2002 BMW 325xi

The 2002 BMW 325xi is an all-wheel drive variant of the popular E46 3-Series. It came equipped with a 2.5-liter inline-6 cylinder engine (M54B25) producing 184 horsepower and 175 lb-ft of torque. Other engine options for the E46 3-Series include a smaller 2.0-liter inline-4 and a larger 3.0-liter inline-6. The 325xi came standard with a 5-speed manual transmission and an optional 5-speed automatic transmission. Owners generally appreciate the car’s sporty handling, comfortable ride, and classic BMW styling. Common dislikes include higher maintenance costs compared to other cars, and some age-related reliability issues that are typical for a 20+ year old vehicle.

Engine

M54B25 2.5L Inline-6

• Oil Filter Housing Gasket Leak
  • Description/Symptoms: Oil leak from the oil filter housing, visible oil dripping, 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 from the valve cover gasket, visible oil dripping down the side of the engine, burning oil smell.
  • Solution: Replace the valve cover gasket.
  • Estimated Cost to Fix: $150 - $300+
  • Recalls: None Found
• Coolant Expansion Tank Failure
  • Description/Symptoms: Coolant leaking from the expansion tank, overheating. Cracks in the expansion tank plastic.
  • Solution: Replace the coolant expansion tank.
  • Estimated Cost to Fix: $150 - $300+
  • Recalls: None Found
• DISA Valve Failure
  • Description/Symptoms: Rattling noise from the intake manifold, rough idle, loss of low-end torque.
  • Solution: Replace the DISA valve.
  • Estimated Cost to Fix: $200 - $400+
  • Recalls: None Found

Transmission

5-Speed Automatic (GM A5S390R / ZF 5HP19)

• Transmission Slipping/Rough Shifting
  • Description/Symptoms: Delayed gear engagement, harsh shifts, slipping between gears.
  • Solution: Fluid change, valve body repair/replacement or full transmission rebuild.
  • Estimated Cost to Fix: $150 (fluid change) - $3,000+ (rebuild)
  • Recalls: None Found

Suspension

• Control Arm Bushing Failure
  • Description/Symptoms: Clunking noise from the front suspension, especially over bumps, wandering steering.
  • Solution: Replace the front control arm bushings or the entire control arms.
  • Estimated Cost to Fix: $200 - $500+ per side
  • Recalls: None Found
• Rear Trailing Arm Bushing Failure
  • Description/Symptoms: Vague rear end feel, clunking noises.
  • Solution: Replace the rear trailing arm bushings.
  • Estimated Cost to Fix: $200 - $400+ per side
  • Recalls: None Found

Electrical

• Window Regulator Failure
  • Description/Symptoms: Window not moving up or down, clicking noise.
  • Solution: Replace the window regulator.
  • Estimated Cost to Fix: $200 - $400+ per window
  • Recalls: None Found
• Final Stage Resistor (FSR) Failure
  • Description/Symptoms: Blower motor speed erratic or not working at all, battery drain.
  • Solution: Replace the final stage resistor (FSR).
  • Estimated Cost to Fix: $100 - $200+
  • Recalls: None Found

Exterior

• Rust on Wheel Arches/Fenders
  • Description/Symptoms: Rust bubbling and forming on the edges of the wheel arches and fenders.
  • Solution: Rust repair, panel replacement, and paint.
  • Estimated Cost to Fix: $300 - $1000+ per panel
  • Recalls: None Found

Interior

• Pixel Loss in Instrument Cluster/Radio Display
  • Description/Symptoms: Pixels missing or faded in 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: $150 - $500+ (repair) $300-$1000+ (replacement)
  • Recalls: None Found

Summary

The 2002 BMW 325xi, while a desirable car, is over 20 years old and prone to certain age-related issues. The most common problems revolve around oil leaks from engine gaskets and bushings, suspension components wearing out, and electrical gremlins. Repairs can range from relatively inexpensive fixes like replacing gaskets or resistors to more costly procedures such as transmission work or rust repair. While the car offers a great driving experience, potential buyers should be aware of these potential maintenance costs and be prepared to address them to keep the car in good running condition.