat b ac[...]

  • Page 914

    Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Seats h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /5... 4 of 4 2/ 25/ 2009 11: 03 PM[...]

  • Page 915

    520-3 Rea r Sea ts Rear seat c us hion a nd bac k rest , r em oving a nd ins ta lli ng (f i x ed seat ba ck m odel s) - Pu l l fron t of rea r seat cu sh io n u p to rel ea se cl ip s. Wh il e h old in g fron t of cu sh ion u p , p u l l cu sh ion forwa rd t o remo v e. Re mov e rea r seat b ackre st : Pu l l top out er corn ers of b ackrest forwa [...]

  • Page 916

    - Pu l l fron t of rea r seat cu sh io n u p and out of cl ips. Wh ile h ol d in g fron t of cu sh ion u p , p u l l cu sh ion forwa rd t o remo v e. - T il t b ackre st s forwa r d . No te: Re move rea r hea drests, i f eq u i pp ed , by pu l l i ng strai ght up . Re mov e b ackre st sid e sectio n b y p u l l in g ou t ( A ) and u p ( B ). - Work[...]

  • Page 917

    540-1 Gen era l T h is r epair g roup cov ers th e sl ide-t ilt su n roo f assembl y. Co mp on en t l ocatio n s, initializatio n , su n roo f p an el repl acem ent , an d su n roo f h eigh t adj u st ment are cov e red. Re p l ace m ent of t h e cabl e asse mb l y or frame requ ire th at t h e h eadl i n er b e remo v ed. Remo v al an d rep air of[...]

  • Page 918

    Press and h ol d su n roo f switch in " l ift" d ire ct ion. A ft er reaching en d p ositio n , kee p swi t ch p ressed for ap p rox ima tel y 20 second s l on g er. T h e su n roof motor wi l l b riefl y j erk u p wa rd s, sig n al l in g n orma l iza tion is compl ete. Char acte ris ti c curv e T h e ch ara cteristic resi stance cu rv e[...]

  • Page 919

    I n sert h ex key int o d riv e in su n roof motor, an d t u rn h ex key t o manu al l y cl ose su n roo f. No te: The he x key f or man uall y (emerg ency) cl osing the sun r oo f can be f ou nd i n t he tool ki t l oca t ed i n the trunk l i d (seda n, cou pe an d conve rti bl e) or und er t he carg o area f l oo r pan el (Spo rt W ag on ). Sunro[...]

  • Page 920

    Su n roof h as b een remov ed Wh en ev er th e top of th e cl ose d su n roof b eco m es misa l ig n ed wi t h t h e roo f of th e car, if it d oes n ot cl ose squ are l y, if th ere are wind n oise s at sp ee d , if th ere are water l eaks, or if t h e su n r oo f h as b ee n remov ed. Co rrect su n roo f alig n men t: Su n roof mu st b e fu l l y[...]

  • Page 921

    T h e su n roof p an el is retained b y t h ree T orx screw s ( arr o ws ) on ea ch sid e. T o adj u st su n roof h ei g h t : Lo osen T orx screw s u n til su n roof can j u st b e mov ed . Pu sh su n roof p an el f orwa rd . Pu sh su n roof p an el u p or d own u n t il correct h eigh t is ach iev ed . T ig h t en screws. Recheck h eigh t . Check[...]

  • Page 922

    540-2 Su n roof Com pon en ts Su n roof asse m b l y remo v al an d inst all at io n in v ol v es h eadl in er remo v al, and is n ot cov ere d in t h is man u al . A f ter su n roo f repairs b e su re to f oll ow initializatio n an d adj u st men t p roce d u res g iv en ear l ier. Sunroof a s sem bly 1 - To rx b o lt M 5 2 - Sli der 3 - Gl as s s[...]

  • Page 923

    (31 in -l b ) 16 - Eme rgency op er ati on cra nk hand l e 17 - He x b o lt wi th washer 18 - To rx b o lt M 4 Sunroof pane l, re m ov i ng and inst a ll ing T o remo v e su n roo f p an el , open su n roo f and remov e wind b l ocke r b y remo v ing T orx screw ( arr o w ) on ea ch sid e. Close su n roof an d sl ide su n roo f l in er b ack int o [...]

  • Page 924

    A d j u st su n r oo f h ei g h t an d g ap as d escribed ear l ier. Ti gh tenin g torqu e Win d b l ocker to roo f (T orx ) 1 Nm (9 in -l b ) Su n roof p an el to roo f (T orx ) 4.5 Nm (40 in -l b ) Sunroof pane l gasket, re pla c ing - R emo v e su n roof p an el as sh own abov e. Pu l l old sea l f rom p anel . Co at n ew sea l and ch ann el in [...]

  • Page 925

    rea rmost edg e with a p l astic tool. Re mov e su n r oo f m otor moun t in g screw s ( ar row s ). - I n st al l atio n is th e rev erse of remo v al. Perf orm int itia l iza tion p roce d u re as d escribed earlier. Ti gh tenin g torqu e Su n roof motor to su n roo f carrie r 2.8 Nm (25 in -l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All [...]

  • Page 926

    541-1 Gen era l T h is r epair g roup cov ers th e aut oma tic electro-hyd rau l ic conv ertibl e top . I n formatio n on th e Roll ov er Protection System is also incl u d ed h ere . No te: The con verti ble top con tr ol mod ule (CVM I I) i s l oca ted be hi nd the l ef t rea r si de tri m pan el . F or the l oca t i on of ot he r con verti bl e [...]

  • Page 927

    Con vertible ba tt ery BM W h as d esi g n ed a sp ecia l b attery t ray for t h e Conv ertib l e wh ich serv es to d ampen Co n v ertib l e b od y f l ex in g an d v ibrat io n . CA UTI ON! Th e E46 Co nver ti b le requ i res a specia l batter y w h ich is desig n ed fo r co n sta n t vibratio n . A batter y n ot desig n ed f o r thi s w il l fail[...]

  • Page 928

    T op monitoring d u ring op era tion u sin g Hall sen sors and an g l e Hall sensors Em e rge ncy opera tion - M a n u al l y u n l ock top st orage cov er: Re mov e cent er arm rest. Li f t sea t u p h ol st ery b elow ski b ag . Press b u t ton on motor asse m b l y to release motor f rom g ea r l inkag e. Use h an d crank (st ore d on asse m b l[...]

  • Page 929

    - Worki n g in t ru n k, remov e tru n k t rim l iner an d soun d p roofing . I f n ecessa ry, p artia l l y remo ve h yd rau l ic u n it t o g ai n v iew of f il l p l u g an d fl u id refere n ce mark (circle). DO NOT d etach h yd rau l ic l ines. T o ch eck: Le v el mu st b e b etwe en M AX and M IN marks. Re f erence mark is circl e in tran sl [...]

  • Page 930

    C o nver t ibl e to p fl ui d H yd rau l ic f l u id A ral V itamol Ti gh tenin g torqu es Fil l er p l u g to h yd raul ic u n it 10 + 1 Nm (89 + 9 in-l b ) H yd rau l ic u n it t o b ody 10 Nm (89 in-l b ) No te: The con verti ble t op hydra ul i c f l ui d i s sup pl i ed i n t he spa re pa r ts ki t . T o restock fl ui d, che ck w i t h an au t[...]

  • Page 931

    Con vertible T op M odule (CVM II) T h e CV M I I is inst all ed in t h e l eft rear of th e car b ehin d th e side t rim (n ex t to th e sea t ). It con tain s t h e p rocessi n g , cont roll ing an d monitoring el ectronics f or top op eratio n . T h e CV M I I commun icates wi th th e Gen era l M odu l e (GM V ) ov er th e K-b u s for op era tio[...]

  • Page 932

    Fault m e m ory s torage Co n ve rt ibl e To p M od u l e (CV M I I ) fau l t memo ry is st ore d in NV R A M . Up to 16 fau l t cod es can b e st ored in order of occurren ce. A d istin ct io n is mad e b etwee n p ermanen t and sp oradic f au l t s. I f a fau l t occurs d u rin g r ai sing or l ow eri n g th e top , all t op m ov ement wil l cea [...]

  • Page 933

    cea se ope r ati on i f the hyd rau l i c fl uid tempe rature exce ed s 95°C (20 3°F ). Ho w ever , any functi on s t ha t have be en started w i l l be co mpleted be f ore the system i s sw i t che d off. If t he t emp era ture exce eds 10 5° C (22 1°F) t he system i s i mmed i atel y sw i t che d o f f. Cl ose the top using the eme rgen cy cl[...]

  • Page 934

    Win d sh ield l ock sensor p rov id es l ow sign al when top frame is un l ocked f rom wi n d sh ield . LED in con v ertib l e top switch wi l l fl ash . T en sion p oint p ositio n sen sor p rov ides h ig h sig n al wh en t op f rame is raise d p ast t en sio n p oin t. The an g l e sen sor p rov ides a l in ea r v ol t age si g n al in p u t t o [...]

  • Page 935

    T h e conv ertib l e top st ora g e comp artment cov er l ock motor is on d riv eshaft tu n n el u n d er rear sea t . It con sists of a motor wi th Ha l l sensor, g ear asse m b l y and t wo b ow d en cab l es con n ected to cov er l ocks on two sides of cov er. The Hall sen sor d etects l ocke d /u n l ocked p ositio n of cov er. Durin g conv ert[...]

  • Page 936

    when soft top is r ai sed or remo v ed f or h ard t op inst al l ation. T h e p l astic v ari ab l e comp artment f l oo r is h in g ed at f ou r p oi n t so t h at i t can articul ate and b e rotated u p in t o top storage sp ace. A l ev er on righ t side of v aria b l e fl oo r actu ates and l ocks fl oor int o p ositio n . A d ampen in g p iston[...]

  • Page 937

    541-2 Con v erti bl e T op Com po n en ts M ec hanic a l to p com ponents T h e metal fol d in g fr ame of t h e t op is b olt ed t o th e sides of t h e car b eh ind th e d oo r p il l ars (B-p il l ars). T h e th r ee l ayer soft top con sists of: Fab ric out er l ayer M idd l e fl ee ce l iner I n n er l in er Re f er t o th e acco mp an yin g i[...]

  • Page 938

    fra me cove r 7 - Eme rgency me chani sm cove r 8 - Eme rgency op er ati on cra nk 9 - Tensio n rop e In sulatio n 10 - Tensio n b ow 11 - Ha l l sensor 12 - Gas pres surized spring 13 - M ai n p i ll ar Ha l l se n sor 14 - Consol e 15 - Wi nd shi eld latch (l eft side) Hydrauli c s y s te m re pai rs CA UTI ON! Wh en w or kin g on h ydrau li c sy[...]

  • Page 939

    On ce h ydra u l i c li n es h av e been di sc o n n ect ed fro m hydra ulic co mpo nents, to p mu st n o t b e mo ve d. F l u id wi ll leak fro m se p ar ate d co upli ng. A v o i d scr atc h i ng hydrau li c p i sto n ro ds. Even p aint mist and w eldi n g spo ts ar e h arm ful. Wh en w or kin g aro und hydrau li c cy l i nd er s, co ver w i th a[...]

  • Page 940

    cy l in d er s: Op era t e on t op frame l in kage t o rai se and l owe r b ow Lo cated on two sides of ten sion b ow , at sid es of rea r wi n d ow A n g l e Ha l l sensor on l eft t ension b ow l inkag e d etects b ow p osi t ion Hydrau l ic l in es f or righ t ten sion b ow cyl ind er rout ed u n d er t op f abr i c alon g ten sion b ow 2 - M ai[...]

  • Page 941

    3 - To p storage compar tment cove r h ydra ul i c cy l in d er s: Op en and cl ose storage compartmen t cov er Lo cated in t ru n k Le f t cyl ind er equ ip p ed with Ha l l sensor t o d etect fu l l y open ed p osi t ion of cov e r 4 - Sol enoi d valve bl ock on left side of to p fra me: Solen oi d V 1 cont rols op era tion of mai n p il l ar h y[...]

  • Page 942

    I n l eft side of tr u n k b ehin d t rim M ou n ted on ru b b er b u sh in g s and cov ered b y soun d insu l atio n Unit consists of: Hydrau l ic motor an d p u mp , Storage cov er solenoid v alv e, Drai n solen oid v alv e, Hydrau l ic f l u id rese rv oi r, Hydrau l ic fl u id t emperatu re sensor Op era t es at p ressur es of u p t o 20 0 b ar[...]

  • Page 943

    Tab le a. De fin iti o n o f h ydra ul i c sy stem term s Term A cti on Notes Hydrau l ic syst em at zero p ressure T u rn ign ition t o 0 p ositio n . Wait 15 seco n d s. Hydrau l ic syst em h as n o or v ery l ow p ressure. Unt ensioned state M ech anica l (eme r g ency) actu atio n O p en or cl ose top b y h an d . See Emerg ency op era tion Clo[...]

  • Page 944

    O p era ti on Pr o ce d ures l id. Fol l ow d irectio n s in Hyd raul ic fl u id l ev el , ch ecki n g or fil l in g , earlier in t h is g rou p . Fl u id top p in g u p or d rainin g Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Con v er t ib l e Top h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai[...]

  • Page 945

    [...]

  • Page 946

    forwa rd so t h at roll b ar can b e p u sh ed d ow n and l ocked in t o th e solen oids. WA RN I NG! Ensu re that are a abo ve and adj ac ent to ro l l o ver b ar s re main s cle ar and u n obstr uc ted at all ti mes . CA UTI ON! I t is not pos sib l e to clos e co nver tib le top w i th ro l lov er bars exte n ded. I f a h ar dtop i s mo u n ted,[...]

  • Page 947

    600-1 Gen era l A b rie f d escript io n of t h e p rincip al p arts of th e elect rica l syst em is p resented h ere . A l so cov ered h ere are basic electrical system t rou b l eshooting tip s. See also 121 Battery, A l t ernat or, Starter . Ele c trica l test equipm ent M any el ectrica l t ests d escri b ed in t h is manu al cal l f or mea su [...]

  • Page 948

    A u t omo t iv e d igital m u l t imete r F l u ke 87 LED t ester wi t h th in sp ad e p rob es Baum 1115 (Source: Bau m To ols Unl imited) Scan tools BM W D I S/M oDi C A ft ermarke t scan tool Baum CS20 00 (Source: Baum T oo l s Unl imited) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Elec trica l Sy stem - Gen er al h t[...]

  • Page 949

    600-2 E46 El ectri ca l Sys tem E46 cars are el ectrica l l y compl ex . M an y v ehicl e systems an d su b systems are int erco n n ected or in teg rated. I n add ition, t h e req u ireme n t s of second g eneratio n O n -Board Di agn ostics ( OBD I I) are su ch t h at th ere are now many more circuits an d wi r es in th e v ehicl e th an ev er b [...]

  • Page 950

    Tabl e a. E46 bu sse s Bus Circ ui ts cove red Co d ed an ti-th eft (EWS I II ) and an t i-th eft (DWA ) Re m ote ent ry (FZ V ) Park d istan ce cont rol (PDC ) M -b u s Hea t ing and air cond itionin g (I HKA ) compon ent s CA N -b u s En g ine man agement system (DM E) T ran smissio n con trol (A GS) A n t ilock b r ake s (A BS) T raction con tro[...]

  • Page 951

    Voltage a nd polari ty T h e v ehicl e el ectrica l system is a 12- v olt d irect cu rren t (DC) n egativ e-grou n d system. A v ol tag e reg u l ator cont rol s system v olt age at app rox i mately 12- v ol ts. A l l circu its are g roun d ed b y d irect or ind ire ct con n ection t o th e n egativ e (-) terminal of t h e b att ery. A n u mb er of[...]

  • Page 952

    mai n f u se b ox ( ar row ) abov e t h e g l ov e compartmen t . Fu ses are col or coded t o ind ica t e cu rren t capacities. T h e relays an d cont rol mod u l es are moun t ed in v ario u s p l ace s th roug h out th e v ehicl e. See 610 El ectrical Co mp onen t Loca t ions . Central B od y El e ctronics (Z KE V) E46 v eh icles are equ ip p ed [...]

  • Page 953

    Ot h er f u n ct io n s are n ot d irectl y cont roll ed b y t h e GM V b u t int erco n n ected : Ra in sen sor (A IC ). See 611 Wip ers and W ash ers . Su n roof op era tion ( SHD ). See 540 Su n r oo f . Sea t m emo r y (SM ) an d electrical operatio n . See 52 0 Seats . Ou tsid e rea r-v ie w m irro r con t rol an d h eating . See 51 0 Ex t eri[...]

  • Page 954

    a fau l t cod e (DT C) will b e set. Re sett in g an d resyn ch ronizing of cod es and d ata req u ires th e u se of BM W scan tools DI S or M oD iC . Car M e m ory /Key M e m ory A n u mb er of featu res and f u n ctions can b e cu st omi zed to t h e d riv er(s) p reference. T h e iden tity of t h e v ehicl e u ser is p rov ided b y a sig n al f [...]

  • Page 955

    K-b u s Do or j amb sensors T r u n k l id l ock cyl ind er micro switch I n t eri or t ru n k l id r elease p u sh -b u tt on microswi t ch Ce n t ral l ocki n g b u t ton En g in e h ood l atch micro sw itch T r u n k key p osi tion switch I n t eri or l igh t switch I n t ernal motion sensor T il t sensor Dri ve r' s d oo r l ock sensors No[...]

  • Page 956

    A n ai rbag unit hou ses an ex p l o si ve p o w erfu l char ge . Mak ing repairs wi th ou t the pro p er kno w l edg e and spec ial tes t equ i p me n t ma y ca u se se ri o us pers onal inj u ry. See 721 A irbag Sys tem (SRS) . Th e i g n i tion sys tem of the car o p era tes at lethal vo l tag es. Peo p le wi th pace ma ker s or w ea k hear t s [...]

  • Page 957

    the fro n t of th is ma n ua l o n pag e viii . Co n nect and di sc onnec t i g n iti on sy stem wires , mu lt ip le co nn ecto rs and igniti o n tes t equ i p me n t l ea d s only wh i le t he igniti o n i s o ff. Do n ot di sc o n n ec t th e b atte ry wi th th e engine ru n ni n g . Do n ot quick -charg e the batter y (fo r boo st sta rtin g) fo[...]

