BMW 328 328i 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series (E46) Specific Model: 328i Year: 2002 Generation Chassis Code: E46 Body Styles Covered: Sedan (4-door), Coupe (2-door), Convertible (2-door), Sports Wagon (5-door) 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Wagon Target Audience: Enthusiast owners, independent repair shops, BMW dealerships Competitive Analysis Key Competitors: Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35 Key Features Driving Dynamics: Renowned for its balanced chassis, responsive steering, and engaging driving experience Build Quality: High level of German engineering and premium interior materials Powertrain Options: Smooth inline-six engines known for their refinement and performance 📋 Manual Details Coverage Areas Primary Coverage: Maintenance, Repair, Troubleshooting, Diagnostics, Specifications Engine Coverage: All gasoline engine variants for the 2002 model year 328i Transmission Coverage: All automatic and manual transmission types Drivetrain Coverage: Rear-wheel drive (RWD) Trim Level Coverage: All factory trim levels and options Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Repair and Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine block, cylinder head, pistons, crankshaft, camshafts, valve train, cooling system, lubrication system Engine Management: Fuel injection, ignition system, emission controls, sensors, actuators, ECU diagnostics Transmission Manual: Clutch system, gearbox components, shift mechanisms, linkages Transmission Automatic: Torque converter, valve body, planetary gear sets, transmission control module (TCM), hydraulic systems Drivetrain: Driveshafts, differential, rear axle assembly, hub bearings Suspension: Front and rear suspension components, springs, shock absorbers, control arms, bushings, sway bars Steering: Steering rack, power steering pump, steering column, tie rods, ball joints Brakes: Brake discs, brake pads, calipers, ABS system, hydraulic lines, parking brake Electrical System: Battery, alternator, starter motor, lighting system, fuses, relays, wiring diagrams Body And Chassis: Body panels, doors, hood, trunk, bumpers, interior trim, chassis components Climate Control: HVAC system, air conditioning, heating, ventilation, blower motor, evaporator, condenser Infotainment: Radio, CD player, navigation system (if equipped), speaker systems Safety Systems: Airbags, seatbelts, ABS, traction control Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection Engine Repair: Head gasket replacement, piston ring replacement, bearing service, timing belt/chain service (if applicable), component removal and installation Transmission Service: Fluid and filter changes, seal replacement, transmission overhaul (detailed rebuild procedures) Brake Service: Pad and rotor replacement, caliper service, brake fluid bleeding, ABS component diagnosis and replacement Suspension And Steering Repair: Component replacement, alignment specifications, troubleshooting steering issues Electrical Diagnostics: Troubleshooting circuits, component testing, wiring harness repair, diagnostic trouble code (DTC) interpretation Bodywork And Interior: Panel replacement, trim removal and installation, glass replacement, door and lock repair HVAC Service: Refrigerant system service, component replacement, leak detection, blower and actuator diagnosis Troubleshooting Guides: Systematic approaches to diagnosing common and uncommon problems Diagnostic Procedures: Step-by-step guides for identifying faults using diagnostic tools and visual inspection Technical Depth Depth: Comprehensive, from basic maintenance to in-depth mechanical and electrical system overhauls Diagnostic Tools Reference: Mentions and utilizes BMW proprietary diagnostic tools and common OBD-II scanners Torque Specifications: Detailed torque values for all critical fasteners and components Special Tools: Lists and describes required BMW special tools for specific procedures 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Searchable text content for quick information retrieval Printability: Printable pages for offline use Print Quality Image Resolution: High-resolution diagrams, illustrations, and photographs Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M54B30 Engine Type: 3.0L Inline 6-cylinder (I6) Displacement: 2979 cc (3.0 Liters) Bore X Stroke: 84.0 mm x 89.6 mm Compression Ratio: 10.2:1 Performance Horsepower: 225 hp @ 5900 rpm Torque: 214 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Multi-point injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management ECU Type: MS43 (Motronic System) Lubrication Oil Capacity: 6.5 liters (6.9 US quarts) Recommended Oil Viscosity: SAE 5W-30 Synthetic Cooling System Coolant Capacity: 7.5 liters (7.9 US quarts) Coolant Type: BMW Blue Antifreeze/Coolant (G48 specification) 🔧 Transmission Standard Type: 5-speed Manual Transmission (Getrag 260/6 or similar) Optional Type: 5-speed Steptronic Automatic Transmission (GM A5S 325Z or ZF 5HP19) Features Manual Gear Ratios: Specific ratios detailed in manual (e.g., 4.23:1 first gear) Automatic Features: Driver-selectable modes (Sport/Comfort), manual shifting capability (Steptronic) Fluid Type Manual Fluid Specification: BMW Manual Transmission Fluid (MTF) - e.g., Pentosin MTF.2 or equivalent Fluid Capacity Manual Capacity: Approx. 1.5 liters (1.6 US quarts) Fluid Type Automatic Fluid Specification: BMW ATF LT-3 or equivalent (e.g., Pentosin ATF1) Fluid Capacity Automatic Capacity: Approx. 8.0 liters (8.5 US quarts) for total fill, 3.5-4.0 liters for drain and fill 📐 Dimensions Exterior Sedan Length: 4471 mm (176.0 inches) Sedan Width: 1739 mm (68.5 inches) Sedan Height: 1412 mm (55.6 inches) Coupe Length: 4471 mm (176.0 inches) Coupe Width: 1739 mm (68.5 inches) Coupe Height: 1367 mm (53.8...

