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Home1998-2006 3 Series (E46)BMW E46 Starter Replacement - 1998-2006 3 Series - M52/M54

BMW E46 Starter Replacement – 1998-2006 3 Series – M52/M54

Repair Summary
This article gives detailed instructions on replacing the starter motor in a BMW E46 3 series vehicle. Even though we used a 2000 323i with the M52 engine to perform this repair, this article can be applied to any 1998-2006 vehicle with minor modifications to the repair steps.

A BMW E46 starter replacement may be necessary if your 1998-2006 3 series engine is struggling to turn over.

One of the most often used mechanical parts in your BMW is the engine's starter motor. Depending on your driving habits, the starter motor in your BMW E46 3 series can be used over a thousand times a year. And like all regularly used mechanical parts in your vehicle's engine, the starter motor has a finite lifespan and will eventually fail.
The BMW E46 starter is simply an electric motor that rotates the engine's crankshaft when the ignition key is turned. It contains an electromagnet which when energized, pushes out a pinion gear on the end of a shaft. This pinion gear engages the engine's flywheel which in turn spins the crankshaft. When the engine "turns over" the ignition key is released, which causes the shaft to retract and the starter motor to shut off.
Due to age and general wear and tear, the internal components of the starter motor can begin to fail. The most common symptom of a failing BMW E46 starter motor is the vehicle becomes difficult to start (or won't start at all)...even with a fully charged battery. In fact, many 3 series owners mistakenly install a new battery in the vehicle when in reality they need a starter replacement. Another common symptom of a failing starter motor is a clicking sound when attempting to start the vehicle - this is caused by the starter shaft engaging the flywheel but being unable to turn it.
Where is the starter motor on a BMW E46 3 series?
The starter motor in all 1998-2006 3 series vehicles is at the bottom of the engine underneath the intake manifold. We feel the easiest way for the home mechanic to perform a BMW E46 starter replacement is by removing the intake manifold. The starter motor can also be removed from underneath the vehicle, but this requires unbolting the transmission.  This can be a major undertaking for the DIY mechanic working in his garage - removing the intake manifold to access the BMW E46 starter motor is a much more realistic approach and is the procedure covered in this repair article.
Don't be intimidated by removing the intake manifold in this repair! If you closely follow our step-by-step instructions it is actually a relatively easy procedure. Most importantly it gives you a chance to replace the infamous intake manifold gaskets that are prone to vacuum leaks on the BMW E46 3 series vehicle.
Required Parts
OEM
FREE Prime Shipping + Returns
Bosch is an OE supplier for most of the worlds automobile manufacturers. Bosch produces premium grade aftermarket parts for BMW that equal or surpass the original equipment installed in the vehicle.
OEM
E46 323i and 328i
Bosch is an OE supplier for most of the worlds automobile manufacturers. Bosch produces premium grade aftermarket parts for BMW that equal or surpass the original equipment installed in the vehicle.
Amazon's choice + Prime Shipping and Returns (M52 and M54)
Set includes both gaskets. Established in 1972, AJUSA is one of the world's leading manufacturers of gaskets/sets, cylinder head bolt sets, and hydraulic lifters. AJUSA offers the widest coverage for European and Asian applications, especially late model vehicles. Fits the following models: E39, E46, E53, E60, E83, Z3 and Z4 with M52 or M54 6 cylinder engine.
Factory Part
All M52 and M54 six-cylinder engines
Set includes both gaskets. These are the same factory gaskets that would be installed at the BMW dealership. Fits the following models: E39, E46, E53, E60, E83, Z3 and Z4 with M52 or M54 6 cylinder engine.
BMW E35 and E46 323i and 328i. E39 528i. Z3 2.8
This profile gasket is used in between the throttle body unit and the intake manifold. This Part Fits the Following Vehicles: BMW E35 and E46 323i and 328i. E39 528i. Z3 2.8
Amazon's Choice + Prime Delivery (BMW E46 323i, 325i and 328i)
The first part of the intake boot...connects to the mass air flow (MAF) sensor. This Part Fits the Following Vehicles: BMW E46 323i, 325i and 328i.
Repair Steps
Section 1 - Removing the Intake Manifold
In order to perform a BMW E46 starter replacement, the intake manifold must be removed. This should not be an intimidating process...in fact we urge home mechanics to look at this as an opportunity to install new manifold and throttle gaskets, as well as replace old vacuum lines that are prone to leaking. For detailed step by step instructions on removing the intake manifold for this repair, please see our article BMW M52 Intake Manifold Removal – 1995-2000 3,5,7,Z3 Series 6 Cyl.
Section 2 - Removing the Starter Motor