  • Page 958

    Do n ot try to sta rt th e engine o f a ca r w h ich has been h eate d ab o ve 17 6F/ 80C , (fo r exa mple, in a pain t drying boo th) . A ll o w it to co o l to nor mal t em p era tur e. Disc onn ec t the batter y b efo re doing any elec tric w eld in g on t he ca r. Do n ot wash th e eng in e wh i le i t is ru nn i n g , or a nyti me the igniti o[...]

  • Page 959

    600-3 W i ri n g Di a gra m s T h e wi r ing d iagrams sh own in El ectrica l W iring Dia g rams h av e b een sp eci al l y d esign ed to en ab l e q u ick an d efficie n t d iagn osis and t roub l eshooting of elect rica l m alf u n ct io n s. Wi ring c odes and abbre v i ations A l ot of in formatio n is in cl u d ed in each wi rin g d iagram if [...]

  • Page 960

    Tabl e b. W ire colo r codes Germ an code Eng l ish code Colo r GR GRY Grey ORG Oran g e RT RED Re d V I V I O V io l et WS W HT Wh ite GE YEL Yell ow M ost t ermi n al s are iden t i f ie d b y n u mb ers on comp on ent s and h arn ess conn ectors. T ermi n al n u mb ers f or major el ectrica l con n ections are sh ow n in th e d ia g rams. T h ou[...]

  • Page 961

    Tabl e c. T erm i n al and circ u it nu mbers Number Circ u it desc rip ti o n 30 Battery p ositiv e (+) v olt ag e. Su p p l ies p ow er when ev er b attery is con n ected . (No t d epen d en t on ign ition switch p osi t ion, u n f u sed ) 31 Grou n d , b att ery n egativ e (-) t erminal 50 Su p p l ie s p owe r f rom b attery t o st arter solen [...]

  • Page 962

    Abbrev iatio n Compon ent o r sys tem Abb re viation Compo n ent o r sy stem A DB, A DB-X a u toma t ic d ifferent ia l l ock LEV l ow emi ssion v eh icl e A G S ad apt iv e transm issi on cont rol LSZ l igh t swi tch mod u l e A I C rai n sen sor M A F ma ss air fl ow sensor A SC tractio n con trol M BC max imum b r aki n g con trol A UC au tomati[...]

  • Page 963

    Abbrev iatio n Compon ent o r sys tem Abb re viation Compo n ent o r sy stem GM g eneral mod u l e (see ZKE) SRS su p p l ement al restraint system-ai rb ag HPS h ead p rote ct io n syst em TC M tra n smissio n con trol modu l e I HKA au toma t ic h ea t in g and air cond itionin g system T DC t op d ead cent er I HKR man u al h ea t in g and air c[...]

  • Page 964

    600-4 El ectri ca l T rou bl es h oot i n g Fou r t h in g s are req u ired f or cu rren t t o fl ow in an y el ectrica l circu it: a v olt age source, wi res or conn ections to tran sp ort th e vo l t age, a l oad or d ev ice th at u ses t h e elect rici ty, an d a conn ection t o g roun d . M ost p robl ems ca n b e f oun d u sin g a d igital mu [...]

  • Page 965

    compon ent s or conn ections in t h e wi rin g h arn ess. W h en con n ectin g j u mp er wire s, u se b l ad e conn ectors at th e wire end s th at match th e size of t h e terminal b ei n g t ested. The small int ernal con t acts are ea sily sp read apart, an d th is can cause in t ermi t t ent or fau l ty con n ections th at can l ea d t o more p[...]

  • Page 966

    resist an ce as small as 0.02 ohms w ould result s i n a 3 volt dro p i n a typi cal 150 amp st arter ci rcui t. (15 0 amps x 0.02 oh ms =3 volt s). Kee p i n m i nd t ha t volt age w i th t he key on an d volt ag e w i th t he eng i ne run ni ng are no t the same . W i t h t he i gn i ti on on a nd the eng i ne off (ba t t ery volt ag e), vol tage[...]

  • Page 967

    Voltage drop, test i ng V olt age d rop can on l y b e ch ecke d when t h ere is a l oa d on th e circuit, su ch as when op erating th e starter motor or tu rn ing on t h e h eadl ig h ts. A d igital mu l t ime ter sh ou l d b e u sed t o ensu re accu rate rea d in g s. Co n n ect d ig ital mu l t ime ter p ositiv e l ea d to p ositiv e (+) b att e[...]

  • Page 968

    for f aul t s u sin g an ohmmeter. A n op en circuit or a circuit with h igh resista n ce wi l l n ot al l ow cu rrent to f l ow. A circu it wi t h l itt l e or n o resistance all ow s cu rrent to f l ow ea sil y. Wh en ch ecki n g cont in u ity, t h e ign ition sh oul d b e off. On circu its t h at are p ow ered at all t imes, th e b att ery sh ou[...]

  • Page 969

    b attery v ol t age), a fu se will b l ow and th e circu it m ay p ossi b l y b e d amaged . Sh orts t o g rou n d can b e l ocated with a d igital mu l t ime ter. Sh ort circuits are often d iff icu l t t o l ocate a n d may v ary in n atu re. Sh ort circu its can b e f oun d u sing a l og ical app roa ch b ased on cu rrent p ath . CA UTI ON! On c[...]

  • Page 970

    p anel and mov e or wi g g l e wire s whil e observ ing mete r. Cont inu e t o mov e d ow n h arness u n t il mete r d ispl ays a rea d ing . T h is is t h e l oca t ion of sh ort t o g rou n d . - V isual l y insp ect wire h arn ess at th is p oi n t for an y fau l t s. If n o fau l t s are v isibl e, carefu l l y sl ice open h arness cov er or wi[...]

  • Page 971

    th is p oi n t for an y fau l t s. If n o fau l t s are v isibl e, carefu l l y sl ice open h arness cov er or wi re insu l atio n for f u rt h er in sp ectio n . Repai r an y faul t s f oun d . Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Elec trica l Sy stem - Gen er al h tt p: // e bah n .ben t l e y pu bli s h e rs .co[...]

  • Page 972

    610-1 Gen era l T h is r epair g roup cov ers fu se, rel ay and cont rol mod u l e l oca tion inf orma t ion. G rou n d p oint s an d oth er compon ent l oca t ions are a l so cov ered, p rima rily v ia ph otos or ill u str atio n s. For add itional E46 electrical system inf orma t ion, see: 60 0 El ectrical System– General . El ectrica l W iring[...]

  • Page 973

    caution s b ef ore d oing an y work on your electrical system. WA RN I NG! Th e b att er y sa fety term i nal, pyro tec hn ic sea t b elt tensio n ers , and airbag s u t il ize explos ive dev i ce s and mu st be h and led wi th extr eme car e. Re fer to th e warnin gs and cau tions in 121 B atte ry , A l terna to r, Starte r ; 72 0 Seat B elts ; an[...]

  • Page 974

    On l y u se a di g ital mu l ti me ter fo r elec trical tests . Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Elec trica l Com pon e n t L oca tion s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /6... 3 of 3 2/ 25/ 2009 11: 08 PM[...]

  • Page 975

    610-2 Fu s e Pos i ti on s T h ere are th ree locations f or f u ses in E46 cars: M ai n h arness f u se in t ru n k Fu se pan el ab ov e g l ov e compartmen t E-b ox in eng in e comp artment l eft side No te: I n BMW repa i r i nforma t i on, f use s are num be red F 1 throu gh F108 . There are tw o fuses w i th t he same de si gnati on : F 5 i n [...]

  • Page 976

    Pee l b ack l iner t o acce ss F 10 8 (20 0 amp ) f u se ( a rr o w ) in mai n p ow er d istrib u tion circuit. Ele c tronics box (E-b ox) fus e ca rri er Fig . 2 En g in e el ectronics f u se p ack in E-b ox : Working in l eft rea r of eng in e compartmen t, remo v e E-b ox p l astic cov er. Pu sh on h old -d own l ock cl ip ( A ) to release fu se[...]

  • Page 977

    Tabl e a. E-b o x fu se p ac k Fu se R ating Protecte d circ u it s (20 01 model s) 2 3 0A D M E con tr ol modu l e (ECM ) Ev aporativ e emi ssion s v al v e Fu el inj ect ors I d l e sp eed cont rol v alv e Re son an ce v alv e, int ake ma n ifol d Seco n d ary ai r inj ection p u mp Su ction j et p u mp v alv e, LDP system V anos sol en oi d s 3 [...]

  • Page 978

    M ain fus e pane l Fig . 3 F u se p an el abov e g l ov e compartmen t: Op en g l ov e compartmen t d oor. Working in side comp artment , t wi st ea ch p l astic l ock t ab ( ar row s ) at top of comp artment 90°. Pu l l d own on f u se p an el t o swi n g it d own. No te: W hen t he fuse bo x i s up i n l ocked po si ti on, t he plasti c tabs sho[...]

  • Page 979

    foun d on t op of t h e g l ov e compartmen t fu se p anel b eneath an access p an el. Lo wer g l ov e compartmen t f u se p an el fu l l y. Sl ide h arn ess con n ector b l ock off top of p an el ( curve d ar row ). De t ach access pan el b y sq u eezi n g retainin g cl ips ( ar row s ). Fig . 4 High amperage f u ses ab ov e mai n f u se p an el: [...]

  • Page 980

    Tabl e b. High ampe rage fu se po siti on s Fu se R ating Protec ted circuits 10 6 50A Ligh t switchin g cent er cont rol modu l e 10 7 50A Ligh t switchin g cent er cont rol modu l e T r ai l er modu l e 10 8 20 0A M ai n h arness f u se (in t run k, see F ig . 1 ) E46 main fuse pan el Tab le c. 19 99 fuse po siti on s Fu se R ating Protec ted cir[...]

  • Page 981

    Fu se Rating Protect ed ci rc u i t 7 5A Nav igatio n (see al so fu se 41 ) On - b oa r d m onitor (see also fu se 41 ) Ra d io (see al so f u se 41 ) T el ep h on e (see also f u se 39) 8 n ot u sed 9 5A B rake l ig h t Li g h t mod u l e (see also f u se 32) On - b oa r d comp u t er Sp ee d contr ol 10 5A Inst ru men t cl u ster (see also f u se[...]

  • Page 982

    Fu se Rating Protect ed ci rc u i t 28 5A Hea ter-A / C (see al so fu ses 62 , 63 ) He ater-A / C b l owe r (see also fu se 37 ) 29 5A E n g ine cont rol (see also f u se 30) 30 7.5A En g in e con tr ol (see al so fu se 29 ) OBD II syst em 31 5A O u t sid e mirro r T ire p ressu re cont rol (see also fu se 69 ) 32 5A Ligh t mod u l e (see a l so f [...]

  • Page 983

    Fu se Rating Protect ed ci rc u i t Pow er wind ow, fron t (see a l so f u se 48) Win d sh ield washer syst em (see al so fu ses 52 , 59 ) 50 25 A Se at h eating 51 30 A H eadl ig h t cl eaning syst em 52 30 A C en tr al l ocking system, t ru n k Gl ov e b ox l igh t I n terio r l ig h t ( see also fu se 49) Passe n g er compartmen t /t ru n k l ig[...]

  • Page 984

    Fu se Rating Protect ed ci rc u i t 70 30 A Pa ssen g er seat adj u st ment 71 30 A (10 A C oup e) Hi n g ed wind ow (Co u p e) Win d ow, rea r Tab le d . 20 00 -20 01 fuse po siti on s Fu se R ating Protec ted circuit 1 n ot u sed 2 3 4 5 5A Horn (see also f u se 55 ) 6 5A M ake - u p mirro r l ig h t Pow er top (Conv ertibl e, see al so fu ses 12[...]

  • Page 985

    Fu se Rating Protect ed ci rc u i t 46 ) Sea t h ea tin g (see al so fu se 42 ) Ro l l er su n b l ind (see a l so f u se 42) T ire p ressu re cont rol (see also f u ses 31 , 42, 69) 13 7.5A Roll -ov er p rotection system (Co n v ertibl e) 14 5A E l ectronic immobil izer (EWS) (see al so fu se 6 7) Starter in terl ock 15 5A Rain sen sor Re ar w ip [...]

  • Page 986

    Fu se Rating Protect ed ci rc u i t 31 5A O u t sid e mirro r (see also f u se 57 ) T ire p ressu re cont rol (see also fu ses 12 , 42 , 69) 32 5A Ligh t mod u l e (see a l so f u se 9) 33 5A A B S/A SC (see also f u ses 12, 42, 53, 56) A BS/DSC (see al so fu ses 12 , 40 , 42 , 53 , 56, 61 ) A BS/DSC al l -wheel d riv e (see al so fu ses 12 , 35 , [...]

  • Page 987

    Fu se Rating Protect ed ci rc u i t 46 30 A (20 A conv ertib l e) Pow er top (Conv ertibl e, see al so fu ses 6, 12, 35, 42 ) M an u al top (Co n v ertibl e, see al so fu ses 12, 42) Su n roof 47 15 A (20 A ) Ci g are tt e l igh ter / p ow er out l et (A u st ral ia , see also f u se 26) 48 30 A Po wer wi n d ow, fron t ( see also fu se 49) 49 5A A[...]

  • Page 988

    Fu se Rating Protect ed ci rc u i t 60 25 A C en tr al l ocking (see a l so fu ses 49 , 52 , Sp ort Wag on, see f u se 58) 61 30 A A BS/ DSC (see also f u ses 12, 33, 40 , 42, 53, 56 , 61 ) 62 7.5A Hea t er-A /C (see also f u ses 28 , 63) He ater (see also f u ses 23 , 28) 63 7.5A Hea t er-A /C (see also f u ses 28 , 62) 64 n ot u sed 65 30 A Dri v[...]

  • Page 989

    610-3 Grou n d Loca ti on s Grou n d s are widel y d istrib u ted th r oug h out t h e v eh icl e b ody. Sev e ral are f oun d u n d er t h e in terio r carp ets. Lug s and con n ectors att ach ed t o g roun d are su scept i b l e t o d amage an d corro sion. Cl ean or renew th em as n ece ssary. Fig . 5 Le f t fron t en g ine compartmen t, b ehin [...]

  • Page 990

    Fig . 8 Und er l eft f ron t carpet on d oo r sill 1 - Grou n d conn ect or X 17 3 Fig . 9 On d oo r sil l , u n d er d riv er sea t carpet 1 - Grou n d conn ect or X 11 08 2 - Side impact airbag cr ash sensor Fig . 10 Und er rig h t f ron t carpet on d oor sill 1 - Grou n d conn ect or X 49 0 Fig . 11 Be h in d rig h t r ea r seat b ackrest 1 - Gr[...]

  • Page 991

    Fig . 12 Ri g h t side t ru n k, b eh ind t rim 1 - Grou n d X 49 8 Fig . 13 L eft side tru n k, b eh ind t rim 1 - Grou n d X 13 01 6 Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Elec trica l Com pon e n t L oca tion s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /6... 3 of 3 2[...]

  • Page 992

    610-4 Com po n en t Loca ti on s On t h e fol l ow in g p ages are p h otos an d ill u strations sh owi n g t h e l ocation of major el ectrica l comp onen t s in E 46 v ehicl es. No te: Every comp one nt i s no t i nstal l ed i n eve ry car. Du e t o cha ng es i n pro du ct i on, comp one nt l ocati on s may vary from w ha t i s i l l ust rated . [...]

  • Page 993

    1 - A /C rel ay 2 - Seco n d ary ai r p u mp relay 3 - Fu el p u mp rel ay 4 - A /C rel ay 5 - Fog l ig h t rel ay 6 - Ho rn rel ay 7 - General mod u l e (G M V ) Fig . 15 Be h in d g l ov e compartmen t (wi t h h eadl ig h t cl ea n ing syst em) 1 - He ad l ig h t cl ean ing rel ay 2 - Seco n d ary ai r p u mp relay 3 - A /C rel ay 4 - Fu el p u m[...]

  • Page 994

    Fig . 16 E-b ox 1 - En g ine cont rol mod u l e (ECM ) 2 - A u t oma t ic t ransmissio n con t rol modu l e (T CM ) 3 - DM E main r elay 4 - Win d sh ield washer d ou b l e rel ay 5 - E-b ox t emperatu re sen sor 6 - B+ conn ector 7 - En g ine electron ics fu se p ack 8 - 19 99 - 200 0 mo d el s: Unl oa d er relay 200 1 mod els: fu el inj ector rel[...]

  • Page 995

    Tab le e. E46 compo nent l ocation s Compon ent Ye ar, mod el Lo ca tio n Re f er to 12 v ol t au x il ia ry p ow er socke t see Powe r socket, 12-v ol t 3/2-w ay v alv e 1999 - 200 0 U n d er car ahead of f u el f il ter, u n d er p rotectiv e co v er A / C b l owe r f inal stag e (resisto r p ack) 19 99 - 20 01 Ri g h t sid e of I HKA h ou sing b[...]

  • Page 996

    Compon ent Y ea r, mod el Lo ca tio n Re fer to A BS/A S C/DSC wa rn ing l ig h t s 19 99 - 20 01 In inst ru men t cl u ster A BS/DSC ch arg e p ressure sen sor 19 99 - 20 0 rea r wh ee l d riv e wi th DSC Ba se of m aster cyl ind er, l eft side F ig. 18 A BS/DSC ch arg e p ressure sen sor 20 01 rea r wh ee l d riv e I n A BS/DSC h yd raul ic u n i[...]

  • Page 997

    Compon ent Y ea r, mod el Lo ca tio n Re fer to reci r cu l atio n system) A irbag conn ect or, p asseng er side 19 99 - 20 01 Ri g h t sid e d ash b oard su p p ort F ig. 41 A irbag conn ect or, steeri n g wh eel 19 99 - 20 01 Un d er steeri n g wheel air b ag F ig . 34 A irbag cont rol modu l e (M RS modu l e) 19 99 - 20 01 Un d er p arki n g b r[...]

  • Page 998

    Compon ent Y ea r, mod el Lo ca tio n Re fer to A n t enn a ampl ifier, d iv er sity Co n v ertibl e O n con v ertib l e t op st ora g e cov er A n t enn a ampl ifier, d iv er sity Sp ort W ag on Be h in d l eft sid e cargo area st ora g e cov er F ig. 57 A n t enn a ampl ifier, mai n Co n v ertibl e Below mast an t en n a in t run k A n t enn a am[...]