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Description

🏷️ Basic Information

Identification

Make:

Model:

3 Series (E46)

Specific Model:

Year:

Generation

Chassis Code:

Body Styles Covered:

Sedan (4-door), Coupe (2-door), Convertible (2-door), Sports Wagon (5-door)

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Coupe/Wagon

Target Audience:

Enthusiast owners, independent repair shops, BMW dealerships

Competitive Analysis

Key Competitors:

Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35

Key Features

Driving Dynamics:

Renowned for its balanced chassis, responsive steering, and engaging driving experience

Build Quality:

High level of German engineering and premium interior materials

Powertrain Options:

Smooth inline-six engines known for their refinement and performance

📋 Manual Details

Coverage Areas

Primary Coverage:

Maintenance, Repair, Troubleshooting, Diagnostics, Specifications

Engine Coverage:

All gasoline engine variants for the 2002 model year 328i

Transmission Coverage:

All automatic and manual transmission types

Drivetrain Coverage:

Rear-wheel drive (RWD)

Trim Level Coverage:

All factory trim levels and options

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Workshop Repair and Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine block, cylinder head, pistons, crankshaft, camshafts, valve train, cooling system, lubrication system

Engine Management:

Fuel injection, ignition system, emission controls, sensors, actuators, ECU diagnostics

Transmission Manual:

Clutch system, gearbox components, shift mechanisms, linkages

Transmission Automatic:

Torque converter, valve body, planetary gear sets, transmission control module (TCM), hydraulic systems

Drivetrain:

Driveshafts, differential, rear axle assembly, hub bearings

Suspension:

Front and rear suspension components, springs, shock absorbers, control arms, bushings, sway bars

Steering:

Steering rack, power steering pump, steering column, tie rods, ball joints

Brakes:

Brake discs, brake pads, calipers, ABS system, hydraulic lines, parking brake

Electrical System:

Battery, alternator, starter motor, lighting system, fuses, relays, wiring diagrams

Body And Chassis:

Body panels, doors, hood, trunk, bumpers, interior trim, chassis components

Climate Control:

HVAC system, air conditioning, heating, ventilation, blower motor, evaporator, condenser

Infotainment:

Radio, CD player, navigation system (if equipped), speaker systems

Safety Systems:

Airbags, seatbelts, ABS, traction control

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection

Engine Repair:

Head gasket replacement, piston ring replacement, bearing service, timing belt/chain service (if applicable), component removal and installation

Transmission Service:

Fluid and filter changes, seal replacement, transmission overhaul (detailed rebuild procedures)

Brake Service:

Pad and rotor replacement, caliper service, brake fluid bleeding, ABS component diagnosis and replacement

Suspension And Steering Repair:

Component replacement, alignment specifications, troubleshooting steering issues

Electrical Diagnostics:

Troubleshooting circuits, component testing, wiring harness repair, diagnostic trouble code (DTC) interpretation

