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BMW 328i 1999 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 328i Year: 1999 Codes Chassis Code: E36 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Competitors 1999: Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus IS300, Acura TL Key Features Driving Dynamics: Renowned for sporty handling, rear-wheel-drive bias, and balanced chassis Engine Performance: Smooth, powerful inline-six engine Build Quality: Excellent German engineering and materials 📋 Manual Details Coverage Areas Engine Coverage: M52B28 engine Transmission Coverage: Getrag 420G manual transmission, ZF 5HP18/5HP19 automatic transmission Electrical System Coverage: Complete wiring diagrams, diagnostics, component locations Body And Chassis Coverage: Suspension, steering, brakes, body panels, interior trim Page Count Estimated Pages: 1500+ Manual Type Type: Full Service Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, component replacement, timing, lubrication, cooling, fuel injection, ignition Transmission: Manual and automatic transmission repair, clutch replacement, torque converter, gear shifting mechanisms Brakes: Hydraulic system, ABS, brake pad/rotor replacement, caliper overhaul, bleeding procedures Suspension And Steering: Shock absorbers, struts, control arms, ball joints, tie rods, power steering system Electrical System: Battery, alternator, starter, lighting, fuses, relays, ECU diagnostics, sensor testing Climate Control: HVAC system operation, blower motor, refrigerant charging, troubleshooting Exhaust System: Catalytic converter, mufflers, exhaust manifold, O2 sensors Fuel System: Fuel pump, fuel filter, injectors, fuel pressure regulator, EVAP system Procedures Included Maintenance: Oil change, filter replacement, spark plug replacement, fluid checks, belt inspection/replacement Troubleshooting: Diagnostic flowcharts, common symptom analysis, DTC explanations Repair And Rebuild: Engine component rebuilds, transmission overhaul, suspension component replacement Diagnostics: OBD-II diagnostics, sensor testing, component voltage checks Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical schematics 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Printability: Printable pages Print Quality Image Resolution: High-resolution diagrams and images Binding Type Binding: N/A (Digital format) Paper Type Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Code: M52B28 Engine Type: Inline 6-cylinder, DOHC, 24 valves Displacement: 2.8 Liters (2793 cc) Performance Horsepower Hp: 190 hp @ 5500 rpm Torque Lb Ft: 200 lb-ft @ 3950 rpm Fuel System Fuel Delivery: Sequential Multi-Point Fuel Injection (Bosch Motronic) Fuel Type: Premium Unleaded Gasoline (91+ Octane) Engine Management ECU: Bosch Motronic M5.2 🔧 Transmission Standard Transmission Type Std: Getrag 420G 5-speed Manual Transmission Optional Transmission Type Opt: ZF 5HP18 5-speed Automatic Transmission (with Steptronic on some models) Features Rear Axle Ratio: 3.07:1 (Manual), 3.46:1 (Automatic - typically) Fluid Specifications Manual Trans Fluid: BMW Synchromesh Oil or equivalent (e.g., Castrol TAF-X) Automatic Trans Fluid: ZF Lifeguardfluid 5 (LT 71141) or Dexron III/Mercon 📐 Dimensions Exterior Length: 174.5 inches (4432 mm) Width: 67.3 inches (1709 mm) Height: 54.7 inches (1390 mm) Wheelbase: 106.0 inches (2692 mm) Weights Curb Weight Lbs: 3300 - 3400 lbs (approx.) Wheelbase: 106.0 inches (2692 mm) Wheels And Tires Wheel Size Std: 15x7 inch Tire Size Std: 205/60VR15 Wheel Bolt Pattern: 5x120mm Lug Nut Torque: 140 Nm (103 lb-ft) 🛡️ Safety Features Ratings NHTSA Frontal Crash Driver: 4/5 Stars (1999 Model Year) NHTSA Frontal Crash Passenger: 4/5 Stars (1999 Model Year) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional ASC+T (Automatic Stability Control and Traction) Passive Features Airbags: Driver and front passenger airbags, optional side airbags Seatbelts: 3-point inertia-reel seatbelts with pretensioners Chassis Structure: Reinforced safety cell, crumple zones 💡 Technology Features Infotainment Head Unit: BMW Business CD or BMW Professional RDS cassette/CD player Speakers: Up to 10 speaker Hi-Fi system available Navigation: Optional BMW Professional Navigation System (MKII or MKIII unit) Driver Assistance Cruise Control: Standard cruise control Parking Sensors: Optional rear Park Distance Control (PDC) Connectivity Phone: Optional integrated car phone or Bluetooth preparation on later models 🔧 Maintenance Service Intervals Oil Change Interval: Approximately every 7,500-10,000 miles or 12-15,000 km (depending on driving conditions and oil used; check oil level indicator via OBC) Spark Plug Replacement: Around 60,000 miles (100,000 km) for standard plugs, potentially longer for iridium plugs if fitted. Coolant Flush Interval: Every 2-3 years or 30,000 miles (50,000 km) Brake Fluid Flush Interval: Every 2 years Fluid Specifications Engine Oil Type: BMW Longlife-98 specification synthetic oil (e.g., Castrol Edge 5W-40 or 0W-40, Mobil 1 0W-40) Engine Oil Capacity: 6.5 Liters (6.9 US Quarts) with filter change Coolant Type: BMW Blue Antifreeze/Coolant (G48 specification) or equivalent, mixed 50/50 with distilled water. Power Steering Fluid: ATF Dexron III or Pentosin CHF 11S (depending on exact system) Brake Fluid Type: DOT 4 Known Issues Cooling System: Plastic coolant expansion tank, water pump, and thermostat housing prone to cracking; fan clutch failure. Oil Leaks: Valve cover gasket, oil pan gasket, oil filter housing gasket (O-rings) are common leak points. Suspension: Subframe bushings, control arm bushings, rear trailing arm bushings can wear out, leading to clunking noises and poor handling. Electrical: ABS/ASC sensor failures, VANOS (Variable Valve Timing)...
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BMW 328i 1999 Full Service Repair ManualBMW 328i 1999 Full Service Repair ManualBMW 328i 1999 Full Service Repair ManualBMW 328i 1999 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
328i
Year:
1999
Codes
Chassis Code:
E36
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Competitors 1999:
Mercedes-Benz C-Class (W202), Audi A4 (B5), Lexus IS300, Acura TL
Key Features
Driving Dynamics:
Renowned for sporty handling, rear-wheel-drive bias, and balanced chassis
Engine Performance:
Smooth, powerful inline-six engine
Build Quality:
Excellent German engineering and materials
📋 Manual Details
Coverage Areas
Engine Coverage:
M52B28 engine
Transmission Coverage:
Getrag 420G manual transmission, ZF 5HP18/5HP19 automatic transmission
Electrical System Coverage:
Complete wiring diagrams, diagnostics, component locations
Body And Chassis Coverage:
Suspension, steering, brakes, body panels, interior trim
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed overhaul, component replacement, timing, lubrication, cooling, fuel injection, ignition
Transmission:
Manual and automatic transmission repair, clutch replacement, torque converter, gear shifting mechanisms
Brakes:
Hydraulic system, ABS, brake pad/rotor replacement, caliper overhaul, bleeding procedures
Suspension And Steering:
Shock absorbers, struts, control arms, ball joints, tie rods, power steering system
Electrical System:
Battery, alternator, starter, lighting, fuses, relays, ECU diagnostics, sensor testing
Climate Control:
HVAC system operation, blower motor, refrigerant charging, troubleshooting
Exhaust System:
Catalytic converter, mufflers, exhaust manifold, O2 sensors
Fuel System:
Fuel pump, fuel filter, injectors, fuel pressure regulator, EVAP system
Procedures Included
Maintenance:
Oil change, filter replacement, spark plug replacement, fluid checks, belt inspection/replacement
Troubleshooting:
Diagnostic flowcharts, common symptom analysis, DTC explanations
Repair And Rebuild:
Engine component rebuilds, transmission overhaul, suspension component replacement
Diagnostics:
OBD-II diagnostics, sensor testing, component voltage checks
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical schematics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Print Quality
Image Resolution:
High-resolution diagrams and images
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M52B28
Engine Type:
Inline 6-cylinder, DOHC, 24 valves
Displacement:
2.8 Liters (2793 cc)
Performance
Horsepower Hp:
190 hp @ 5500 rpm
Torque Lb Ft:
200 lb-ft @ 3950 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Point Fuel Injection (Bosch Motronic)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Engine Management
ECU:
Bosch Motronic M5.2
🔧 Transmission
Standard
Transmission Type Std:
Getrag 420G 5-speed Manual Transmission
Optional
Transmission Type Opt:
ZF 5HP18 5-speed Automatic Transmission (with Steptronic on some models)
Features
Rear Axle Ratio:
3.07:1 (Manual), 3.46:1 (Automatic - typically)
Fluid Specifications
Manual Trans Fluid:
BMW Synchromesh Oil or equivalent (e.g., Castrol TAF-X)
Automatic Trans Fluid:
ZF Lifeguardfluid 5 (LT 71141) or Dexron III/Mercon
📐 Dimensions
Exterior
Length:
174.5 inches (4432 mm)
Width:
67.3 inches (1709 mm)
Height:
54.7 inches (1390 mm)
Wheelbase:
106.0 inches (2692 mm)
Weights
Curb Weight Lbs:
3300 - 3400 lbs (approx.)