  • Page 999

    Compon ent Y ea r, mod el Lo ca tio n Re fer to A SC/DSC switch 1999 - 20 01 Bottom of cent er con sole, l eft of sh ifter A ST see A BS/ A SC en tries A u t oma tic cl imate cont rol (IH KA ) see A / C ent ries A u t oma tic tran smissi on cont rol modu l e (T CM ) 19 99 - 20 01 Left r ea r en g in e com p artmen t in E-b ox F ig. 16 A u t oma tic[...]

  • Page 1000

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Bl owe r see A / C b l owe r Body electron ics cont rol mod u l e see Gen era l modu l e (G M V ) Brake f l u id l ev el sensor 19 99 - 20 01 To p of b rake f l u id rese rv oi r, l eft r ea r eng in e compartmen t F ig. 17 , Fig . 18 Brake f l u id p ressure sensor see A BS/ DSC ch arg e p ressu re s[...]

  • Page 1001

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Charg e p ressur e sensor see A BS/ DSC ch arg e p ressu re sensor Chil d p rotection wi n d ow con trol see W ind ow l ock-o u t switch , rear Chime modu l e, p ark d istance con t rol (PDC ) 19 99 - 20 01 In l eft f oo t well t op t rim Clock 19 99 - 20 01 In on-b oard compu t er d ispl ay of i n st[...]

  • Page 1002

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Co n ve rt ibl e top swi tch Co n v ertibl e Bott om of cen t er co n sol e, ah ea d of sh ifter F ig. 66 Co n ve rt ibl e top ten sion b ow Hall sensor Co n v ertibl e To p rear of con v ertibl e top F ig. 66 Co n ve rt ibl e top vi sor l atch Ha l l sensor Co n v ertibl e To p of wi n d sh ield Fig [...]

  • Page 1003

    Compon ent Y ea r, mod el Lo ca tio n Re fer to DM TL 200 1 see Fu el t an k l ea kag e d iagn osis p u mp (LD P or DM T L) Do or l ock 19 99 - 20 01 In d oor Do or l ock Ha l l sensor 199 9 - 200 1 I n d oor l ock mechan ism Do or l ock micro sw itch 19 99 - 20 01 In d oor l ock mechan ism Dri ve -aw ay p rotectio n see EW S DSC see A BS/ DSC en t[...]

  • Page 1004

    Compon ent Y ea r, mod el Lo ca tio n Re fer to M od els wi th st and ard t ransmissio n : I n b ack of rad iato r En g ine coo l ing f an fin al st age (resistor) 19 99 - 20 01 In eng in e coolin g f an h ousin g En g ine electron ics fu se p ack see F u ses, en g in e electron ics En g ine h oo d cont act swi tch 19 99 - 20 01 Ri g h t r ea r en [...]

  • Page 1005

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Fu el l ev el sensor, l eft 19 99 - 20 01 To p of fu el tan k, u n d er l eft r ea r seat cu sh io n F ig. 52 Fu el l ev el sensor, righ t 19 99 - 20 01 To p of fu el tan k, u n d er rig h t rear sea t cu sh ion, comb in ed with f u el p u mp F ig. 52 Fu el p u mp 199 9 - 200 1 T op of f u el t an k, [...]

  • Page 1006

    Compon ent Y ea r, mod el Lo ca tio n Re fer to GPS rece iv er mod u l e 19 99 - 20 01 In tru n k, moun ted b ehin d l eft rea r w el l Grou n d j u mp er conn ection 19 99 - 20 01 Ri g h t r ea r en g ine compartmen t F ig. 19 Grou n d s: X 11 08 19 99 - 20 01 Un d er d riv er sea t carpet on d oo r sill F ig . 9 X 13 01 6 19 99 - 200 1 Le f t sid[...]

  • Page 1007

    Compon ent Y ea r, mod el Lo ca tio n Re fer to He ad l ig h t v ertica l ai m l oad sen sor, fron t 19 99 - 20 01 F ront su b f rame , righ t sid e F ig. 59 He ad l ig h t v ertica l ai m l oad sen sor, rear 19 99 - 20 01 Rea r su b f rame , rig h t sid e He ad l ig h t washer p u mp 19 99 - 20 01 F ront of washer t ank, righ t fron t eng in e com[...]

  • Page 1008

    Compon ent Y ea r, mod el Lo ca tio n Re fer to I n d iv idu al cont rol int ake system v al v e see Re sonan ce v alv e, int ake manifol d I n fl at or asse mb l y, ai rb ag see A irb ag ent ries I n stru men t cl u st er cont rol u n it 19 99 - 20 01 In inst ru men t cl u ster I n take ai r temp erature (IA T ) sensor 19 99 - 20 01 Cent er top of[...]

  • Page 1009

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Lumb ar su p p ort ai r compressor 19 99 - 20 01 Un d er ea ch sea t eq u ip p ed with su p p ort syst em Lumb ar su p p ort cont rol switch 19 99 - 20 01 Below seat b ase trim Lumb ar su p p ort swi tch 19 99 - 20 01 F our-way tog g l e switch at b ase of sea t , n ear sea t cont rol switch es M ai n[...]

  • Page 1010

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Ox yg en sensor conn ector, p ost-catalyst 19 99 - 20 01 To p of eng ine, b etwe en in take manifol d an d cyl in d er h ead cov er F ig. 25 Ox yg en sensor conn ector, p reca tal yst 19 99 - 20 01 To p of eng ine, b etwe en ex h aust manifol d an d cyl in d er h ead cov er F ig. 25 Ox yg en sensor, p[...]

  • Page 1011

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Ra d io sp eake r : fron t twee t er (l eft /rig h t ) 19 99 - 20 01 F ront d oo r wind ow frame (l eft /rig h t ) F ig. 33 Ra d io/cassette/CD p l ayer 19 99 - 20 01 Cent er of d ashb oard Ra in sen sor 1 99 9 - 20 01 To p cen ter of in terio r wind sh ield su rface, d irectl y ahead of rear v iew mi[...]

  • Page 1012

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Sea t cu sh ion t il t motor 19 99 - 20 01 Bott om of seat cu sh ion F ig. 50 Sea t f orwa rd -b ack motor 19 99 -200 1 Bo t tom of sea t cu sh ion F ig . 50 Sea t h ea d rest mot or 199 9 - 200 1 T op of f ront seat b ackre st F ig. 51 Sea t h ea ter 199 9 - 20 01 In fr ont seat cu sh io n an d b ack[...]

  • Page 1013

    Compon ent Y ea r, mod el Lo ca tio n Re fer to Sp ee d sensor see A BS wheel sp eed sensor en t rie s Sp ira l sp ring see V ol u te sp ring Starter 199 9 - 200 1 Le f t rear of en g ine, u n d er int ake manifol d Starter immo b ilizatio n switch (manu al tran smissi on) On cl u tch p ed al Starter t ermi n als 30, 50 19 99 - 20 01 Left r ea r of[...]

  • Page 1014

    Compon ent Y ea r, mod el Lo ca tio n Re fer to T el ep h on e tran scei v er Sedan , Coup e I n t ru n k b el ow p arcel sh el f T h ermo stat, ch ara cteristic map coo l in g see Co olan t t h ermostat T h rottl e h ou si n g (M DK/EDK) 19 99 - 20 01 Un d er int ake manifol d Fig . 23 T h rottl e p osi tion sensor see A ccel era t or p edal sen s[...]

  • Page 1015

    Compon ent Y ea r, mod el Lo ca tio n Re fer to V al et p ositio n switch 199 9 - 200 1 On tr u n k l ock cyl in d er V A NOS solen oi d , ex h au st sid e 19 99 - 20 01 Ri g h t f ron t of cyl ind er h ead F ig. 29 V A NOS solen oi d , int ake side 19 99 - 20 01 Left f ron t of cyl ind er h ead F ig. 17 V ari abl e camshaft cont rol see V A NOS V [...]

  • Page 1016

    Engine c om par tm e nt ele c trica l com ponents Fig . 17 En g ine comp artmen t (199 9 323 i) 1 - Data l in k con n ector (DLC ) (19 99 - mid-200 0 mod el s) 2 - Hoo d contact switch 3 - B+ j u mp er conn ector 4 - DSC cont rol mod u l e/h yd raul ic u n it 5 - Second ary ai r p u mp 6 - Int erio r micro fil ter h ousin g 7 - Reso n ance v al v e[...]

  • Page 1017

    Fig . 19 Ri g h t rear corner of en g in e compartmen t (Te v es DSC M K 20/6 0) 1 - DSC h yd rau l ic u n it 2 - G rou n d j u mp er conn ection 3 - Hoo d contact switch 4 - B+ j u mp er conn ectio n 5 - DSC cont rol mod u l e Fig . 20 Re ar of eng ine comp artment , b ehin d b u l kh ead 1 - W ip er asse mb l y electrical h arn ess conn ector Fig[...]

  • Page 1018

    4 - Bore h ole f or cran ksh aft l ocking t oo l Fig . 23 Und er in take manifol d 1 - Idl e sp ee d cont rol v al v e 2 - Thrott l e h ou sin g ( M DK/EDK) Fig . 24 Und er in take manifol d , at cyl ind er h ead 1 - Kn ock sensor cyl i n d er 1 - 3 2 - Kn ock sensor h arn ess con n ector 3 - Kn ock sensor cyl i n d er 4 - 6 Fig . 25 Ce n ter t op [...]

  • Page 1019

    Fig . 27 Le f t sid e of en g in e comp artment 1 - Hea t er con trol va l v e Fig . 28 Cylin d er h ead, l eft f ront 1 - Int ake ca msh aft p osi t ion sensor Fig . 29 Ri g h t fr ont of en g in e, t op 1 - Exhaust camshaft p osi tion sensor 2 - Exhaust camshaft V A NOS sol en oi d 3 - Ai r q u al ity sen sor (A UC) (for aut oma t ic recircul ati[...]

  • Page 1020

    Fig . 30 Ri g h t fr ont of en g in e 1 - Second ary ai r in j ectio n p u mp 2 - Second ary ai r in j ectio n p u mp v al v e Fig . 31 Ri g h t fr ont of en g in e, l ow 1 - Exhaust camshaft p osi tion sensor 2 - Coo l an t out l et temp eratur e sensor Fig . 32 T op of A /C rece iv e r/ d rie r , rig h t fron t en g ine compartmen t 1 - A/C press[...]

  • Page 1021

    Fig . 34 Und ern ea th h orn p ad at steeri n g wheel 1 - Ai rb ag conn ector Fig . 35 Le f t sid e of st eer ing col u mn , b el ow d ash b oa rd 1 - St ee rin g an g l e sen sor Fig . 36 A t ig n itio n switch 1 - EW S ( electron ic immobilizer) ring ant enn a Elec trica l Com pon e n t L oca tion s h tt p: // e bah n .ben t l e y pu bli s h e rs[...]

  • Page 1022

    Fig . 37 A t p ed al cl u ster 1 - Cru ise contr ol cu t -off swi tch (if equ ip p ed ) 2 - Brake l ig h t switch Fig . 38 A b ov e p edal cl u ster 1 - EW S con t rol mod u l e Fig . 39 Le f t sid e I HKA h ou sing , b el ow inst ru men t cl u ster 1 - A/C e v aporator temp era tu re sensor Fig . 40 Ri g h t side I HKA h ou sing , b el ow g l ov e[...]

  • Page 1023

    Fig . 41 Ri g h t side d ash b oa r d 1 - Passeng er ai rb ag 2 - Passeng er ai rb ag conn ector Fig . 42 I n wind sh ie l d p ill ar (A -p il l ar) 1 - Hea d p rotectio n ai rb ag (HPS) electrical con n ector Fig . 43 I n h eadl iner 1 - Su n roo f motor Elec trica l Com pon e n t L oca tion s h tt p: // e bah n .ben t l e y pu bli s h e rs .com /[...]

  • Page 1024

    Fig . 44 I n l eft rea r roof p il l ar (C p il l ar) 1 - Anten n a amp l ifier Fig . 45 Be h in d cen t er consol e u t ility b i n 1 - Hea t er core temp erature sen sor Fig . 46 Und er sh ift er b ezel 1 - Sh iftl ock solen oi d Fig . 47 A t sh ift er b eze l 1 - G ear position in d i cator l ig h t Elec trica l Com pon e n t L oca tion s h tt p[...]

  • Page 1025

    Fig . 48 Und er cen ter con sol e 1 - Teleph on e con n ector Fig . 49 Und er cen ter con sol e, rear of p arking b rake han d l e 1 - Parking b r ake wa rn in g switch Fig . 50 Dri v er seat (Co n v ertibl e sea t fr ont v ie w) 1 - Seat memory modu l e 2 - Seat con trol swi t ch mod u l e 3 - Seat t ilt motor 4 - Seat f orwa rd -b ack motor Elec [...]

  • Page 1026

    5 - Seat h ei g h t motor Fig . 51 Pa sseng er sea t (Co n v ertib l e seat rea r v iew ) 1 - Hea d rest m otor 2 - Comfort en t ry switch 3 - Backrest motor Fig . 52 Be l ow rea r sea t cu sh ion, u n d er acce ss cov ers (top of f u el t ank) 1 - Righ t sid e: El ectric f u el p u mp an d fu el l ev el send er conn ector 2 - Left sid e: F u el l [...]

  • Page 1027

    4 - G rou n d X 498 Fig . 54 Le f t sid e tru n k 1 - Sou n d syst em ampl ifie r 2 - G rou n d X 130 16 Fig . 55 T ru n k, b elow parcel sh el f 1 - Teleph on e t ransceiv er Fig . 56 Ri g h t carg o are a, b eh in d t rim p anel (Sp ort W ag on) 1 - Rea r wind ow wa sh er p u mp Fig . 57 Le f t carg o are a (Sp ort W ag on) Elec trica l Com pon e[...]

  • Page 1028

    1 - Anten n a d i v ersity amp l ifier 2 - Sou n d syst em compon en ts 3 - Powe r socket, 12 v olt El ec trica l c om ponents undernea th ca r Fig . 58 Und ern ea th rig h t sid e of en g in e, at l ow er en d of f ron t ex hau st p ipes 1 - Post-catal yst ox yg en sen sors Fig . 59 A t f ront su b f rame , righ t side 1 - F ront ride l ev el sens[...]

  • Page 1029

    1 - AB S wh eel sp ee d sen sor, f ron t No te: Le f t f ront w he el speed sen sor i s si m i l ar. Fig . 61 Ri g h t rear wheel b ear ing h ou sin g (19 99 rea r wh eel d riv e model sh ow n ) A BS wh eel sp ee d sensor, rea r No te: Le f t rear w he el spee d senso r i s si mi l ar. Fig . 62 I n l eft fron t wh eel h ousin g 1 - AB S wh eel sp e[...]

  • Page 1030

    1 - Tra n smissi on cont rol ( A GS) conn ector Fig . 64 Le f t sid e of au tomatic tran smissi on (Z F) 1 - Tra n smissi on ran g e swi tch /b ack-u p l igh t switch h arness con n ector 2 - Tra n smissi on ran g e swi tch /b ack-u p l igh t switch 3 - Tra n smissi on cont rol ( A GS) h arn ess conn ector Fig . 65 Und ern ea th t ru n k 1 - LDP/DM[...]

  • Page 1031

    5 - Conv ert ibl e t op mod u l e (CV M II ) 6 - Hyd rau l ic motor 7 - G en era l modu l e (GM V ) 8 - Top st orage cov er l ock motor 9 - Rea r wind ow d efogg er relays 10 - Storage cov er l ock h al l sensor 11 - Ro l l -ov er casse t t es and sen sors 12 - Storage comp artment f l oor micro swi t ch 13 - Co n v ertibl e top switch 14 - Co v er[...]

  • Page 1032

    611-1 Gen era l T h is r epair g roup cov ers repair inf orma t ion for w in d sh ie l d , h eadl ig h t (opt io n al) and rea r wind ow (Sp ort Wag on) wiper and washer syst ems. Re p l ace m ent of t h e wiper/washer st alk swi t ch asse m b l y is cov e red in 612 Swi t ch es . El ectrica l wi ring d i agrams and relays for t h e wiper/washer sy[...]

  • Page 1033

    Wi per and w asher s y s tem T h e wi p er and washer f u n ct io n s in E46 v ehicl es are con t roll ed b y t h e Z KE V g eneral modu l e (GM V ). Driv er in p u t to th e syst em is v ia th e m u l ti-fu n ct io n stal k switch to t h e righ t of th e steeri n g colu mn . Op eratio n al f aul t s in th e wiper/washer system will set Di agn osti[...]

  • Page 1034

    T h e wi n d sh ield washer syst em is activ ated b y p u l l in g t h e st alk swi tch towa rd t h e d riv er. I n Sp ort W agon mod el s with rea r wi p er/wa sh er, p u sh in g t h e st alk switch one d eten t awa y f rom th e d riv e r activ ates t h e int erv al rear wi p er. Pu sh ing th e st al k f u rt h er forwar d activ ates t h e rear wi[...]

  • Page 1035

    automatica l l y h eated. The n ozzl e h ea t ers, b eing of t h e p ositiv e temp era t u re coe f ficie n t (PTC ) d esign , increase resi stan ce as t h ey h ea t u p and aut omatica l l y cu t b ack on cu rrent consu mp t ion. He adl i gh t w ashe r sy stem (opt io n al). He ad l ig h t washer n ozzl es are on t op of th e f ron t b u mp er. Th[...]

  • Page 1036

    Wi n dshi eld w i per/was h er sy ste m W i per s an d Wash er s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /6... 5 of 11 2/ 25/ 2009 11: 10 PM[...]

  • Page 1037

    Rain sens or sys tem (op tion al ) T h e opt ional rain sensor syst em u ses an inf rare d sensor, l ocated at t h e t op of t h e wi n d sh ield in f ron t of t h e rear v ie w mirro r, to d etect t h e p resence of wa t er d rops (or d irt) on t h e wind sh ie l d . The sign al from t h e sen sor is commun ica ted to t h e G M V , wh ich activ at[...]

  • Page 1038

    Co n t rol m odu l e (conn ected to G M V v ia K-b u s) T h e rai n sen sor is on -l ine as soo n as it rece iv es KL R (ig n ition on) op era t in g p ow er. Wh en th e wi n d sh ield wiper st alk swi tch is p l ace d in t h e in termitten t p osi t ion, t h e GM V sign als th e rai n sensor con trol modu l e v ia th e K-b u s of t h e req u est f[...]

