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BMW 328i-3 Series (E46) 1999-2005 Service Repair Manual

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Basic Information Identification Make: BMW Model: 3 Series Model Variant: 328i Generation Chassis Code: E46 Production Years Covered: 1999-2005 Codes Engine Code Primary: M52TU B28 (2.8L Inline-6) Engine Code Later:...
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BMW 328i-3 Series (E46) 1999-2005 Service Repair Manual
Basic Information
Identification
Make: BMW
Model: 3 Series
Model Variant: 328i
Generation
Chassis Code: E46
Production Years Covered: 1999-2005
Codes
Engine Code Primary: M52TU B28 (2.8L Inline-6)
Engine Code Later: M54 B30 (3.0L Inline-6, often found in later 330i, but the 328i designation predominantly refers to the M52TU in this E46 generation, with some markets potentially having transitional models or specific trims.
Introduction
Market Position
Segment: Compact Executive Sedan/Coupe/Convertible
Brand Philosophy: Known for sporty handling, premium interior, and advanced engineering.
Competitive Analysis
Key Competitors: Mercedes-Benz C-Class, Audi A4, Lexus IS, Acura TL.
Key Features
Performance Focus: Emphasis on driver engagement, balanced chassis, and smooth inline-6 power delivery.
Premium Appointments: High-quality interior materials, ergonomic design, and refined ride quality.
Manual Details
Coverage Areas
General Coverage: Comprehensive repair and service information for BMW 3 Series (E46) 328i models.
Specific Coverage: Engine, Drivetrain, Suspension, Brakes, Electrical Systems, HVAC, Bodywork, Diagnostics.
Page Count
Estimated Pages: Extensive (exact count not provided, but typical for comprehensive service manuals).
Manual Type
Type: Service and Repair Manual
Language
Language: English
Format
Format: Digital PDF (Instant Download)
Manual Coverage
Systems Covered
Engine Systems: Engine mechanicals, lubrication, cooling, fuel injection, ignition, exhaust, emissions control, engine management (DME).
Drivetrain: Clutch, manual transmission, automatic transmission, driveshafts, differential, axles.
Suspension Steering: Front and rear suspension components, shock absorbers, springs, bushings, steering system, power steering.
Brakes: Brake system components (pads, rotors, calipers), hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control).
Electrical: Battery, charging system, starter, lighting, wipers, horn, instrument cluster, body electrical modules, CAN bus communication.
HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components and operation.
Bodywork: Exterior panels, interior trim, doors, windows, locks, mirrors.
Procedures Included
Maintenance: Routine maintenance tasks, oil changes, filter replacements, fluid checks and changes, spark plug replacement.
Repair Rebuild: Component removal, disassembly, inspection, repair, reassembly, and installation procedures.
Diagnostics Troubleshooting: Systematic diagnostic procedures, common fault codes (DTCs), symptom-based troubleshooting guides.
Specifications Tolerances: Detailed technical specifications, torque values, clearances, and alignment data.
Technical Depth
Depth Level: Comprehensive, from basic maintenance to advanced diagnostics and component overhaul.
Diagnostic Tools: Information on diagnostic connectors, software (e.g., ISTA/DIS), and scan tools.
Manual Specifications
File Format
Format: PDF
Searchability: Searchable text content for quick information retrieval.
Compatibility: Accessible on all common operating systems and devices (Windows, macOS, Linux, tablets, smartphones) with a PDF reader.
Print Quality
Printability: Printable pages for physical reference.
Binding Type
Binding: N/A (Digital Download)
Paper Type
Paper: N/A (Digital Download)
Engine Specifications
Primary Engine
Engine Type: Naturally Aspirated Inline 6-Cylinder (M52TU B28)
Displacement: 2.8 Liters (2793 cc)
Bore X Stroke: 84.0 mm x 83.6 mm
Compression Ratio: 10.2:1
Valve Train: DOHC, 24 Valves (4 per cylinder), VANOS (Variable Valve Timing)
Performance
Horsepower Est: 193 hp @ 5500 rpm
Torque Est: 206 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI)
Fuel Type: Premium Unleaded (91 Octane or higher recommended)
Engine Management
ECM: Siemens MS43 Engine Control Module (ECM)
Transmission
Standard
Type Standard: 5-Speed Manual (Getrag 260/5 or ZF S5-31)
Optional
Type Optional: 5-Speed Automatic (Steptronic - GM 5L40-E)
Features
Traction Control: Available with ASC+T (Automatic Stability Control + Traction) or DSC (Dynamic Stability Control).