Wheelbase:
106.0 inches (2692 mm)
Wheels And Tires
Wheel Size Std:
15x7 inch
Tire Size Std:
205/60VR15
Wheel Bolt Pattern:
5x120mm
Lug Nut Torque:
140 Nm (103 lb-ft)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Driver:
4/5 Stars (1999 Model Year)
NHTSA Frontal Crash Passenger:
4/5 Stars (1999 Model Year)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional ASC+T (Automatic Stability Control and Traction)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Chassis Structure:
Reinforced safety cell, crumple zones
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD or BMW Professional RDS cassette/CD player
Speakers:
Up to 10 speaker Hi-Fi system available
Navigation:
Optional BMW Professional Navigation System (MKII or MKIII unit)
Driver Assistance
Cruise Control:
Standard cruise control
Parking Sensors:
Optional rear Park Distance Control (PDC)
Connectivity
Phone:
Optional integrated car phone or Bluetooth preparation on later models
🔧 Maintenance
Service Intervals
Oil Change Interval:
Approximately every 7,500-10,000 miles or 12-15,000 km (depending on driving conditions and oil used; check oil level indicator via OBC)
Spark Plug Replacement:
Around 60,000 miles (100,000 km) for standard plugs, potentially longer for iridium plugs if fitted.
Coolant Flush Interval:
Every 2-3 years or 30,000 miles (50,000 km)
Brake Fluid Flush Interval:
Every 2 years
Fluid Specifications
Engine Oil Type:
BMW Longlife-98 specification synthetic oil (e.g., Castrol Edge 5W-40 or 0W-40, Mobil 1 0W-40)
Engine Oil Capacity:
6.5 Liters (6.9 US Quarts) with filter change
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 specification) or equivalent, mixed 50/50 with distilled water.
Power Steering Fluid:
ATF Dexron III or Pentosin CHF 11S (depending on exact system)
Brake Fluid Type:
DOT 4
Known Issues
Cooling System:
Plastic coolant expansion tank, water pump, and thermostat housing prone to cracking; fan clutch failure.
Oil Leaks:
Valve cover gasket, oil pan gasket, oil filter housing gasket (O-rings) are common leak points.
Suspension:
Subframe bushings, control arm bushings, rear trailing arm bushings can wear out, leading to clunking noises and poor handling.
Electrical:
ABS/ASC sensor failures, VANOS (Variable Valve Timing) solenoids/seals, heater core leaks.
Interior:
Headliner sagging, pixelation on the instrument cluster OBC display.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW (Bayerische Motoren Werke AG) is a German company with a long history of producing high-performance luxury vehicles, particularly known for its sophisticated engineering and driving dynamics.
Model Evolution
E36 Generation:
The 328i is part of the E36 generation of the BMW 3 Series, produced from 1990 to 2000. It succeeded the E30 and was known for its improved chassis, multi-link rear suspension, and more refined interior.
328I Introduction:
The 328i variant was introduced in 1996, replacing the 325i as the top-tier inline-six model for the US market, featuring the larger M52B28 engine.
Production
Production Years E36:
1990-2000 (sedan, coupe, convertible, touring); 1993-1999 (compact/hatchback)
Manufacturing Locations:
Primary production in Munich, Germany; also produced in Dingolfing, Germany, and Rosslyn, South Africa.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E36 3 Series (including variants like the 328i) was a consistent winner of Car and Driver's '10Best' lists during its production run.
Overall Reputation:
Widely praised for its driving dynamics, build quality, and performance, establishing BMW's reputation for sport sedans.
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