BMW 3 Series (E46)

Interior

In 1993, the development programme for the E46 began under the lead of chief engineer Wolfgang Ziebart and head of R&D Wolfgang Reitzle.[17] In late 1993, design work began under the lead of chief designer Chris Bangle and continued into 1995.[18] In May 1995, the general exterior design of the E46 by Erik Goplen of DesignworksUSA was approved and as a result DesignworksUSA was contracted by BMW to work alongside BMW Group's in-house design team to create the exterior bodywork for the 3 Series range in February 1996.[19][20][21] The design team put an emphasis on improving aerodynamics and increasing the car's aggressive stance.[20] Design patents were filed in Germany on 16 July 1997[22] and in the US on 16 January 1998.[23]

Chris Bangle and Wolfgang Reitzle were responsible through 1995 for the production sedan's exterior,[24][25] as evident in the 1997 design patent. Production development of the sedan took 24 months following design freeze and was 31 months from executive board styling approval in 1995 to its start of series production in December 1997.[26] Erik Goplen designed the production coupé, convertible and station wagon during between 1996 and 1997. The E46 sedan was unveiled via press release on 11 November 1997 and was launched on the market at the end of April 1998 with customer deliveries.[27]

The body shell of the E46 was claimed by BMW to be 70% more rigid than its E36 predecessor.[28] Aluminium was used for an increased quantity of suspension components, in order to decrease unsprung mass.[28] However, with a curb weight of 1,450 kg (3,197 lb),[29][30] the E46 328ci is 55 kg (121 lb) heavier than the E36 equivalent.[31][32]

In tune with BMW's core values regarding handling dynamics,[33] the E46 was initially available with a rear-wheel drive layout and a 50/50 weight distribution.[28][34] All-wheel drive, which was last available in the 3 Series in 1991,[35] was reintroduced for the E46 on the 325xi, 330xi and 330xd models.[36][37]

The electronic components in the E46 are more integrated than previous generations of 3 Series, including the use of a CAN bus system.[38] Drivetrain information (such as engine, transmission and stability control) is communicated using the CAN bus.[39][40] Vehicle electronics (such as the radio, navigation, television and telecommunications) can communicate to each other via the K-bus.[41]

The E46 was the first 3 Series to be available with an engine using Valvetronic (variable valve lift).[42] Various electronic features were also introduced to the 3 Series in the E46 generation, including satellite navigation, electronic brake-force distribution, rain-sensing wipers and LED tail-lights.[43][44][45]

The E46 was produced in Germany (Leipzig, Munich and Regensburg) and in South Africa (Rosslyn).[46] Local assembly of complete knock-down (CKD) kits was used for cars sold in China, Egypt,[47] Indonesia, Malaysia,[48] Mexico,[49] Thailand[50] and Russia.[51]

The highest selling year for the E46 chassis was 2002, when 561,249 vehicles were sold worldwide.[52]

3 Series Compact (E46/5)

The shorter three-door hatchback version of the E46 was marketed as the BMW 3 Series Compact. The exterior styling has several differences to the rest of the E46 3 Series range, notably the distinctive headlights and tail-lights.[61] Mechanically, the Compact shares many elements with the rest of the E46 range, however the steering rack has a faster ratio.[62]

• 5-speed ZF S5-39[64] (325xi, 330xi)[65]
• 5-speed Getrag 250G (316i, 318i,[66] 320i, 325i[67])
• 5 speed ZF S5-31 (320d, 330i, 330Ci, 325xi)
• 6-speed ZF S6-37 (325ti, 330i, 330Ci, 320d, 320Cd)[68][69]
• 6-speed ZF S6-53 (330d, 330 Cd)[70]
• 6-speed Getrag 420G (M3)[71]

• 4-speed GM 4L30-E (A4S270R)
• 5-speed GM 5L40-E (A5S360R)[72][73]
• 5-speed GM 5L40-E (A5S390R)
• 5-speed ZF 5HP19 (A5S325Z)[74]
• 5-speed GM 5L50-E (A5S390R)
• 6-speed SMG-II
• 6-speed Non-M SMG-I

In order for the M3 GTR race car to compete in the American Le Mans Series, BMW produced 10 examples of the "M3 GTR Straßen Version" (street version) in 2001.[76] As per the race M3 GTR, the roadgoing Version was powered by the BMW P60B40 4.0 L V8 engine which was slightly detuned and generated a maximum power output of 283 kW (380 hp) at 7,000 rpm.[77][78] Power was delivered to the rear wheels via a race type 6-speed dual clutch sequential transmission with M locking differential. The engine featured dry sump lubrication as its racing counterpart and bigger radiators.

