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BMW 328i 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 328i Year: 2002 Codes Chassis Code: E46 Engine Code Primary: M52TUB28 👋 Introduction Market Position Market Segment: Compact Executive Sedan Target Audience: Enthusiasts, DIY mechanics, and professional workshops seeking detailed repair information. Competitive Analysis Key Competitors: Audi A4, Mercedes-Benz C-Class, Lexus IS300, Infiniti G35 Key Features Model Strengths: Sporty handling, refined interior, powerful inline-six engine, excellent build quality. Manual Value Proposition Value Proposition: Provides the definitive resource for maintaining and repairing the BMW 328i (E46), enabling cost savings and in-depth understanding of the vehicle's systems. 📋 Manual Details Coverage Areas Coverage Focus: Full Service Repair and Maintenance Page Count Estimated Pages: 1000+ Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, timing, fuel, ignition, cooling, lubrication, emissions control Transmission: Automatic and Manual transmission service, repair, diagnostics, fluid changes Drivetrain: Driveshafts, differentials, clutch (manual transmission), wheel bearings Suspension: Front and rear suspension components, struts, shock absorbers, control arms, bushings, wheel alignment Brakes: Brake system diagnostics, ABS, component replacement (pads, rotors, lines), bleeding procedures Steering: Power steering system, steering rack, tie rods, pump, fluid replacement Electrical: Complete electrical system schematics, wiring diagrams, battery, alternator, starter, lighting, power windows, locks, mirrors, climate control electronics Body: Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass replacement HVAC: Heating, ventilation, and air conditioning system diagnostics, refrigerant handling, component replacement Chassis: Frame, unibody structure, rust prevention, chassis components Diagnostics: OBD-II (On-Board Diagnostics II) system, fault code interpretation, diagnostic procedures for all major systems Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes Repair: Detailed step-by-step repair instructions for all components and systems Rebuild: Engine and transmission rebuilding procedures, including torque specifications and clearances Troubleshooting: Comprehensive troubleshooting guides and flowcharts for common and complex issues Installation: Installation procedures for aftermarket parts and upgrades, where applicable Technical Depth Technical Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system schematics. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text for quick information retrieval Print Quality Print Quality: High-resolution scans suitable for printing Binding Type Binding Type: N/A (Digital) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Name: BMW M52TUB28 Engine Type: Inline-6 Cylinder, DOHC (Double Overhead Camshaft), 24 Valves Displacement: 2.8 Liters (2793 cc) Bore X Stroke: 84.0 mm x 90.0 mm Compression Ratio: 10.2:1 Engine Control System: Siemens MS43 Electronic Engine Control Unit (ECU) Performance Horsepower: 193 hp @ 5500 rpm (SAE Net) Torque: 206 lb-ft @ 3500 rpm (SAE Net) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with VANOS (Variable Valve Timing) Fuel Type: Premium Unleaded Gasoline (91+ Octane Recommended) Fuel Tank Capacity: 60 Liters (15.8 US Gallons) Lubrication Oil Type: BMW Longlife-01 (LL-01) Synthetic, SAE 5W-30 or 5W-40 Oil Capacity: 6.5 Liters (6.9 US Quarts) with filter change Cooling Coolant Type: BMW Blue Antifreeze/Coolant (G48), 50/50 mix with distilled water Ignition Spark Plugs: NGK BKR6EQUP (Platinum) or equivalent 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (Getrag S5D 250G) Optional Transmission Type Optional: 5-speed Automatic Transmission (GM A5S 325Z) Features Manual Gear Ratios 1-5: 3.50, 2.14, 1.42, 1.00, 0.81 Manual Reverse Gear Ratio: 3.00 Automatic Transmission Features: Steptronic (manual shifting mode) Fluid Specs Manual Transmission Fluid: BMW MTF LT-2 (or equivalent GL-4/GL-5 gear oil) Automatic Transmission Fluid: Dexron III (or equivalent ATF) 📐 Dimensions Exterior Length: 4471 mm (176.0 in) Width: 1739 mm (68.5 in) Height: 1415 mm (55.7 in) Wheelbase: 2760 mm (108.7 in) Front Track: 1471 mm (57.9 in) Rear Track: 1474 mm (58.0 in) Weights Curb Weight Manual: 1480 kg (3263 lbs) Curb Weight Automatic: 1510 kg (3329 lbs) Gross Vehicle Weight Rating: 1910 kg (4211 lbs) Front Axle Weight Rating: 875 kg (1929 lbs) Rear Axle Weight Rating: 1035 kg (2282 lbs) Cargo Trunk Capacity: 440 Liters (15.5 cu ft) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-Star NHTSA Front Impact Passenger: 5-Star IIHS Front Offset Crash Rating: Good Active Features ABS: Standard Anti-lock Braking System (ABS) Asc: Standard Automatic Stability Control (ASC) DTC: Optional Dynamic Traction Control (DTC) Passive Features Airbags Front: Standard driver and front passenger airbags Airbags Side: Optional front side-impact airbags Seatbelts: 3-point inertia-reel seatbelts with pretensioners and force limiters 💡 Technology Features Infotainment Infotainment System: BMW Business CD, BMW Professional CD, optional Navigation System (MK III or MK IV). Audio System: Standard 6-speaker audio, optional premium sound systems (e.g., Harman Kardon). Driver Assistance Cruise Control: Standard cruise control. Parking Assistance: Optional rear parking sensors (Park Distance Control - PDC). Connectivity Connectivity Features: Optional Bluetooth hands-free system (BMW Assist). 🔧 Maintenance Service Intervals Oil Change Interval: Variable (BMW Condition Based Service), typically...
