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BMW 328 328i 1999-2005 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Sub Model: 328i Generation: E46 Codes Chassis Code: E46 Engine Codes: M52TU B28 (2.8L I6) 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Philosophy: 'The Ultimate Driving Machine', emphasizing performance and handling Competitive Analysis Key Competitors: Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35 Key Features Vehicle Focus: Rear-wheel drive platform, balanced chassis, refined inline-six engines Manual Value: Essential resource for DIY enthusiasts and professional mechanics to maintain and repair the E46 328i Download Benefit: Instant access, no shipping delays or costs 📋 Manual Details Coverage Areas Primary Regions: North America Specific Models: 328i Sedan, Coupe, Convertible, Sports Wagon Page Count Total Pages: 1258 Manual Type Type: Workshop Service Manual Purpose: Repair and Maintenance Guide Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine Mechanical, Engine Control, Fuel System, Cooling System, Exhaust System, Ignition System Transmission: Manual Transmission, Automatic Transmission, Clutch System, Drive Axles Chassis: Suspension System (Front and Rear), Steering System, Brake System (ABS, DSC), Wheel Alignment Electrical: Electrical System Overview, Lighting System, Instrumentation, Power Accessories, Battery, Alternator, Starter Body: Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, HVAC System Electronics: Engine Management Systems (DME), ABS/DSC Control Modules, Immobilizer System (EWS), Instrument Cluster Diagnostics Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Replacement Repair: Component Removal and Installation, Diagnostic Procedures, Troubleshooting Guides, Wiring Diagrams Diagnostics: Fault Code Diagnosis, Live Data Interpretation, Component Testing Technical Depth Depth: Comprehensive - from basic maintenance to complete engine and transmission rebuilds Diagnostic Tools: Covers procedures for use with BMW diagnostic tools (e.g., GT1, DIS, ISTA/D) and common OBD-II scanners 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (Text-searchable PDF) Printable: Yes Print Quality Quality: High-resolution scans suitable for printing individual sections or the entire manual Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M52TU B28 Configuration: 2.8 Liter, 24-Valve, Inline 6-Cylinder Bore X Stroke: 84.0 mm x 87.0 mm Compression Ratio: 10.2:1 Performance Horsepower: 193 hp @ 5500 rpm Torque: 206 lb-ft @ 3250 rpm Fuel System Induction: Electronic Fuel Injection (Bosch Motronic ME 7.2) Fuel Type: Premium Unleaded Gasoline (91 Octane Recommended) Technical Features Valvetrain: Double Overhead Camshafts (DOHC), VANOS (Variable Valve Timing) 🔧 Transmission Standard Type: 5-Speed Manual (Getrag Type D or ZF S5-31) Optional Type: 5-Speed Automatic (Steptronic GM A5S-325Z) Features Clutch: Hydraulic Actuation, Single Dry Plate Fluid Specs Manual Transmission Fluid: BMW MTF LT-1 or equivalent (check manual for specific part number) Automatic Transmission Fluid: BMW ATF LT-3 or equivalent (check manual for specific part number) 📐 Dimensions Exterior Wheelbase: 107.4 inches (2728 mm) Length: 177.4 inches (4506 mm) (Sedan) Width: 68.7 inches (1745 mm) Height: 55.7 inches (1415 mm) (Sedan) Weights Curb Weight: Approx. 3350-3450 lbs (1520-1565 kg) Gross Vehicle Weight Rating: Approx. 4398 lbs (1995 kg) Cargo Trunk Volume: 13.6 cu ft (385 L) (Sedan) 🛡️ Safety Features Ratings NHTSA Front Crash Test: 4 Stars (Driver), 4 Stars (Passenger) IIHS Side Impact: Good (for vehicles of similar design) Active Features Traction Control: Automatic Stability Control (ASC) / Dynamic Stability Control (DSC) Braking System: 4-wheel Anti-lock Braking System (ABS), ventilated front discs, solid rear discs Passive Features Airbags: Driver and front passenger airbags, optional side-impact airbags Seatbelts: 3-point inertia-reel seat belts with pretensioners Body Structure: Reinforced safety cage, crumple