BMW 328i 1999-2005 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 328i Generation Chassis Code: E46 Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Codes Engine Code Primary:...

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类型: Car

斯库: 383650

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

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Description

🏷️ Basic Information

Identification

Make:

Model:

3 Series

Model Variant:

Generation Chassis Code:

Production Years Covered:

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

Codes

Engine Code Primary:

M52TU B28

👋 Introduction

Market Position

Vehicle Segment:

Compact Executive Sedan/Coupe/Convertible

Bmw Positioning:

The E46 3 Series represented BMW's core offering in the compact executive segment, known for its balanced handling and premium feel.

Competitive Analysis

Key Competitors:

Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS, Infiniti G35.

Key Features

Driver Focus:

Emphasis on driving dynamics, precise steering, and a driver-centric cockpit.

Engine Performance:

Smooth inline-six engines offering a blend of power and refinement.

Build Quality:

Renowned BMW build quality and premium interior materials for its class.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Thousands of pages (comprehensive official documentation)

📖 Manual Coverage

Systems Covered

Engine:

Detailed disassembly, assembly, overhaul, diagnostics, and repair for the M52TU B28 engine.

Fuel System:

Fuel pump, injectors, fuel lines, fuel pressure regulator, EVAP system diagnostics and repair.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan clutch, heater core diagnosis and replacement.

Ignition System:

Spark plugs, ignition coils, ignition control module (DISA unit), wiring diagrams, and troubleshooting.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, oxygen sensors, and exhaust hangers.

Transmission Manual:

Clutch, flywheel, gearbox internals, shift linkage, and related components for manual transmissions (e.g., Getrag).

Transmission Automatic:

Steptronic automatic transmission (e.g., GM 5L40-E) overhaul, diagnostics, fluid service, and electronic control module (TCU) information.

Drivetrain:

Driveshaft, CV joints, differential, axle shafts, and wheel bearings.

Suspension Front:

Struts, control arms, ball joints, sway bar, wheel bearings, and alignment specifications.

Suspension Rear:

Multi-link rear suspension components, shock absorbers, control arms, sway bar, and alignment.

Steering:

Power steering pump, steering rack, tie rods, steering column, and alignment.

Brakes Front:

Brake calipers, rotors, brake pads, brake lines, and ABS components.

Brakes Rear:

Brake calipers, rotors, brake pads, parking brake mechanism, and brake lines.

Anti Lock Braking System ABS:

ABS hydraulic unit, wheel speed sensors, ABS control module, and troubleshooting.

Traction Control System Asc DTC:

ASC (Automatic Stability Control) and DTC (Dynamic Traction Control) system components and operation.

Electrical System Power:

Battery, alternator, starter motor, charging system diagnostics.

Lighting System:

Headlights, taillights, interior lighting, fog lights, and associated wiring and control modules.

Body Exterior:

Bumpers, fenders, doors, hood, trunk, glass, seals, and body panel removal/installation.

Body Interior:

Dashboard, seats, door panels, headliner, carpeting, and interior trim components.

HVAC Climate Control:

Heater, air conditioning (A/C) system, blower motor, control panel, refrigerant system, and climate control module.

Infotainment Audio:

Radio, CD player, speakers, antenna, and amplifier (if equipped).

Instrumentation Gauges:

Instrument cluster, tachometer, speedometer, fuel gauge, temperature gauge, warning lights, and diagnostics.

Security System Alarms:

Factory alarm system, central locking, keyless entry, and immobilizer system.

Airbags Safety Restraints:

Airbag modules, seat belt pre-tensioners, SRS control module, and related wiring and diagnostics.

ECU Dme Control Modules:

Digital Motor Electronics (DME) control unit, transmission control unit (TCU), ABS/ASC control module, and other ECUs.

Diagnostic Troubleshooting:

OBD-II diagnostic procedures, fault code interpretation, and diagnostic tool usage.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid level checks and top-offs.

Major Engine Repair:

Engine overhaul, piston ring replacement, valve seal replacement, timing chain/guide/tensioner replacement.

Transmission Service:

Transmission fluid and filter changes (automatic and manual), clutch replacement, clutch fluid service.

Brake System Repair:

Brake pad and rotor replacement, caliper servicing, brake fluid bleeding and replacement.

Suspension Component Replacement:

Strut/shock absorber replacement, control arm replacement, ball joint replacement, bushing replacement.

Steering System Repair:

Tie rod end replacement, power steering pump replacement, steering rack replacement.

Electrical Troubleshooting:

Wiring harness repair, component testing, circuit tracing using wiring diagrams.

HVAC System Repair:

A/C compressor replacement, condenser replacement, evaporator service, blower motor replacement, refrigerant charging.

Body Panel Replacement:

Door replacement, fender replacement, bumper cover repair/replacement, hood and trunk alignment.

Interior Trim Removal:

Dashboard removal, door panel removal, seat removal, headliner repair.

Diagnostic Procedures:

Step-by-step troubleshooting guides for common and uncommon issues.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic fluid checks to complete engine and transmission rebuilds.

Diagnostic Detail:

Detailed diagnostic procedures, including symptom identification, test procedures, and component testing.

Torque Specifications:

Includes specific torque values for all critical fasteners.

Alignment Specifications:

Wheel alignment angles (camber, caster, toe) and chassis alignment procedures.

Wiring Diagrams:

Detailed electrical system wiring diagrams for all major circuits.

