Recalls: BMW E46 3-Series sedan
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 3-Series Sedan
1998-99 BMW E46 3-Series Sedan: airbags may deploy unexpectedly
In May 1999, a recall was issued for BMW E46 3-Series sedans produced from June 1998. In these vehicles, the side airbags may unexpectedly deploy, for example when driving at speed over a large pothole or curbside, requiring the airbag control unit to be re-programmed. Furthermore, the clip between the brake pedal and brake may not have been installed correctly (PRA 1999/3971).
BMW E46 3-Series Sedan: engine could overheat
In October 2001, a recall was issued for BMW E46 3-Series sedans due to a manufacturing problem with the auxiliary cooling fan electronics that could cause the fan to become thermally overloaded, reducing the cooling system’s performance and causing the engine to overheat (PRA 2001/5017).
2004 BMW E46 3-Series Sedan: wheel bolts could work loose
In July 2004, a recall was issued for BMW E46 3-Series sedan 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 3-Series Sedan: Takata airbag recall
In May 2013, a recall was issued for E46 3-Series sedans 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 3-Series Sedan: Takata airbag recall
In August 2016, a recall was issued for BMW E46 3-Series Sedans 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 3-Series Sedan: Takata airbag recall
In March 2017, a recall was issued for BMW E46 3-Series Sedan 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.
1999-06 model year BMW E46 3-Series Sedan: replacement Takata airbags
In January 2019, recall campaign 0072960100 was issued for 1999-06 model year BMW E46 3-Series Sedans that had previously had their front passenger airbags replaced with ‘like-for-like’ Takata airbags as part of recall PRA 2013/13576. For the VINs of the recalled BMW E46 3-Series Sedans, please see PRA 2019/17279.
1998-00 BMW E46 3-Series Sedan: Takata airbag recall
In November 2019, recall campaign 0032950200 was issued for BMW E46 3-Series Sedans that were manufactured prior to 30 June 2000 – this included the 316i, 318i, 320i, 323i, 325i, 328i and 330i models. The driver’s front airbag module for these vehicles had a Takata non-azide driver inflator (NADI). These inflators contained propellant wafers that could absorb moisture over time. In the event or airbag deployment, this could cause excessive pressure in the airbag inflator housing such that it could explode project metal fragments into the vehicle’s cabin. These metal fragments posed a serious risk of injury (including death); the airbag may also underinflate and not protect the driver as intended. BMW advised owners of these vehicles that they should stop driving their vehicle immediately and contact BMW (via https://findadealer.bmw.com.au/ or calling 1800 243 675) to arrange for their vehicle to be inspected. For the VINs of the recalled vehicles, please see PRA 2019/17946.
Problems and faults: BMW E46 3-Series Sedan
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.
BMW E46 320i, 325i, 328i and 330i: M52 and M54 VANOS failure
For the M52 and M54 engines, the VANOS units may fail due to deterioration of the VANOS piston seal O-rings which are made from Buna (a material with limited temperature resistance). Over time, the O-rings harden and shrink, causing them to lose their functional characteristics – this can cause symptoms such as a loss of power below 3000 rpm, surging around 3000 rpm, a louder idle and rough running.
The piston O-rings lies under and provides support to a Teflon piston seal ring. Replacing the O-rings requires the Teflon seals to be removed for access. Since the Teflon seals cannot be removed from the piston seal groove without damaging it, the Teflon and O-ring seals must be replaced simultaneously. For greater longevity, the Buna O-rings can be replaced with O-rings made from Viton.
The VANOS unit had two piston seals with O-rings, while each piston had two O-ring sizes to provide hydraulic sealing in two VANOS cylinders of different sizes and an additional, smaller O-ring that was used to seal off a piston bearing. It is understood that the O-ring for this cap was also made from Buna and deteriorated in the same manner as the piston seal O-rings.
For more information about the M54 engine, please see BMW M54 and S54 engines.
