BMW E46/2 Coupe, Manual

Page 1: ...8 Hood and Headlights 9 Doors 10 Door Anchoring System 11 Door Handles 12 Sunroof 13 Interior Features 14 Driver Information Displays 15 Seats 16 Power Distribution 18 Front Suspension 20 Rear Suspension 22 Final Drive 23 Brake System 23 E46 Sport Wagon 24 Body Specifications 25 Body 26 Interior 27 Table of Contents E46 MODELS ...

Page 2: ...37 Technical Data 38 Body Shell Floor Pan 40 Windshiel Frame 40 Rear Bulkheads 41 Tension Strut 41 Aluminum Support Plate 41 Rear Seats 42 Variable Top Storage Compartment 43 E46 All Wheel Drive 45 Introduction 46 Chassis Front Axle 48 Steering 49 Differential and Front Axles 50 Rear Axle 51 Tires and Wheels 51 Transmissions 52 Transfer Case 53 Review Questions 55 ...

Page 3: ...rom 6 98 E46 2 from 6 99 Objectives After Completing this module you should be able to Identify the location and purpose of the Door Anchoring Hooks Describe the Suspension Systems used on the E46 Describe how to make a Camber adjustment to the front wheels Identify vehicle fuse locations ...

Page 4: ...The E46 3 series vehicle offers more comfort safety space and equipment than the previ ous E36 without compromising the sporty characteristics of the 3 series vehicle Since start of production two engine variants have been offered the M52TU and the M54 six cylinders Both engines introduced changes and design improvements that will be cov ered in the Engine and Engine Management chapters ...

Page 5: ...5 E46 Models E46 4 Dimensions ...

Page 6: ...ign technology of the E46 4 was used to create the E46 Coupe The Coupe is even longer and wider than the sedan The E46 Coupes have been given the Ci coupe injected trunk badge designation This is a departure from the is injected sport from previous 3 series coupes Since start of production two engine variants have been offered the M52TU and the M54 six cylinders Both engines introduced changes and...

Page 7: ...7 E46 Models E46 2 Dimensions ...

Page 8: ...t The second area of focus of the body shell is structural dynamics This deals with vibra tion frequencies that effect the ride quality and rigid feel The E46 body shell was designed so that the frequencies for torsional twisting and bending are separated and are in an inaudible range The ranges match the E39 for twisting at 29 hertz and bending at 26 hertz The E46 continues with BMW s safety cage...

Page 9: ...ver located inside the vehicle and then releasing the secondary catch that pops out of the grille The E46 carries on with the traditional four head lamp configuration however no internal lens is used over each lamp The free form reflectors are clearly visible through the smooth plastic covers The plastic covers are lighter in weight and more resistant to breakage than the previous glass covers Ver...

Page 10: ...troduced with the E38 The anchor consists of a horizontal bar in the door and a hook at the rear edge The hook rests in a recess in the B and C pillars and it reinforces the body in the event of a side impact The door seal design is copied from the E39 and is a single piece seal ...

Page 11: ...or and B pillar in the normal closed posi tion Upon severe impact the hook locks into the recessed notch to provide a unitized side impact pro tection system After impact the door springs back and unhooks the notch The door is clear of the B pillar and can be opened ...

Page 12: ...ability and security against theft The micro switches for door position and lock condition have been replaced by hall sensors There are no serviceable components on the lock assembly and it must be replaced as a unit From September 2000 production there was a modification done to the door handles of the E46 The modified door handles when pulled fold upward instead of straight out as previous The l...

Page 13: ...roof design is similar to the E38 E39 however the sunroof cassette is not service able and must be replaced as a complete unit The sunroof is an option on the E46 and will come with a glass panel moon roof instead of a steel panel ...

Page 14: ...eering wheel is available on both the 323 325 models and standard on 328 330 models There are two different steering wheels available the four spoke wheel with MFL and a three spoke sport wheel with MFL The three spoke sport wheel is option al for sedans and standard in coupes The MFL includes the controls for the audio system on the left and the cruise control on the right The E46 comes equipped ...

Page 15: ...d in the console below the heater control panel These include the ASC switch and the heated seat switches Later production vehicles 2000 M Y utilize the SZM Center Console Switching Center in place of the separate switches A new design push to open pull up to close window switches are located in the center con sole on either side of the gear shift lever The power window circuits include the one to...