Bodywork And Interior:

Panel replacement, trim removal and installation, glass replacement, door and lock repair

HVAC Service:

Refrigerant system service, component replacement, leak detection, blower and actuator diagnosis

Troubleshooting Guides:

Systematic approaches to diagnosing common and uncommon problems

Diagnostic Procedures:

Step-by-step guides for identifying faults using diagnostic tools and visual inspection

Technical Depth

Depth:

Comprehensive, from basic maintenance to in-depth mechanical and electrical system overhauls

Diagnostic Tools Reference:

Mentions and utilizes BMW proprietary diagnostic tools and common OBD-II scanners

Torque Specifications:

Detailed torque values for all critical fasteners and components

Special Tools:

Lists and describes required BMW special tools for specific procedures

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Searchability:

Searchable text content for quick information retrieval

Printability:

Printable pages for offline use

Print Quality

Image Resolution:

High-resolution diagrams, illustrations, and photographs

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B30

Engine Type:

3.0L Inline 6-cylinder (I6)

Displacement:

2979 cc (3.0 Liters)

Bore X Stroke:

84.0 mm x 89.6 mm

Compression Ratio:

10.2:1

Performance

Horsepower:

225 hp @ 5900 rpm

Torque:

214 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Multi-point injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Engine Management

ECU Type:

MS43 (Motronic System)

Lubrication

Oil Capacity:

6.5 liters (6.9 US quarts)

Recommended Oil Viscosity:

SAE 5W-30 Synthetic

Cooling System

Coolant Capacity:

7.5 liters (7.9 US quarts)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 specification)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (Getrag 260/6 or similar)

Optional

Type:

5-speed Steptronic Automatic Transmission (GM A5S 325Z or ZF 5HP19)

Features

Manual Gear Ratios:

Specific ratios detailed in manual (e.g., 4.23:1 first gear)

Automatic Features:

Driver-selectable modes (Sport/Comfort), manual shifting capability (Steptronic)

Fluid Type Manual

Fluid Specification:

BMW Manual Transmission Fluid (MTF) - e.g., Pentosin MTF.2 or equivalent

Fluid Capacity Manual

Capacity:

Approx. 1.5 liters (1.6 US quarts)

Fluid Type Automatic

Fluid Specification:

BMW ATF LT-3 or equivalent (e.g., Pentosin ATF1)

Fluid Capacity Automatic

Capacity:

Approx. 8.0 liters (8.5 US quarts) for total fill, 3.5-4.0 liters for drain and fill

📐 Dimensions

Exterior

Sedan Length:

4471 mm (176.0 inches)

Sedan Width:

1739 mm (68.5 inches)

Sedan Height:

1412 mm (55.6 inches)

Coupe Length:

4471 mm (176.0 inches)

Coupe Width:

1739 mm (68.5 inches)

Coupe Height:

1367 mm (53.8 inches)

Wheelbase

Wheelbase:

2760 mm (108.7 inches)

Weights

Curb Weight Sedan:

Approx. 1500 kg (3307 lbs)

Curb Weight Coupe:

Approx. 1480 kg (3263 lbs)

Gross Vehicle Weight Rating:

Approx. 1950 kg (4299 lbs)

Towing Capacity:

Not generally recommended or specified for this model

Cargo

Sedan Trunk Volume:

440 liters (15.5 cubic feet)

Coupe Trunk Volume:

410 liters (14.5 cubic feet)

Wheel And Tire

Standard Wheel Size:

16-inch alloy (e.g., Style 45)

Optional Wheel Size:

17-inch alloy (e.g., Style 45, Style 55, M Double Spoke)

Standard Tire Size:

205/55R16

Optional Tire Size:

225/45R17 (front), 245/40R17 (rear) for 17-inch wheels

Bolt Pattern:

5x120 mm

Center Bore:

72.5 mm

🛡️ Safety Features

Ratings

NHTSA Front Impact:

★★★★★ (5-star)

IIHS Side Impact:

IIHS Head Restraints Seat Belts:

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Standard Dynamic Stability Control (DSC) or Automatic Stability Control + Traction (ASC+T)

Cruise Control:

Standard Cruise Control system

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags and optional head protection airbags (HPS)

Seatbelts:

3-point inertia-reel seat belts with pretensioners and force limiters

Immobilizer:

Standard Immobilizer system

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD, BMW Professional CD RDS, or optional Navigation system (Mk III or Mk IV).

