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BMW 328 328i 1999-2005 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 328i Codes Chassis Code: E46 Engine Code Primary: M52TUB28 👋 Introduction Market Position Segment: Compact Executive Sedan Bmw Positioning:...
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BMW 328 328i 1999-2005 Service Repair Workshop ManualBMW 328 328i 1999-2005 Service Repair Workshop ManualBMW 328 328i 1999-2005 Service Repair Workshop ManualBMW 328 328i 1999-2005 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Model Variant:
328i
Codes
Chassis Code:
E46
Engine Code Primary:
M52TUB28
👋 Introduction
Market Position
Segment:
Compact Executive Sedan
Bmw Positioning:
Represents BMW's entry-level executive sedan offering, known for its engaging driving dynamics and premium build quality.
Competitive Analysis
Key Competitors:
Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS (XE10), Infiniti G35
Key Features
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel-drive platform, and communicative steering.
Engine Performance:
Smooth and torquey inline-six engine providing a refined power delivery.
Build Quality:
Typical BMW premium interior materials and solid construction.
📋 Manual Details
Coverage Areas
Covered Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Specific Models Covered:
BMW 328i
Page Count
Estimated Page Count:
Approximately 1500-2500 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Manual Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, often printable and searchable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, pistons, crankshaft, camshafts, timing, lubrication system, cooling system
Engine Management:
Fuel injection system (MS43/MS45 DME), ignition system, emissions control, sensor diagnostics, ECU testing
Transmission Manual:
Clutch, gearbox overhaul, shift mechanism, driveshafts
Transmission Automatic:
GM A5S360R/A5S390R transmission overhaul, valve body, torque converter, electronic control
Drivetrain:
Differential, rear axle, limited-slip differential (if equipped)
Suspension:
Front struts, rear multi-link suspension, control arms, bushings, springs, shock absorbers
Brakes:
Front and rear disc brakes (vented front), ABS system, DSC (Dynamic Stability Control), brake hydraulics, bleeding procedures
Steering:
Power steering system, steering rack, steering column, alignment specifications
Electrical System:
Battery, alternator, starter, lighting, fuses, relays, wiring diagrams, power distribution
Body And Chassis:
Body panels, doors, windows, sunroof, interior trim, bumpers, underbody protection
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant service
Safety Systems:
Airbag system (SRS), seat belt pre-tensioners, diagnostic codes
Procedures Included
Preventative Maintenance:
Oil change intervals, fluid checks and replacements, filter replacement, spark plug replacement
Troubleshooting:
Diagnostic procedures for common faults, symptom-based troubleshooting guides, error code interpretation
Repair And Rebuild:
Detailed step-by-step instructions for component removal, installation, and overhaul
Diagnostics:
Information on using diagnostic tools (e.g., INPA, DIS) and interpreting sensor data
Electrical Repairs:
Component testing, wiring harness repair, connector diagnosis
Technical Depth
Depth Of Coverage:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts
Diagnostic Detail:
Includes specific diagnostic trouble codes (DTCs), circuit descriptions, and component testing procedures
Torque Specifications:
Detailed torque values for all critical fasteners
Alignment Specs:
Front and rear wheel alignment specifications
Schematics Included:
Extensive electrical wiring diagrams for various systems
📊 Manual Specifications
File Format
File Format Type:
Likely PDF (Portable Document Format)
Searchability:
Typically includes searchable text for quick information retrieval
Printability:
Designed for printing specific sections or the entire manual
Print Quality
Image Resolution:
High-resolution for clear diagrams and illustrations
Binding Type
Binding:
N/A (for digital format)
Paper Type
Paper Quality:
N/A (for digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, DOHC, 24 Valves
Displacement:
2.8 Liters (2793 cc)
Bore X Stroke:
84.0 mm x 84.0 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
193 hp @ 5500 rpm
Torque:
206 lb-ft (280 Nm) @ 3200 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (Bosch Motronic MS43 or MS45)
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