Page 16: ...eats with new internal construction to improve their support and comfort Memory for the drivers seat position is available The seat controls including memory storage buttons are located on the side of the seat base An optional lumbar support is also available for the E46 ...

Page 17: ...vailable as an option on sedans and standard on coupe models The release for the folding seat backs is located in the trunk on the left and right sides near the wheel arches This increases the security aspect when keeping items locked in the trunk ...

Page 18: ...cle specific wiring harness This harness is based on the ordered optional equipment of the vehicle so that it contains the proper connectors and connections Options can not be added at a later time without replacing the entire harness Specific kits are available to repair the harness in the event of an accident or damage to the harness These repair kits include Engine compartment Vehicle s rear ar...

Page 19: ... fuses on the E46 The fuse holder above the glove box The E Box in the engine compartment In the trunk near the battery The E46 uses high amperage fuses for circuit protection The battery power supply is pro tected by a 250 amp fuse in the trunk ...

Page 20: ...ntages of weight reduction and lower unsprung mass Hydraulic bushings are used for the rear lower control arm support Hollow strut piston rods are used to reduce weight The steering knuckles are press fit into the strut tubes which reduces the tolerances of the front suspension geometry The caster has been increased to improve straight line stability The track has been widened for improved corneri...

Page 21: ... corrections need to be made to the front end alignment the pin can be driven down and the strut can be moved in the slots to adjust the camber Approximately 5o of adjustment is available by moving the strut in the slots Follow the instructions for making the Camber adjust ment described in Repair Manual 32 00 610 Use Special Tool 32 3 140 to make the adjustment ...

Page 22: ... Noise reduction The sub frame is a new design employing steel tubes and metal sections It is more rigid than the previous sub frame This provides a stable platform for the rear suspension to work from The differential is mounted to the sub frame using a hydraulic mount The sub frame is mounted to the body at four vibration absorbing rubber mounts The upper transverse control arms are made from ca...

Page 23: ... transmission tunnel to be narrower increasing the interior passenger space With this change the axle shafts are now different in length and are no longer interchange able Brake System The braking system is upgraded for the E46 to match the vehicle s size and braking require ments The dual circuit front back distribution system continues to be used for optimized braking response and performance Re...

Page 24: ...E46 sedan The rear doors have been remodeled for wagon usage and the tail gate is similar to the E39 Sport Wagon with an opening rear window The rear seats fold down to provide 1345 liters of cargo space With the seats up the rear compartment provides 435 liters of load space 24 E46 Models 00E46SPTWGN0400 Objectives After completing this module you should be able to Identify the changes to the bod...

Page 25: ... width and turning radius are the same as the E46 sedan The fol lowing are the maximum cargo capacity loads 435 Liters luggage capacity with rear seat back up 1345 Liters luggage capacity with back rest down 540KG in the rear 75 KG on the roof 1471 mm 1739 mm 1478 mm 1932 mm 758 mm 2725 mm 4478 mm 995mm 1382mm 1378mm 41E46SPTWGNSPEC0000 ...

Page 26: ...rear window New Rear Bumper No tail gate lock cylinder Roof rails as optional equipment The structural rigidity and structural dynamic characteristics introduced with the E46 sedan are carried over to the E46 Sport wagon As with the sedan and coupe the Sport Wagon body shell acts as the passenger s safety cage along with the tubular impact struc tures for the front and rear bumper mountings 26 E46...

Page 27: ...e seats are folded down for cargo loading The rear seats backs are a 60 40 split with the center arm rest section on the left seat back The center passenger s inertia reel is mounted to the left seat back while the left right rear passenger s belt reels are mounted on the wheel housings The lower section of the seat back is separate foam piece that enables the back rest pivot point to be higher on...

Page 28: ...rest incorporates the non adjustable center head rest The center arm rest is folded down to gain access to the storage compartment and cup holders which are integrated into the rear of the head rest 52E46SPTWGNCUP0500 STORAGE COMPARTMENT CUPHOLDER ...

Page 29: ...9 E46 Models Child Seat Anchor There are three child seat hold down anchors positioned behind the rear seat back rest The plastic covers must be removed to access the hold down anchors CHILD SEAT ANCHOR ...

