BMW 3-Series 1999-2005, Z4 2003-2005

This Haynes DIY repair and service manual, covers 1999-2005 BMW 3-Series models, E46 chassis, and 2003-2005 BMW Z4 models, coupe and convertibles, including:

• BMW 323ci, 1999-2000
• BMW 328ci, 1999-2000
• BMW 325ci, 2001-2006
• BMW 330ci, 2001-2006
• BMW Z4, 2003-2005

Cars in this manual are powered by 2.5L, 2.8L and 3.0L 6-cylinder DOHC engines. They are also equipped with computer-controlled ignition systems and electronic fuel injection.

Transmissions are either a 5- or 6-speed manual or a 4- or 5-speed automatic with overdrive.

General information contained in this manual can also be applied to xi models.

Note: This manual does not cover the 318ti, 323is, 328is, Z3 or information specific to M3 models or all-wheel drive cars.

PRIMARY CHAIN TENSIONER NOTE: Removal and installation is described as part of the primary timing chain removal procedure in Section 7. VARIABLE VALVE TIMING (VANOS) COMPONENTS | REMOVAL, INSPECTION AND INSTALLATION VANOS ADJUSTMENT UNIT REMOVAL (Refer to illustrations 9.3, 9.4, 9.8, 9.9 and 9.10)

1. Remove the viscous cooling fan/electric cooling fan and fan cowl assembly (see Chapter 3).
2. Remove the valve cover (see Section 4).
3. Unscrew the union bolt, and disconnect the oil feed pipe from the front of the VANOS adjustment unit (see illustration). Recover the sealing rings.
4. Disconnect the exhaust camshaft position sensor and solenoid valve electrical connectors (see illustration).
5. Unscrew the retaining nut and bolt, and remove the engine lifting bracket from the front of the engine.
6. Unclip the plastic cover from the intake camshaft.
7. Position the crankshaft and camshafts at TDC on Number 1 piston (see Section 3).
8. Unscrew the two cover plugs from the front of the VANOS adjustment unit (see illustration). Be prepared for oil spillage and discard the sealing rings (new ones must be installed).
9. Using a pair of needle-nose pliers, pull the sealing caps from the end of the camshafts (see illustration).
10. Using a Torx bit, unscrew the setscrews from the end of the camshafts (see illustration). Note: the setscrews have left-hand threads (turn clockwise to loosen).
11. Remove the retaining nuts and remove the VANOS adjustment unit from the front of the engine. Remove the gasket.
12. Do not rotate the crankshaft, camshafts or move the splined shaft in the end of the camshafts with the VANOS unit removed; otherwise the pistons may come in contact with the valves.

SIDE TRIM PANEL | COUPE
(Refer to illustrations 27.31, 27.33, 27.35) NOTE: On models fitted with rear side airbags, due to the proximity of side airbags, disconnect the battery as described in Chapter 5, and then wait two minutes before proceeding.

29. Using a plastic wedge, carefully lever away the plastic cap over the window link rod (see illustration 15.2).
30. Lever the window link rod from the mounting on the window (see illustration 15.3).
31. Push the seat belt to one side, and push down the center pin of the expanding rivet securing the plastic trim at the top of the seat side cushion (see illustration). Maneuver the plastic trim over the hinged window link rod.
32. Remove the rear seat cushion as described in Section 24.
33. Fold the seat backrest forward and, using a screwdriver, release the retaining clip at the top and pull the seat side cushion from its location (see illustration). Note how the fitting at the base of the trim engage with the fitting on the wheel arch.