BMW E46 320i, 325i and 330i: M54 engine deposits
In February 2008, BMW issued technical service bulletin SI B 13 01 07 for E46 3-Series Sedans with M54 engines (i.e. the 320i, 325i and 330i). 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.
BMW E46 320i, 325i and 330i: M54 engine and cold climates
In February 2009, BMW issued technical service bulletin SI B11 08 03 for BMW E46 320i, 325i and 330i sedans with the M54 engine. In these vehicles, extremely cold climate conditions could cause moisture to accumulate and freeze in the:
- Engine oil separator;
- Hose to oil dipstick guide tube; or,
- Orifice in the dipstick guide tube.
Depending on the position of the crankcase ventilation valve when this occurred, the following may occur:
- High crankcase pressures (stuck closed) resulting in valve cover leakage and/or breakage; or,
- An oil hydro-lock condition (stuck open) which could result in engine damage.
To fix, the crankcase ventilation valve, hoses and dipstick guide hoses were to be replaced; a new insulated style of oil separator and hoses were also introduced.
BMW E46 318i: N42B20 chain tensioners and oil leaks
The original timing chain tensioners could wear prematurely and slacken. If this occurred, the chain may slip and jump one tooth at a time, adversely affecting the exhaust camshaft timing. If the chain slips, this will also cause the chain guides to break as the surface comes into contact with the chain – this makes it more likely than the chain will jump. At worst, the change in exhaust camshaft timing can cause the valves to hit the piston crowns such that the valve rods bend – if this occurs, the engine will need to be rebuilt. If the chain jumps, diagnostics may indicate a camshaft sensor fault. It is understood that BMW introduced redesigned, longer chain tensioners in 2003 – these tensioners could be identified by their smaller heads. For preventive maintenance, it is common for the original tensioners to be replaced with the redesigned tensioners.
The N42 engine was susceptible to oil leaks from the rocker cover gaskets, top profile gaskets and VANOS solenoid seals.
BMW E46 328i and 330i: manual shift lever sticks in 5th and reverse
In January 2005, BMW issued technical service bulletin SI B04 04 02 for E46 328i and 330i sedans manufactured prior to January 2003 with manual transmissions. In these vehicles, the manual gearshift lever:
- May be difficult to move into and out of 5th gear and reverse;
- May not automatically move from the 5th and reverse gears back to the centre/neutral position; and,
- May have a loose shift feel (i.e. lack of guidance).
The service bulletin attributed this condition to the fifth gear and reverse gear selector shaft pin sticking due to a defective bushing that was mounted in the selector shaft bore of the transmission. To fix, the fifth and reverse gear selector shaft pin bushing needed to be replaced.
BMW E46 325i and 330i: delay engaging drive gear
In April 2008, BMW issued technical bulletin SI B 24 07 03 for the following E46 vehicles with automatic transmissions –
- BMW E46 325i vehicles manufactured from October 2002 to December 2003; and,
- BMW E46 330i vehicles manufactured from March 2003 to December 2003.
After a cold start, the driver may – when shifting from ‘park’ – experience a delay of between two and thirty seconds when engaging ‘drive’. According to the technical bulletin, this delay was due to insufficient pressure boost for the C1 forward clutch during the first ‘park’ to ‘drive’ shift after extended (overnight) parking. To fix, the Automatic Electronic Gearbox Control (‘EGS’) control module was to be re-programmed using the ‘manual entry’ method.
BMW E46 3-Series: squeaking when steering from left to right
In March 2009, BMW issued technical service bulletin SI B 32 07 08 for BMW E46 3-Series Sedans. In these vehicles, there may be a squeaking or squealing noise from the pinion shaft of the steering gear when the steering wheel is turned from left to right. The service bulletin attributed this condition to insufficient lubrication of the steering gear pinion shaft seal. To fix, Lubrizol treatment was to be added to the power steering fluid to lubricate the pinion shaft seal.
Problems and faults: BMW E46 3-Series sedan
- 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.