zones 💡 Technology Features Infotainment Head Unit: Optional BMW Professional Radio/Cassette or CD player, optional navigation system (MK III or MK IV) Speakers: Typically 10-speaker Hi-Fi system Driver Assistance Cruise Control: Standard Parking Sensors: Optional Rear Park Distance Control (PDC) Connectivity Phone Integration: Optional Bluetooth preparation with cradle Comfort Features Climate Control: Manual or Automatic Climate Control Seating: Power-adjustable front seats with memory function (optional) 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000-15,000 miles or 12-24 months, based on Condition Based Service (CBS) or manufacturer recommendation. Spark Plug Replacement: Approx. 60,000-100,000 miles (depending on plug type, typically iridium) Coolant Flush: Every 2-4 years or 30,000-60,000 miles Fluid Specifications Engine Oil Type: SAE 5W-30 Synthetic (BMW Longlife-01 or LL-01) Engine Oil Capacity: 6.5 US quarts (6.2 liters) with filter change Coolant Type: BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) Brake Fluid Type: DOT 4 (BMW Super DOT 4 recommended) Known Issues Cooling System: Plastic expansion tank cracking, water pump failure (often plastic impeller), thermostat housing leaks Suspension: Control arm bushings (bushings fail), rear shock mounts, front strut mounts Electrical: ABS/DSC sensor failures, VANOS solenoid issues, CCV (Crankcase Ventilation) system clogging (can lead to oil leaks/rough idle) Engine: Oil pan gasket leaks, valve cover gasket leaks 📚 Vehicle History Brand Heritage Philosophy: BMW's reputation for engineering excellence, performance, and luxury driving dynamics Model Evolution E46 Introduction: Introduced in 1998 (for model year 1999), replacing the E36 generation 328I...
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BMW 328 328i 1999-2005 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Sub Model:
328i
Generation:
E46
Codes
Chassis Code:
E46
Engine Codes:
M52TU B28 (2.8L I6)
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Philosophy:
'The Ultimate Driving Machine', emphasizing performance and handling
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class, Audi A4, Lexus IS, Infiniti G35
Key Features
Vehicle Focus:
Rear-wheel drive platform, balanced chassis, refined inline-six engines
Manual Value:
Essential resource for DIY enthusiasts and professional mechanics to maintain and repair the E46 328i
Download Benefit:
Instant access, no shipping delays or costs
📋 Manual Details
Coverage Areas
Primary Regions:
North America
Specific Models:
328i Sedan, Coupe, Convertible, Sports Wagon
Page Count
Total Pages:
1258
Manual Type
Type:
Workshop Service Manual
Purpose:
Repair and Maintenance Guide
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine Mechanical, Engine Control, Fuel System, Cooling System, Exhaust System, Ignition System
Transmission:
Manual Transmission, Automatic Transmission, Clutch System, Drive Axles
Chassis:
Suspension System (Front and Rear), Steering System, Brake System (ABS, DSC), Wheel Alignment
Electrical:
Electrical System Overview, Lighting System, Instrumentation, Power Accessories, Battery, Alternator, Starter
Body:
Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, HVAC System
Electronics:
Engine Management Systems (DME), ABS/DSC Control Modules, Immobilizer System (EWS), Instrument Cluster Diagnostics
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Replacement
Repair:
Component Removal and Installation, Diagnostic Procedures, Troubleshooting Guides, Wiring Diagrams
Diagnostics:
Fault Code Diagnosis, Live Data Interpretation, Component Testing
Technical Depth
Depth:
Comprehensive - from basic maintenance to complete engine and transmission rebuilds
Diagnostic Tools:
Covers procedures for use with BMW diagnostic tools (e.g., GT1, DIS, ISTA/D) and common OBD-II scanners
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (Text-searchable PDF)
Printable:
Yes
Print Quality
Quality:
High-resolution scans suitable for printing individual sections or the entire manual