Speakers:

Standard 6-speaker system, optional Hi-Fi or Harman Kardon premium audio systems.

Connectivity:

Optional CD changer, optional Bluetooth preparation (for phone integration), optional Sirius Satellite Radio.

Driver Assistance

Parking Assistance:

Optional Rear Park Distance Control (PDC)

Lighting:

Standard Halogen headlights, optional Xenon Adaptive Headlights

Climate Control

System Type:

Automatic climate control with dual-zone temperature settings

Features:

Integrated cabin microfilter, pollen filter, residual heat function.

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) system typically recommends every 10,000-15,000 miles or 12-24 months, depending on driving conditions. Check manual for specific CBS reset procedures.

Engine Air Filter:

Inspect every 24,000 miles, replace as needed or every 48,000 miles

Cabin Air Filter:

Replace every 12,000-15,000 miles or annually

Spark Plugs:

Replace every 60,000 miles (Bosch FGR7DPP33+ or equivalent)

Coolant Flush:

Replace every 2-3 years or 30,000 miles

Transmission Fluid Change Automatic:

BMW traditionally stated 'lifetime' fill, but recommended replacement every 50,000-80,000 miles for longevity, especially for high-mileage vehicles.

Transmission Fluid Change Manual:

Inspect for leaks, replace every 60,000-100,000 miles or if shifting becomes rough.

Brake Fluid Flush:

Replace every 2 years regardless of mileage

Fluid Specifications

Power Steering Fluid:

Pentosin CHF 11S or BMW power steering fluid

Brake Fluid:

DOT 4, Low Viscosity (LV) Brake Fluid (e.g., Pentosin DOT 4 LV)

Known Issues

Cooling System:

Plastic expansion tank cracks, water pump failure (often electric for M54), thermostat housing leaks, radiator hoses degradation.

Engine M54:

CCV (Crankcase Ventilation) system failure (leads to oil leaks and rough idle), oil pan gasket leaks, VANOS solenoid failure, spark plug well seals.

Electrical:

ABS/ASC sensor failures, VANOS solenoid failure, headlight moisture ingress, window regulator failure, instrument cluster dead pixels.

Suspension:

Worn control arm bushings (e.g., front lower control arm bushings), rear shock mounts, ball joints.

Transmission:

Automatic transmission torque converter lock-up issues, transmission control module (TCM) issues, clutch release bearing noise (manual).

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW's long-standing reputation for performance, luxury, and engineering excellence.

Model Evolution

E46 Introduction:

The E46 generation of the 3 Series debuted in 1998 for the 1999 model year, replacing the E36. The 328i was part of the initial E46 lineup.

E46 Facelift:

The E46 received a significant facelift (LCI) for the 2002 model year, affecting exterior styling (headlights, taillights, bumpers) and interior updates, including the introduction of the M54 engine for the 328i.

328I Engine Change:

The 328i model in 2001 transitioned from the M52TU engine to the M54B28 (2.8L) for some markets, and then for 2002, it was replaced by the 330i (M54B30) in many regions, while some markets retained a 328i badge with the M54B30 engine. This manual specifically covers the 328i and likely refers to the M54B30 engine or the later M54B28 if applicable for specific regional models.

Production

Production Years E46:

1998-2006 (varies by body style)

Manufacturing Locations:

Germany (Munich, Dingolfing), USA (Spartanburg, SC), South Africa, Austria, Russia

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

The E46 generation 3 Series was a perennial recipient of Car and Driver's '10Best' list for multiple years during its production run, including the 2002 model year.

Ward Best Engines:

The M54 engine family was recognized by Ward's AutoWorld as one of the '10Best Engines' in North America.

Ratings

Consumer Reports Reliability:

Mixed to Average reliability ratings for the E46 generation; specific year and model ratings varied. Maintenance is key.

Certifications

Emissions Certification:

Meets EPA and CARB emissions standards for the 2002 model year.