BMW 3 Series (E46) 328i 1999-2005 Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Code: E46 Specific Variant: 328i Codes Chassis Code: E46 Engine Code Prefix: M52TU 👋 Introduction Market Position Positioning: The E46 generation BMW 3 Series, particularly the 328i, was positioned as a compact executive sports sedan and coupe, celebrated for its driving dynamics, build quality, and refined engineering. It competed against other premium offerings like the Mercedes-Benz C-Class and Audi A4. Competitive Analysis Analysis: The 328i represented a strong contender in its segment, often praised for its superior handling and driver engagement compared to some rivals, thanks to its balanced chassis and rear-wheel-drive architecture. The M52TU engine provided a good blend of performance and efficiency for its class. Key Features Features: The 328i (E46) is known for its sophisticated suspension, powerful inline-six engine, comfortable yet sporty interior, and hallmark BMW driving experience. This manual provides essential guidance for maintaining and repairing these key attributes. 📋 Manual Details Coverage Areas Engine Mechanical: Yes Engine Management: Yes Fuel System: Yes Exhaust System: Yes Transmission Manual: Yes Transmission Automatic: Yes Drivetrain Components: Yes Suspension System: Yes Steering System: Yes Brake System: Yes Electrical System: Yes Body And Chassis: Yes HVAC System: Yes Interior Trim: Yes Exterior Trim: Yes Diagnostic Troubleshooting: Yes Page Count Estimated Pages: 1500+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (cylinder head, block, crankshaft, pistons, connecting rods, camshafts), lubrication system, cooling system, fuel injection system (Bosch Motronic), ignition system, exhaust system, engine management (DME). Drivetrain Systems: Manual transmission (Getrag 5-speed), Automatic transmission (Steptronic GM 5L40-E), clutch assembly, driveshafts, differential, rear axle. Suspension Steering: Front suspension (MacPherson struts), rear suspension (multi-link Z-axle), steering system (rack and pinion, power steering), wheel alignment specifications. Braking Systems: Front and rear disc brakes (ABS, DSC), brake system bleeding, component replacement (pads, rotors, calipers, lines). Electrical Systems: Battery, charging system (alternator), starting system, lighting, instrumentation, power windows, central locking, airbags, instrument cluster, ECU diagnostics, wiring diagrams for all major systems. Body Chassis: Body panels, doors, hood, trunk, bumpers, glass replacement, chassis lubrication, rust prevention, corrosion control. Climate Control: Manual and automatic climate control systems, A/C service and recharge, heater core, blower motor, evaporator. Procedures Included Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and replacement, brake fluid flush, fuel filter replacement, belt inspection and replacement, routine inspections. Repair: Engine overhaul, transmission repair, clutch replacement, suspension component replacement, brake system repair, electrical component diagnosis and replacement, exhaust system repair, body panel repair. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation, symptom-based troubleshooting guides for engine performance, electrical faults, and drivability problems. Specifications Data: Torque specifications for all fasteners, fluid capacities and types, engine timing procedures, diagnostic parameters, wiring diagrams, dimensional data. Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures and electrical system analysis. 📊 Manual Specifications File Format Quality: High-resolution PDF, ensuring clarity and readability of diagrams and text. Searchable text for quick information retrieval. Print Quality Printable: Yes, pages can be printed for workshop use. Binding Type Binding: N/A (PDF Format) Paper Type Paper Type: N/A (PDF Format) ⚙️ Engine Specifications Primary Engine Engine Model: M52TU B28 Engine Type: Inline 6-cylinder, Naturally Aspirated Displacement: 2793 cc (2.8 Liters) Bore X Stroke: 84.0 mm x 90.0 mm Compression Ratio: 10.2:1 Valve Train: DOHC, 24 valves, Double VANOS (Variable Valve Timing) Performance Horsepower: 193 hp @ 5500 rpm Torque: 206 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (Bosch Motronic ME 7.2) Fuel Type: Premium Unleaded Gasoline (91+ Octane) Ignition System: Distributorless Electronic Ignition (Coil-on-Plug) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Manual Transmission Model: Getrag Type D (Synchronized) Optional Transmission Type: 5-Speed Automatic (Steptronic) Automatic Transmission Model: GM 5L40-E Features Clutch Type: Hydraulically Actuated, Single Dry Plate Drive Type: Rear-Wheel Drive (RWD) 📐 Dimensions Exterior Length: 4471 mm (176.0 in) Width: 1739 mm (68.5 in) Height: 1371 mm (54.0 in) Wheelbase: 2725 mm (107.3 in) Front Track: 1471 mm (57.9 in) Rear Track: 1474 mm (58.0 in) Wheel Bolt Pattern: 5x120 mm Wheel Size: 16x7.0J (Standard) Tire Size: 205/55R16 (Standard) Interior Passenger Volume: Approx. 95 cu ft Cargo Trunk Capacity: Approx. 11 cu ft Weights Curb Weight: Approx. 3250 lbs (1474 kg) 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (Driver/Passenger) IIHS Side Impact: Good Active Features ABS: Standard (Anti-lock Braking System) Dsc: Standard (Dynamic Stability Control) Traction Control: Standard (Automatic Stability Control + Traction - ASC+T) Passive Features Airbags Front: Dual Front SRS airbags Airbags Side: Optional/Standard (depending on market) Side-impact airbags Seatbelts: 3-point Inertia-reel seat belts with pretensioners Chassis Design: Reinforced safety cage, crumple zones. 💡 Technology Features Infotainment Infotainment System: BMW Professional Radio/Cassette or optional CD Player. Navigation...