  • Page 1039

    GM V sooner. De p en d in g on t h e in ten sity of t h e rain th e wi p ers can b e operated cont in u ou sl y as if set in t h e n ormal wi p er st alk switch p osi t ion reg ardl ess of t h e kn u rl ed wheel settin g . F or t h is reaso n , th e v eh icl e sp eed sig n al on th e K-b u s is n ot u t ilized on rai n sensor eq u ip p ed wi p er s[...]

  • Page 1040

    a d irty wind sh ield (d irt, road salt , wa x residu e) after a comp l eted wipe cycl e. A d irty wind sh ie l d h as a fil m on it t h at d iminish es th e abil ity of inf rare d to refract int o water d ropl ets t h at are p rese n t. This causes a d elay in t h e rain sensor d etectio n capab ilities which l en g th en s th e time int erv a l s[...]

  • Page 1041

    Rea r w i ndo w w i per/ w a s her s y st e m (Sport W a gon ) T h e rea r wiper motor asse mb l y in Sp ort Wag on mod els is moun ted in t h e tailg ate th r oug h a sou n d -in su l atin g ru b b er b u sh in g . T h e rea r wiper/washer is cont rol l ed b y th e wiper/washer st eer ing col u mn stal k swi tch v ia th e Z KE V system. T h e fu n[...]

  • Page 1042

    is in rev erse . T h e sign al is p rov ided b y th e b ack-up l ig h t switch v ia th e LSZ (l ig h t cont rol mod u l e). Re ar w in d ow washin g is activ ated when th e st al k switch is p u sh ed f orwa rd p ast th e f irst d eten t: Wash cycl e 1. W ash er p u mp O N for 1.5 seco n d s. W iper O N 1 seco n d l ater. Wash cycl e 2. W ash er p [...]

  • Page 1043

    611-2 W i per Bl a d es Wi per blade c l ea ning problem s Co mmon cl ea n ing p robl ems wi t h t h e wi p ers incl u d e st rea kin g or sh ee t ing , wa t er d rop s aft er wiping , and b l ad e ch atter. CA UTI ON! Ne ver tur n o n the w i per bl ades w h il e the h o o d is open. Dam ag e to the wi p er sys tem a n d h oo d may oc cu r. To ens[...]

  • Page 1044

    No te: BMW ha s avail able a special tool/gaug e (BMW special too l 00 9 21 0) to ali gn the ang l e of t he w i per arm to the w i ndshiel d glass. T h e wi p er b l ad es can b e ren ew ed in one of two wa ys: Co mp l ete b l ad e repl ace m ent Rub b er insert repl ace m ent I n sert rep l acem ent is th e most eco n omica l meth od , alt h ou g[...]

  • Page 1045

    Wi per blade i ns erts , r epla c ing T o rep l ace wi p er inserts: Re mov e wi p er b l ad e as d escribed ea rl ier. Unh ook wi p er b l ad e insert f rom wi p er arm g u id e. If n ecessa ry, g u id e sl igh t l y u sin g n eedl e n ose p l ier s. Pu l l old i n sert from wiper arm g u id es, n otin g in stal l atio n p osi tion. Re mov e metal[...]

  • Page 1046

    I t may be nece ssary t o raise t he en gi ne h oo d to t he servi ce po si ti on to access the f ront w i per arm fastene rs. See 410 Fend ers, Eng i ne Ho od . CA UTI ON! Mak e su re wi p er s ar e p ar ke d (sta l k swi tch i n O FF pos i ti o n) and the i gniti o n is also O FF . Us e fend er co ve r to pro tec t wi n dshi eld. - With en g ine [...]

  • Page 1047

    Ti gh teni n g torqu e Fron t wiper arm t o wi p er sh aft 3 0 Nm (22 f t-l b ) Re ar wi p er arm to wi p er sh aft 9.5 Nm (7 f t-l b ) - Check to make su re b l ades are p osi t ioned correctl y Fron t wiper arms sh oul d b e inst all ed with t ip s to th e rig h t (p asseng er) sid e of th e v ehicl e. Me asu re d istan ce of wiper arms from l ow[...]

  • Page 1048

    611-3 W i per A s s em bl i es Wi nds hie ld w iper a s sem bly , rem oving and inst a lli ng T h e wi n d sh ield wiper assem b l y (l inkag e an d motor) is remov ed as a sing l e u n it. O n ce t h e assembl y is remo v ed, t h e wiper motor an d ot h er l inkag e p arts can b e rep ai red or repl aced. 1 - Wip er asse mb l y moun tin g n u t -t[...]

  • Page 1049

    Us e fend er co ve r to pro tec t wi n dshi eld. To av oid d am ag in g the wi p er ar ms and pi vo ts, d o n o t ma n u ally sli d e o r fo rce th e wi p er ar ms ac ro ss th e wi n dshi eld. - Re mov e wi p er arms as d escribed ea rl ier. Re mov e h ou sing f or micro f il t er for int eri or ve n t ilat io n . Re mov e u p p er cov er an d micr[...]

  • Page 1050

    Re mov e righ t sid e wi p er rod ( arr o w ) from t ransmissio n arm . - Re l ea se retainin g cl ip s an d remo v e wi n d sh ield b ase trim t ray. Re mov e l arg e n u t s ( ar row ) at b ase of wi p er arm sh afts in cowl p an el. Re mov e assem b l y. No te: Co ver i nsi de ed ges of cow l pan el she et metal w i t h thi ck t ape to preve nt [...]

  • Page 1051

    Ne x t, in stal l wiper arms b u t n ot b l ad es. Close hood an d fit wi p er b l ades. Re ch eck wiper b l ad e p ositio n as d escri b ed earlier u n d er W iper arms, remov in g and in st all in g . Check all electrical h arn ess fitt ing s an d sea l ing g rommets for corre ct rei n stal l ation. Repl ace any wi re t ie s cu t off d u r ing re[...]

  • Page 1052

    5 - Wip er motor asse mb l y 6 - T orx b olt M6 -tig h t en t o 9.5 Nm (7 ft -l b ) 7 - Da mp er rin g 8 - M oun tin g sl eev e 9 - Re ar wiper motor assembl y - T o in st all : Re mov e rea r wind ow l ock asse mb l y f rom rear d eck. I n stal l wi p er motor asse mb l y and th r ea d mou n t ing b ol ts f in g er tig h t . Pl ace BM W sp eci al [...]

  • Page 1053

    Wa gon) - Re mov e rea r wiper arm. - Li f t rear wi n d ow a n d remo v e wiper sh aft h ou sing p l astic trim cov ers. - Re mov e h ou sing mou n t ing n u ts. Re mov e h ou sing . - Sl acke n r ea r wi n d ow l ift n u t. Re mov e wi p er sh aft assembl y moun t ing n u t ( arr o w ). Pu l l sh aft and b ea r ing ou t of h ousin g . - I n stal [...]

  • Page 1054

    611-4 W a s he r Sys tem s T h e wi n d sh ield washer syst em incl u d es th e h ea t ed sp ray n ozzl es in th e en g in e h ood, t h e washer fl u id p u mp , an d t h e wa sh er fl u id reserv oir in th e f ron t p asseng er sid e of t h e en g in e compartmen t. T h e h ea d l ig h t washer syst em (opt io n al ) consists of t h e f ront wa sh[...]

  • Page 1055

    1b - 44 5 mm (17.5 in. ) 2a - 40 0 mm (15.7 in . ) 2b - 27 0 mm (10.6 in. ) 3a - 26 0 mm (10.2 in . ) 3b - 55 0 mm (21.7 in. ) 4a - 50 0 mm (19.6 in . ) 4b - 35 0 mm (13.8 in. ) No te: The w i ndsh i eld spray noz z l es can be aimed by u si ng a se w i ng nee dl e or a si mi l ar di amete r st i f f pi ece of w i re. Headl ight w a sh er sp r ay n[...]

  • Page 1056

    so th at sp ray j ets st rike ap p rox ima tel y in cent er of ea ch b eam ( ar rows ). No te: To t urn on he adli gh t w ashe r jets, turn on i gnit i on, l i ghts and w i ndsh i eld w ashe r syst em. T o repe at spra y pro cedu re, t urn off i gni ti on , then back on aga i n. Ot herw i se the he ad l i ght w ashe rs are d i sabled for 3 mi nutes[...]

  • Page 1057

    T o remov e wi n d sh ield washer p u mp ( ar row ) an d h eadl ig h t wash er p u mp if equ ip p ed : Di scon n ect electr i cal con n ection at p u mp . T wist p u mp cl ockwi se. Pu l l p u mp ou t of rese r v oir . - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : T wist washer f l u i d l ev el sen sor cl ockw ise t[...]

  • Page 1058

    ( ar row ) cl ockw ise t o remo ve from b ase of rese rv oi r. I n stal l ation is r ev er se of remov a l . Rear w i ndo w spray nozzle, rem oving and inst a lli ng (Sport Wa gon) - Use p l ast i c p rying t oo l to l ev er n ozzle ou t of ru b b er st rip at top of rea r wind ow. - Pu sh n ew nozzl e in to ru b b er str ip. A d j u st n ozzl e sp[...]

  • Page 1059

    T o remov e tan k: De t ach f il l ing an d p ressur e h ose s ( A ). Re mov e wa sh er p u mp el ectrical h arness con n ector ( B ). Lo osen mou n tin g n u t s at b ott om of tan k ( C ) sl ig h tl y. Re mov e t op moun t in g n u t ( D ) and remo v e rese rv oi r. - T o remov e fl u id p u mp : De t ach el ectrica l h arness conn ector ( B ). P[...]

  • Page 1060

    612-1 Gen era l T h is sect io n cov ers rep l ace men t of electrical swi t ch es at t h e st ee rin g wheel, st ee ring col u mn , d ashb oa rd , p edal cl u ster, cen t er consol e and oth er l oca t ions. See also t h e f ol l owi n g sections: 11 9 Lub r ica tion S ystem f or inf orma t ion on t esting t h e oi l p ressure switch 25 0 G ea rsh[...]

  • Page 1061

    th e rep ai rs d et ai l ed in t h is sectio n . Pl astic p ryin g t ool BM W 00 9 32 1 I g n itio n cyl ind er remo va l tool BM W 32 3 11 0 Ri n g an t enn a remo v al tool BM W 61 3 30 0 CA UTI ON! Wh en w o rk in g o n el ec trical switches o r l ights, always di sc o n n ec t th e n eg ative (-) ca bl e fro m the b atte ry and i n su l ate th [...]

  • Page 1062

    612-2 Steeri n g W h eel Sw i tch e s E46 v eh icles are equ ip p ed with either th e mu l ti-f u n ct io n (MFL ) st ee ring wh ee l or th e sp orts st ee ring wh ee l . I n corporated in t o ea ch steeri n g wh eel are an SRS airbag , h orn con t acts, selected cel l u l ar p h on e and rad io contr ols an d cru ise cont rol b u t ton s. T o rep [...]

  • Page 1063

    De t ach el ectrica l h arness con n ectors 1 - Cruise cont rol/ rad io /t elep h one electrical h arn ess 2 - Ho rn b u tt on el ectrica l h arness 3 - A irbag el ectrical h arn ess 4 - Ra d io/tel ep h on e cont rol swi tch set 5 - A irbag 6 - Cruise cont rol swi t ch set - Re mov e small screws on b ack side of ai rbag p ad t o rel ea se l eft o[...]

  • Page 1064

    5 - Ho rn b u tt on an d airb ag el ectrica l h arness - Pu l l switch carrie r and trim d own to d etach from st ee r ing wheel . Re mov e el ectrica l h arness conn ector. - Separate bot tom t rim p iece fr om swi t ch carrie r. No te: BMW do es no t provi de t he ho rn con t act sw i t ch as a sepa rate part. Co pyrigh t © 2006 Robert Ben tley,[...]

  • Page 1065

    612-3 Steeri n g Col u m n Sw i tch es T o remov e any of t h e st ee ring col u mn swi t ch es, it is n ece ssary to f irst remov e th e u p p er an d l ow er colu m n t rim p ie ces. See 5 13 I n t eri or T rim . CA UTI ON! To prev ent mar rin g i n ter i o r trim, wor k w it h p lastic pry i ng to ols o r wrap th e tip s of sc rewdriver s and pl[...]

  • Page 1066

    Stee ring c olum n st a lk sw i tch ass e m bl y, re m ov ing a nd ins ta lli ng T o rep l ace ei t h er t h e d ire ct ional /h ea d l igh t d immer stal k swi t ch or th e wi p er/wa sh er stal k swi t ch , you m u st f irst remov e th e en t ire stal k swi t ch asse m b l y fr om th e st eer ing colu mn . CA UTI ON! To prev ent mar rin g i n ter[...]

  • Page 1067

    - With fr ont wh eels p oi n t ed st rai g h t ahead, remov e st eer ing wh ee l . See 320 Steering and W h eel A l ign men t . No te: To help w i th r ea ssembly, mark st eering w hee l and spi nd l e sha ft before disassemb l y. - Re mov e st ee rin g colu m n t rim. See 513 I n t eri or T r i m . De t ach EW S rin g ant en n a el ectrica l h arn[...]

  • Page 1068

    De t ach airbag el ectrical h arness conn ector ( arr o w ). Re mov e st alk switch h ou sing retainin g screw s ( ar rows ). Sl id e swi tch h ou sin g off st eeri n g colu m n . - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : Pl ace t u rn sign al ind icato r in center p osi t i on b efore inst all ing . En su re t h[...]

  • Page 1069

    d escri b ed ab ov e, t u rn swi t ch asse mb l y f ace -d own on wo rk b ench . Sq u ee ze l ocking t abs ( ar row s ) on sides of swi t ch an d sl ide sw itch out of asse mb l y h old er. - Pu sh in n ew swi t ch u n t il it p osi t iv ely sn ap s in t o switch h ousin g . Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Swi[...]

  • Page 1070

    612-4 Peda l Cl u s ter Sw i tch es T o access ei t h er t h e b r ake p ed al or t h e cl u tch p edal swi tch , r emo v e th e l eft footwe l l trim (ab ov e p edal s). See 513 Interior Tri m . B r ak e li ght s w i tch, re pla c ing Working at p edal cl u st er: De t ach el ectrica l h arness conn ector ( arr o w ) f rom b rake l ig h t swi t ch[...]

  • Page 1071

    conn ector f rom swi t ch . Sq u ee ze tog eth er retai n in g cl ip s at fr ont of switch . Sl id e swi t ch ou t of h ol d er (t ow ard rea r of car). - I n stal l n ew swi t ch , t h en all ow cl u tch p edal to sp rin g b ack sl owly, automatica l l y ad j u st in g switch p osi t ion. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s [...]

  • Page 1072

    612-5 Oth er I n teri or Sw i tc h es M any of t h e re maining el ectrical swi t ch es are h oused at t h e b ott om center of t h e d ash b oard, or i n th e center consol e. T h e A SC or DC S switch is ah ead of t h e sh ifter con sol e at t h e b ott om of t h e center d ashb oa rd . Wh en eq u ipp ed, sea t h ea ter switch es are in th e same[...]

  • Page 1073

    - Pry u p on r ea r of sh ift b oot/b ezel to u n cl ip, t h en remov e b oot f rom fron t retainers. Re mov e retai n in g screws ( arr o ws ) u n d er t ransm issi on sel ector b oot/t rim. Pow er w in d ow switches, replacing - T o remov e l eft or righ t g an g ed wi n d ow switch es: Sh ifter b eze l : Lift u p b y p rying g ent l y. Sh ifter [...]

  • Page 1074

    ASC / DSC/se at h ea ter swit ches , re p l ac i n g Eith er th e A SC or DSC switch is l oca t ed in th e storage compartmen t/ ash t ray h ou sing . Sea t h ea t er switch es are al so l oca t ed h ere , if equ ip p ed. T h is p roce d u re can b e skipp ed in order to access center consol e swi tch es. Re mov e st ora g e compartmen t b el ow I [...]

  • Page 1075

    ashtr ay. - Re mov e retai n in g screws and storage tr ay h ousin g . Di scon n ect electrical h arn ess conn ector f or storage tr ay court esy l ig h t . - Re mov e screws a t b ase of st ora g e tray compart ment in consol e. Uncl ip t rim b oot f or p arking b rake l ev er and p u l l b oo t and h and l e forwa rd off b rake l ev er. - Sl ide [...]

  • Page 1076

    from switch . - I n stal l ation is r ev er se of remov a l . Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Swi tch e s h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /6... 5 of 5 2/ 25/ 2009 11: 13 PM[...]

  • Page 1077

    620-1 Gen era l T h is r epair g roup cov ers remo v al an d inst all at io n of t h e inst ru men t cl u ster. I n stru men t cl u st er se l f -test p rocedu r es are al so incl u d ed. Spec ia l tools I n d iv idu al inst ru men t cl u st er compon ent s are n ot av ai l abl e. Since inst ru men t cl u st ers are o n l y av ai l abl e as compl e[...]

  • Page 1078

    620-2 I n s tru m en t Cl u s ter T h e d ash b oa r d mou n t ed in stru men t cl u ster is th e contr ol an d in formation center of t h e E46 cars. It is con n ected to most of t h e syst ems and sen sors in th e car t h rou g h t h e u se of " b u s" n etwo r ks: K-b u s conn ects t o Ce n tral Body El ectronics (Z KE V ) f u n ctions[...]

  • Page 1079

    Cruising ran g e A v erage v eh icle sp eed T h ese fu n ct io n s are more f u l l y ex p l ai n ed in t h e O wn er's M an u al . T h e cl u st er also st ore s imp ortant v ehicl e memo ry f u n ctions su ch as t otal mileage and serv ice int erv al d ata. I n stru men t cl u st er repl aceme n t mu st b e fol l owe d b y sp ecia l p roce d[...]

  • Page 1080

    8 - Ri g h t d irectio n al 9 - T emp erature g aug e 10 - W arnin g l igh ts (Check En g ine, etc.) 11 - Le ft rese t b u tt on (odometer/se rv ice int erv al ) 12 - Check Cont rol LCD 13 - Od ome t er/O n -Board Compu t er LC D 14 - A SC/DSC warnin g l ig h t 15 - Fu el eco n omy g au g e 16 - T ransmissio n ran g e/ p rogr am LC D (incl u d es t[...]

  • Page 1081

    E46 i nstrume n t cluster I n stru m en ts h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /6... 4 of 9 2/ 25/ 2009 11: 14 PM[...]