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M52TU B28
Configuration:
2.8 Liter, 24-Valve, Inline 6-Cylinder
Bore X Stroke:
84.0 mm x 87.0 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
193 hp @ 5500 rpm
Torque:
206 lb-ft @ 3250 rpm
Fuel System
Induction:
Electronic Fuel Injection (Bosch Motronic ME 7.2)
Fuel Type:
Premium Unleaded Gasoline (91 Octane Recommended)
Technical Features
Valvetrain:
Double Overhead Camshafts (DOHC), VANOS (Variable Valve Timing)
🔧 Transmission
Standard
Type:
5-Speed Manual (Getrag Type D or ZF S5-31)
Optional
Type:
5-Speed Automatic (Steptronic GM A5S-325Z)
Features
Clutch:
Hydraulic Actuation, Single Dry Plate
Fluid Specs
Manual Transmission Fluid:
BMW MTF LT-1 or equivalent (check manual for specific part number)
Automatic Transmission Fluid:
BMW ATF LT-3 or equivalent (check manual for specific part number)
📐 Dimensions
Exterior
Wheelbase:
107.4 inches (2728 mm)
Length:
177.4 inches (4506 mm) (Sedan)
Width:
68.7 inches (1745 mm)
Height:
55.7 inches (1415 mm) (Sedan)
Weights
Curb Weight:
Approx. 3350-3450 lbs (1520-1565 kg)
Gross Vehicle Weight Rating:
Approx. 4398 lbs (1995 kg)
Cargo
Trunk Volume:
13.6 cu ft (385 L) (Sedan)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
4 Stars (Driver), 4 Stars (Passenger)
IIHS Side Impact:
Good (for vehicles of similar design)
Active Features
Traction Control:
Automatic Stability Control (ASC) / Dynamic Stability Control (DSC)
Braking System:
4-wheel Anti-lock Braking System (ABS), ventilated front discs, solid rear discs
Passive Features
Airbags:
Driver and front passenger airbags, optional side-impact airbags
Seatbelts:
3-point inertia-reel seat belts with pretensioners
Body Structure:
Reinforced safety cage, crumple zones
💡 Technology Features
Infotainment
Head Unit:
Optional BMW Professional Radio/Cassette or CD player, optional navigation system (MK III or MK IV)
Speakers:
Typically 10-speaker Hi-Fi system
Driver Assistance
Cruise Control:
Standard
Parking Sensors:
Optional Rear Park Distance Control (PDC)
Connectivity
Phone Integration:
Optional Bluetooth preparation with cradle
Comfort Features
Climate Control:
Manual or Automatic Climate Control
Seating:
Power-adjustable front seats with memory function (optional)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000-15,000 miles or 12-24 months, based on Condition Based Service (CBS) or manufacturer recommendation.
Spark Plug Replacement:
Approx. 60,000-100,000 miles (depending on plug type, typically iridium)
Coolant Flush:
Every 2-4 years or 30,000-60,000 miles
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic (BMW Longlife-01 or LL-01)
Engine Oil Capacity:
6.5 US quarts (6.2 liters) with filter change
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)
Brake Fluid Type:
DOT 4 (BMW Super DOT 4 recommended)
Known Issues
Cooling System:
Plastic expansion tank cracking, water pump failure (often plastic impeller), thermostat housing leaks
Suspension:
Control arm bushings (bushings fail), rear shock mounts, front strut mounts
Electrical:
ABS/DSC sensor failures, VANOS solenoid issues, CCV (Crankcase Ventilation) system clogging (can lead to oil leaks/rough idle)
Engine:
Oil pan gasket leaks, valve cover gasket leaks
📚 Vehicle History
Brand Heritage
Philosophy:
BMW's reputation for engineering excellence, performance, and luxury driving dynamics
Model Evolution
E46 Introduction:
Introduced in 1998 (for model year 1999), replacing the E36 generation
328I Positioning:
Offered a potent inline-six engine as a step up from the 323i, below the M3
Production
Production Years Covered:
1999, 2000
Manufacturing Location:
Germany (primarily Dingolfing)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
E46 3 Series was a perennial 10Best winner during its production run for its driving dynamics.
Ratings
Consumer Reports:
Consistently rated well for performance and handling, though reliability scores varied over its lifecycle.
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