Page 30: ...offers 435 liters of cargo space with the rear seat back rest raised and 1345 liters with it lowered The cargo area offers a spring loaded roller blind and cargo net sim ilar to the E39 Sport Wagon 00E46SPTWGNCARGO0500 51E46SPTWGNCARGONET0000 ...

Page 31: ...the spare tire and control module mounting area located beneath A strap is provided to hold the load floor up while accessing the storage area The interior trim panel must also be removed for access to the spare and control modules Power Socket A 12 Volt power socket is installed on the left side of the cargo area behind the rear seat back WINDOW WASHER FLUID RESERVOIR SOUND SYSTEM COMPONENTS SPAR...

Page 32: ...cluding the rear glass that is hinged separately and can be opened independently from the tail gate Rear Actuator The actuator for the tailgate release is mounted on the rear apron behind the trim panel Control of the actuator is a function of the GM ZKE system TAILGATE RELEASE SWITCH ...

Page 33: ...event of an electrical failure The release is located along the lower edge of the rear apron behind a small access cover After removing the cover the lever is pushed to the right to mechanically release the tail gate The rear apron of the E46 Sport Wagon is lowered for easier loading unloading A plastic rubbing strip prevents the bumper from being scratched when cargo is being loaded unloaded EMER...

Page 34: ...l carrier which is hinged to the body If the rear window needs replacement it is supplied with the glass bonded to the metal carrier The release switch for opening the rear glass is incorporates into the rear wiper arm cover under the triangle trim plate REAR WINDOW SWITCH ...

Page 35: ...bolts The gap of the window should be uniform on all sides The height of the rear window is adjust ed using shims on the hinge mounts Refer to the repair manual for complete adjustment procedures and sequence Rear Washer Nozzle The rear window washer spray nozzle as well as the third brake light is mounted at the top left side integrated into the spoiler 63E46SPTWGNTAILLIGHT0000 41460001 ...

Page 36: ...rsional Rigidity Identify the floor pan reinforcements for energy absorption on the SGS seats Identify the body shell reinforcements necessary for the addition of the Variable Convertible Top Storage Compartment Floor Describe how the windshield frame is reinforced Identify and describe the functions of the Tension Strut Identify and describe the function of the Aluminum plate ...

Page 37: ... comes with a manual top as standard equipment The new fully automatic electro hydraulic top is available as an option The 330 E46iC will come with the fully auto matic top as standard equipment The roll over protection system is standard equipment and is similar in design to the E36 system The roll over protection bars are hidden by the rear headrest and deployed under the same criteria as the E3...

Page 38: ...38 E46 Models TECHNICAL DATA ...

Page 39: ...rned Acceleration 0 60 MPH sec 7 7 8 8 auto 8 8 9 7 auto preliminary TECHNICAL DATA Outside Car Dimensions E36 E46 Convertible Convertible Inside Car Dimensions Length mm 4433 4488 Width mm With Mirrors 1710 1875 1757 1947 Height mm 1648 1672 General Information Shoulder Room front mm 1352 1384 Shoulder Room rear mm 1108 1165 Elbow Room front mm 1412 1443 Elbow Room rear mm 1120 1208 Effective hea...

Page 40: ...e variable convertible top storage compartment floor Components Floor Pan The floor pan is reinforced to support the SGS seat by heavier cross brace members rein forced tunnel floor pan and reinforced engine support brackets During a collision all forces occurring on the seat are channeled to be absorbed by the floor pan Windshield Frame The windshield frame is reinforced with stepped reinforcing ...

Page 41: ...ompartment is opened to enlarge the storage area Tension Strut Tension struts are integrated into the rear of the body shell to improve the torsional rigidity by not allowing body twist in the rear It also keeps the rear end of the car intact with the middle floor pan Aluminum Support Plate An aluminum support plate is incorporated into the front suspension carrier to achieve a high degree of rigi...

Page 42: ...f the E36iC The E46iC is equipped with child seat mounting brackets on the left and right sides below the seat base The brackets conform to ISO International Organization of Standardization for placement on the rear floor pan Any ISO child seat can be installed by simply sliding the seat into position between the seat base and backrest and locking it into place ...