Engine Features
Valvetrain:
Double VANOS (variable intake and exhaust camshaft timing)
Engine Block Material:
Aluminum
Cylinder Head Material:
Aluminum
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual (Getrag GS5-39DZ)
Optional
Optional Transmission:
5-Speed Steptronic Automatic (GM A5S360R/A5S390R)
Features
Transmission Cooling:
External transmission fluid cooler for automatic transmission
📐 Dimensions
Exterior
Length:
177.4 inches (4506 mm)
Width:
68.5 inches (1740 mm)
Height:
55.7 inches (1415 mm)
Wheelbase:
107.4 inches (2729 mm)
Interior
Front Headroom:
38.4 inches (975 mm)
Front Legroom:
41.5 inches (1054 mm)
Rear Headroom:
37.7 inches (958 mm)
Rear Legroom:
33.4 inches (848 mm)
Cargo
Trunk Volume:
11.7 cu ft (331 L)
Weights
Curb Weight:
Approximately 3350-3500 lbs (1520-1588 kg)
Gross Vehicle Weight Rating:
Approximately 4500 lbs (2041 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars (Driver), 4 Stars (Passenger) - 1999-2000 models, varies by year/testing protocol
IIHS Side Impact:
Good - Models with side airbags
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard ASC+T (Automatic Stability Control and Traction)
Stability Control:
Optional DSC (Dynamic Stability Control) on later models
Passive Features
Airbags:
Frontal airbags, optional front side-impact airbags
Seat Belts:
Three-point inertia-reel seatbelts with pretensioners
💡 Technology Features
Infotainment
Head Unit:
Factory Professional Radio/CD player, optional navigation system (MK III/MK IV).
Display:
Central LCD display for radio, climate, and navigation information.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Connectivity
Bluetooth:
Not available from factory; aftermarket solutions required.
Features
Headlights:
Standard halogen headlights, optional Xenon HID headlights with adaptive beam.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles or annually, depending on driving conditions and oil used (BMW's Condition Based Service system is key)
Coolant Change:
Every 2-4 years or 30,000-60,000 miles
Spark Plug Replacement:
Approximately every 60,000 miles (check specific type, e.g., NGK BKR6EQUP)
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or LL-98 approved synthetic oil, SAE 5W-30 or 5W-40 recommended
Engine Oil Capacity:
6.5 U.S. quarts (6.2 Liters) with filter
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 formulation) mixed 50/50 with distilled water
Transmission Fluid Manual:
BMW MTF LT-2 or equivalent (e.g., Red Line D4 ATF for some applications, check manual)
Transmission Fluid Automatic:
BMW ATF LT-3 or equivalent (e.g., Pentosin ATF1 or ZF LifeguardFluid 5)
Brake Fluid:
DOT 4 (BMW recommends DOT 4 HP or Super DOT 4)
Known Issues
Cooling System Failure:
Plastic expansion tank and coolant hoses prone to cracking; water pump failure is common.
Oil Leaks:
Valve cover gasket, oil pan gasket, and oil filter housing gasket can leak.
Suspension Wear:
Control arm bushings, sway bar links, and rear shock mounts are common wear items.
Window Regulator Failure:
Plastic components in the window regulator mechanism are prone to breaking.
Ccv System:
Crankcase Ventilation (CCV) system can clog, leading to increased oil consumption and potential seal failure.
ABS Wheel Speed Sensors:
Front ABS wheel speed sensors are known to fail, triggering ABS and brake warning lights.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's reputation for engineering excellence, performance, and driver engagement originated in the early 20th century.
Model Evolution
E46 Generation:
The E46 generation (1998-2006) succeeded the E36 and is widely regarded as one of BMW's most successful and critically acclaimed generations of the 3 Series.
328I Placement:
The 328i occupied the upper-mid-range of the E46 sedan lineup, offering a potent blend of performance and luxury before the introduction of the 330i.
Production
Production Years E46:
1998-2006 (sedan and wagon), 1999-2006 (coupe and convertible)
Manufacturing Locations:
Primarily Dingolfing, Germany; also assembled in South Africa, Thailand, and Mexico
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
E46 3 Series models (including 323i, 328i, and later 330i) were frequently named to Car and Driver's 10Best list for their exceptional driving dynamics.
Ratings
Edmunds Review:
Edmunds consistently praised the E46 3 Series for its performance, handling, and luxury appointments.
Certifications
Euro Ncap:
E46 sedan achieved a 4-star Euro NCAP rating.
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