  • Page 1082

    Inst rum e nt c lust e r, s e lf- test i ng I n add ition to t h e st oring d iagn ostic trou b l e cod es (DT Cs) an d commun ica t in g t h rou g h t h e d iagn ostic l ink, th e inst ru men t cl u ster is p rogr amme d with a serie s of test menu s th at can b e accesse d t o ch eck v ari ous fu n ctions and v alu es. The odometer/On -Boa rd Com[...]

  • Page 1083

    d isp l ay su b men u s or cont inu e on t o n ex t main test menu . No te: Tests 1 and 2 are alw ays unlocked . Tests 3 - 21 are only acce ssi ble after unlocki ng t he t est functi on . Test 19 i s t he unlock f unction for acce ssi ng t he di splays. I f ad ju st ment i s ne cessary, enter i nto Test 20 u si ng the cl uster bu tt on . The corre [...]

  • Page 1084

    M enu Submenu Sample ou tpu t M ea n i ng T est 2: Cl u st er syst em test - act iv at es g aug e d riv er s, in d ica tors an d LEDs to conf irm f u n ct ion (see Note ) T est 3: S I d ata 3 . 0 15 00 Liters 3.1 0 Perio d ic insp ectio n d ays ( n ot app l ica b l e for US) T est 4: F u el consu mp t ion d ata (cu rrent ) 4.0 0 267 26 . 7 l iters/[...]

  • Page 1085

    M enu Submenu Sample ou tpu t M ea n i ng T est 9: B attery v olt ag e 9.0 1 25 12 .5 v ol t s T est 10: Co u n t ry codin g 10 . 0 02 U S (= 02 ) T est 11: Clu st er code 11 . 0 000 003 Cl u ster cod e T est 12: No t u sed T est 13: G ong t est 13 . 0 " G on g " A ctiv ate g on g b y p ressi n g b u t ton (g ong resp onse is d el ayed). [...]

  • Page 1086

    Pl ace a t owe l ov er steeri n g col u mn . Ca ref u l l y til t top of cl u st er ou t of d ash p anel . Un l ock an d d isco n n ect h arn ess conn ectors ( arr o w s) from b ack of cl u st er. No te: Steering w hee l doe s not nee d t o be remo ved to remove i nst rume nt cl uster. I f it i s n ece ssary to rep l ace cl u ster, d etach t rim b [...]

  • Page 1087

    630-1 Gen era l T h is r epair g roup cov ers int erio r and ex t eri or l ig h t ing , in cl u d ing repairs to t h e l igh t swi tch assembl y. Spec ia l tools Some sp ecia l t oo l s may b e n ecessa ry to inst al l or adj u st l igh t s and l ig h t fix tu res. Pl astic trim p rying t oo l BM W 00 9 321 Fog l ig h t/ h eadl igh t ad j u stin g [...]

  • Page 1088

    Tabl e a. E46 bu l b app li ca tio n s Lo cation T ype & rating Lo w b ea n (Xe n on ) D2 -S Fog l ig h ts Fron t H B4 Re ar (Eu ro onl y) 12V 21W T u r n sig n al and t ai l l igh t Back-up 1 2V 21 W Brake 1 2V 21 W Brake /t ai l l ig h t 12 V 21/4W Li cen ce p l at e 1 2V 5W Side t u rn sig n al W5W T h ird b rake l ig h t LED T u rn sign al [...]

  • Page 1089

    He ad l ig h t /t ai l l ig h t /ru n n in g l igh t contr ol switch Fog l ig h t switch I n stru men t d immer cont rol Li g h t cont rol mod u l e I n ad d ition to n ormal l i g h t con t rol , th e LSZ p rov ides t h e f ol l owi n g f u n ct io n s: Ho t and col d monitoring of t h e ex t eri or b u l b s Emergen cy l ig h t in g fu n ct ion S[...]

  • Page 1090

    Parki n g l igh t s Side marker lig h ts Li cen se p l ate l igh t s Ho t and col d monitoring of l igh t b u l b s all ows th e LSZ t o d etect d efectiv e b u l b s. Ho t monitoring ch ecks th e contin u ity of circuits whil e t h e l ig h t s are swi t ch ed on. Cold mon itori n g consists of a b rief p u l se of cu rren t which is t oo sh ort f[...]

  • Page 1091

    modu l e and tr ansf erre d to t h e repl aceme n t u n it. Em e rgenc y (f ai l safe) lighting T h e l igh t cont rol mod u l e p rov ides eme rg en cy l ig h tin g in t h e ev ent of an electron ic modu l e failu re. Back u p h ardware al l ows th e f oll ow in g l ig h t in g circuits t o fu n ction: Lo w b eam h eadl ig h t s T aill igh ts Brak[...]

  • Page 1092

    Chec k Co ntro l di splay. To av oid mar rin g car p aint o r trim, w o rk w ith p l as tic p ry in g to ols or w rap th e tip s of to ols wi th tape. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. L ig h ts h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /6... 6 of 6 2/ 25/ 2009 11:[...]

  • Page 1093

    630-2 Li gh t Sw i tch Light sw itch a ss e m bly, rem oving and inst a lli ng Pry g en t l y at l eft d ashb oard t rim t o remo v e. CA UTI ON! To av oid mar rin g i n ter i or trim, wor k wi th a p lastic prying to ol. Re mov e l ig h t switch moun t in g screw s ( ar row s ). - Li f t switch sl igh tl y an d with d raw from d ash b oard. No te:[...]

  • Page 1094

    Swi n g l atch b ackw ard ( ar row ) . Pu l l electr ica l h arn ess con n ector off switch asse mb l y. - I n stal l ation is r ev er se of remov a l . Light control m odule, s e par ating - Re mov e l ig h t switch asse mb l y as d escri b ed earlier . Press in on tab s ( ar rows ) in l igh t swi t ch asse m b l y to separate l ig h t swi t ch fr[...]

  • Page 1095

    630-3 Hea dl ig h ts E46 cars are eq u ip p ed with Ha l ogen h ea d l ig h ts as st an d ard equ ipmen t . Ha l ogen b u l b rep l ace ment is p erforme d f rom t h e b ack (en g ine) side of th e h eadl ig h t assembl y. The fr ont face of ea ch h ea d l ig h t asse mb l y is a remo v abl e p l astic cov e r. Op t io n al X enon l ow -b eam h ead[...]

  • Page 1096

    No te: W hen ad ju sti ng he ad l i gh t s w i t h au t omatic adj uster syst em (LW R), w ai t at l east 30 seco nds for t he LW R t o cycl e an d ad just t o i t s cal cul ated po si ti on. Ha l o gen h ea d l ig h t as sem b l y 1 - M o u nti n g scr ew 2 - Expandin g nu t 3 - High b eam cove r 4 - High b eam bu l b 5 - High b eam bu l b sock et[...]

  • Page 1097

    1 - Automatic headlig h t adju stm ent (LW R) ste p p er motor 2 - Electr i ca l harnes s conn ec tor 3 - Expandin g nu t 4 - M o u nti n g scr ew 5 - Xenon b u lb control modu le 6 - Control mod u le brac ket 7 - High b eam cove r 8 - High b eam bu l b 9 - High b eam bu l b sock et 10 - Lo w b ea m cov er 11 - Xenon b u lb ig ni ti on elem ent 12 [...]

  • Page 1098

    18 - Cove r l o ck str ip Hea dlight bulb (Halogen), re plac ing Working in b ack of h ead l igh t asse mb l y: Ro t ate h eadl ig h t b u l b retainin g ring ( ar row s ) coun t erclockwi se. Pu l l b u l b socket and b u l b out of h eadl ig h t assembl y. Di sconn ect h arn ess conn ect or from socke t . Gen tl y wigg l e b u l b an d p u l l st[...]

  • Page 1099

    re plac ing - Worki n g in b ack of h eadl ig h t asse m b l y: Re mov e l ow b eam (X enon ) cov er. T wist X enon ig n ition element coun t ercl ockw ise and remo v e. Ro t ate h eadl ig h t b u l b retainin g ring coun t ercl ockw ise . Pu l l b u l b out of h eadl ig h t assembl y. I n st all ation is rev er se of r emo v al . He ad l ig h t b [...]

  • Page 1100

    from h ea d l igh t asse mb l y. - I f n ece ssary, remov e h eadl igh t wa sh er sp ray n ozzl es. See 61 1 Wip ers and W ash ers . - R emo v e fron t t u rn sig n al assembl y as d escri b ed l ater in t h is rep air g roup . Use p l astic p ryin g t ool to d etach and remo v e trim p iece bel ow h ea d l ig h t asse m b l y. Re mov e h eadl igh [...]

  • Page 1101

    Close eng in e h ood and ch eck to make su re t h at g ap b et w een h oo d and h eadl ig h t asse m b l y ( A ) is corre ct . Se e sp ecifica t io n b elow. Op en h ood an d t igh t en d own moun t in g screw s. Re main d er of assembl y is rev erse of remov al . H eadli gh t to h oo d g ap D imensio n A 5.0 ± 1.0 mm (0.2 0.± 04 in .) - A d j u [...]

  • Page 1102

    Uncl ip sea l ing g aske t ( ar rows ) an d remo v e. Re l ea se cl ips ( arr o ws ) retai n ing f ront l en s. Pu l l l en s forwa rd t o remo v e. - I n st al l atio n is rev erse of remov al . Re p l ace gasket b etwe en l en s an d b ody of l ig h t if n ece ssary. A utom a tic hea dlight adjust m e nt (L W R) V ehicl es eq u ipp ed with t h e [...]

  • Page 1103

    ang l e ch ang es. LWR monitors v eh icl e l oa d v ia two h all effect sen sors moun t ed to th e fron t and rea r su sp ension members. W h en an adj u stmen t t o th e ang l e of t h e h eadl igh t b eam s is n ece ssary, LWR simul tan eo u sl y activ ates two step p er motors (one in each h eadl ig h t asse m b l y). The st epp er motors d riv [...]

  • Page 1104

    5 - Fron t rid e heig h t se nso r li n k 6 - Self-lo ck i n g n ut M 8 7 - Bolt M 5 8 - Righ t rea r ride heig h t se nso r moun tin g brac ket 9 - Bolt M 6 10 - Re ar ride h eigh t se n sor 11 - Self-lo ck i n g n ut M 6 12 - Re ar ride h eigh t se n sor li n k 13 - Exte n sion 14 - Br ack et 15 - Bolt M 6 Co pyrigh t © 2006 Robert Ben tley, I n[...]

  • Page 1105

    630-4 Fron t Fogl i gh ts Fog light aim , a djust ing Sedan or Sp ort W agon : Use 4 mm A l l en wren ch t o t u rn p l astic ad j u st er ( ar row ) on ou ter ed g e of f og l ig h t. Co u p e or Co n v ertibl e: Use ad j u st er ( ar row ) on insid e u p p er edg e of fogl ig h t. 20 01 model s: Usi n g p l astic p ry tool, p ry of f fogl ig h t [...]

  • Page 1106

    Fog light ass e m bly , rem oving and inst al ling Sedan or Spo rt W agon : Use p l ast i c p rying t oo l to l ev er out fogl ig h t assembl y. De t ach el ectrica l h arness conn ector. - Coup e or C o nver ti bl e : Gent l y remov e l ow er b u mp er t rim. Working at f og l ig h t , d etach g rill e and l oose n mou n t ing screws. Re mov e f o[...]

  • Page 1107

    - I n stal l ation is r ev er se of remov a l , n oting t h e f oll owi n g : Sedan/ Sp ort W agon : F og l igh t mu st b e sn app ed f irml y in to b u mp er retainers. Co u p e/Co n v ertib l e: K ee p v ent ilation g r omm ets u n kin ked and f irmly sea ted . A d j u st fog l ig h t aim as d escri b ed ea rl ier. Fog light bulb, repl ac i ng - [...]

  • Page 1108

    630-5 T u rn Si gn a l s , T a il l i g h ts Front tu rn signal a s sem bly , rem oving and inst a lli ng T h e p roce d u re b el ow also incl u d es tu r n sig n al b u l b rep l ace ment . With en g ine h oo d open , u se a screw d r iv er t o p ress t u rn sig n al asse mb l y ret ai n ing cl ip d ow n to d ise n g age from retainin g t ab on h[...]

  • Page 1109

    Before reinstal l i ng , make sure rub ber sea l on w rap-a rou nd tri m (und ern eath he adli ghts) i s fi rml y gl ue d to t ri m. Re gl ue i f ne cessa r y. Fron t turn sig nal T u rn sign al b u l b 1 2V 21W Side turn s i gnal ass e m bly T h e yell ow marke r l igh t s on th e sides of th e fr ont f en d ers are tu rn sign als. Use p l ast i c[...]

  • Page 1110

    I n E46 cars, t ai l l ig h t f u n ct io n s are sp l it. T h e corner b u l b carri er on ea ch sid e contain s: T aill igh t b u l b T u r n sig n al b u l b Brake l ig h t b u l b T ru n k l igh t b u l b T h e b u l b carrie r on each side of t h e tru n k or t ai l g ate cont ai n s: Back-up l ig h t Re ar f ogl igh t (Eu rop ea n mod el s on[...]

  • Page 1111

    a clea n cl o th dampened w i th ru b bi n g alco hol. T o access tru n k l id t ai l l ig h t b u l b s: Partia l l y r emo v e t ru n k l id tr i m p anel b y remo v ing p l astic ex p an sion riv et s ( ar row s ). Ex p an sio n riv ets are re l ease d b y p rying u p p er p ortion out ( in se t ), th en p u l l ing off t ru n k l id . - T o acc[...]

  • Page 1112

    T h e cent er b rake lig h t in al l model s is an LED u n it. There a re n o repl ace ab l e b u l b s. Sedan or Coup e : Working f rom rea r sea t in p asse n g er comp artment , g ent l y p u l l off t rim cov er ov e r t h ird b rake l ig h t (at t op of rea r g l ass). De t ach el ectrica l h arness conn ector ( A ). Re mov e retai n in g cl i[...]

  • Page 1113

    h ose are n ot d ama g ed or kinked . No te: Re pl ace seali ng plast i c an d gromme t s as ne cessary du ri ng reasse mbl y. TI gh teni n g torqu e Re ar sp oi l er to rea r g l ass 6 Nm (4 f t-l b ) Lice nse plate li ght , re m oving and inst al ling Usi n g a fl at tip p ed screw d riv er, p ry g ent l y on rig h t sid e of l ice n se p l ate l[...]

  • Page 1114

    630-6 I n teri or Li gh ts T h e ZKE V g eneral mod u l e (G M V) contr ols th e int erio r l ig h t ing automatica l l y u sin g in p u t f rom sev er al monitors. Th e l ig h tin g can al so b e manu al l y cont roll ed . Each d oor l ock actu ator cont ains a h all effect sensor f or th e p u rp ose of monitoring d oor open /cl osed st atu s. T [...]

  • Page 1115

    b ack on u n l ess th e swi tch is p ressed again. T h ere are two readin g / map l ig h t s l oca t ed in th e fron t in terio r l ig h t asse mb l y. Each is mech an ica l l y contr oll ed b y d ep ressi n g t h e corre sp on d in g swi tch . T h e p owe r su p p l y f or th e map l ig h ts is su p p l ied b y th e G M V . T h ere is a court esy [...]

  • Page 1116

    Interior light autom a tic c ontrols T h e GM V p rov ides 12 v ol ts to th e int erio r l ig h tin g circuit wh en th e stat u s of one of t h e fol l owi n g in p u t sig n als ch ang es: Do or contact h al l sen sor activ e (d oo r op en ) " Unl ock" req u est rece iv e d f rom d riv er door key l ock h al l sen sor (ign ition switch O[...]

  • Page 1117

    activ ated , l ig h t s aut oma t i cal l y t u rn off (soft off ) aft er 8 second s. A f ter 16 minu t es wi th d oor cont act activ e ( open d oor) and key off , l igh ts are swi t ch ed off ( consu mer cu t off fu n ction ). T h e compon ent activ at io n f u n ct ion of DI S also h as t h e ab ility to swi t ch th e l igh ts. Interior light, fo[...]

  • Page 1118

    In ter i o r li gh t app li ca tio n s fron t or rea r R eading b u l b , f ron t or rea r 6W T ailg at e court esy l igh t b u l b Softl ite 10 W V iso r v an ity l igh t b u l b Softl ite 10 W T runk li ght bulb, re pla ci ng T h e tr u n k l ig h ts are in teg rated with th e taill ig h t asse m b l y. Pry t ru n k l ig h t cov er ( arr o w ) g [...]

  • Page 1119

    640-1 Gen era l T h e repair inf orma t ion g iv en u n d er th is h ea d ing ap p l ies to t h e h eating an d ai r cond itionin g system. M an y of t h e p roce d u res req u ire th at th e A /C refrigerant ch arge b e ev acuated . See A /C syst em wa rn in g s an d caut ions l ater in th is repair g rou p . For in formatio n on th e en g in e co[...]

  • Page 1120

    be yond t he scope of thi s manu al. Integrated he a ting a nd cooling s y st e m (IHKA ) T h e E46 in teg rated au tomatic cl ima te contr ol system (I HKA ) offers p owe r fu l coo l in g and h ea t in g , eff ectiv e v ent ilation , and smooth op eratio n in A /C mod e. T h e E46 IH KA d esign in cl u d es t h e fol l owi n g : Use of R134 a ref[...]

  • Page 1121

    He ater con tr ol p ersonal iza tion v ia Ca r M emory/Key M emo r y E46 I HK A co n tr ol Heat i ng and Air Con di tion i n g h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /6... 3 of 22 2/ 25/ 2009 11: 16 PM[...]

  • Page 1122

    Control panel and mod u le He atin g an d air cond ition ing f u n ct io n s are p rog ramme d v ia th e cent er con sole moun t ed con t rol p anel . T h e cont rol p anel h as l arg e, easy to u se soft-t ouch cont rols, an LED disp l ay and a sing l e temp eratur e settin g . 1 - M an u al air d istrib u t io n cont rol b u t ton s 2 - Int erio [...]

  • Page 1123

    th e fron t p an el, incl u d es an EEPROM ch ip f or storage of Di agn ostic Tro u b l e Co d es (DT Cs). I n p u t s t o t h e modu l e incl u d e: He ater core temp erature sensor A / C ev ap orato r t emp era t u re sen sor Ot h er p rog rammed f u n ctions from Ca r M emory (su ch as rea r wind ow d efrost timing ). T h e modu l e can g o in t[...]

