BMW 328i 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 328i Year: 2002 Codes Chassis Code: E46 Engine Code Primary: M52TUB28 👋 Introduction Market Position Market Segment: Compact Executive Sedan Target Audience: Enthusiasts,...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Engine Code Primary:

M52TUB28

👋 Introduction

Market Position

Market Segment:

Compact Executive Sedan

Target Audience:

Enthusiasts, DIY mechanics, and professional workshops seeking detailed repair information.

Competitive Analysis

Key Competitors:

Audi A4, Mercedes-Benz C-Class, Lexus IS300, Infiniti G35

Key Features

Model Strengths:

Sporty handling, refined interior, powerful inline-six engine, excellent build quality.

Manual Value Proposition

Value Proposition:

Provides the definitive resource for maintaining and repairing the BMW 328i (E46), enabling cost savings and in-depth understanding of the vehicle's systems.

📋 Manual Details

Coverage Areas

Coverage Focus:

Full Service Repair and Maintenance

Page Count

Estimated Pages:

1000+

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, diagnostics, timing, fuel, ignition, cooling, lubrication, emissions control

Transmission:

Automatic and Manual transmission service, repair, diagnostics, fluid changes

Drivetrain:

Driveshafts, differentials, clutch (manual transmission), wheel bearings

Suspension:

Front and rear suspension components, struts, shock absorbers, control arms, bushings, wheel alignment

Brakes:

Brake system diagnostics, ABS, component replacement (pads, rotors, lines), bleeding procedures

Steering:

Power steering system, steering rack, tie rods, pump, fluid replacement

Electrical:

Complete electrical system schematics, wiring diagrams, battery, alternator, starter, lighting, power windows, locks, mirrors, climate control electronics

Body:

Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass replacement

HVAC:

Heating, ventilation, and air conditioning system diagnostics, refrigerant handling, component replacement

Chassis:

Frame, unibody structure, rust prevention, chassis components

Diagnostics:

OBD-II (On-Board Diagnostics II) system, fault code interpretation, diagnostic procedures for all major systems

Procedures Included

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes

Repair:

Detailed step-by-step repair instructions for all components and systems

Rebuild:

Engine and transmission rebuilding procedures, including torque specifications and clearances

Troubleshooting:

Comprehensive troubleshooting guides and flowcharts for common and complex issues

Installation:

Installation procedures for aftermarket parts and upgrades, where applicable

Technical Depth

Technical Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system schematics.

📊 Manual Specifications

File Format

File Format:

Searchability:

Searchable text for quick information retrieval

Print Quality

Print Quality:

High-resolution scans suitable for printing

Binding Type

Binding Type:

N/A (Digital)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Name:

BMW M52TUB28

Engine Type:

Inline-6 Cylinder, DOHC (Double Overhead Camshaft), 24 Valves

Displacement:

2.8 Liters (2793 cc)

Bore X Stroke:

84.0 mm x 90.0 mm

Compression Ratio:

10.2:1

Engine Control System:

Siemens MS43 Electronic Engine Control Unit (ECU)

Performance

Horsepower:

193 hp @ 5500 rpm (SAE Net)

Torque:

206 lb-ft @ 3500 rpm (SAE Net)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) with VANOS (Variable Valve Timing)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane Recommended)

Fuel Tank Capacity:

60 Liters (15.8 US Gallons)

Lubrication

Oil Type:

BMW Longlife-01 (LL-01) Synthetic, SAE 5W-30 or 5W-40

Oil Capacity:

6.5 Liters (6.9 US Quarts) with filter change

Cooling

Coolant Type:

BMW Blue Antifreeze/Coolant (G48), 50/50 mix with distilled water

Ignition

Spark Plugs:

NGK BKR6EQUP (Platinum) or equivalent

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission (Getrag S5D 250G)

Optional

Transmission Type Optional:

5-speed Automatic Transmission (GM A5S 325Z)

