- OUT OF PRINT - This Chilton repair and service manual covers 1999-2005 BMW 3-Series (E46 chassis) and Z4. General information contained in this manual can also be applied to xi models. Models covered by this manual are powered by a 2,5L, 2.8L or 3.0L six-cylinder DOHC engine, equipped with computer-controlled ignition and fuel delivery system with electronic fuel injection (EFI) system. Transmissions are five- or six-speed manual and four- or five-speed automatic with overdrive. Models covered include:

• 323i, 323ci
• 325i, 325Ci, 325it
• 328i, 328ci
• 330i, 330ci
• Z4

Note: This manual does NOT cover the 318ti, 323is, 328is, Z3 or information specific to M3 models or all-wheel drive cars.
Book Excerpt: 1999-2005 BMW 3-Series (E46), and Z4 Repair Manual GENERAL ENGINE OVERHAUL PROCEDURES

REMOVAL
(Refer to illustrations 6.8 and 6.24)

1. Relieve the fuel system pressure (see Chapter 4).
2. Disconnect cable from the negative terminal of the battery (see Chapter 5, Section 1).
3. Remove the air filter housing and air intake duct (see Chapter 4).
4. Remove the engine cover (see Chapter 24).
5. Remove the hood (see Chapter 11) or open it up all the way into the service position.
6. Remove the intake manifold (see Chapter 4).
7. Working at the engine compartment fuse/relay center, disconnect the engine harness connectors and position the harness over the engine. If necessary, tape the harness looms together to prevent them from interfering with other components during engine removal.
8. Label and disconnect all vacuum hoses and any other wires from the engine (that aren't connected to the main harnesses that were disconnected in the previous step) (see illustration). Masking tape and/or a touch-up paint applicator work well for marking items.
9. Disconnect the accelerator cable, if equipped, from the throttle body (see Chapter4).
10. Remove the secondary air injection (AIR) pump (see Chapter 6).
11. Disconnect the fuel lines at the engine (see Chapter 4) and plug the lines to prevent fuel loss.
12. Raise the vehicle and support it securely on jack stands.
13. Drain the cooling system and remove the drive belt (s) (see Chapter 1).
14. Remove the power steering reservoir and power steering pump, without disconnecting the hoses, and tie it out of the way (see Chapter 10).
15. Remove the air conditioning compressor, without disconnecting the refrigerant lines, and tie it out of the way (see Chapter 3).
16. Remove the engine reinforcement plate/bar (see Chapter 2A, Section 12).
17. Remove the starter (see Chapter 8).
18. Support the rear of the engine from above with an engine support fixture, then remove the transmission (see Chapter 7).
19. Drain the engine oil (see Chapter !).
20. Remove the transmission cooler lines and brackets from the engine (see Chapter 7).

CHASSIS ELECTRICAL SYSTEM

RELAYS | GENERAL INFORMATION AND TESTING
(Refer to illustrations 3.2, 3.2b, 3.3a and 3.3b)

1. Many electrical accessories in the vehicle utilize relays to transmit current to the component.If the relay is defective, the component will not operate properly. The majority of the fuses and relays are located behind the passenger's side glove box, while some others are located in the "E"-box located in the left-hand corner of the engine compartment.
2. To remove the main fuse box cover, open the glove box, turn the white quick-release fasteners and pull down the cover. A list of the circuits each fuse protects is given on the label attached to the inside of the main fuse box cover (see illustrations).
Note: When the fuse box is retracted or in the up position, the plastic tabs face each other. When the fuse box is released , the plastic tabs face the rear of the glove box.
3. The relays and fuse pack in the E-box are accessed once the cover retaining screws have been removed (see illustrations).
4. If a faulty relay is suspected, it can be removed and tested using the procedure below or by a dealer service department or a repair shop. Defective relays must be replaced as a unit.

Subject: 1999, 2000, 2001, 2002, 2003, 2004, 2005 BMW 3-Series, Z4 service, maintenance, repair. ISBN-10: 1563926091 | ISBN-13: 9781563926099 | Chilton 18401