2002 BMW 325xi Service and Repair Manual

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Factory-Grade Data

2002 BMW 325xi 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.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, 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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Vehicle Safety Data

2002 BMW 325xi 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.

20140914Component: AIR BAGSCrash reported2 injured

I WAS DRIVING THE CAR AND MY WIFE WAS A PASSENGER IN THE FRONT SEAT. ANOTHER CAR HIT OUR CAR ON THE FRONT DRIVER SIDE DEPLOYING BOTH FRONT AIRBAGS. I HAD BACK INJURIES AND MY WIFE LOST VISION IN BOT

20170511Component: UNKNOWN OR OTHERFire reported

CAR WAS PARKED IN PRIVATE DRIVEWAY, 200 FEET FROM STREET, AND HAD NOT BEEN DRIVEN OR STARTED FOR 4 DAYS. AWOKE TO CAR COMPLETELY ENGULFED IN FLAMES. FIRE TRUCK NEEDED TO PUT OUT FIRE, AND TO PROTECT

20111123Component: EXTERIOR LIGHTINGFire reported

TL* THE CONTACT OWNS A 2002 BMW 325XI. THE CONTACT STATED THAT NONE OF THE REAR LIGHTS FUNCTIONED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE WIRING HARNESS WA

20160819Component: AIR BAGS1 injured

TL* TAKATA RECALL. THE CONTACT OWNS A 2002 BMW 325XI. WHILE DRIVING APPROXIMATELY 60 MPH, THE DRIVER SIDE AIR BAG DEPLOYED WITHOUT WARNING OR IMPACT. THE CONTACT SUSTAINED BURNS AND BRUISES ON THE LEF

20040602Component: AIR BAGS:FRONTAL1 injured

WHILE DRIVING 50 MPH DRIVER RAN OVER PIECES OF DEBRIS ON THE HIGHWAY AND BOTH FRONTAL AIR BAGS WENT OFF INADVERTENTLY. DRIVER SUSTAINED HEAD AND BACK INJURIES , AND WAS TRANSPORTED BY AMBULANCE TO T

Showing the 5 most serious of 93 complaints filed with NHTSA.

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