  • Page 1124

    Solar sen sor inp u t (if app l ica b l e) A rocke r switch is u sed to sel ect t h e d esi r ed cab in temp eratur e, sh ow n in t h e d isp l ay matrix of t h e cont rol p an el. T h e rang e for t emperatu re d isp l ay is fr om 15 ° to 32°C (60 ° to 90 ° F ). A "serv ice statio n " f eatu re is int eg rated int o th e E46 IH KA . [...]

  • Page 1125

    T h e operatio n of t h e A / C compressor is modu l ated, el iminatin g n oticea b l e on / off cycl ing . In ord er t o redu ce fu el consu mp tion an d imp rov e v ehicl e p erforma n ce, th e syst em d efau l t is with th e com p ressor OF F. T h e A / C system u ses a v ari abl e d isp l ace ment comp ressor. The swa sh p l ate of th e comp re[...]

  • Page 1126

    sign al to t h e ECM en abl es t h e ECM to modify th e idl e sp ee d , t imi n g and f u el inj ect io n amoun t b ase d on t h e l oad t h at is imposed wh en t h e compressor is activ ated . Re g u lated engi ne coo li n g fan op era ti on T h e eng ine coolin g f an ( ar row ) operates at v aria b l e sp eeds (15 st ages) b ased on coo l in g s[...]

  • Page 1127

    M ax i mum defrostin g Pressi n g th e d efrost b u tt on t u rn s on max imu m d efrost fu n ctions: Fresh ai r d istrib u t io n va l v es are open ed . Re circu l atio n v al v es are closed . Win d sh ield d efro st v ents are open ed . A l l oth er air d istribu tion v en ts are cl ose d . Bl owe r r u n s at max imu m sp ee d . Re ar wi n d o[...]

  • Page 1128

    2 - Defrost 3 - F ootwe l l 4 - Reci rcu l ation 5 - F resh air T wo d iff ere n t t yp es of ai r d istrib u t io n motors are u sed in th e system. F ast acting motors ( A ) are u sed for th e fresh ai r/ recircul atio n f l aps. (Ri g h t sid e sh ow n . ) - Sl owe r act ing motors ( B ) are u sed for t h e oth er op era tions. T h e cent er d a[...]

  • Page 1129

    IHKA p er sonali zation Ca r M emory/Key M emor y al l ows v ario u s fu n ctions and featu res of IH KA con t rol to b e tailored to th e d riv er ' s wishes. T h e fu n ctions of IHKA th at can b e p rogr amme d b y t h e d riv er in cl u d e: A u t oma tic activ atio n of recircul ation when t h e v ehicl e is started Bl owe r sp ee d adj u[...]

  • Page 1130

    Automatic air re circulatio n A s of mod el year 200 0, au tomatic reci r cu l atio n cont rol is av ai l abl e. This system u ses an ai r q u al ity sensor (AU C) ( ar row ), l oca t ed at t h e t op r igh t corner of th e ra d iator, t o d etect h igh l ev el s of ai r p ol l u t io n and aut omatica l l y switch th e I HKA to recircul atio n of [...]

  • Page 1131

    Co ol ing System . Serv icing t h e A / C system requ ires t h e u se of sp eci alized equ ip men t. Fol l ow th e equ ip men t manu f actur er's in str u ction s. Rea r w i ndow de fog ge r T h e electric rear wi n d ow d efogg er swi t ch is int egrat ed in t h e I HKA cont rol p an el . Pressi n g th e rea r wind ow d efogg er b u t ton act[...]

  • Page 1132

    On h ard top : Re ar relay is en ergized. Pow er to h ard t op wind ow is su p p l ie d th rou g h conn ector strip on h ard t op l ock. On con v ertib l e top : Re ar relay is en ergized. I t p ow ers fron t rel ay. I f conv ertibl e top con tr ol modu l e (CV M ) sig n al s t h at conv ertibl e t op is l ocke d to wind sh ie l d frame, f ront rel[...]

  • Page 1133

    modu l e. The mod u l e t h en cal cu l ates v olt ag e d rop across th e p h otore sistor and d etermines t h e d eg ree of solar h eating b ase d on t h e ch ang e in v ol tag e. V ol tage d rop across th e p h otore sistor increase s as sol ar radiatio n in crease s. T h e I HKA con trol modu l e p roce sses th e p h otoresi st or in p u t ev er[...]

  • Page 1134

    No isy or sei zed comp ressor No isy comp ressor cl u t ch M alf u n ct ionin g b el t Di agn osis of n oi sy eng ine comp artment compon ent s is cov ered in 100 En g in e– Gen era l . A / C b el t rep l ace ment is cov ered in 020 M ai n t enan ce . Cool in g sys tem p robl ems Co ol an t p rob l ems Co ol ing fan p robl ems Co ol ing system p [...]

  • Page 1135

    - Po ke a sp ray wand t h rou g h IH KA h ousin g open in g an d sp ray comme rciall y av ailab l e cl eanin g agen t on ev ap ora t or. M ov e wa n d b ack and f orth to cov er ev aporator fin s wi t h l iq u id . - A l l ow 5 mi n u t es f or l iqu id to d rip th roug h ev aporator d rain. - Start car an d ru n h eater and A / C at max imu m p ow[...]

  • Page 1136

    p rogr amme d su b stitu t e v alu e. See Ta b l e a . Tabl e a. Su bstitu te p rog ra mme d va l u es fo r IHKA compo nent in p u ts In pu t Workin g ra ng e Sub stitute va l u e H eat ex ch an g er sensor 5° t o 12 4°C (41 ° t o 25 5°F ) 55 ° C (13 1°F ) Ev aporator sensor -10 ° t o 30 ° C (14° to 86°F) 0°C (32 ° F ) I n terio r temp [...]

  • Page 1137

    Tabl e b. T emper ature se nsor re sistance values a t 25°C (77 °F ) Se nso r Res i stance F aul t li mit 12 5°C (25 7°F ) Ev aporator 9 k ± 2% Te mp > 12 0°C (24 8°F) I n terio r 10 k ± 2% T emp ≤ -46 °C (-51 ° F ) Ta b l e c l ists A /C ev aporator temp eratur e-dep end ent resistance v alu es. Tabl e c. A/C eva p o ra tor temper a[...]

  • Page 1138

    Tabl e d. E xpansion va l ve p res sure va l u es I n l et p ressure 14 b ar (20 3 p si) Ou t l et p ressu re 1 . 8 b ar (26 p si) Le ak t est with d etector p ressure 1 - 2 b ar (14 .5 - 29 p si ) A / C sys tem w a rnings and ca utions WA RN I NG! A lways wea r hand and ey e pro t ec ti on (glo ves and go gg les) wh en wor king ar ou n d the A /C [...]

  • Page 1139

    Th e A /C sys tem is fi ll ed wi th re frig era n t g as w hi ch i s under pres su re . Pre ssu rized refrig era n t in the p re sence o f ox yg en may fo rm a co mbus t ib le mixtu re. Ne ver i n tro duc e co mpre ssed air in to any re frige ra n t container (full o r empty). Electr i c w eldi ng near refr ige rant hos es ca u ses R-13 4a to deco [...]

  • Page 1140

    co mpo nents i n R-13 4a sy ste m. Co mpone nt d am ag e and sy ste m co ntamin atio n res ults . Th e mixtu re o f re frige ra nt oil (PA G oil ) and re frige ra n t R-134 a atta cks s o me me tals and all o ys (fo r ex ample, co p per) and brea ks down ce rta i n h os e mate rials. Use o n l y hos es and l i nes that are id enti fied wi th a g re[...]

  • Page 1141

    640-2 Ven ts a n d Du cts T h e I HK A ai r d istrib u t ion syst em incl u d es 5 ai r d istrib u t ion motors (step p er motors), righ t and l eft f ootwe l l d u ct s, d ash b oa rd m oun t ed d efroster v ent s, an d th ree sets of f ace l ev el v ent s. Re mov al of at l east on e of t h e step p er motors (righ t footwe l l v ent ) in v ol v [...]

  • Page 1142

    Sq u ee ze p l astic cl ip ( ar row ) t o release motor. T il t motor ou t of h ou sing . - During inst all at io n , b e su r e to alig n ai r d istrib u t io n fl ap and motor dr iv e ( A ). Right s i de ai r distribut i on m otors , a c ce s sing Fou r of t h e air d istr ibu t io n motors are u n d er t h e rig h t sid e of t h e d ashb oard: R[...]

  • Page 1143

    Ri g h t sid e fresh air/recir cu l ation motor ( ar row ): For access, remov e rig h t f oo t w el l d u ct as d escribed b elow. Unh ook l in kage, th en remo v e motor. De f roster ai r d istribu t ion motor ( ar row ) V ent il atio n d istrib u t ion m otor ( ar row ) For access, remov e d efr oster ai r d istribu tion motor. Ri g h t f oo twel[...]

  • Page 1144

    Unh ook l in kage, th en remo v e motor. Left side a ir di s tribut i on m oto r, ac c ess i ng T h e fresh air d istrib u t io n motor is u n d er th e l eft side of th e d ash b oard. Remo v e th e l eft footwe l l (p edal cl u st er) tr im p anel for access. CA UTI ON! Disa sse mble in terio r trim ca refu ll y to av oid d am ag e. - M ov e st e[...]

  • Page 1145

    Right fo otw e ll duct, re m ov ing and inst al ling - Re mov e g l ov e comp artment as d escri b ed in 513 I n t eri or Tri m . - Re mov e I HKA con tr ol p an el or GPS O n -Boa r d M on itor, as app l ica b l e (d escribed b elow). Re ach t h rou g h con tr ol p an el open ing to d etach ai r d u ct l ocking cl ip ( ar row ) from h eater/ev ap [...]

  • Page 1146

    Re mov e ai r v ent moun t ing screw s ( ar row s ). - Li f t v en t sl igh t l y and wi t h d r aw f rom d ashb oa r d . - I n stal l ation is r ev er se of remov a l . No te: Re moval of ri gh t or cen ter da shbo ard vent i s si mi l ar. To f ull y remove t he cen t er da shbo ard vent, use pli ers to de t ach co ntrol cab l e hou si ng an d rem[...]

  • Page 1147

    [...]

  • Page 1148

    remo v e. Re mov e screws ( a rr o w s ) at r ea r of sh ifter t rim (wind ow swi t ch carrie r). Li f t trim at b ack t o u n h ook from f ront . Re mov e screws ( a rr o w s ) at f ron t and rea r of ash t ray carri er. Lift u p asht ray carri er. - Re ach u p t h roug h op enin g an d p u sh I HKA con trol mod u l e and p anel out . - De t ach e[...]

  • Page 1149

    - Pu l l off menu b u t ton on face of monitor. Reach th roug h ap ertu res wi t h screw d riv er to t wist catch es. T h is r elease s monitor from console. - Pu l l out monitor an d d etach electrical h arn ess conn ectors in b ack. Heate r core tem pera ture s e ns or, rem oving and ins ta lli ng - Re mov e I HKA con tr ol p an el or On - Bo ard[...]

  • Page 1150

    p ipes. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Heat i ng and Air Con di tion i n g h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /6... 4 of 4 2/ 25/ 2009 11: 17 PM[...]

  • Page 1151

    640-4 Bl ow er Com p on en ts B l ow e r m oto r, rem ov ing a nd ins ta lli ng Re mov e h ou sing f or int eri or v ent il ation micro f ilt er. Re mov e u p p er cov er an d micro f ilt er. Op en wi ring h arn ess l oo m ( A ) and remo v e wi res. Unf asten screw s ( B ) a n d remo v e l ow er h ousin g . Re mov e h eate r b u l kh ea d cov er: R[...]

  • Page 1152

    Working in side rig h t sid e of cow l , p u l l u p on l ev er ( ar row ) and d etach righ t ai r int ake f l ap f rom b l owe r h ou sin g . Pry off b l ow er cov er retainin g cl ip s ( A ). Re mov e screw ( B ) and l ift off out er b l owe r h ou sing cov er. Re mov e b l owe r cov er retai n ing screws ( ar row s ). Li ft off cov er. De t ach [...]

  • Page 1153

    Pry off b l ow er motor retai n ing st rap . - Pu l l b l owe r motor f orwa rd t o remo v e. - I n stal l ation is r ev er se of remov a l : A l ign sl ot in b l owe r motor with moun t ing tab in b l owe r motor h ousin g . B l ow e r m oto r re sis tor pac k , repla c ing No te: The blow er motor resi stor pack i s also referre d t o as t he fi [...]

  • Page 1154

    ( ar row s ). De t ach el ectrica l h arness conn ector. Press retai n in g cl ip awa y f rom swi t ch to relea se swi t ch . - I n stal l ation is r ev er se of remov a l . M ake su re el ectrica l h arn ess is rout ed as b efore. A l ign g u id es and cl ip s correctl y. Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Heat [...]

  • Page 1155

    640-5 Hea ter Com pon en ts T h e h ea t er v al v e is l ocated in t h e l eft side of th e eng in e comp artment, attach ed t o th e l eft st ru t t ow er. The solenoid op era ted va l v e cont rols coo l an t f l ow th roug h t h e h ea t er core . T h e I HK A h ou sing , l ocate d u n d ern ea th th e cen ter of t h e d ash b oard, h ou ses th[...]

  • Page 1156

    - I n stal l ation is r ev er se of remov a l . I n sp ect h ose s an d ru b b er mou n t s. Re p l ace as n ecessa ry. Use n ew h ose cl amp s. Ti gh teni n g torqu e Co ol an t h ose cl amp 32 - 48 mm (2 1/4 - 4 in . ) 2 .5 Nm (22 in-l b ) Heate r core , re pla ci ng Re mov e h ou sing f or int eri or v ent il ation micro f ilt er. Re mov e u p p[...]

  • Page 1157

    Working at r ea r en g ine compartmen t b u l kh ea d , l oose n h ose cl amps ( ar row s ) and d etach h eater h ose s. - Bl ow ou t ex cess coo l ant from h ea t er core usin g comp ressed air at coolan t l in es. - Re l ea se rig h t ai r d u ct fr om I HKA h ousin g . Working in side p asseng er compartmen t at I HKA h ousin g : De t ach wiri n[...]

  • Page 1158

    ( ar row s ) t o d etach p ip es. T il t h ea t er core to remov e f rom h ousin g . - I n stal l ation is r ev er se of remov a l . Fit l u g s in b ack of h ou sin g cov er in h eate r h ousin g sl ots. Use n ew sea l ing O -ring s an d coa t wi t h an ti-sei ze ag ent . Fil l and b l ee d coolin g syst em. See 170 Ra d iator and Coo l in g Syste[...]

  • Page 1159

    mo to r ve h i cle air co n di tioner mu st, b y law , b e pro p er l y tra i ned and ce rtifi ed, and u se appro ved refr i ge rant rec yclin g equ i pment. T ec hn ici ans mu st co mplete an EPA -app ro ve d re cyc l i ng co ur se to be ce rtifi ed Re mov e h ou sing f or int eri or v ent il ation micro f ilt er. Re mov e u p p er cov er an d mic[...]

  • Page 1160

    - Bl ow ou t ex cess coo l ant from h ea t er core usin g comp ressed air at coolan t l in es. - Fol l ow in g man u f actu rer's inst ru ct io n s, conn ect ap p rov ed refrigerant recov e ry/recycl ing /rech argin g u n it to A /C syst em and d isch arge syst em. Working in rig h t r ea r of en g in e compartmen t, d etach A / C l in es: Re [...]

  • Page 1161

    - Working in side p asseng er compartmen t b el ow st eer ing colu mn , d ril l out steeri n g col u mn sh ea r b ol t . See 320 Steeri n g and W h ee l Align ment . Re mov e st ee rin g colu m n moun t ing b olt s. Lo wer colu mn . Und er d ash attach men ts 1 - Bu l kh ead 2 - Le f t A -p ill ar 3 - He ad p rotectio n airbag 4 - Steeri n g col u [...]

  • Page 1162

    Working at r igh t sid e of d ash : Cut wire t ie ( A ) at d ash b oard rei n f orceme n t su p p ort f or rel ay p anel . T u r n f u se p an el l ock tab s ( B ) 90 ° and swi n g fu se p an el d own. De t ach f u se p an el p iv ots ( C ) from d ashb oa r d reinf orcem ent . - Li f t off d ashb oard reinf orce ment , maki n g su re all el ectric[...]

  • Page 1163

    Re p lace hea ter and A /C f lange O-rin g s and tighten fas teners to spec i fied tor q ue s. Ti gh teni n g torqu es Co ol an t h ose cl amp 32 - 48 mm (2 1/4 - 4 in . ) 2.5 Nm (22 i n -l b ) Steeri n g col u mn t o d ashb oa rd rei n forceme n t 22 Nm (16 f t-l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Heat i ng [...]

  • Page 1164

    640-6 A i r Con di tio n i n g Com po n en ts T h is sect io n cov ers remo v al an d inst all at io n of air con d itioning refrigerant comp on ent s. A / C testin g and d iagn osis, refrig erant d isch arg e, ev acu ation an d recharg e are not cov ered h ere. T h e A /C con d en ser, compressor , rece iv er d ryer, p ressur e sensor, refrigerant[...]

  • Page 1165

    5 - Compre ssor 6 - Lo w p re ssure li n e 7 - Ac ces s po rt 8 - Doub le pi pe 9 - Expansion valve 10 - Eva p o ra to r 11 - Ac ces s po rt 12 - Pre ssure sensor A / C c om pre ss or, re pla c ing - Fol l ow ing manu f actur er's inst ru ct io n s, conn ect an app rov ed refrigerant reco v ery/ recycling /rech argin g u n it t o A / C system [...]

  • Page 1166

    Re mov e d riv e b el t. - D etach and set asi d e fr ont washer fl u id reserv oir. See 61 1 W ipers and W ashers . - D isco n n ect el ectrical h arness conn ector f rom comp resso r. Re mov e A / C p ressu re h ose a n d su ct io n h ose fl an g e b ol ts ( arr o ws ) from compressor. Pl u g h ose s immediately. - A l l -wheel- d riv e m odel: U[...]

  • Page 1167

    - R echarg e system f ol l owi n g equ ip men t manu f actur er's inst ru ct io n s. See Ta b l e e f or A /C system f l u id sp eci ficatio n s. Tabl e e. A/C sys t em fl ui d spe cificatio ns Fl ui d Q u anti ty R -13 4a refrig era n t 74 0 ± 25 g (2 l b ± 1 oz.) R efrigerant oi l PA G oi l A / C c ond enser, repla c ing T h e A / C cond e[...]