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BMW 328i 2002 Full Service Repair ManualBMW 328i 2002 Full Service Repair ManualBMW 328i 2002 Full Service Repair ManualBMW 328i 2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
328i
Year:
2002
Codes
Chassis Code:
E46
Engine Code Primary:
M52TUB28
👋 Introduction
Market Position
Market Segment:
Compact Executive Sedan
Target Audience:
Enthusiasts, DIY mechanics, and professional workshops seeking detailed repair information.
Competitive Analysis
Key Competitors:
Audi A4, Mercedes-Benz C-Class, Lexus IS300, Infiniti G35
Key Features
Model Strengths:
Sporty handling, refined interior, powerful inline-six engine, excellent build quality.
Manual Value Proposition
Value Proposition:
Provides the definitive resource for maintaining and repairing the BMW 328i (E46), enabling cost savings and in-depth understanding of the vehicle's systems.
📋 Manual Details
Coverage Areas
Coverage Focus:
Full Service Repair and Maintenance
Page Count
Estimated Pages:
1000+
Manual Type
Manual Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnostics, timing, fuel, ignition, cooling, lubrication, emissions control
Transmission:
Automatic and Manual transmission service, repair, diagnostics, fluid changes
Drivetrain:
Driveshafts, differentials, clutch (manual transmission), wheel bearings
Suspension:
Front and rear suspension components, struts, shock absorbers, control arms, bushings, wheel alignment
Brakes:
Brake system diagnostics, ABS, component replacement (pads, rotors, lines), bleeding procedures
Steering:
Power steering system, steering rack, tie rods, pump, fluid replacement
Electrical:
Complete electrical system schematics, wiring diagrams, battery, alternator, starter, lighting, power windows, locks, mirrors, climate control electronics
Body:
Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass replacement
HVAC:
Heating, ventilation, and air conditioning system diagnostics, refrigerant handling, component replacement
Chassis:
Frame, unibody structure, rust prevention, chassis components
Diagnostics:
OBD-II (On-Board Diagnostics II) system, fault code interpretation, diagnostic procedures for all major systems
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes
Repair:
Detailed step-by-step repair instructions for all components and systems
Rebuild:
Engine and transmission rebuilding procedures, including torque specifications and clearances
Troubleshooting:
Comprehensive troubleshooting guides and flowcharts for common and complex issues
Installation:
Installation procedures for aftermarket parts and upgrades, where applicable
Technical Depth
Technical Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system schematics.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable text for quick information retrieval
Print Quality
Print Quality:
High-resolution scans suitable for printing
Binding Type
Binding Type:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Name:
BMW M52TUB28
Engine Type:
Inline-6 Cylinder, DOHC (Double Overhead Camshaft), 24 Valves
Displacement:
2.8 Liters (2793 cc)
Bore X Stroke:
84.0 mm x 90.0 mm
Compression Ratio:
10.2:1
Engine Control System:
Siemens MS43 Electronic Engine Control Unit (ECU)
Performance
Horsepower:
193 hp @ 5500 rpm (SAE Net)
Torque:
206 lb-ft @ 3500 rpm (SAE Net)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) with VANOS (Variable Valve Timing)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane Recommended)
Fuel Tank Capacity:
60 Liters (15.8 US Gallons)
Lubrication
Oil Type:
BMW Longlife-01 (LL-01) Synthetic, SAE 5W-30 or 5W-40
Oil Capacity:
6.5 Liters (6.9 US Quarts) with filter change
Cooling
Coolant Type:
BMW Blue Antifreeze/Coolant (G48), 50/50 mix with distilled water
Ignition
Spark Plugs:
NGK BKR6EQUP (Platinum) or equivalent
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (Getrag S5D 250G)
Optional
Transmission Type Optional:
5-speed Automatic Transmission (GM A5S 325Z)
Features
Manual Gear Ratios 1-5:
3.50, 2.14, 1.42, 1.00, 0.81
Manual Reverse Gear Ratio:
3.00
Automatic Transmission Features:
Steptronic (manual shifting mode)
Fluid Specs
Manual Transmission Fluid:
BMW MTF LT-2 (or equivalent GL-4/GL-5 gear oil)
Automatic Transmission Fluid:
Dexron III (or equivalent ATF)
📐 Dimensions
Exterior
Length:
4471 mm (176.0 in)
Width:
1739 mm (68.5 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2760 mm (108.7 in)
Front Track:
1471 mm (57.9 in)
Rear Track:
1474 mm (58.0 in)
Weights
Curb Weight Manual:
1480 kg (3263 lbs)
Curb Weight Automatic:
1510 kg (3329 lbs)
Gross Vehicle Weight Rating:
1910 kg (4211 lbs)
Front Axle Weight Rating:
875 kg (1929 lbs)
Rear Axle Weight Rating:
1035 kg (2282 lbs)
Cargo
Trunk Capacity:
440 Liters (15.5 cu ft)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star
NHTSA Front Impact Passenger:
5-Star
IIHS Front Offset Crash Rating:
Good
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Asc:
Standard Automatic Stability Control (ASC)
DTC:
Optional Dynamic Traction Control (DTC)
Passive Features
Airbags Front:
Standard driver and front passenger airbags
Airbags Side:
Optional front side-impact airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters
💡 Technology Features
Infotainment
Infotainment System:
BMW Business CD, BMW Professional CD, optional Navigation System (MK III or MK IV).
Audio System:
Standard 6-speaker audio, optional premium sound systems (e.g., Harman Kardon).
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Assistance:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Connectivity Features:
Optional Bluetooth hands-free system (BMW Assist).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable (BMW Condition Based Service), typically 10,000-15,000 miles or 1 year.
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Cabin Air Filter:
Replace every 15,000 miles or 1 year.
Spark Plugs:
Replace every 60,000 miles for platinum plugs.
Coolant Flush:
Replace coolant every 4 years or 60,000 miles.
Brake Fluid Flush:
Replace brake fluid every 2 years or 24,000 miles.
Fluid Specifications
Power Steering Fluid:
Pentosin CHF 11S (or compatible hydraulic fluid)
Windshield Washer Fluid:
BMW Windshield Washer Fluid Concentrate or equivalent, mixed with water.
Known Issues
Cooling System:
Plastic expansion tank failures, water pump impeller failure, thermostat housing leaks.
Vanos:
Degradation of O-rings in the VANOS system leading to rough idle and loss of low-end torque.
Oil Leaks:
Valve cover gasket, oil filter housing gasket, oil pan gasket are common leak points.
Subframe:
Cracking of the rear subframe mounting points due to stress.
Ccv System:
Crankcase Ventilation system (CCV) failure, leading to oil consumption and rough running.
📚 Vehicle History
Brand Heritage
Brand Heritage:
BMW (Bayerische Motoren Werke AG) is a German luxury vehicle manufacturer renowned for its performance-oriented cars and motorcycles.
Model Evolution
E46 Generation:
The E46 generation of the 3 Series was produced from 1998 to 2006, representing the fifth generation of BMW's compact executive car.
Production
Production Years E46 328I:
1999-2000 (pre-facelift), replaced by 330i with the 2001 facelift. However, the 328i moniker continued in certain markets like North America.
Manufacturing Locations:
Primarily Germany (Munich, Dingolfing), also South Africa, Egypt, Thailand, Russia, Indonesia, China, India, Malaysia, Vietnam.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
E46 3 Series (including 328i variants) was frequently recognized on Car and Driver's 10Best lists during its production run for its driving dynamics.
Ward Auto World Engine Of The Year:
BMW's inline-6 engines, including the M52 family, were often lauded for their smoothness and power delivery.
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