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BMW 328i 1999-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 328i Product Type: Workshop Service Repair Manual Generation Chassis Code: E46 Codes Engine Code: M52TUB28 👋 Introduction Market Position Segment: Entry-level luxury sedan,...
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BMW 328i 1999-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
328i
Product Type:
Workshop Service Repair Manual
Generation
Chassis Code:
E46
Codes
Engine Code:
M52TUB28
👋 Introduction
Market Position
Segment:
Entry-level luxury sedan, known for sporty handling and driver engagement.
Competitive Analysis
Competitors:
Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS300, Acura TL.
Key Features
Driving Dynamics:
Rear-wheel drive platform, balanced chassis, responsive steering, performance-oriented suspension.
Powertrain:
Smooth and powerful inline-six engine, robust transmissions.
Build Quality:
Renowned BMW build quality and interior materials for its era.
📋 Manual Details
Coverage Areas
Covered Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Estimated Pages:
Varies by specific manual edition, typically 1000+ pages for a complete E46 service manual.
Manual Type
Type:
Comprehensive Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (e.g., PDF, downloadable archive)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (M52TUB28), fuel injection (DME), ignition, cooling, lubrication, emissions control.
Transmission Systems:
Manual and automatic transmissions (e.g., Getrag 5-speed, ZF 5HP19), clutch, driveline, differential.
Chassis Systems:
Suspension (front strut, rear multi-link), steering, brakes (ABS, DSC), wheels, tires.
Electrical Systems:
Wiring diagrams, battery, charging system, starter, lighting, instrument cluster, power accessories, comfort systems, DME control modules.
Body And Interior:
Body panels, doors, windows, seats, HVAC system, interior trim, safety restraint systems (airbags).
Procedures Included
Maintenance:
Oil change, filter replacements, spark plug service, coolant flush, brake fluid service, belt inspection/replacement, diagnostic checks.
Repair:
Engine component overhaul, transmission rebuild, brake caliper replacement, suspension component repair, electrical diagnostic and repair, bodywork.
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical circuit analysis.
Specifications:
Torque specifications for all fasteners, fluid capacities, component clearances, alignment settings.
Technical Depth
Depth:
Expert level, covering diagnostics, troubleshooting, repair, and overhaul procedures for all major vehicle systems.
📊 Manual Specifications
File Format
Digital Format:
Searchable PDF with high-resolution diagrams and schematics.
Print Quality
Quality:
High-quality digital reproduction of original factory documentation.
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M52TUB28
Engine Type:
2.8L DOHC Inline-6 (Straight-6)
Displacement:
2793 cc (2.8 Liters)
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 @ 3500 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (SMPI) with Double VANOS
Fuel Type:
Premium Unleaded (91 AKI or higher recommended)
Engine Management
ECU:
Bosch Motronic ME 7.2 or similar.
🔧 Transmission
Standard
Transmission Type Std:
5-speed Manual (Getrag GS5-39DZ)
Optional
Transmission Type Opt:
5-speed Automatic (ZF 5HP19)
Features
Transmission Features:
Rear-wheel drive layout, electronic clutch control (automatic), sport mode.
📐 Dimensions
Exterior
Length:
4,471 mm (176.0 in)
Width:
1,739 mm (68.5 in)
Height:
1,415 mm (55.7 in)
Wheelbase:
2,725 mm (107.3 in)
Weights
Curb Weight:
Approx. 1,500-1,550 kg (3,300-3,420 lbs)
Gross Weight Rating:
Approx. 1,900 kg (4,180 lbs)
Cargo
Trunk Volume:
440 Liters (15.5 cu ft)
🛡️ Safety Features
Ratings
NHTSA Front Crash:
Not explicitly rated for these specific model years by NHTSA in all categories, but generally considered safe for its time.
IIHS Safety Pick:
Generally well-regarded for structural integrity in frontal and side impacts of its era.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Dynamic Stability Control (DSC) on most models.
Brake Assist:
Included as part of DSC system functionality.
Passive Features
Airbags:
Frontal airbags for driver and passenger, optional side airbags.
Seatbelts:
Three-point seatbelts with pretensioners, active head restraints (front).
Chassis Structure:
Reinforced safety cell, crumple zones.
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD, BMW Professional CD, or optional Professional Navigation System (MK III/MK IV).
Audio System:
Standard 6-speaker system, optional Harman Kardon premium audio.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Assistance:
Optional rear park distance control (PDC).
Connectivity
Phone Integration:
Optional Bluetooth hands-free interface (BMW Assist/TeleAid system).
Lighting
Headlights:
Halogen projector headlights, optional Xenon Adaptive Headlights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system; typically 10,000-15,000 miles or 12-24 months, depending on driving conditions.
Spark Plug Replacement:
Typically around 60,000 miles for iridium spark plugs.
Coolant Flush:
Recommended every 2-3 years or 30,000 miles.
Fluid Specifications
Engine Oil Type:
SAE 0W-30 or 5W-30 Synthetic, meeting BMW Longlife-01 (LL-01) specification is highly recommended.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) mixed with distilled water (50/50).
Transmission Fluid Manual:
GL-4 SAE 75W-90 synthetic gear oil.
Transmission Fluid Automatic:
Dexron III/VI ATF (ZF specified fluid).
Brake Fluid Type:
DOT 4 Low Viscosity (LV) brake fluid.
Known Issues
Cooling System:
Plastic coolant expansion tank can become brittle and crack, leading to leaks. Water pump impellers can degrade. M52TU VANOS solenoids can fail.
Suspension:
Control arm bushings (RTABs) wear out, leading to rear-end instability. Strut mounts and ball joints are common wear items.
Electrical:
ABS/DSC sensor failures, eccentric shaft sensor failure (affecting idle and power), ignition coil failures, blower motor resistor failure.
Oil Leaks:
Valve cover gasket and oil pan gasket are common sources of leaks.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused, sporty vehicles with advanced engineering.
Model Evolution
E46 Introduction:
The E46 generation replaced the E36 3 Series and introduced significant advancements in chassis, engine technology, and interior refinement.
328I Positioning:
The 328i was positioned as a powerful and refined mid-range option within the E46 sedan lineup, slotting below the 330i but offering more performance than the 325i.
Production
Production Years:
1998-2006 (for E46 sedan/coupe/convertible variants globally).
Manufacturing Locations:
Primarily Dingolfing, Germany; also produced in Regensburg, Germany, and Rosslyn, South Africa.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
E46 3 Series models were frequently named to Car and Driver's '10Best' list during their production run.
Ward S 10 Best Engines:
The M52 engine family, including the M52TUB28, received accolades for its smoothness and performance.
Ratings
Owner Satisfaction:
Generally high owner satisfaction for driving dynamics, build quality, and engine performance, though maintenance costs can be a factor.
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