Special Tools:

Lists required special tools and their BMW part numbers where applicable.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Method:

N/A (Digital PDF Download)

Paper Type

Paper Quality:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M52TU B28

Engine Type:

DOHC Inline 6-cylinder, 24 valves

Displacement:

2.8 Liters (2793 cc)

Bore X Stroke:

84.0 mm x 83.6 mm

Compression Ratio:

10.2:1

Performance

Horsepower:

193 hp @ 5500 rpm

Torque:

206 lb-ft (280 Nm) @ 3500 rpm

Fuel System

Fuel Delivery:

Bosch Motronic Electronic Fuel Injection (EFI) with sequential port injection.

Recommended Fuel:

Premium Unleaded (91 Octane or higher)

Engine Management

Engine Control Unit:

Bosch Motronic DME (Digital Motor Electronics)

Variable Valve Timing:

Double VANOS (Variable Valve Timing System on intake and exhaust camshafts)

Intake System:

Dual-Stage Intake Manifold (DISA - Differential Air Stream)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

5-Speed Steptronic Automatic Transmission (GM 5L40-E)

Features

Steptronic Operation:

Allows manual gear selection via shifter or steering wheel buttons.

Fluid Specifications

Manual Transmission Fluid:

BMW Manual Transmission Fluid MTF LT-2 or equivalent (e.g., Pentosin MTF2)

Automatic Transmission Fluid:

Dexron III or Dexron VI automatic transmission fluid.

📐 Dimensions

Exterior

Length:

Approx. 177.4 inches (4506 mm)

Width:

Approx. 68.7 inches (1745 mm)

Height:

Approx. 56.1 inches (1425 mm)

Wheelbase:

Approx. 107.4 inches (2729 mm)

Weights

Curb Weight Manual:

Approx. 3351 lbs (1520 kg)

Curb Weight Automatic:

Approx. 3461 lbs (1570 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star (for models equipped with optional side airbags)

NHTSA Front Impact Passenger:

5-Star (for models equipped with optional side airbags)

IIHS Side Impact:

Good (for models with side airbags)

Active Features

Standard Anti-lock Braking System

Traction Control:

Standard Automatic Stability Control (ASC) / Dynamic Traction Control (DTC)

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags, optional rear side-impact airbags.

Seat Belts:

3-point front and rear seat belts with pre-tensioners.

💡 Technology Features

Infotainment

Audio System:

BMW Professional CD player with RDS, AM/FM radio. Optional Harman Kardon sound system available.

Navigation System:

Optional MK III or MK IV navigation system with a trunk-mounted CD-ROM based map unit and dashboard screen.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Sensors:

Optional Park Distance Control (PDC) rear parking sensors.

Connectivity

Telematics:

Optional BMW Assist telematics system, providing emergency services and vehicle information.

Bluetooth:

Optional Bluetooth interface for mobile phone integration (often requires an adapter or cradle).

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) system, typically around 10,000-15,000 miles or annually, depending on driving conditions.

Air Filter Replacement:

Recommended every 30,000 miles or as indicated by CBS.

Cabin Filter Replacement:

Recommended every 15,000-30,000 miles or annually.

Spark Plug Replacement:

Recommended every 100,000 miles (long-life plugs).

Coolant Flush:

BMW recommends coolant service every 2-4 years or 50,000 miles.

Brake Fluid Flush:

Recommended every 2 years, regardless of mileage.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 synthetic engine oil meeting BMW Longlife-01 (LL-01) specification is highly recommended. Older recommendations may include 5W-40 LL-01.

Engine Oil Capacity:

6.5 US quarts (6.2 liters) with filter change.

Coolant Type:

BMW Blue Coolant (G48 Ethylene Glycol based) or equivalent.

Power Steering Fluid:

Pentosin CHF 11S or ZF Servolenkungsaft (Green)

Known Issues

Cooling System Leaks:

Common issues include failure of the plastic coolant expansion tank, water pump, and thermostat housing, leading to leaks.

Crankcase Ventilation System:

Clogged PCV (Positive Crankcase Ventilation) valve or hoses can lead to rough idle, oil leaks, and vacuum issues.

Oil Pan Gasket Leaks:

Oil pan gaskets and valve cover gaskets are prone to hardening and leaking over time.

Vanos System:

VANOS solenoid seals can degrade, causing rough idle, hesitation, and loss of low-end torque.

Window Regulators:

Common failure of the electric window regulators, leading to windows not operating.

Subframe Mounts:

Rear subframe mounting points can crack or fail over time due to stress, affecting handling and alignment.

ABS Wheel Speed Sensors:

ABS and traction control warning lights may illuminate due to failing wheel speed sensors.

Headlight Aiming Mechanism:

Plastic gears in the headlight leveling system can break, causing headlights to be misaligned.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW has a long-standing reputation for producing performance-oriented luxury vehicles with a focus on driving pleasure.

Model Evolution

E46 Introduction:

The E46 generation replaced the E36 3 Series and was produced from 1998 to 2006 globally, with the 328i variant prominent in the earlier years of this generation.

Engine Updates:

The M52TU (Technical Update) engine featured VANOS on both intake and exhaust camshafts, improving performance and efficiency over the earlier M52.

Production

Manufacturing Locations:

Primarily manufactured in Germany, with some production in other BMW global facilities.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E46 3 Series, including variants like the 328i and later 330i, was a consistent recipient of Car and Driver's '10Best' awards during its production run.