The BMW E46 starter motor mounting bolts are notoriously difficult to remove from the engine for two reasons; there is very little clearance to get a socket wrench squarely on the head of the bolts, and the bolts are usually seized from age. These two conditions can create a recipe for disaster if you are not careful...you can strip the mounting bolt heads. We have found the best method for removing the starter mounting bolts is to use a long 1/4" drive swivel head ratchet, with a 3/8" adapter and E12 external torx socket. The reason why you must use a 1/4" socket wrench is that the head on a 3/8" wrench is too large....it will not allow the Torx socket to fit squarely on the head of the bolt. It is also important to use a long handle ratchet in order to get the proper amount of leverage to loosen the bolts. If used correctly as shown in the below steps, you will be able to safely extract the mounting bolts without any issues. If you need to order any of these tools prior to starting this repair, we have the same ones we used in the above tool list.bmw e46 starter replacement - The proper tools for extracting the mounting boltsUse an E12 socket and 1/4 bmw e46 starter replacement - The proper setup for extracting starter mounting bolts  
  1. Locate the BMW E46 starter motor. It is located at the rear of the engine.bmw e46 starter replacement - Locate the starter motor at the rear of the engine
  2. Use a 13mm socket wrench to remove the positive battery cable and alternator cable from the starter solenoid.Remove the positive battery and alternator cable from the starter solenoid
  3. Use an 8mm and 10mm socket wrench to remove the two wiring harness leads from the starter solenoid.bmw e46 starter replacement - Remove the top wiring harness lead from the starter solenoid bmw e46 starter replacement - Remove the lower wiring harness lead from the solenoid Remove the wiring harness leads from the solenoid
  4. Using a metal pick or small flat blade screwdriver, remove the coolant line on the side of the engine block. Have a 5 gallon drain pan ready to catch any coolant that comes out.bmw e46 starter replacement - Disconnect the engine coolant line.
  5. The starter is anchored to the engine with two E12 torx bolts. Before attempting to remove them, spray both bolts liberally with Blaster PB penetrating oil and allow to soak for 5-10 minutes. You may need to apply the penetrating lubricant several times if the bolts are seized (see next steps). Not pre-soaking the starter mounting bolts with penetrating lubricant could cause the heads to strip during removal.PB Blaster penetrating oilbmw e46 starter replacement - Soak the mounting bolts in penetrating lubricant
  6. Using a long 1/4" swivel socket wrench with 3/8" adapter and E12 torx socket, remove the first mounting bolt as shown below. If the bolt is seized, proceed to the next step. If you are able to remove the bolt, proceed to step 8 below.bmw e46 starter replacement - Remove the first mounting bolt
  7. If the bolt is seized and won't break free, spray it again with penetrating lubricant and allow it to soak for a few minutes. Using a ball peen hammer, gently tap on the bolt 10-20 times. Keep repeating this process until the bolt breaks free and can be removed. Be patient...it may take some time. We had to repeat this procedure 6 times before our mounting bolt finally loosened.Gently strike the starter with a ball peen hammer if the bolts are seizedbmw e46 starter replacement - A successfully removed starter bolt
  8. Repeat the above steps on the second mounting bolt.bmw e46 starter replacement - Remove the second starter mounting bolt
  9. When both mounting bolts are removed, grasp the starter and remove it from the engine.bmw e46 starter replacement - Remove the starter motor from the engine
Section 3 - Installing the Start Motor
Installing the new starter is a simple process except for one caveat. It is virtually impossible to get a torque wrench on the starter mounting bolts...there is simply not enough clearance to get the wrench in place. This raises the issue of proper torquing of the bolts. As we have always said here at the BMW Repair Guide, sometimes an important procedure within the repair must be changed or adapted to avoid more complicated circumstances. In this instance, "guessing" at the final torque values of our starter mounting bolts presents less of a risk than dropping the transmission so they can be tightened with a torque wrench. In simple terms, make your starter mounting bolts as tight as you can without stripping the heads and you will be fine.
  1. Install a new starter motor back into the engine. Make sure the mounting holes are properly aligned.bmw e46 starter replacement - Install the new starter motor into the engine
  2. Install the mounting bolts and tighten as much as possible without stripping the heads. You unfortunately will not be able to get a torque wrench on them. (see our discussion at the beginning of this section).You will not be able to get a torque wrench on the starter mounting bolts so just make them as tight as you can without stripping the torx head
  3. Reconnect the engine coolant line. Make sure to put firm pressure on it until it clicks into place.bmw e46 starter replacement - Reconnect the engine coolant line
  4. Reinstall the two wiring harness leads and torque their nuts to 6 Nm (4.5 ft-lb).bmw e46 starter replacement - Reinstall the wiring harness leads and torque to 6 Nm (4.5 ft-lb).
  5. Reinstall the positive battery and alternator cables. Torque their mounting nut to 12 Nm (9 ft-lb).bmw e46 starter replacement - Reinstall the battery and alternator cables and torque to 12 Nm (9 ft-lb).
  6. Reinstall the intake manifold following the procedure in our article BMW M52 Intake Manifold Removal – 1995-2000 3,5,7,Z3 Series 6 Cyl.
  7. Refill the coolant reservoir and check to make sure there is no air in the system. For more information on refilling the coolant system on your BMW E46 3 series, please see the end of our article BMW E46 Water Pump Repair – 1998-2006 3 Series – All Models.
 
BMW E46 Starter Replacement Finished
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