BMW 328i 1999-2005 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 328i Generation Platform: E46 Codes Model Code: E46 328i 👋 Introduction Market Position Vehicle Segment: Compact Executive Sedan/Coupe/Convertible/Wagon Key Competitors: Mercedes-Benz C-Class (W203),...

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类型: Car

斯库: 390615

标签: 1999 2000 2001 2002 2003 2004 2005 328i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Generation

Platform:

Codes

Model Code:

E46 328i

👋 Introduction

Market Position

Vehicle Segment:

Compact Executive Sedan/Coupe/Convertible/Wagon

Key Competitors:

Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS300, Acura TL

Competitive Analysis

Bmw Strengths:

Renowned driving dynamics, sophisticated inline-6 engines, premium interior, and strong brand prestige.

Key Features

Engine Technology:

M52TU Double VANOS (Variable Valve Timing) for improved performance and efficiency.

Chassis Design:

Balanced chassis with a near 50/50 weight distribution, contributing to exceptional handling.

📋 Manual Details

Coverage Areas

Supported Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005

Page Count

Estimated Page Count:

Over 1000 pages (typical for full service manuals of this era)

Manual Type

Type:

Full Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, as per product description implying 'everything you will ever need...')

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul and repair procedures for the M52TU Inline-6 engine, including cylinder head, block, crankshaft, pistons, connecting rods, timing system (dual VANOS), lubrication, and cooling systems.

Engine Management:

Diagnosis and repair of the engine control unit (ECU), fuel injection system (Bosch Motronic), ignition system, emissions control systems (secondary air injection, EVAP), and sensors (MAF, O2, crankshaft, camshaft).

Transmission Manual:

Repair and overhaul procedures for the Getrag 5-speed manual transmission, including clutch system, gear selection, and shifting mechanisms.

Transmission Automatic:

Repair and overhaul procedures for the ZF 5HP19/5HP19FLA 5-speed automatic transmission, including hydraulic control, torque converter, and electronic control unit (TCU).

Drivetrain:

Maintenance and repair of the rear-wheel drive system, including driveshaft, universal joints, differential, and axles.

Suspension:

Front and rear suspension component replacement, alignment specifications, shock absorber and strut service, control arm and bushing replacement, and subframe service.

Steering:

Servotronic power steering system diagnosis and repair, steering column, tie rods, and steering gear maintenance.

Brakes:

Front and rear brake system service (discs and calipers), ABS (Anti-lock Braking System) diagnosis and component replacement, brake fluid flush procedures, and parking brake system.

Electrical System:

Wiring diagrams for all vehicle systems, fuse and relay identification, battery and charging system service, starter and alternator diagnosis, lighting system, and instrument cluster.

Climate Control:

HVAC system diagnosis and repair, refrigerant handling, blower motor, evaporator, condenser, and heater core service. Automatic climate control (IHKA) system.

Body And Trim:

Body panel removal and installation, interior trim components, door mechanisms, window regulators, and exterior trim.

Comfort And Convenience:

Power windows, power seats, central locking, remote keyless entry, sunroof operation, and cruise control system.

Procedures Included

Preventative Maintenance:

Detailed service intervals for oil changes, filter replacements, coolant flushes, brake fluid changes, spark plug replacement, and drive belt inspection/replacement.

Diagnostic Troubleshooting:

Systematic troubleshooting guides based on symptoms, fault codes, and component testing procedures.

Repair Procedures:

Step-by-step instructions for component removal, installation, adjustment, and overhaul for all major vehicle systems.

Component Rebuild:

In-depth guidance for rebuilding key components such as the engine, transmission, and differential.

Torque Specifications:

Precise torque values for all fasteners, essential for correct assembly and preventing component failure.

Wiring Diagrams:

Comprehensive, system-specific electrical schematics for accurate diagnosis and repair of electrical faults.

Technical Depth

Depth:

Expert-level detail, covering routine maintenance to complete engine and transmission overhauls, advanced diagnostics, and bodywork repairs.

Diagnostic Tools:

Information on using OBD-II scanners and BMW-specific diagnostic tools (e.g., DIS, ISTA) for fault code retrieval and live data analysis.

Special Tools:

Identification and usage instructions for specialized tools required for specific BMW E46 repairs (e.g., VANOS alignment tools, clutch alignment tools, engine support brackets).

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable, allowing for quick navigation to specific topics.

Printability:

Printable pages, allowing users to create physical copies of sections for workshop use.

Print Quality

Image Resolution:

High-resolution images, diagrams, and illustrations for clear visual guidance.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M52TU B28

Engine Type:

Naturally Aspirated Inline-6 Cylinder, DOHC, 24 Valves

Displacement:

2.8 Liters (2793 cc)

Performance

Horsepower:

190 hp @ 5500 rpm

Torque:

206 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Point Fuel Injection (Bosch Motronic ME 7.2)

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Cooling System

Coolant Capacity:

Approximately 8.0 Liters (16.9 US Quarts) with 50/50 coolant/water mix

Lubrication System

Oil Type:

SAE 0W-30 or 5W-30 Synthetic Engine Oil (BMW Longlife-01 or Longlife-04 specification recommended)

Oil Capacity:

Approximately 6.5 Liters (6.9 US Quarts) with filter change

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission (Getrag 420G)

