2002 BMW 325i Service and Repair Manual

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Factory-Grade Data

2002 BMW 325i service and repair manual a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What's included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Sedan 4-Door
  • Base Wagon 4-Door

Engines covered

  • 2.5L 2494CC 152Cu. In. l6 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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  • Visa

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Vehicle Safety Data

2002 BMW 325i Recalls & Complaints

NHTSA #11V43800026/08/2011Component: EXTERIOR LIGHTING:TAIL LIGHTS

BMW IS RECALLING CERTAIN MODEL YEAR 2002-2005 325I, 325XI, 330I, AND 330XI VEHICLES MANUFACTURED FROM SEPTEMBER 1, 2001, THROUGH MARCH 1, 2005. OVER TIME, RESISTANCE IN THE ELECTRICAL CONTACTS MAY CA

Consequence

INTERMITTENT LIGHT OPERATION REDUCES THE ABILITY TO WARN OTHER MOTORISTS OF THE DRIVER'S INTENTIONS.

Remedy

BMW WILL NOTIFY OWNERS, AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGA

NHTSA #20V01800015/01/2020Component: AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

BMW of North America, LLC (BMW) is recalling certain 2000-2005 323iT, 325iT, 325xiT, 320i, 323i, 325i, 325xi, 328i, 330i and 330xi and 2000-2006 323Ci, 325Ci, 328Ci, 330Ci, M3 Coupe, 323Cic, 325Cic, 3

Consequence

An inflator explosion may result in sharp metal fragments striking the driver or other occupants res

Remedy

BMW will notify owners, and dealers will replace the passenger's front air bag, free of charge. The

NHTSA #13V17200002/05/2013Component: AIR BAGS

BMW is recalling certain model year 2002-2003 325i, 325xi, 330i, 330xi sedans; 325Ci and 330Ci coupes and convertibles; 325iT and 325xiT Sports Wagons; and M3 coupes and convertibles to address a safe

Consequence

In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator co

Remedy

Owners are advised not to drive their vehicles until they have been repaired. BMW intends to issue i

TSB #10249437

The basic conditions for initializing the power windows are not met.

TSB #10194296

Diagnosis of Compound Brake System Complaints in M Vehicles: 1. Visible cracks are caused by high thermal stresses during rapid heating and cooling of the brake discs. Braking from high speed with cold brake components (less than 212 degree

TSB #10184591

SERVICE ACTION - HEAD AIR BAG HOLDER RETROFIT: A rattle noise may develop from the head air bag (ITS) gas generator contacting adjacent component. This noise can be heard while driving on an uneven roadway.

TSB #10160287

TAKATA AIR BAG RECALL-RELATED SHORT-TERM ALTERNATE TRANSPORTATION AND CONSEQUENTIAL REPAIRS This Service Information bulletin supersedes SI B01 31 18 dated October 2018.

TSB #10160244

TAKATA AIR BAG RECALL-RELATED SHORT-TERM ALTERNATE TRANSPORTATION AND CONSEQUENTIAL REPAIRS This Service Information bulletin supersedes SI B01 31 18 dated October 2018.

TSB #10154816

In an effort to improve the completion rate on Takata air bag recall affected vehicles; BMW NA has expanded the BMW Ultimate Rewards platform to include a new Recall Support page. This page will allow IRFs to check their customers VINs for

TSB #10153726

TAKATA CLASS ACTION SETTLEMENT. CUSTOMER SUPPORT PROGRAM. FRONT DRIVER SIDE AIRBAG MODULES.

TSB #10150160

State Inspection and Emission (I/M) Test Fails Due To an Invalid VIN Number. The customer of an affected vehicle may fail to pass an I/M test due to a non-compliant 17digit vehicle identification number (VIN) stored in the DME (Digital Moto

Showing the 8 most recent of 16 technical service bulletins on file with NHTSA.

20050902Component: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULECrash reportedFire reported1 injured

T-BONED AN EIGHTEEN WHEELER GOING 55 MPH AFTER HE PULLED OUT IN FRONT OF ME TO MAKE A LEFT-HAND TURN ON A HIGHWAY. THE AIRBAG OF MY BMW 325I FAILED TO DEPLOY RESULTING IN INJURY.

20190324Component: AIR BAGSCrash reported1 injured

ON SEPTEMBER 7, 2018 I LEND MY CAR TO MY SON SO HE COULD RUN SOME SCHOOL RELATED ERRANDS HE NEEDED TO ATTEND TO. THAT DAY HE HAD ALSO TAKEN MY DAUGHTER WITH HIM AS THEY WERE GOING TO HAVE LUNCH AFTER

20070208Component: AIR BAGS:SIDE/WINDOWCrash reported1 injured

ON 12/21/06, I WAS DRIVING ON A TWO-LANE ROAD WHEN ANOTHER DRIVER LOST CONTROL OF HIS TRUCK, HIS BACKEND SLID OFF THE ROAD AND WHEN THE BACK TIRES GAINED TRACTION, IT SHOT HIS TRUCK ACROSS HIS LANE AN

20040202Component: AIR BAGS:FRONTALCrash reported1 injured

RIGHT FRONT PASSENGER SUSTAINED SEVERE EYE INJURY AS A RESULT OF THE DEPLOYMENT OF THE RIGHT FRONT AIRBAG IN A CRASH. PASSENGER SUFFERS PARTIAL BLINDNESS. UNDERGONE SEVERAL SURGERIES. PASSENGER WAS

20110419Component: AIR BAGS:SIDE/WINDOWCrash reported1 fatalities

TL*THE DRIVER OWNED A 2002 BMW 325I. WHILE DRIVING APPROXIMATELY 45 MPH A VEHICLE CRASHED INTO THE FRONT DRIVERS SIDE OF THE VEHICLE. THE SIDE AIR BAGS DID NOT DEPLOY. THE VEHICLE WAS TOWED TO AN IMPO

Showing the 5 most serious of 198 complaints filed with NHTSA.

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