BMW E46/4 Sedan User manual

Initial Print Date: 11/00 Revision Date:11/16/00
Subject Page
E46 Sedan and Coupe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E46/4 Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
E46/2 Coupe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bod
Bod Shell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Hood and Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Door Anchoring S stem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Door Handles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sunroof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Interior Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Driver Information Displa s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake S stem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
E46 Sport Wagon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Bod Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Bod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of Contents
E46 MODELS

Subject Page
Rear Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Center Arm Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Child Seat Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cargo Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Emergenc Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
E46 Convertible. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bod 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 ll-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

3
E46 Models
E46 Sedan and Coupe
Model: E46/4: Sedan, E46/2: Coupe
Production Dates: E46/4 from 6/98, E46/2 from 6/99
Objectives:
After Completing this module ou should be able to:
• Identif the location and purpose of the Door Anchoring Hooks.
• Describe the Suspension S stems used on the E46.
• Describe how to make a Camber adjustment to the front wheels.
• Identif vehicle fuse locations.

4
E46 Models
E46/4 Sedan
The E46 is the successor to the E36 and is the next evolution in the 3 series development.
The E46/4 Sedan was introduced as a 1999 model as both the 323i and 328i.
The E46 3 series vehicle offers more comfort, safet , space and equipment than the previ-
ous E36, without compromising the sport characteristics of the 3 series vehicle.
Since start of production,two engine variants have been offered, the M52TU and the M54
six c linders. Both engines introduced changes and design improvements that will be cov-
ered in the Engine and Engine Management chapters.

5
E46 Models
E46/4 Dimensions

6
E46 Models
E46/2 Coupe
The E46/2 Coupe was introduced as a 2000 model ear vehicle in both 323Ci and 328Ci
variants.
The bod of the E46 /2 Coupe is not a modified sedan, but is a completel distinct bod .
There are no sheet metal parts shared between the Sedan and the Coupe Onl the design
technolog 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 c linders. Both engines introduced changes and design improvements that will be cov-
ered in the Engine and Engine Management chapters.

7
E46 Models
E46/2 Dimensions

8
E46 Models
Body
Body Shell
The structural rigidit of the E46 bod shell was increased using computer aided design
(CAD) techniques. Ever component of the new bod structure was designed using this
method. CAD allows the design to be translated into computer aided manufacturing (CAM)
more efficientl . To reduce the weight of the vehicle, while retaining strength, high strength
steels are used and now amount to 50% of the bod shell weight.
The second area of focus of the bod shell is "structural d namics". This deals with vibra-
tion frequencies that effect the ride qualit and rigid feel. The E46 bod 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 safet cage concept for passenger protection. The tubular
impact structures continue to provide protection against bod damage during front or rear
impacts.
The E46 is 1.8 times more able to absorb energ in a 40mph offset frontal crash than the
E36.

9
E46 Models
Hood and Headlights
The E46 follows the E38/E39 design with the kidne grille being integrated into the hood.
The grille openings are more rounded and sweep down to the front bumper. The cowl
opening is now integrated in the hood and is similar to the E38. The hood can be opened
to a maximum of 90°, the workshop position, b disconnecting the gas struts and insert-
ing a pin in the aligned holes.
The hood is opened b first pulling the release lever located inside the vehicle and then
releasing the secondar 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 clearl visible through the smooth,
plastic covers. The plastic covers are lighter in weight and more resistant to breakage than
the previous glass covers.
Vertical and horizontal adjustments for the head lamps are located on the upper rear edge
of the assemblies.
Xenon low beam head lamps will be an available option starting with 9/98 production.
Xenon headlights are discussed in the E46 Driver Information Chapter.

10
E46 Models
Doors
The doors on the E46 feature the door anchoring s stem introduced 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 bod in the event of a side impact.
The door seal design is copied from the E39 and is a single piece seal.

11
E46 Models
Door nchoring System
Cross section of driver’s door 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 s stem.
After impact, the door springs
back and unhooks the notch.
The door is clear of the “B” pillar
and can be opened.

12
E46 Models
Door Handles
The door handles and locking s stem on the E46 are of a new design. The new bow t pe
handles allow the doors to be opened easier. The locks are full encapsulated including the
electrical components. The new door handle/latch/lock assembl offers improved reliabilit
and securit against theft. The micro-switches for door position and lock condition have
been replaced b hall sensors.
There are no serviceable components on the lock assembl 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 lock assembl was also modified to accommodate the new articulation of
the door handles.

13
E46 Models
Sunroof
The sunroof 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.

14
E46 Models
Interior Features
The interior of the E46 has been completel redesigned with an emphasis on more space,
luxur and convenience without compromising the 3 series sport characteristics.
The new instrument panel/dash is similar in design to the E39 with a slightl less pro-
nounced orientation to the driver. The E38/E39 t pe face vent grills are used for air distrib-
ution.
The multi-function steering 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 s stem
on the left and the cruise control on the right.
The E46 comes equipped with a manuall adjustable (tilt/telescopic) steering column. There
is 30 mm of vertical and horizontal adjustment for the steering column.
1. Spring
2. Clamping mechanism
3. Steering lock with
steering column tube

15
E46 Models
Driver information Displays
The primar displa for driver information is located in the instrument cluster. The coupe and
sedan have different cluster lettering and faces. The secondar displa in the console con-
sists of the audio s stem and automatic climate control panel (if equipped with IHKA).
Two different radio t pes are available. One
with the integrated tape pla er and the other
radio incorporating a single in dash CD pla er.
Accessor switches are located 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-touch
and anti-trap features.
Instrument Cluster electronics and audio systems
are covered in the E46 Driver Information Chapter.
UNLEADED GASOLINE ONLY
0
12
20
km/h
MPH
1/min
x1000
40
6080 100 120 140 160
180
200
220
240
1
0
2345
6
7
50 30 20 15 12
20
40
60 80 100
120
140
11

16
E46 Models
Seats
The front seats are similar in design to the E36 seats with new internal construction to
improve their support and comfort. Memor for the drivers seat position is available. The
seat controls, including memor storage buttons are located on the side of the seat base.
An optional lumbar support is also available for the E46.

17
E46 Models
A split folding (40/60) seat is available 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 securit aspect when keeping items locked in the
trunk.

18
E46 Models
Power Distribution
The batter is installed in the trunk of the E46 and features lead/calcium plate material for
true maintenance free operation. The water usage of this batter is low throughout its ser-
vice life.
The Batter Safet Terminal is installed at the positive terminal of the batter . A repair kit is
available for the BST.
The E46 is produced with a vehicle 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 area
If the entire harness need to be replaced, a new harness with the maximum equipment or
options must be ordered. This is the onl harness that will be stocked in the parts s stem.

19
E46 Models
There are three locations for fuses on the E46:
• The fuse holder above the glove box
• The E-Box in the engine compartment
• In the trunk near the batter
The E46 uses high amperage fuses for circuit protection. The batter power suppl is pro-
tected b a 250 amp fuse in the trunk.

20
E46 Models
Front Suspension
The single ball joint, strut axle of the E46 is based on the E36 design. Design and compo-
nent changes were developed to improve the ride qualit and handling characteristics. The
following changes are incorporated into the E46 front suspension s stem:
• A new forged aluminum control arm is used on the E46 (except all-wheel drive). It offers
the advantages of weight reduction and lower unsprung mass.
• H draulic 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 geometr .
• The caster has been increased to improve straight line stabilit .
• The track has been widened for improved cornering.
• Aluminum brake dust shields are used for weight reduction
Altogether there is 5.72 lbs less unsprung weight in the front suspension which enhances
ride comfort and handling.