Optional

Transmission Type:

5-Speed Automatic Transmission (ZF 5HP19 / 5HP19FLA)

Features

Automatic Features:

Steptronic manual shifting mode

Fluid Specifications

Manual Transmission Fluid:

BMW MTF LT-2 (or equivalent GL-4/GL-5 synthetic gear oil)

Automatic Transmission Fluid:

ZF Lifeguardfluid 5 (or equivalent ATF, e.g., Dexron III/Mercon compatible but specific ZF fluid preferred)

📐 Dimensions

Exterior

Length:

Sedan: 177.4 in (4506 mm)

Width:

Sedan: 68.9 in (1750 mm)

Height:

Sedan: 55.7 in (1415 mm)

Wheelbase:

Sedan: 107.4 in (2728 mm)

Weights

Curb Weight:

Sedan (Automatic): Approx. 3428 lbs (1555 kg)

Gross Vehicle Weight Rating:

Approx. 4500 lbs (2041 kg)

Wheels And Tires

Standard Wheel Size:

16-inch alloy wheels (e.g., Style 45)

Optional Wheel Size:

17-inch alloy wheels (e.g., Style 32, Style 68)

Standard Tire Size:

205/55R16

Optional Tire Size:

225/45R17 (Front), 245/40R17 (Rear) for 17-inch wheels

Bolt Pattern:

5 x 120 mm

Offset:

ET 47 (for 16x7J), ET 47 (for 17x8J)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star Rating

IIHS Side Impact:

Good (for vehicles equipped with side airbags)

Active Features

Standard Anti-lock Braking System

Traction Control:

Standard Dynamic Stability Control (DSC)

Stability Control:

Standard Dynamic Stability Control (DSC)

Passive Features

Airbags:

Frontal airbags (driver and passenger), optional front-side airbags.

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners and force limiters.

Head Restraints:

Active head restraints for front seats (reducing whiplash injuries in certain impacts).

💡 Technology Features

Infotainment

Audio System:

Standard BMW Business CD or optional BMW Professional CD/Radio with premium speaker options (e.g., Harman Kardon).

Navigation:

Optional MKIV navigation system with a trunk-mounted CD-ROM drive.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Sensors:

Optional Park Distance Control (PDC) system.

Connectivity

Phone Integration:

Optional Bluetooth phone preparation with cradle.

Telematics:

Optional BMW Assist telematics system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 - 10,000 miles or 12-15,000 km, or as indicated by the vehicle's Condition Based Service (CBS) system, using synthetic oil.

Air Filter Replacement:

Every 30,000 miles or 48,000 km, or as needed based on inspection.

Cabin Filter Replacement:

Every 15,000 miles or 24,000 km, or annually.

Spark Plug Replacement:

Every 60,000 miles or 96,000 km for original plugs (e.g., NGK BKR6EQUP), or as per manufacturer recommendation.

Coolant Flush:

Every 30,000 miles or 48,000 km, or every two years, using BMW-approved coolant (e.g., BMW Blue Coolant).

Brake Fluid Flush:

Every 24,000 miles or 2 years, using DOT 4 brake fluid.

Fluid Specifications

Power Steering Fluid:

Pentosin CHF 11S or an approved hydraulic fluid (check manual for exact specification).

Brake Fluid:

DOT 4 (e.g., Ate Super Blue/Gold, Pentosin DOT 4 LV)

Washer Fluid:

BMW Windshield Washer Fluid Concentrate (diluted) or equivalent.

Known Issues

Common E46 Issues:

Cracked rear subframe mounting points, VANOS solenoid failure, oil leaks (valve cover gasket, oil pan gasket), cooling system component failure (water pump, thermostat, expansion tank), ABS/ASC sensor failure, sagging headliner.

M52Tu Specific Issues:

VANOS system leaks, oil separator (CCV) system clogging leading to vacuum leaks and rough idle.

Common Repairs

Cooling System Overhaul:

Replacement of water pump, thermostat, coolant hoses, and expansion tank is a common preventative maintenance item.

Suspension Refresh:

Replacement of control arm bushings, tie rods, sway bar links, and rear shock mounts is often necessary due to age and mileage.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's long-standing reputation for building driver-focused vehicles with excellent engineering and performance.

Model Evolution

E46 Introduction:

The E46 generation of the 3 Series was introduced in 1998 (for the 1999 model year) as the successor to the popular E36.

328I Positioning:

The 328i was positioned as the mid-to-high range model within the E46 lineup during its initial years, before the introduction of the 330i.

Engine Update:

The M52 engine in the 328i was updated in 2001 to the M54 engine in the 325i and 330i models. The 328i specifically was produced with the M52TU engine throughout its run in this manual's coverage.

Production

Production Years E46:

1998-2006 (Global)

Manufacturing Locations:

Primary manufacturing was at BMW's main plant in Dingolfing, Germany. Also assembled in Rosslyn, South Africa, and various other locations globally.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E46 3 Series (including the 328i) was frequently named to Car and Driver's 10Best list during its production run for its outstanding driving dynamics.

Consumers Guide Best Buy:

Received numerous 'Best Buy' awards from automotive publications like Consumer's Guide.

Ratings

Seg Rating:

Consistently rated highly for performance, handling, and build quality in its segment.