  • Page 1168

    Re mov e f ilt er h ou sin g mou n tin g screw s ( D ). De t ach air d u ct con n ections ( E ) and l ift comp l ete air f ilt er h ousin g out of eng in e compart ment , p u l l in g it forwa rd awa y f rom mass ai r f l ow sensor. - R emo v e int ake h oo d , coo l ing f an and sh rou d , an d rad ia t or, as d escribed in 17 0 R adiator and Co o[...]

  • Page 1169

    A / C sy stem fl ui d specification s Fl ui d Q u anti ty R -13 4a refrig era n t 74 0 ± 25 g (2 l b ± 1 oz.) R efrigerant oi l PA G oi l A / C re ce iver/ drier , r epl ac ing T h e rece iv er/d r ie r is mou n t ed in t h e f ront righ t corner of th e en g ine comp artment b ehin d and b elow th e head l igh t asse m b l y. - Fol l ow ing manu[...]

  • Page 1170

    Re mov e refrig era n t p ressu re l in e moun t in g b ol ts ( A ) from recei ve r/ d rie r. Pl u g l in es immedia tel y. Di sconn ect h ig h p ressur e swi t ch h arness conn ector ( B ). - Worki n g b en ea t h righ t f ront of car, remo v e sp l ash sh ie l d retai n ing screw s. Re mov e sp l ash sh ield . - L oosen r ece iv er/d rier moun ti[...]

  • Page 1171

    WA RN I NG! Do n ot di sc harg e/char g e the A /C sy stem with ou t p ro p er e quipment and tra i n in g. Dam ag e t o th e ve h icl e and pers onal inj u ry ma y res u l t. Re mov e h ou sin g f or int erio r v en til ation micro fil ter. Re mov e u p p er cov er an d microfilt er. Op en wi ring h arn ess l oom ( A ) and remo v e wi res. Unf ast[...]

  • Page 1172

    Working in side rig h t sid e of cow l , p u l l u p on l ev er ( ar row ) an d d et ach r igh t air int ake fl ap f rom b l owe r h ou sin g . - Worki n g in rig h t f ron t of IH KA h ousin g , d etach d ou b l e p ipe (A / C l ine) f rom ex p an sio n v al v e. La y d ou b l e p ip e aside. Pl u g u p op en A / C p orts. - R emo v e ex pan sion [...]

  • Page 1173

    - D rai n en g in e coo l ant . See 17 0 Ra d iator an d Coo l in g Syst em . - R emo v e compl ete I HKA h ousin g as d escribed ear l ier. - R emo v e h ea t er core as d escri b ed ea r l ie r. - Worki n g on l eft sid e of IHKA h ousin g : De t ach ev aporator temp erature sensor el ectrica l h arness con n ector and p u l l out sensor. De t ac[...]

  • Page 1174

    Re mov e d ou b l e coolan t p ip e. - Pry off ev aporator h ousin g retai n in g cl ips an d r emo v e cov er . Pu l l ev ap ora tor an d ex p ansion v al v e out of b ott om of h ousin g . - I f in st all in g n ew ev ap ora tor, switch ov er ex p an sion v alve . Use n ew sea l in g O -ring s. CA UTI ON! Do n ot bend co o l i ng fin s on ev apor[...]

  • Page 1175

    650-1 Gen era l T h is sect io n cov ers th e BM W f actory- inst all ed soun d syst em, incl u d in g radio, amp l ifier an d sp eake r remov al . Ra d io an tenn a inf ormatio n is al so incl u d ed. Spec ia l tools Use BM W sp eci al t oo l 00 9 32 1 or equ iv alen t p l astic p ryin g t ool to p ry ou t p l astic in terio r p arts withou t d am[...]

  • Page 1176

    T h e stan d ard E46 radio fea t u res a casse t te p l aye r. The op tional r adio h as a sing l e in-d ash CD p l aye r. Both rad ios are p rewi red for t h e op tional CD ch ang er th at moun ts in t h e t ru n k. A n oth er op t i on, th e On -Boa rd M on itor, int egrates G PS n av i g ation wi t h rad io and IH KA cont rol s. Basic radio co n[...]

  • Page 1177

    T roublesho oting A l th oug h el ectron ic radio and sou n d system t roub l eshooting is b eyon d t h e scope of th is manu al , t h ere are n u mb er of self -t ests th at are p ossi b l e wi th t h e stand ard BM W radio inst all ed in E46 cars. Ra d io test f u n ct ions are activ at ed b y p ressi n g th e M b u tt on with in 8 second s of sw[...]

  • Page 1178

    650-2 Ra di o a n d A u di o A cces s ori es Radio, re m oving a nd ins tal ling CA UTI ON! B efo re b eg in n in g w or k on th e ra d i o or so und sy ste m, ver i fy that th e ra di o i s an o ri g i n al equ i pment B MW radio and th at the w irin g harnes s h as n o t bee n mo di fi ed. Ser vicin g o f after mar ket so u nd equ i pment sho uld[...]

  • Page 1179

    A m pli fier I n al l model s th e soun d syst em ampl ifier is inst al l ed b eh ind t h e t rim on th e l eft side of th e car. - Sedan or Coup e: To acce ss ampl ifier, carefu l l y remov e t ru n k trim cl i p s on l eft sid e an d p ee l b ack trim. Sp ort W ag on: Remo ve l eft carg o compartmen t t rim cov er. Soun d system ampl ifier ( ar r[...]

  • Page 1180

    650-3 Spea kers Each model in th e E46 model l in e-up featu res a sl igh tl y d ifferent sp ea ker setup . Sp eake r an d oth er compon ent l oca t ions also v ary d ep end in g on t h e typ e of sou n d syst em in st all ed . Some of th e commo n sp ea ker inst all atio n s are cov ere d in t h is section. Sedan an d Sp ort W ag on: T h e stan d [...]

  • Page 1181

    wi n d ow d efroster relay wh en th e top is l ow ere d . T h is swi t ch es off th e stereo p h onic f u n ction. Doo r m ount e d speak e r, rem oving WA RN I NG! A l l E46 ca rs ar e e q u i p ped wi th fro nt doo r airbag s. Re ar doo r airbag s ar e o p ti o n al. B efo re perfo rming any wo rk in vo l ving airbag s, d isco n nect th e neg ati[...]

  • Page 1182

    Prio r to di sco nn ect in g the b atte ry, re ad th e batter y d isco n nectio n ca utio n s give n at the fro nt o f th is ma n u al on p ag e vii i . - Re mov e l owe r sectio n of rear sea t side tr im. - I f n ecessa ry, remov e conv ertib l e top mod u l e. See 541 Co n ve rt ibl e T op (l eft sid e onl y). - Sp ea ker is attach ed t o side w[...]

  • Page 1183

    screw s. Unh ook and p u l l su b woo f er d own. Re mov e el ectrica l h arness conn ector. - Co n ve rt ibl e: Working in t ru n k, u n h oo k an d swi n g ou t su b wo ofer. Sq u ee ze p l astic h arness cov er and remov e. De t ach el ectrica l h arness conn ector. Usi n g p l astic p ry tool, g ent l y p ry su b wo ofer at b ot tom l eft and p[...]

  • Page 1184

    650-4 A n ten n a A ntenna and diversity T h e ant enn a u sed f or th e radio, tel eph one an d FZ V r emo t e en t ry system is in teg rated with t h e rear wi n d ow d efogg er in th e Se d an an d Co u p e mod els. Co n ve rt ibl e and Sp ort W agon mod el s featu re a d iv ersi t y an t en n a system t o p rov id e t h e st rong est p ossibl e[...]

  • Page 1185

    FZ V ( keyless en try) an ten n a combin ed wi th F M 2 an ten n a T h e FM 1/ FM 2 an ten n a amp l ifier is l oca t ed b eneath t h e rear sp oi l er. T h e sign al from t h is amp l ifie r i s tran smitted to th e d iv ersi t y mod u l e in t h e carg o compartmen t b eh ind t h e l eft t rim p anel . 1 - Su p p ressio n f ilt er 2 - A n t enn a[...]

  • Page 1186

    Di v ersity swi tch in g mod u l e, moun t ed b el ow an t enn a mast in tru n k M ore in formatio n on t h e rea r wind ow d efogg er/an t enn a system is in 64 0 He atin g and A ir Co n d itio n in g . No te: The tel ep hon e an ten na i s w ou nd arou nd the main anten na mast. A ntenna, re m ov ing (C onv ertible m od e ls) Unscrew and remo v e[...]

  • Page 1187

    Pl ace ant enn a b ase d own on b racke t. Re mov e ant en n a h ead f rom ab ov e fend er. - T o remov e b ase , sl id e towa r d r ea r of car, th en d etach cab l e conn ections. - Wh en inst all ing , make sure t h e offset of an ten n a h ead p oint s towa rd b ack of car. A ntenna am plifier, a cc e ss ing - Co n ve rt ibl e mai n an t enn a [...]

  • Page 1188

    - Sedan or Coup e an t enn a su p p ressor: Re mov e righ t roo f p il l ar (C-p ill ar) trim p an el t o access sup p resso r . Sp ort W ag on FM 3 ant enn a/d iv ersi t y modu l e: Re mov e l eft carg o compart ment trim cov er to g ain access to modu l e ( ar row ). - Sp ort W ag on FM 1/FM 2 ant enn a ampl ifier: Re mov e rea r sp oi l er. See [...]

  • Page 1189

    720-1 Gen era l T h is sect io n cov ers rep ai rs to th e sea t b elt s. M u l t ip l e Re straint Syst em (M RS II ) electron ics int egrat e sea t b elt operatio n s an d ai rbag d ep l oyme n t . A irbag r epair inf orma tion is cov er ed in 72 1 A irb ag Syst em (SRS) . A l l E46 mod el s are equ ip p ed w ith 3-point sh oul d er b el ts at f [...]

  • Page 1190

    T roublesho oting T h e sea t b el t ree l sh ou l d l ock when d riv ing q u ickl y t h rou g h cu rv es, d u ring sev ere b raki n g or in case of a col l isi on. T h e aut oma tic reel d oes not req u ire any serv icing an d sh oul d n ev er b e open ed. I n case of an acciden t , fol l ow th e sea t b elt trou b l esh ooting p rocedu res p rese[...]

  • Page 1191

    wi th a l u ke -w ar m so ap solu ti o n o n l y. Sea t b elts sho uld be perio d i ca l l y in spect ed for webb in g defe cts su ch as c ut s o r pulled th re ads. I mme di ate l y after replacing a dama ge d or w or n se at belt, destr oy th e old b elt to p rev ent it fro m bein g us ed ag ai n. Tab le a. Trou bl eshoo ti ng th e automatic se a[...]

  • Page 1192

    Probl em Probabl e ca use Repa i rs Sea t b el t d oes not retract aut oma t icall y. (See n ote.) A u t oma tic reel l oose Ti g h t en ree l moun tin g b ol t. Re t u rn sp ring b roken in side ree l Re p l ace re el assem b l y. A u t oma tic b el t sq u ea ks wh en b elt fasten ed or u n fasten ed. Ex cessiv e f riction in b elt g u id es Re p [...]

  • Page 1193

    Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Seat Belts h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /7... 5 of 5 2/ 25/ 2009 11: 20 PM[...]

  • Page 1194

    720-2 Fron t Sea t Bel t A s s em bl y Front s e a t belt tensioner, rem oving and inst a lli ng T h e fron t sea t b el t l ocks are equ ipp ed wi t h p yrotech n ic (ex p l osiv e ch arg e) automatic ten sioners. T h ese t en sio n ers are d esign ed t o au tomatica l l y retract and t ension th e sea t b el t b y 55 mm (app rox imate l y 2 inch [...]

  • Page 1195

    Do n ot ex p os e p yr ote chni c co mpo nents to tem p er atu res abo ve 75 °C (167 ° F ). Pyr ote chni c co mpo nen ts c an o n l y be teste d elec t rica l ly w h en in sta ll ed, us i n g B MW se rv ice tes ter DI S, MoD i C o r equ ivalent sc an too l. Do n ot fire a pyr ot ec h n ic ga s g enera to r p rio r to di spo sa l . I t mu st be fi[...]

  • Page 1196

    De t ach h arn ess con n ectio n ( B ). Re mov e t ensioner mou n tin g b ol t ( C ). Check ten sioner mou n t ing b r acke t ( ar row ) f or d ama g e or b end ing . Re p l ace if n ecessa ry. CA UTI ON! A b ent tensioner mo untin g brac ket ma y mak e it impos si bl e to adj us t se at h eight. Wh en rei n stal l in g : Re p l ace wire t ie s t o[...]

  • Page 1197

    as sem b l y (Sedan, Coup e, Spo rt Wago n ) 1 - Sea t b elt b u ck l e 2 - Tensio ner moun tin g b ol t tig h t en t o 48 Nm (35 ft -l b ) 3 - Sea t b elt l ock wi th pyrotec h n ic tension er 4 - Sea t b elt stop bu tton 5 - Sea t b elt ancho r bo lt tig h t en t o 48 Nm (35 ft -l b ) 6 - Sea t b elt ree l as sem b l y 6a - Sea t b elt ancho r en[...]

  • Page 1198

    12 - Space r 13 - Sea t b elt ancho r bar (Coup e on ly) 14 - Ca p 15 - Gromme t 16 - Sea t b elt ree l moun tin g b ol t M 10 tig h t en t o 31 Nm (23 ft -l b ) 17 - Sea t b elt h eigh t adju ste r Front seat bel t ree l, re m ov ing and inst al li ng ( Se dan, Coup e or Sport Wa gon m odels) - D etach b att ery n egat iv e (-) cabl e in l u g g a[...]

  • Page 1199

    Re mov e anch or b ar b ol t an d sl ip off end of sea t b el t fr om b ar. No te: Re pl ace an chor ba r i f i t i s ben t . Prying g en t l y u p ward, remov e p l astic d oor sil l p rotector str ip. Sedan or Sp ort W ag on m odel s: Remo v e l ow er B-p il l ar (d oor pil l ar) p l astic t rim. Pry g ent l y al on g b ottom of t rim t o d ise n[...]

  • Page 1200

    Pu l l B-p il l ar u p p er t rim d ow n t o remov e. Re mov e aut omatic ree l f rom B-p il l ar: Re mov e u p p er sea t b el t anch or b ol t ( A ). Re mov e cross-b race mou n tin g b ol ts ( B ). Re mov e soun d insu l atio n at b ase of B-p ill ar. Then r emo v e aut oma tic sea t b elt ree l m oun tin g b olt ( C ). Li f t out reel. - I f it[...]

  • Page 1201

    B-p ill ar b y sl id ing tab int o l ocating sl ot. Ti gh tenin g torqu es Fron t seat to f l oo r (M 10 f astener) 45 Nm (33 ft -l b ) Se at b elt anch or b ar to d oor sill 3 1 Nm (23 f t-l b ) Se at b elt to seat 48 Nm (35 f t -l b ) Se at b elt to B-p i l l ar sl idin g anch or 31 Nm (23 ft -l b ) Se at b elt ree l t o B-p ill ar b ottom 3 1 Nm[...]

  • Page 1202

    conn ected to t h e b ackrest h ing e t h rou g h a l ev er and a cab l e d riv e (coup l er mechan ism). As th e ang l e of t h e b ackre st is adj u sted , t h e cab l e d r iv e will ch ang e th e an g l e of t h e in ertia l ock. I n th is wa y t h e ree l is in th e p rop er p osi tion for l ocki n g at an y seat b ack an g l e. T h e sea t b [...]

  • Page 1203

    4 - Fron t sea t back res t 5 - Sup po rt 6 - SGS b elt re el moun tin g n ut M 10 tig h t en t o 39 Nm (29 ft -l b ) 7 - SGS i n ertia re el as sem b l y 8 - To rx b o lt M 6 tig h t en t o 4.5 Nm (40 in -l b ) 9 - Sea t b elt g u id e cove r, front 10 - Sea t b elt g u id e cove r, re ar 11 - Conn ec t or 12 - Clip 13 - Sea t b elt b u tton 14 - [...]

  • Page 1204

    720-3 Rea r Sea t Bel t A ss em bl y Rear seat bel ts (Se dan or Cou pe m odel s ) - Re mov e rea r p arce l sh el f to acce ss sh ou l d er b el t assembl y moun t ing b olt s. - Re mov e rea r seat cu sh io n t o acce ss rear seat b el t l ock moun t ing b olt s. See 520 Seats . - T h e acco mp anyin g ill u str atio n p rov id es in formatio n o[...]

  • Page 1205

    equi p ped) 2 - Righ t sho u ld er belt lo ck 3 - Lap-b elt as sem b l y 4 - Left sho ul d er belt lo ck 5 - Bolt M 10 tig h t en t o 31 Nm (23 ft -l b ) 6 - Left sho ul d er belt re el as sem b l y 7 - Ce n ter sho u ld er belt lo ck (if equi p ped) 8 - Bolt M 12 tig h t en t o 31 Nm (23 ft -l b ) Rea r seat bel ts (Sport W agon m ode ls) - C ent [...]

  • Page 1206

    Re mov e sh ou l d er b elt r ee l moun t in g b ol t insid e b ackrest. No te: Re move bo w den cable fr om ba ckrest bra ckets and un hook from ba ckr est release l atch. Ce nter sea t be l t reel can be t he n be remo ved . - Ou t b oa rd sh oul d er b el t: Re mov e roo f -p ill ar (C-pil l ar) t rim. Re mov e cent er sh ou l d er b elt . - L i[...]

  • Page 1207

    strap . I n st all l eft b elt l ock strap u n d ern ea th cen t er l ap b el t st rap. M etal st rap en d s mu st rest against stop on fl oo r u n d erneath seat. Rea r seat bel ts (C onv er tible m ode ls) - A ccess shou l d er b elt or seat b elt l ock moun tin g b ol ts: Re mov e cent er armrest. Pu sh sh oul d er b el ts t ow ard sid es and f [...]

  • Page 1208

    T h e acco m p an yi n g il l u st ratio n p rov id es inf orma t ion on rear sea t b elt comp on ent l oca t ions an d f astener torq u es. 1 - Bol t M 10 -tig h t en t o 31 Nm (23 ft -l b ) 2 - Left sh ou l d er b el t ree l assembl y. 3 - Seat b elt st op b u tt on 4 - Left b el t l ock 5 - Bol t M 12 -tig h t en t o 31 Nm (23 ft -l b ) Co pyrig[...]