Page 43: ...o be enlarged by approximately 40 liters when the soft top is raised or removed for hard top installation Components of the system Variable Compartment Floor The variable compartment floor is constructed of plastic with fabric covering It is hinged mechanically so that it can be rotated up into the top storage area providing additional lug gage storage space in the trunk The floor is hinged at fou...

Page 44: ...set position retracted or extended The lower dampening piston hinge switches the micro switch integrated on the right side of the compartment floor when the variable compartment floor is in the raised position This signal is provided to the CVM to lock out the operation of the convert ible top System Operation Opening the variable compartment floor The convertible top must be raised or removed fro...

Page 45: ...30xi A 325xi A 325xi A Sport Wagon Production date 330xi 8 00 325xi 9 00 Objectives After completing this module you should be able to Identify the changes made to the E46 to accommodate all wheel drive Understand the construction of the NV124 transfer case ...

Page 46: ...argely been taken from the X5 concept It uses two open differentials and a single speed transfer case Power distribution is 38 to the front and 62 to the rear giving the E46 16 the feel of a genuine rear drive road car With it s additional 17mm ground clearance the xi is particularly suited to stretches of snow and ice covered roads and its sure footedness is made possible by the use of the Bosch ...

Page 47: ...n tunnel and modifications on the driver s side to accept the transfer case Modified oil pan and engine mounts to provide access for the front axles A completely new front engine carrier Re reinforcements for the front strut bearings A compact new transfer case NV 124 New transmission cross member Bosch DSC III 5 7 ...

Page 48: ...e 2wd model attach at the rear to the axle carrier The pivot at the apex of the lower control arms are a separate ball joint bolted to the axle carrier The purpose of the re design of the lower control arms and mounting points is to provide clearance for the front axle shafts The hydraulic engine mounts are different from the 2wd version and have also been relocated to provide front axle clearance...

Page 49: ...ront axle spring travel is due to the limited angle of deflection of the front axle shafts Steering The rack and pinion steering unit has been modified from the 2wd It is constructed with a larger diameter piston This is necessary to counter the additional drag of the all wheel drive system and the wider standard wheels and tires The lower steering spindle is different than the 2wd and connects to...

Page 50: ...ime fluid fill SAF XO The oil sump has been modified to accommodate the right side axle A connecting tube is welded into the oil pan A shaft runs inside of the connecting tube between the front differential and the axle shaft on the right side Two drive shafts of equal length are used to transmit power to the front wheels The steering knuckle is modified to accept the CV joint of the front axles T...

Page 51: ... approximately 17mm less than the 2wd version The reason for the reduced travel in the rear is to oppose any excessive body roll as a result of the higher body profile The rear sway bar has been increased in diameter to 20mm 2wd standard 18mm sports suspension 19mm to accommodate the additional weight Tires and wheels Standard wheel size is 17x 7 0 to ensure there is enough room for the front axle...

Page 52: ...LT1 synthetic transmission fluid The automatic transmission for both the 330xi and 325xi is the A5S 390 R General Motors transmission with GS 20 AGS control and Steptronic shifter The transmission has a lifetime fill of Texaco 8072B Transmission Cross member Along with the lower transfer case section the cast aluminum transmission cross member is a low profile design to optomize ground clear ance ...

Page 53: ...bution 38 62 Maximum Torque 300Nm The transfer case is only one speed and does not use any viscous coupler The transmission ratio of the planetary gear set provides a fixed torque transfer of 38 62 front Rear The output speeds to the front and rear axle are the same 1 1 The input to the Planetary Carrier is from the output shaft of the transmission The Sun Gear of the Planetary assembly is turned ...

Page 54: ... The transfer case is filled with a lifetime fill of MTF LT1 P N 83 22 9 408 942 The only repairs possible are the replacement of the three oil seals and the hydraulic mount Oil Volume 0 24 liter Drain Fill plug torque 33Nm Planetary Ring Gear Output to Rear Axle Torque Transfer from the Planetary Gear Set ...

Page 55: ... previous 3 series E36 5 Where is the emergency release for the tailgate located on the E46 Sport Wagon 6 What allows the windshield frame of the E46 Convertible to act as a roll over protection device 7 How is the floor pan on the E46 Convertible improved for structural rigidity 8 Describe the components used in the E46 all wheel drive running gear 9 Describe the changes made to the front suspens...