The E46 generation BMW 3 Series, particularly the 328i, was positioned as a compact executive sports sedan and coupe, celebrated for its driving dynamics, build quality, and refined engineering. It competed against other premium offerings like the Mercedes-Benz C-Class and Audi A4.
Competitive Analysis
Analysis:
The 328i represented a strong contender in its segment, often praised for its superior handling and driver engagement compared to some rivals, thanks to its balanced chassis and rear-wheel-drive architecture. The M52TU engine provided a good blend of performance and efficiency for its class.
Key Features
Features:
The 328i (E46) is known for its sophisticated suspension, powerful inline-six engine, comfortable yet sporty interior, and hallmark BMW driving experience. This manual provides essential guidance for maintaining and repairing these key attributes.
Front suspension (MacPherson struts), rear suspension (multi-link Z-axle), steering system (rack and pinion, power steering), wheel alignment specifications.
Braking Systems:
Front and rear disc brakes (ABS, DSC), brake system bleeding, component replacement (pads, rotors, calipers, lines).
Electrical Systems:
Battery, charging system (alternator), starting system, lighting, instrumentation, power windows, central locking, airbags, instrument cluster, ECU diagnostics, wiring diagrams for all major systems.
Manual and automatic climate control systems, A/C service and recharge, heater core, blower motor, evaporator.
Procedures Included
Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and replacement, brake fluid flush, fuel filter replacement, belt inspection and replacement, routine inspections.
Repair:
Engine overhaul, transmission repair, clutch replacement, suspension component replacement, brake system repair, electrical component diagnosis and replacement, exhaust system repair, body panel repair.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation, symptom-based troubleshooting guides for engine performance, electrical faults, and drivability problems.
Specifications Data:
Torque specifications for all fasteners, fluid capacities and types, engine timing procedures, diagnostic parameters, wiring diagrams, dimensional data.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures and electrical system analysis.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, ensuring clarity and readability of diagrams and text. Searchable text for quick information retrieval.
Standard (Automatic Stability Control + Traction - ASC+T)
Passive Features
Airbags Front:
Dual Front SRS airbags
Airbags Side:
Optional/Standard (depending on market) Side-impact airbags
Seatbelts:
3-point Inertia-reel seat belts with pretensioners
Chassis Design:
Reinforced safety cage, crumple zones.
💡 Technology Features
Infotainment
Infotainment System:
BMW Professional Radio/Cassette or optional CD Player. Navigation system (MK III/IV) available. Basic sound systems with limited connectivity.
Driver Assistance
Driver Assistance:
ABS, DSC (Dynamic Stability Control), Traction Control (ASC+T). Cruise control was standard or optional.
Connectivity
Connectivity Features:
Limited by modern standards. Features like Bluetooth and AUX input were not standard on most models, often requiring aftermarket additions or specific option packages.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, depending on driving conditions and oil used. Refer to Condition Based Service (CBS) system.
Air Filter Replacement:
Every 30,000 miles (48,000 km)
Spark Plug Replacement:
Every 100,000 miles (160,000 km) with long-life plugs (e.g., NGK BKR6EQUP), or consult manual for shorter intervals with standard plugs.
Coolant Replacement:
Every 2-3 years or as indicated by the service interval indicator.
Brake Fluid Flush:
Every 2 years
Fluid Specifications
Engine Oil:
SAE 5W-30 or 5W-40 Synthetic (BMW Longlife-01 or Longlife-98 specification)
Coolant:
BMW Blue Antifreeze/Coolant (G48) mixed 50/50 with distilled water
Brake Fluid:
DOT 4 (or DOT 4 LV for systems with DSC)
Transmission Fluid Manual:
MTF LT-2 (BMW Genuine)
Transmission Fluid Automatic:
LT 71141 (Dexron III equivalent, often ATF) - consult manual for exact fill and change recommendations.
Power Steering Fluid:
CHF 11S (Pentosin)
Known Issues
Cooling System:
Plastic expansion tank cracking, water pump failure (especially plastic impeller versions), thermostat housing leaks.
Engine:
VANOS solenoid issues (hesitation, rough idle), oil filter housing gasket leaks, PCV system clogging leading to rough running or oil consumption.
Control arm bushings (thrust arm bushings), rear shock mounts, sway bar links.
Interior:
Headliner sagging, door panel vapor barrier adhesive failure leading to water ingress.
📚 Vehicle History
Brand Heritage
Heritage:
BMW has a long-standing reputation for building driver-focused, performance-oriented vehicles, tracing its roots back to aircraft engine manufacturing in the early 20th century.
Model Evolution
E46 Generation:
The E46 generation, launched in 1998 for the 1999 model year, succeeded the E36. It represented a significant refinement in styling, chassis dynamics, and interior quality, setting a new benchmark for the compact executive segment.
328I Placement:
The 328i slot was occupied by the M52B28 engine, offering a strong balance of power and refinement before the introduction of the 330i models.
Production
Production Years:
1999-2000 (for the 328i variant)
Manufacturing Locations:
Germany (Dingolfing, Munich)
🏆 Awards & Recognition
Recognitions
Car And Driver Otr:
Car and Driver's '10Best' list multiple times during its production run.
Popular Mechanics Otr:
Often lauded for its engineering and driving dynamics by automotive publications.
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