  • Page 1209

    721-1 Gen era l T h is r epair g roup cov ers ai rb ag compon ent s. A i rb ag syst em repair and faul t d iagn osi s is n ot cov ere d h ere. Di ag n ostics, comp onen t testin g , an d ai rb ag system rep air sh oul d b e carri ed out b y t rained BM W serv ice techn ici ans. No te: Ai rba gs are also kno w n as t he Sup pl emen t al Re strai nt [...]

  • Page 1210

    A i rba g s y st e m T h e E46 air b ag syst em con sists of th e fol l owi n g : Dri ve r airb ag in t h e cent er of th e steeri n g wh eel h u b Passe n g er ai rb ag in t h e rig h t sid e of th e d ash b oard Fron t sid e-i mp act airbag s, on e in ea ch f ron t d oor He ad Prot ectio n Syst em (HPS) ai rb ag s, on e in each fron t roof p ill [...]

  • Page 1211

    2 - Pas senger airbag 3 - He ad Protect io n Sys tem (HPS) airbag 4 - Fron t d o or side-impact airbag 5 - Re ar do o r side-impact airbag (o pt io nal) 2-s tage ai rbag Begin n in g in th e 20 00 model yea r (9/19 99 p rod u ction ) t h e fron t airbag s we re ch ang ed to a 2-stag e styl e ai r b ag . T h is ensu res th at th e force of ai rb ag [...]

  • Page 1212

    Upon sev ere side imp act, a g as g enerator u n it fil l s t h e He ad Protection System (HPS) t u b e with in ert g as. T h e ex p an d in g t u b e p op s out of t h e tr im to form a st rai g h t t u b e 5.1 inch es in d ia m eter and st retch ed in a st raigh t l ine from t h e l owe r wind sh ield p ill ar to ab ov e th e re ar d oor. The in [...]

  • Page 1213

    M RS d ep l oyme n t l og ic p rov ides two th reshol d s for t h e activ atio n of th e safety system, d ep end ing u p on th e sev e rity of impact an d wh eth er or n ot occu p ant s h av e fasten ed t h eir seat b el t s: Belt s f asten ed, l ow imp act sp ee d : Lo wer d ep l oyme n t t h reshol d . On l y sea t b elt p yrotech n ic t ensioner[...]

  • Page 1214

    A i rba g indica tor li ght T h e M RS cont rol mod u l e d etects an d stores system st atu s. T h e ai rb ag ind ica tor l igh t in t h e inst ru men t cl u st er d isp l ays t h e st atu s of th e airbag syst em wh en t h e ig n itio n key is in " acce ssory" or O N p ositio n s. System n ormal: I n d icator l igh t come s on b rie f l[...]

  • Page 1215

    imme d i ate ly. A irbag (s) are in fl ate d by an ex p l o si ve d ev i ce . Handl ed impro p erly o r w i thou t adequ ate sa f eg u ards, th e sys tem ca n be ve ry dange ro u s. Sp ec ial prec au tions mu st be obse rv ed prior to any wo rk at or n ea r the airbag s. Th e airbag i s a vehicle saf ety sy stem . Ser iou s in j u ry may re su l t [...]

  • Page 1216

    spec i al di spo sa l co mpany or ship p ed b ac k to B MW i n the pack ag i n g o f the new co mpo nents. Wh en rem o ving a fire d airbag u ni t, av oid co n tac t w i th th e sk i n ; w ea r g l ov es. In cas e of sk i n contac t, wash w ith w ater . Do n ot allo w airbag sy ste m co mpo nents to co me in co n tac t wi th cleanin g so l utio n s[...]

  • Page 1217

    721-2 A i rba g El ectron i cs A i rba g harne s ses and connec tors I f ai rb ag con n ectio n h arn esses sh ow v isi b l e sig n s of wea r or d amage, th ey mu st b e rep l aced or repaire d . - T o rep ai r airbag h arness: Di scon n ect n eg ativ e (-) cab l e from b attery an d cov er n egativ e terminal with insu l ating materia l . Di scon[...]

  • Page 1218

    CA UTI ON! Prio r to di sco nn ect in g the b atte ry, re ad th e batter y d isco n nectio n ca utio n s give n at the fro nt o f th is ma n u al on p ag e vii i . - Re mov e cent er u t il ity t ray b etwee n fron t sea t s. See 513 Int eri or T rim . Cut op en carp et on t op of cent er t u n n el to access M RS I I mod u l e. - Re mov e modu l e[...]

  • Page 1219

    Re mov e el ectrica l h arness conn ector from crash sen sor ( A ). Re mov e sensor retai n ing screws ( B ) and remov e sensor. No t e d irectio n of sen sor arro w b efore remov in g . - I n stal l ation is r ev er se of remov a l . No te: Arrow on sen sor must point t o doo r si l l . Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r [...]

  • Page 1220

    721-3 A i rba gs Driv e r ai rbag, re m ov i ng and ins ta lli ng - Di scon n ect n eg ativ e (-) cab l e from b attery an d cov er n egativ e terminal with insu l ating materia l . WA RN I NG! A fter di sco nn ect in g the b atte ry, w ait 5 se co n d s befor e b eg i nn in g wor k on airbag co mponents. CA UTI ON! Prio r to di sco nn ect in g the[...]

  • Page 1221

    Sp ort st ee rin g wh eel: I n sert screwdriv er th roug h open ing in rear of st eer ing wh ee l and p u sh ag ai n st sp r ing t ension to rel ea se airbag u n it l ock. Re p eat p roce d u re on oth er sid e of steeri n g wh eel. Li f t off airb ag u n it and d et ach electrical h arn ess conn ectors. WA RN I NG! Sto re the rem ove d airbag unit[...]

  • Page 1222

    the i n di ca to r l ight sta ys o n, the airbag sys t em w il l n o t functio n as d es i gne d . Ha ve the sy stem di ag nose d and re paired b y an au thor ized B MW dealer . - I n stal l ation is r ev er se of remov a l . M FL st ee ring wh eel: To rq u e ai rb ag u sin g sp eci f icatio n l isted b elow. Sp ort st ee rin g wh eel: Press ai rb [...]

  • Page 1223

    ca utio n s give n at the fro nt o f th is ma n u al on p ag e vii i . Pry g en t l y at rig h t d ash b oard tr im to remo v e. CA UTI ON! To av oid mar rin g i n ter i or trim, wor k wi th a p lastic prying to ol. - Re mov e righ t d ash b oar d fresh ai r outl et moun t ing screw s an d p u l l outl et out of d ash . Li f t cov er from t op of p[...]

  • Page 1224

    sing l e stag e air b ag, iden t ifie d b y h av in g onl y on e wire l oom in th e h arness con n ector. La ter p rod u ct io n two stag e ai rb ags are su p p l ied b y two wi re l oo m s in t h e con n ector p l u g . The two kind s of airbag s are NOT int erchan g eabl e. - I n stal l ation is r ev er se of remov a l . M ake su re wiri n g h ar[...]

  • Page 1225

    De t ach h arn ess con n ector. CA UTI ON! Wh en rem o vin g and in sta l li ng the airbag unit, p ay atte n tion t o th e ro u tin g of the electr ica l h ar ness to av oid kinks or brea ks i n the w i re . - Re ar d oo r airbag : De t ach el ectrica l h arness conn ector. Re mov e moun tin g b ol ts an d remo v e ai rb ag fr om d oo r. - I n stal[...]

  • Page 1226

    Co mp l ete d ash b oar d Co mp l ete h eadl in er Win d sh ield p il l ar (A -p ill ar) trim Do or p ill ar (B-p ill ar) trim - Before st arting wor k on th e HPS ai rb ag , d isco n n ect n eg ativ e (-) cabl e f rom b att ery and cov er n egativ e terminal with in su l atin g materi al . CA UTI ON! Prio r to di sco nn ect in g the b atte ry, re [...]

  • Page 1227

    3 - Ca b le ho ld er 4 - Gas gener ator 5 - Self-tappi n g sc rew M 6 tig h t en t o 4 Nm (35 in-l b ) Co pyrigh t © 2006 Robert Ben tley, I n c . All r igh t s r eserv ed. Airba g Sy s t em (SRS) h tt p: // e bah n .ben t l e y pu bli s h e rs .com / BM W/3/ E46/ Repai r% 20Man u al s /7... 8 of 8 2/ 25/ 2009 11: 21 PM[...]

  • Page 1228

    OBD-2 On -Boa r d Di a g n os ti cs (OBD I I ) OBD II is an acronym f or On - Boa rd Di ag n ostics II , t h e seco n d g en era t ion of on-b oard self -d iagn ostic equ ip men t requ ireme n ts. T h ese st and ards wer e ori g in al l y mand ated for Californ ia v ehicl es. Sin ce 199 6 t h ey h av e b een app l ie d t o al l p assen g er v ehicl[...]

  • Page 1229

    rese t using the spe ci al scan t ool. Re movi ng the conn ector f rom t he ECM or disconn ecti ng the ba tt ery w i l l no t era se the fault memory. T h e ex t ra h ard war e n ee d ed t o operate th e O BD I I syst em consists mainl y of th e f ol l ow ing : A d d itional ox yg en sensors d ow n st rea m of t h e catal yt ic conv erters Fu el ta[...]

  • Page 1230

    T h e M I L wi l l come on u n d er th e fol l owi n g con d itions. A n eng i n e man agement system faul t is d etected f or t wo consecu tiv e OB D I I d riv e cycl es. A catal yst d ama g ing fau l t . A comp on ent malfu n ct io n (su ch as catalyst d et eri oratio n ) causes emi ssions t o ex ceed 1.5 t ime s OBD II st and ard s. M anu factu [...]

  • Page 1231

    Addi tio n al i nf orma t io n, M IL : A f aul t cod e is stored wi th in th e ECM u p on th e first occurr ence of a fau l t in t h e syst em b eing ch ecke d . T wo compl ete consecu tiv e d riv e cycl es wi th t h e fau l t p rese n t ill u minate t h e M IL . T h e ex ception to th e two-faul t requ ire ment is a catalyst d ama g ing f aul t , [...]

  • Page 1232

    With th e u se of a u n iv ersa l or 'g en eric' scan t ool con n ected to t h e DLC (Di ag n ostic Link Co n n ector), d iagn ostic trou b l e cod es (DT Cs) can b e ob t ai n ed, along wi th th e cond itio n s associ ated wi t h th e ill u min atio n of th e eng ine serv ice l igh t. Usi n g a more ad v anced or BM W-d edicated scan too[...]

  • Page 1233

    i nstall ed. Professiona l di ag nosti c scan t oo l s ava i l ab l e at t he ti me of thi s printi ng i ncl ud e the BMW factory tools ( DI Splus an d MoDiC) and a small numb er of aftermarke t BMW -spe ci f i c tools. The CS2 000 from Baum Too l s Un l i mi ted , t he Re t ri ever from Assenma cher Spe ci alt y T ools, and t he MT 25 00 from Snap[...]

  • Page 1234

    requ ired t ests. T h e ECM mu st reco g n ize t h e l oss or imp airm ent of t h e sign al or compon ent an d d etermine if a sign al or sensor is f aul ty b ased on 3 cond itions: Sign al or compon ent sh orted t o g roun d Sign al or compon ent sh orted t o B+ Sign al or compon ent missing (open circu it) T h e OBD II syst em mu st monitor al l [...]

  • Page 1235

    ECM cann ot d et ermi n e th e env ironmen t or en g in e operating cond itions d u e t o missing or fau l t y sign al s it will set a fau l t cod e an d , d epen d in g on cond itio n s, il l u min ate th e M I L. Ox yg en sensor mon itoring : W h en d riv e cond itions all ow , respon se rate an d swi t ch in g time of each ox yg en sensor is mon[...]

  • Page 1236

    Sp eci fic cyl in d er(s) Sev erity of t h e misfire ev ent Emissi on s rel ev ant or catalyst d ama g ing M isfire d etectio n is an on -g oing monitoring p rocess th at is onl y d isa b l ed u n d er certai n l imite d cond itions. Seco n d ary ai r in j ection monitoring : Seco n d ary ai r in j ection is u sed t o redu ce HC and CO emissi on s [...]

  • Page 1237

    set an d id en tify th e fau l t y b ank(s) . I f after comp l eting t h e n ex t col d start a faul t is ag ai n p rese n t, th e M IL wi l l b e ill u minated . Fu el system mon itori n g : Th i s monitors rece iv es h ig h p rio rity. It l ooks at t h e fu el d eliv ery n eeded (l on g / sh ort t erm fu el trim) f or p rop er eng in e op era tio[...]

  • Page 1238

    ch eck system in t egrity. O n M S 43 .0 cars, a more so p h isticated DM T L (Di ag n ostic M od u l e - Lea k De t ectio n ) p u mp is u sed . Driv e cy c le T h e OBD II d riv e cycl e is an imp ortant concep t in u n d erstan d ing O BD I I requ ireme n ts. T h e p u rp ose of t h e d riv e cycl e is to ru n all of th e emissio n - related on -[...]

  • Page 1239

    OBD-3 BM W Fa u l t Codes (DT Cs ) Below is a co mp reh ensiv e l isting of BM W DT Cs an d th e corre sp ond ing SA E P-cod es. T a ble a . Diagnos tic trouble c odes (D T Cs ) BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explan ation 1 I g n ition coil cyl . 2 I n p u t an al og timing (100 mV ) DM E in itia t es se con d [...]

  • Page 1240

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 8 P01 01 M ass air fl ow circuit rang e/p erf. I n p u t an al og (0-5 V) Failed sign al r ang e ch eck against p redefin ed d iag n ostic l imi t s. 10 En g ine coo l ant temp . circu it rang e/p erf. I n p u t an al og (0-5 V) Sign al ran g e is ch ecke d against p [...]

  • Page 1241

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 23 P02 06 I n j ector circu it cyl . 6 Ou tp u t d ig ital p u l se widt h (activ e l ow ) DM E f in al stag e will set f l ag wh enev er a sh ort t o g rou n d , a sh ort to b at tery v ol t age or a d isconn ection b etwee n ou tp u t t ransistor an d comp onen t ex[...]

  • Page 1242

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 33 P02 05 I n j ector circu it cyl . 5 Ou tp u t d ig ital p u l se widt h (activ e l ow ) DM E f in al stag e will set f l ag wh enev er a sh ort t o g rou n d , a sh ort to b at tery v ol t age or a d isconn ection b etwee n ou tp u t t ransistor an d comp onen t ex[...]

  • Page 1243

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 45 M u l t i f u n ct io n al steeri n g wh eel, tog g l e-b it I n p u t b inary stream (0-1 2V ) Ev ery 0.5 sec. a messa g e t h at in cl u d es a t ogg l e b it (tog g l es b etwee n 0->1 and 1->0 ) is t ransmitt ed. Chang e b it is monitored t o ind icate p [...]

  • Page 1244

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n sh u n t resistor (l imitatio n v ol t age) t h en seco n d ary ign itio n v olt ag e is d etected and sh u n t r esi stor may b e f aul t y. 57 P03 25 Knock sen sor 1 circuit, (Bank 1) circuit cont inu ity I n p u t an al og ampl itu d e (13 -19 kHz) Pl au sibil ity [...]

  • Page 1245

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n tran sistor and comp onen t ex ists. 74 A C compr esso r relay Ou tp u t d ig ital on/ off (activ e l ow ) DM E f in al stag e will set f l ag wh enev er a sh ort t o g rou n d , a sh ort to b at tery v ol t age or a d isconn ection b etwee n ou tp u t t ransistor an [...]

  • Page 1246

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n sp ring w ith in motor t h rott l e b ody. 11 0 P15 42 Pe d al sen sor p otent io meter 1 I n p u t an al og (0-5 V) Failed sign al r ang e ch eck against p redefin ed d iag n ostic l imi t s. 11 1 P15 42 Pe d al S ensor Potent io meter 2 I n p u t an al og (0-5 V) Fa[...]

  • Page 1247

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 11 7 P15 42 Pe d al sen sor p otent io meter p l au sibil ity I n p u t an al og (0-5 V) I f t h ere is a d ifference g reater t h an sp ecifie d b etwee n t wo redu n d an t sign als f rom p oten tiome t er, fau l t will b e set. 11 8 P01 20 M S 42 M otor th rottl e [...]

  • Page 1248

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n d isconn ection b etwee n ou tp u t tran sistor and comp onen t ex ists. 12 4 P15 93 D ISA , rang e/ p erf. Ou tp u t d ig ital on/ off (activ e l ow ) DM E f in al stag e will set f l ag wh enev er a sh ort t o g rou n d , a sh ort to b at tery v ol t age or a d isco[...]

  • Page 1249

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 13 1 CA N time out (inst r 2) I n p u t b inary stream b it d ata (0-1 2V ) CA N me ssage b et we en DM E /EG S n ot recei v ed wi t h in ex p ected t ime . 13 2 CA N time out (inst r 3) I n p u t b inary stream b it d ata (0-1 2V ) CA N me ssage b et we en DM E /EG S[...]

  • Page 1250

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n swi tch is " l ow" for l ong er t h an p redet ermi n ed t ime . 14 2 M S 43 D M T L mod u l e fau l t DM E in tern al v alu es l ogical 14 3 P14 76 EV A P: cl amped tu b e ch eck I n p u t d igital freq u en cy (0-12 V) Freq u en cy of LDP pu mp s ree d sw [...]

  • Page 1251

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n on inp u t l in e. 15 3 P01 50 Ox yg en sensor p re-ca t (Bank 2), sh ort t o b att ery v olt . I n p u t an al og (0-5 V) O x yg en sen sor sign al rang e is ch ecked to d etermine if el ectrica l sh orts ex ist on in p u t l in e. V olt age sig n al must b e wi th i[...]

  • Page 1252

    BM W code P-code Faul t type and fun ction Sig n al type and ra ng e Explanatio n 16 0 M S 43 T h rottl e v al v e p osi t ion cont rol l er DM E in tern al v alu es l ogical 16 1 M S 43 T h rottl e v al v e p osi t ion cont rol l er DM E in tern al v alu es l ogical 16 2 M S 43 T h rottl e v al v e p osi t ion cont rol l er DM E in tern al v alu e[...]