Recalls: BMW E46 M3 Convertible (2003-06)
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: BMW E46 M3 Convertible
2004 BMW E46 M3: wheel bolts could work loose
In July 2004, a recall was issued for BMW E46 3-Series Convertible vehicles manufactured from 8 May 2004 to 22 June 2004. For these vehicles, the wheel hub bores in the wheel rim may be too small. As a result, the wheel may not make proper contact with the brake discs and, although the wheel bolts were tightened to the correct torque, the wheel bolts could work loose (PRA 2004/7140).
2001-03 BMW E46 M3: Takata airbag recall
In May 2013, a recall was issued for BMW E46 3-Series convertibles that were manufactured between December 2001 and March 2003. In these vehicles, the front passenger air bag inflator may have been assembled with improperly manufactured propellant wafers. In the event of a crash, the inflator may rupture and cause the front passenger airbag to deploy abnormally, increasing the risk of injury to the occupant (PRA 2013/13576).
2002-05 BMW E46 M3: Takata airbag recall
In August 2016, a recall was issued for BMW E46 M3 Convertibles that were available for sale from 1 January 2002 to 31 December 2005. If subjected to high levels of absolute air humidity, the gas generator of the driver’s airbag could malfunction; if the gas generator exploded, metal parts could be propelled out of the airbag due to high internal pressure, potentially causing injury to the driver and/or passengers. For the VINs of the recalled vehicles, please see PRA 2016/15581.
2000-04 BMW E46 M3: Takata airbag recall
In March 2017, a recall was issued for BMW E46 M3 vehicles that were available for sale from 1 January 2000 to 31 December 2004. During the service life of these vehicles, or as part of the Takata airbag recall, the airbag inflator may have been replaced and the replacement airbag module may not deploy correctly. If the replacement airbag module was faulty, deployment of the airbag could cause the airbag’s metal case to rupture and disperse metal fragments throughout the cabin which had the potential to cause serious injury or death. For the VINs of the recalled vehicles, please see PRA 2017/15881.
Problems and faults: BMW E46 M3 Convertible
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
BMW E46 3-Series: floor cracks at rear sub-frame mount position
For the BMW E46 3-Series and E46 M3, the rear differential transmits the torsional load from the engine through the sub-frame and into the chassis – this constant loading and unloading weakens the sheet metal around the rear sub-frame mounts, causing it to fatigue and separate from the chassis.
Compared to the E36 3-Series, the rear suspension for the E46 3-Series had a cross-member on the front two mounting points of the sub-frame – this cross-member protected the front mounting points by placing the bushing and the stud in double-sheer, thereby reducing the twisting action on the sheet metal. As a result, however, the load from the front of the sub-frame was transmitted to the left rear of the sub-frame and caused cracks in the sheet metal in that area.
To overcome this problem, rear chassis reinforcement kits have been developed which thicken the metal and distribute the load over a large area. See, for example,Turner Motorsport: E46 Rear Chassis/Subframe Reinforcement Kit.
In the USA, BMW North America settled a class action lawsuit over for 1999-06 BMW E46 3-Series vehicles, acknowledging that ‘the attachment points of the Sub-Frame may develop a fracture or crack.’ As a part of the settlement, BMW agreed to provide an inspection, repair procedure and reimbursement policy for affected owners. This scheme, however, was only offered in the USA.
E46 M3 Convertible: connecting rod bearing replacement
In October 2004, BMW issued technical service bulletin SI B11 04 04 for BMW E46 M3 Convertibles with the S54B32 engine that were manufactured from 12 February 2001 to 22 May 2003. In these vehicles, the connecting rod bearings were not manufactured to BMW standards and were susceptible to overheating – this could cause premature engine failure if the vehicle was driven at higher engine speeds over an extended timeframe. As part of a service campaign, the connecting rod bearings were to be replaced and the engine control module updated.
Separately, however, premature connecting rod bearing wear has been attributed to insufficient rod bearing clearance which resulted in inadequate oil lubrication between the crank journal and rod bearing.
E46 M3 Convertible: S54 engine deposits
In February 2008, BMW issued technical service bulletin SI B 13 01 07 for E46 M3 Convertibles with S54 engines. In these vehicles, deposits in the injection and induction system may cause driveability complaints and the ‘Service Engine Soon’ light to be illuminated. This condition could be caused by:
- Deposits at the fuel injector’s tip which affected fuel flow and the air/fuel mixture ratio. Symptoms included hesitation or stumble during acceleration or loss of power; poor fuel efficiency; increased HC and CO emissions; and, the ‘Service Engine Soon’ lamp to illuminate due to misfire faults;
- Carbon deposits at the valves and on the intake manifold ports absorbing fuel during the warm-up phase, causing a leaner air/fuel mixture. Carbon deposits (or build-up) could also disturb the mixture flow at low throttle conditions and/or idle speeds. Symptoms of carbon deposits included a loss of power; unstable and/or rough idle; increased HC, CO and NOx emissions; and, the ;Service Engine Soon; lamp to illuminate due to intermittent misfire faults; and,
- Combustion Chamber Deposit Interference (CCDI) when there was contact between carbon deposits on the piston crown and the cylinder head. The noise created by this contact may be misdiagnosed as a ping, knock or other mechanical failure. CCDI occurs first as a cold start noise that can fade as the engine reaches operating temperature. As deposits build, there is an increase in compression temperature that may cause pre-ignition detonations. Symptoms include knocking, pining, poor acceleration, increased NOx emissions and engine idle speed surges.
E46 M3 Convertible: S54 VANOS concerns
For the E46 M3 Convertible’s S54 engine, the following concerns have been reported over the VANOS system:
- VANOS failure: the VANOS unit has an oil pump disc with two holes and the exhaust hub has two driver tabs that insert into the oil pump disc holes. Due to excessive rotational pressure force or rattling/hitting force, one or both of the driver tabs can break – if this occurs, VANOS malfunction and engine fault codes will be issued. A broken tab can stay lodged in the VANOS oil pump disc hole or it can drop to the oil pan. In rare cases, the tab can engage the chain and sprockets, causing engine damage;
- VANOS solenoid failure: the VANOS solenoid coil pack may fail due to cracked solder joints which are the connector pins on the PCB (printed circuit board); and,
- VANOS rattle.
For more information on the S54 engine, please see BMW M54 and S54 Engines.
E46 M3 Convertible: rear differential grinding noise
In January 2009, BMW issued technical service bulletin SI B33 01 02 for E46 M3 Convertibles. In these vehicles, a grinding noise may be heard from the rear differential during slow cornering; the noise was most prevalent during turning manoeuvres with a high degree of lock such as parallel parking or tight circles.
When cornering, a ‘slip stick’ effect was created on the lining and steel discs incorporated in the differential locking clutch, thereby causing the grinding noise. The noise typically dissipated as the locking clutch discs in the differential were ‘broken in’. The break-in time, however, varied according to driving habits.
For the E46 M3, E90/E92/E93 M3, E60 M5 and E63/E64 M6, a specially formulated differential oil (part number 83 22 2 282 583) was recommended.
Problems and faults: BMW E46 M3 Convertible
- Steering wheel vibrations may be attributable to poor isolation of the power steering pump.
- The automatic transmission may slip and/or the ‘check engine’ light may illuminate due to the torque converter clutch (TCC) slipping and/or TCC solenoid failure.
- For models with manual transmissions, the drain plugs may leak and the fill plug may also require replacement.