The stiffer chassis and suspension system were a carryover from the race version. The car was lowered further than a standard M3 and featured additional strut braces between the firewall and strut towers as well as between the right shock towers. The redesigned front and rear fascias and the rear wing optimised aerodynamics.

The roof, the hood, the rear wing and front and rear fascias were made from carbon-fibre in order to reduce weight. Notable changes made to the interior included leather Recaro bucket seats, removal of rear seats and special M3 GTR sill plates.[79]

330ci ZHP

The Performance Package was an option sold in North America, which is commonly referred to by its order code in the United States, ZHP (the order code in Canada was ZAM).[80] It was available for 330i sedans from model years 2003 to 2005, and available for 330ci coupés and convertibles from 2004 to 2006.[81] It included various aesthetic changes over the regular 3 series, as well as functional and mechanical enhancements.

The ZHP was equipped with sportier camshafts and revised engine tuning to increase power output from 168–175 kW (225–235 hp) as well as a shorter final drive gear ratio, and a corresponding increase in redline from 6,500 rpm to 6,800 rpm.[81] Suspension was modified over the standard suspension with firmer springs and dampers, larger anti-roll bars, stronger front control arm ball joints, a lower ride height, heavy duty steering rack, and slightly more negative camber.[82] Car and Driver magazine track-tested the car, which recorded a 0–60 mph (97 km/h) acceleration time of 5.6 seconds and a 1/4 mile time of 14.3 seconds.[82]

BMW M56 SULEV inline-six engine

In some parts of the United States, BMW sold a version of the 325i which met the super ultra low emission vehicle (SULEV) emissions standards. California, New York, and Massachusetts received the SULEV E46's in 2003, and Vermont in 2004.[83] They utilised a variant of the M54 engine named the BMW M56.[83] The M56 meets SULEV standards, as well as partial zero emission vehicle (PZEV) and zero evaporative emissions requirements.[83] The M56 is claimed to have identical power output as its M54 counterpart.[83]

The Clubsport package was available only for the 320Ci/325Ci/330Ci M-Sport models in 2002 and came in these colors: Estoril Blue, Velvet Blue, Titanium Silver and Carbon Black. The package removed 20 kg insulation materials, added an optional rear M spoiler and two spoiler lips on the front bumper, and chromed exhaust tailpipes. Style 71, M-Double Spoke Split rim wheels were standard while interior equipment included M short gear shift, aluminum or black "Alu-Tech" trims, silver rings on cluster, door sills with "M Clubsport" letters, and an interior finished in half-leather and half-fabric "M Texture" cloth. The Clubsport was offered with the 5/6-Speed manual, 6-Speed SMG, or 5-Speed Steptronic transmissions.

• Electronic Stability Control ("Dynamic Stability Control") introduced, replacing the previous ASC+T traction control system.
• Manual shift mode ("Steptronic") added to automatic transmissions

In September 2001, the facelift versions of the sedan and Touring were released for the 2002 model year.

• 325i (M54 engine) replaces 323i (M52TU engine).
• 330i (M54 engine) replaces 328i (M52TU engine).
• 320d engine upgraded from M47 to M47TU.
• Display for navigation system upgraded to widescreen.
• Sedan and Touring receive revised headlights, tail-lights, grille, hood, front fenders and front bumpers.
• Single Xenon headlights for 2001 and in 2002 Xenon were installed for high-beam lamps; Bi-Xenon headlights for 2002.

• 
  pre-facelift sedan
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  pre-facelift sedan
• 
  facelift sedan
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  facelift sedan

In March 2003, the facelift versions of the coupe and convertible models (except M3) were released for the 2004 model year.

• Navigation system upgraded to Mark IV version, which is DVD-based.
• Auxiliary input for sound system becomes available.
• SULEV engine option (M56) becomes available for 325 models with automatic transmission.
• Manual transmission for 330 models upgraded from 5-speed to 6-speed.
• Coupes and convertibles receive revised headlights, tail-lights (LED), grille, hood and front bumper.
• Adaptive headlights available for coupe and convertible models
• 330d engine upgraded from M57 to M57TU.

• 
  pre-facelift coupe (front)
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  pre-facelift coupe (rear)
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  facelift coupe (front)
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  facelift coupe (rear)