Dimensions
Exterior
Wheelbase: Approx. 107.4 inches (2728 mm)
Length: Approx. 177.4 inches (4506 mm) for Sedan, 177.5 inches (4509 mm) for Coupe/Convertible.
Width: Approx. 68.9 inches (1750 mm)
Height: Approx. 55.7 inches (1415 mm) for Sedan, 53.6 inches (1362 mm) for Coupe.
Weights
Curb Weight Est: Approx. 3300 - 3500 lbs (1497 - 1588 kg), varies by body style and transmission.
Gross Vehicle Weight Rating: Refer to vehicle's specific VIN plate and manual.
Safety Features
Ratings
NHTSA Front Impact: 5-Star (for models tested).
IIHS Side Impact: Good (for models tested).
Active Features
ABS: Standard Anti-lock Braking System (ABS)
Stability Control: Available ASC+T or DSC (Dynamic Stability Control)
Passive Features
Airbags: Driver and front passenger airbags, optional side airbags.
Seatbelts: 3-point inertia-reel seatbelts with pretensioners and force limiters.
Technology Features
Infotainment
Head Unit: Original BMW Business CD or Professional RDS radio, with optional navigation system (CCC).
Audio System: Optional Harman Kardon sound system available.
Driver Assistance
Cruise Control: Standard cruise control.
Parking Sensors: Optional rear Park Distance Control (PDC).
Connectivity
Phone Integration: Optional Bluetooth phone preparation available on later models.
Maintenance
Service Intervals
Oil Change: Variable: BMW Condition Based Service (CBS) system typically recommends every 10,000-15,000 miles or annually, whichever comes first. Check oil level frequently via dashboard indicator.
Air Filter: Recommended inspection every 15,000-30,000 miles, replacement as needed or per CBS.
Cabin Filter: Recommended replacement every 15,000-30,000 miles or annually.
Spark Plugs: Recommended replacement every 60,000-100,000 miles for iridium plugs (check specific plug type).
Coolant Flush: BMW Blue Coolant (G48) recommended change every 4 years or 60,000 miles.
Fluid Specifications
Engine Oil: SAE 5W-30 or 5W-40 Synthetic. BMW Longlife-01 (LL-01) or LL-04 specification (check manual for region-specific recommendations).
Engine Oil Capacity: Approx. 6.5 US quarts (6.2 Liters) with filter change.
Transmission Fluid Manual: GL-4 SAE 75W-90 Synthetic Gear Oil (e.g., BMW MTF LT-2).
Transmission Fluid Automatic: Dexron III/VI or equivalent (e.g., BMW ATF LT71141 for earlier models, check specific transmission type).
Power Steering Fluid: ATF Dexron III or Pentosin CHF 11S (check vehicle specifics, as some E46 models switched).
Brake Fluid: DOT 4 (e.g., BMW DOT 4 High Performance)
Known Issues
Cooling System: Common failure points include plastic expansion tanks, water pumps, and thermostat housings leading to coolant leaks and overheating.
Oil Leaks: Valve cover gasket, oil pan gasket, and oil filter housing gasket are prone to leaks.
Rear Subframe: Cracks in the rear subframe mounting points are a well-documented issue, requiring reinforcement or repair.
Suspension Components: Wear in control arm bushings, ball joints, and tie rod ends can lead to steering looseness and premature tire wear.
Window Regulators: Plastic components in window regulator mechanisms can fail, causing windows to drop.
Ccv System: Crankcase Ventilation (CCV) system can become clogged, leading to increased crankcase pressure, oil leaks, and rough idling.
Vehicle History
Brand Heritage
Bmw Legacy: BMW has a long history of producing sporting sedans and coupes, with the 3 Series being its most iconic and volume-selling model line.
Model Evolution
E46 Introduction: The E46 generation replaced the E36 and was praised for its refined chassis dynamics, improved interior quality, and advanced technology compared to its predecessor.
E46 Facelift: Received a significant facelift (LCI) in 2001, updating headlights, taillights, bumpers, and interior trim.
Production
Manufacturing Locations: Primarily produced at BMW's Dingolfing plant in Germany. Some assembly may have occurred in other BMW facilities globally.
Model End Of Life: The E46 generation was succeeded by the E90 generation (for sedans) starting in 2005.
Awards & Recognition
Recognitions
Car And Driver Award: Car and Driver 10Best list multiple times during its production run.
Popular Mechanics Award: Often cited for its design and driving dynamics by automotive publications.
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