2002 BMW 320i

The 2002 BMW 320i is part of the E46 generation of the 3 Series, known for its blend of sporty handling and comfortable ride. In the North American market, the 320i was powered by a 2.2-liter inline-6 engine producing 170 horsepower and 150 lb-ft of torque. This engine was available with either a 5-speed manual or a 5-speed automatic transmission. Owners appreciate the 320i for its engaging driving dynamics, precise steering, and well-balanced chassis. However, common complaints often revolve around the car’s age-related maintenance needs, including cooling system issues, electrical gremlins, and suspension wear. The relatively lower power output compared to other 3 Series models can also be a point of dissatisfaction for some.

Engine

2.2L Inline-6 (M54)

• Oil Filter Housing Gasket Leak
  • Description/Symptoms: Oil leak around the oil filter housing, visible oil drips, burning oil smell.
  • Solution: Replace the oil filter housing gasket.
  • Estimated Cost to Fix: $150 - $300+
  • Recalls: None Found
• Valve Cover Gasket Leak
  • Description/Symptoms: Oil leak around the valve cover, visible oil drips, burning oil smell.
  • Solution: Replace the valve cover gasket.
  • Estimated Cost to Fix: $200 - $400+
  • Recalls: None Found
• Cooling System Failure
  • Description/Symptoms: Overheating, coolant leaks, cracked expansion tank, failing water pump.
  • Solution: Replace the expansion tank, water pump, thermostat, and hoses.
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found
• DISA Valve Failure
  • Description/Symptoms: Rattling noise from the engine bay, loss of low-end torque, rough idle.
  • Solution: Replace the DISA valve.
  • Estimated Cost to Fix: $200 - $400+
  • Recalls: None Found

Transmission

5-Speed Automatic (GM A5S325Z)

• Slipping or Harsh Shifting
  • Description/Symptoms: Transmission slips between gears, harsh or delayed shifting, “Transmission Failsafe Program” warning light.
  • Solution: Fluid flush and filter change, valve body repair/replacement, or transmission rebuild/replacement.
  • Estimated Cost to Fix: $200 (fluid flush) - $3000+ (rebuild/replacement)
  • Recalls: None Found

5-Speed Manual (ZF S5D 250G)

• Clutch Failure
  • Description/Symptoms: Slipping clutch, difficulty shifting, clutch pedal sticking, unusual noises when depressing the clutch.
  • Solution: Replace the clutch disc, pressure plate, throw-out bearing, and pilot bearing.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found

Suspension

• Control Arm Bushing Failure
  • Description/Symptoms: Clunking noise from the front suspension, uneven tire wear, vague steering.
  • Solution: Replace the front control arm bushings (especially the lower control arm bushings).
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Rear Trailing Arm Bushing Failure
  • Description/Symptoms: Clunking noise from the rear suspension, unstable handling, rear end swaying during cornering.
  • Solution: Replace the rear trailing arm bushings.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found

Electrical

• Window Regulator Failure
  • Description/Symptoms: Window not moving, clicking noise from the door panel, window falling into the door.
  • Solution: Replace the window regulator.
  • Estimated Cost to Fix: $200 - $400+
  • Recalls: None Found
• ABS Module Failure
  • Description/Symptoms: ABS and traction control lights illuminated, loss of ABS and traction control functionality.
  • Solution: Repair or replace the ABS module.
  • Estimated Cost to Fix: $300 - $1000+
  • Recalls: None Found
• Ignition Switch Failure
  • Description/Symptoms: Car not starting, intermittent electrical issues, key getting stuck in the ignition.
  • Solution: Replace the ignition switch.
  • Estimated Cost to Fix: $150 - $300+
  • Recalls: None Found

Exterior

• Rust on Wheel Wells and Rocker Panels
  • Description/Symptoms: Rust bubbles or holes appearing on the wheel arches and rocker panels.
  • Solution: Repair or replace affected panels, rust removal, and repainting.
  • Estimated Cost to Fix: $500 - $2000+ (depending on severity)
  • Recalls: None Found

Interior

• Pixel Loss on Instrument Cluster or Radio Display
  • Description/Symptoms: Missing or faded pixels on the instrument cluster or radio display, making it difficult to read information.
  • Solution: Repair or replace the instrument cluster or radio display.
  • Estimated Cost to Fix: $200 - $500+ (repair) / $500 - $1000+ (replacement)
  • Recalls: None Found
• Sagging Headliner
  • Description/Symptoms: The fabric headliner detaching from the roof and sagging down.
  • Solution: Replace the headliner.
  • Estimated Cost to Fix: $300 - $700+
  • Recalls: None Found

Summary

The 2002 BMW 320i, while a desirable vehicle for its driving dynamics, is prone to several age-related issues. Engine issues like gasket leaks and cooling system failures are common and can be moderately expensive to repair. Suspension component wear, particularly bushings, is also prevalent. Electrical problems such as window regulator and ABS module failures can add to the maintenance burden. Interior issues like pixel loss and sagging headliners are mostly cosmetic but can detract from the overall driving experience. The severity and cost of repairs can vary significantly based on the condition of the car and the availability of parts. Overall, prospective buyers should carefully inspect the car’s maintenance history and be prepared for potential repairs.