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2004 BMW 325xi

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By Research the Car 4 min read

The 2004 BMW 325xi is an all-wheel-drive variant of the E46 3 Series, a popular compact executive car known for its sporty handling and refined driving experience. This model year came standard with the 2.5-liter M56 inline-6 engine, producing 184 horsepower and 175 lb-ft of torque. A 5-speed manual or a 5-speed automatic transmission was offered. While owners generally appreciate the 325xi for its balanced performance, all-weather capability, and classic BMW styling, common complaints revolve around maintenance costs, particularly concerning the cooling system and electrical components, as well as certain age-related issues. Other engine options available for the 2004 E46 3 Series include the M54 2.5-liter inline-6 (slightly different specs) and the M54 3.0-liter inline-6 offered on the 330xi, which produced 225 horsepower and 214 lb-ft of torque.

Engine

2.5L M56 Inline-6

  • Cooling System Failure
    • Description/Symptoms: Overheating, coolant leaks, warning lights. Common culprits include a failing water pump (especially those with plastic impellers), radiator leaks, expansion tank cracks, and thermostat failure.
    • Solution: Replace the faulty components. Water pumps should be replaced with ones that have a metal impeller. It’s often recommended to replace the entire cooling system (radiator, hoses, thermostat, water pump, expansion tank) as preventative maintenance.
    • Estimated Cost to Fix: $300 - $1000+ depending on the parts replaced and labor costs.
    • Recalls: None Found
  • Oil Filter Housing Gasket Leak
    • Description/Symptoms: Oil leak around the oil filter housing, often dripping onto the exhaust manifold, causing a burning smell.
    • Solution: Replace the oil filter housing gasket.
    • Estimated Cost to Fix: $150 - $400
    • Recalls: None Found
  • Valve Cover Gasket Leak
    • Description/Symptoms: Oil leaks from the valve cover, leading to burning smells and potential oil consumption.
    • Solution: Replace the valve cover gasket.
    • Estimated Cost to Fix: $150 - $350
    • Recalls: None Found
  • DISA Valve Failure
    • Description/Symptoms: Rough idle, loss of power, and a rattling noise from the engine. The DISA valve controls intake manifold runner length.
    • Solution: Replace the DISA valve. Some aftermarket options offer upgraded designs.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found

Transmission

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

  • Transmission Slipping/Hard Shifting
    • Description/Symptoms: Delayed engagement, slipping between gears, or harsh shifts, especially when the transmission is cold.
    • Solution: Fluid change may help in some cases, but often requires valve body repair or replacement, or a complete transmission rebuild.
    • Estimated Cost to Fix: $200 (fluid change) - $3500+ (rebuild/replacement)
    • Recalls: None Found

Suspension

  • Control Arm Bushing Failure
    • Description/Symptoms: Clunking noises from the front suspension, especially over bumps. Vibrations at highway speeds.
    • Solution: Replace the control arm bushings. It’s often recommended to replace the entire control arm assembly.
    • Estimated Cost to Fix: $200 - $600 per side
    • Recalls: None Found
  • Rear Subframe Mount Failure
    • Description/Symptoms: Clunking or popping noises from the rear of the car, especially during acceleration or cornering. Excessive movement or cracking around the rear subframe mounts. This is a known weak point in the E46 chassis.
    • Solution: Repair or reinforcement of the rear subframe mounts. Welding and reinforcement plates are often required.
    • Estimated Cost to Fix: $1000 - $3000+ depending on the severity of the damage and the repair method.
    • Recalls: None Found

Electrical

  • Window Regulator Failure
    • Description/Symptoms: Window not moving, slow movement, or clicking noises when attempting to operate the window.
    • Solution: Replace the window regulator.
    • Estimated Cost to Fix: $200 - $400 per window
    • Recalls: None Found
  • Instrument Cluster Pixel Failure
    • Description/Symptoms: Pixels disappearing or fading on the instrument cluster display.
    • Solution: Repair or replace the instrument cluster.
    • Estimated Cost to Fix: $150 - $500+
    • Recalls: None Found
  • Mass Air Flow (MAF) Sensor Failure
    • Description/Symptoms: Rough idle, stalling, poor acceleration, and check engine light.
    • Solution: Replace the MAF sensor.
    • Estimated Cost to Fix: $150 - $300
    • Recalls: None Found

Exterior

  • Rust (Especially around wheel wells, door bottoms, and trunk lid)
    • Description/Symptoms: Visible rust bubbling or perforation.
    • Solution: Rust repair and repainting.
    • Estimated Cost to Fix: $300 - $2000+ depending on the extent of the rust.
    • Recalls: None Found

Interior

  • Headliner Sagging
    • Description/Symptoms: Headliner fabric detaching from the headliner board and sagging.
    • Solution: Replace or re-glue the headliner fabric.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found

Summary

The 2004 BMW 325xi, while enjoyable to drive, can present owners with a range of issues, primarily due to its age. The cooling system and suspension components are common problem areas. Engine oil leaks are also common. Repair costs can vary widely, with some fixes being relatively inexpensive while others, like transmission or subframe repairs, can be quite costly. The severity of these issues depends on the vehicle’s maintenance history and the environment in which it was driven. Potential buyers should carefully inspect the vehicle and obtain a pre-purchase inspection from a qualified mechanic familiar with BMWs.

BMW, 325xi
BMW 325xi 2004
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