Features

Manual Gear Ratios 1-5:

3.50, 2.14, 1.42, 1.00, 0.81

Manual Reverse Gear Ratio:

Automatic Transmission Features:

Steptronic (manual shifting mode)

Fluid Specs

Manual Transmission Fluid:

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

Automatic Transmission Fluid:

Dexron III (or equivalent ATF)

📐 Dimensions

Exterior

Length:

4471 mm (176.0 in)

Width:

1739 mm (68.5 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2760 mm (108.7 in)

Front Track:

1471 mm (57.9 in)

Rear Track:

1474 mm (58.0 in)

Weights

Curb Weight Manual:

1480 kg (3263 lbs)

Curb Weight Automatic:

1510 kg (3329 lbs)

Gross Vehicle Weight Rating:

1910 kg (4211 lbs)

Front Axle Weight Rating:

875 kg (1929 lbs)

Rear Axle Weight Rating:

1035 kg (2282 lbs)

Cargo

Trunk Capacity:

440 Liters (15.5 cu ft)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star

NHTSA Front Impact Passenger:

5-Star

IIHS Front Offset Crash Rating:

Active Features

Standard Anti-lock Braking System (ABS)

Standard Automatic Stability Control (ASC)

Optional Dynamic Traction Control (DTC)

Passive Features

Airbags Front:

Standard driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

3-point inertia-reel seatbelts with pretensioners and force limiters

💡 Technology Features

Infotainment

Infotainment System:

BMW Business CD, BMW Professional CD, optional Navigation System (MK III or MK IV).

Audio System:

Standard 6-speaker audio, optional premium sound systems (e.g., Harman Kardon).

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Assistance:

Optional rear parking sensors (Park Distance Control - PDC).

Connectivity

Connectivity Features:

Optional Bluetooth hands-free system (BMW Assist).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable (BMW Condition Based Service), typically 10,000-15,000 miles or 1 year.

Engine Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Cabin Air Filter:

Replace every 15,000 miles or 1 year.

Spark Plugs:

Replace every 60,000 miles for platinum plugs.

Coolant Flush:

Replace coolant every 4 years or 60,000 miles.

Brake Fluid Flush:

Replace brake fluid every 2 years or 24,000 miles.

Fluid Specifications

Power Steering Fluid:

Pentosin CHF 11S (or compatible hydraulic fluid)

Windshield Washer Fluid:

BMW Windshield Washer Fluid Concentrate or equivalent, mixed with water.

Known Issues

Cooling System:

Plastic expansion tank failures, water pump impeller failure, thermostat housing leaks.

Vanos:

Degradation of O-rings in the VANOS system leading to rough idle and loss of low-end torque.

Oil Leaks:

Valve cover gasket, oil filter housing gasket, oil pan gasket are common leak points.

Subframe:

Cracking of the rear subframe mounting points due to stress.

Ccv System:

Crankcase Ventilation system (CCV) failure, leading to oil consumption and rough running.

📚 Vehicle History

Brand Heritage

Brand Heritage:

BMW (Bayerische Motoren Werke AG) is a German luxury vehicle manufacturer renowned for its performance-oriented cars and motorcycles.

Model Evolution

E46 Generation:

The E46 generation of the 3 Series was produced from 1998 to 2006, representing the fifth generation of BMW's compact executive car.

Production

Production Years E46 328I:

1999-2000 (pre-facelift), replaced by 330i with the 2001 facelift. However, the 328i moniker continued in certain markets like North America.

Manufacturing Locations:

Primarily Germany (Munich, Dingolfing), also South Africa, Egypt, Thailand, Russia, Indonesia, China, India, Malaysia, Vietnam.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

E46 3 Series (including 328i variants) was frequently recognized on Car and Driver's 10Best lists during its production run for its driving dynamics.

Ward Auto World Engine Of The Year:

BMW's inline-6 engines, including the M52 family, were often lauded for their smoothness and power delivery.